Description:FIELD OF THE INVENTION

[0001] The present invention relates to a mortar sample preparation and testing device that is capable of providing an automated and efficient solution for preparing and testing construction materials, by streamlining the process to save time and effort while improving accuracy and reliability as well as enabling users to detect defects and determine material quality and accordingly providing real-time feedback and alerts to inform decision-making, thereby enables users to efficiently produce high-quality construction materials.

BACKGROUND OF THE INVENTION

[0002] The construction industry is a vital sector that plays a crucial role in the development and growth of economies worldwide. One of the key factors that determine the quality and durability of construction projects is the quality of the construction materials used. Mortar, a mixture of cement, sand, and water, is a fundamental construction material used in various applications, including bricklaying, plastering, and concrete production. However, the preparation and testing of mortar samples can be a time-consuming and labor-intensive process that requires significant expertise and resources.

[0003] Traditionally, the preparation and testing of mortar samples involve manual mixing, casting, and curing of the samples, followed by visual inspection and physical testing to determine their quality and properties. This manual process is not only time-consuming but also prone to human error, inconsistencies, and variability. Moreover, traditional methods often rely on subjective visual inspections, which can be unreliable and may not detect subtle defects or irregularities in the mortar samples. As a result, traditional methods can lead to inconsistent and unreliable test results, which can compromise the quality and safety of construction projects.

[0004] US3799714A discloses a portable device for applying mortar to desired portions of successive courses of block, brick, or any flat surface to improve the construction of masonry walls. The device includes a hopper, vibrator, and a base assembly having side guides for drawing the applicator along a course of block and dispensing mortar for laying the next course.

[0005] WO2002006182A1 discloses a mortar composition which comprises 100 parts by weight of cement; 1-80 parts by weight of untreated rice husks; 30-200 parts by weight of one or more fillers and additives; and 0.2-10 parts by weight of an accelerator. The invention also provides a settable mortar composition and methods for making the mortar compositions of the invention.

[0006] Conventionally, there exist many devices that are capable of preparing and testing mortar, however these existing devices are incapable of reducing manual effort, time consumption and cost while preparing mortar. In addition, these existing devices also fail in providing real time alert and notification, which leads to damage and accidents.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to be capable of manufacturing and testing mortar in lesser time as compared to other devices, which helps in reducing time consumption, labor cost and manual effort. Furthermore, the developed device also needs to be potent enough of alerting the user in real time to avoid any damage and accidents.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that is capable of providing am automated and efficient solution for preparing and testing construction materials by preparing and testing process, saving time and effort, reducing manual errors, and improving the accuracy and reliability of the test results.

[0010] Another object of the present invention is to develop a device that is capable of enabling the user to detect defects and determine the quality of the construction materials by capturing images and detecting defects, such as irregularities in texture or composition, thereby enabling the user to identify potential issues and take corrective action to improve the quality of the materials.

[0011] Yet another object of the present invention is to develop a device that is capable of providing real-time feedback and alerts to the user to any defects or issues detected during the testing process to allow the user to make informed decisions about the quality of the materials and take corrective action to improve their quality.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a mortar sample preparation and testing device that is capable of optimizing preparation and testing of construction materials, boosting efficiency, accuracy, and reliability while saving time and effort. Additionally, the proposed device is also capable of allowing users to identify defects, assess material quality, and receive instant feedback and alerts, ultimately enabling the production of high-quality construction materials with ease.

[0014] According to an embodiment of the present invention, a mortar sample preparation and testing device, comprising a cuboidal housing features four perpendicularly installed telescopic rods with motorized omnidirectional wheels at the ends, attached underneath the housing, facilitating locomotion, multiple chambers disposed in the housing store raw materials, including marble powder, marble chips, cement, sand, and water, a cylindrical mixing box disposed within the housing receives raw materials from the chambers via connecting pipes configured with first flow control valves, blending the ingredients into a mortar, a motorized four-paddle blade mounted within the box ensures thorough mixing, an artificial intelligence-based imaging unit installed in the housing captures images in the vicinity of the housing in synchronization with a temperature sensor embedded in the box, detecting clump formation during mixing to allow a microcontroller to actuate a heating element embedded in the box to heat the chamber, reducing the material's viscosity for uniform mixing if the detected temperature is below a threshold, multiple hollow cuboidal stencils located underneath the box receive the mortar via tubes configured with second flow control valves, imparting a cuboidal shape to the mortar and creating a cuboidal sample and the stencils' lateral walls are attached to the base of the stencil by means of hinges, enabling easy removal of the sample.

[0015] According to another embodiment of the present invention, the proposed device further comprises of a water tank incorporated within the housing features an articulated nozzle connected with the tank to spray water onto the sample when an ultrasonic sensor embedded in the housing detects the sample to be solidified, determining the sample's porosity based on water absorbed detected by weight sensors embedded in the stencils, an articulated L-shaped arm disposed within the housing features a pneumatic pusher at the end to impact onto the samples with varying forces, detecting defects via the imaging unit and recording the force at which damage occurs in a database linked with the microcontroller, a vibration unit installed in the box removes dissolved air from the material when the imaging unit detects bubble formation during mixing, a weight sensor embedded in the chamber detects the weight of the raw material, triggering the microcontroller to actuate the wireless communication unit to push an alert to the computing unit regarding refilling the chamber, a holographic projection unit installed in the housing projects an image onto the defective region of the sample, providing a reference for the user.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a mortar sample preparation and testing device.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to a mortar sample preparation and testing device that is capable of automating and streamlining preparation and testing of construction materials, enhancing efficiency, accuracy, and reliability while enabling real-time defect detection and quality assessment.

[0022] Referring to Figure 1, an isometric view of a mortar sample preparation and testing device is illustrated, comprising a cuboidal housing 101 having four perpendicularly installed telescopic rods 102 with motorized omnidirectional wheels 103, plurality of chambers 104 disposed in the housing 101, a cylindrical mixing box 105 disposed within the housing 101 by means of connecting pipes 106 configured with first flow control valves 107, a motorized four-paddle blade 108 mounted within the box 105, an artificial intelligence-based imaging unit 109, installed in the housing 101, plurality of hollow cuboidal stencil 110, located underneath the box 105, lateral walls of the stencil 110 are attached to a base of the stencil 110 by means of hinges 111, a water tank 112 incorporated within the housing 101 having an articulated nozzle 113, an articulated L-shaped arm 114 disposed within the housing 101 and having a pneumatic pusher 115 and a holographic projection unit 116 installed in the housing 101.

[0023] The device disclosed herein, comprises of a cuboidal housing 101, which serves as a main structure of the device and developed to be placed over a ground surface. To ensure stability of the housing 101, multiple telescopic rods 102 are installed beneath the housing 101. The rods 102 get extend and retract the housing 101 at optimal height as per requirement. The telescopic rods 102 as mentioned herein are powered by a pneumatic unit that utilizes compressed air to extend and retract the rods 102. The process begins with an air compressor which compresses atmospheric air to a higher pressure.

[0024] The air cylinder of the pneumatic unit contains a piston that moves back and forth within the cylinder. The cylinder is connected to one end of the telescopic rods 102. The piston is attached to the telescopically operated rods 102 and its movement is controlled by the flow of compressed air. To extend the telescopic rods 102 the piston activates the air valve to allow compressed air to flow into the chamber behind the piston. As the pressure increases in the chamber, the piston pushes the telescopic rods 102 to the desired length.

[0025] The housing 101 comprising multiple chambers 104 inside it to store multiple raw materials such as marble powder, marble chips, cement, sand and water, wherein a cylindrical mixing box 105 stored underneath the chambers 104 via connecting pipes 106. The pipes 106 attached with the chambers 104 through first flow control valves 107 for dispensing the raw materials in the chambers 104.

[0026] The process begins where a user provides input commands regarding activation of the device over a computing unit, which is wirelessly associated with the device and linked with a microcontroller of the device. The microcontroller linked with the computing of via a communication module, which includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module.

[0027] After receiving the commands, the microcontroller processes these commands and actuates the first flow control valves 107 to dispense raw materials into the box 105 via connecting pipes 106. The first flow control valves 107 works by utilizing electrical energy to automize the flow solution in a controlled flow pattern by converting the pressure energy of a fluid into kinetic energy, which increases the fluid's velocity. Upon actuation of first flow control valves 107 by the microcontroller, the electric motor or the pump pressurizes the incoming materials, increasing its pressure significantly. High pressure enables the materials to be dispensed out with a high force in the box 105.

[0028] As the materials, get dispensed into the box 105, the microcontroller actuates a motorized four-paddle blade 108, which is arranged inside the box 105 to blend the materials for forming mortar. The motorized four-paddle blade 108 is a type of mixing mechanism used in various blending applications, the motorized four-paddle blade 108 consists of a motorized shaft with four paddles attached to it, which rotate in a circular motion to blend materials. When the motor is activated, the shaft rotates, causing the paddles to move in a circular motion.

[0029] As the paddles rotate, it creates a vortex that draws materials towards the center of the box 105. The paddles then interact with the materials being blended, breaking down any lumps or agglomerates and distributing the components evenly. The rotating paddles create a combination of cutting, folding, and mixing actions that blend the materials together. The four-paddle blade’s 108 shape and angle of attack help to optimize the blending process. As the blending process continues, the materials become increasingly homogenized, ensuring a uniform distribution of components throughout the mixture. The motorized four-paddle blade 108 is designed to efficiently blend and homogenize materials, reducing mixing time and increasing productivity.

[0030] During mixing process, the microcontroller with the help of an artificial intelligence-based imaging unit 109 installed inside the housing 101 keep capturing multiple high-resolution images in proximity of the housing 101. The artificial intelligence based imaging unit 109 is constructed with a camera lens and a processor, wherein the camera lens is adapted to capture a series of images of the surrounding present in proximity to the housing 101.

[0031] The processor carries out a sequence of image processing operations including pre-processing, feature extraction, and classification. The image captured by the imaging unit 109 is real-time images of the housing’s 101 surrounding and utilize artificial intelligence and machine learning protocols. The artificial intelligence based imaging unit 109 transmits the captured image signal in the form of digital bits to the microcontroller.

[0032] Synchronously, the microcontroller actuates a temperature sensor installed in the box 105 for monitoring a clump formation. The temperature sensor converts temperature into an electrical signal. The temperature sensor consists of a temperature-sensing element, such as a thermistor, thermocouple, or resistance temperature detector (RTD), which is connected to an electronic circuit. When the temperature sensor is exposed to a temperature change, heat is transferred from the surrounding environment to the sensor's temperature-sensing element.

[0033] The temperature-sensing element changes its electrical properties in response to the temperature change. For example, a thermistor's resistance decreases as the temperature increases. The change in the temperature-sensing element's electrical properties is converted into an electrical signal by the sensor's electronic circuit. This signal is typically a voltage or current that is proportional to the temperature. The electrical signal is then amplified and conditioned by the sensor's electronic circuit to improve its accuracy and stability.

[0034] The final output signal is transmitted to the microcontroller, where it used to monitor temperature changes and detect clump formation. When monitoring clump formation, the temperature sensor is typically used to detect temperature changes that occur when clumps form. When clumps form, it creates a temperature gradient within the box 105. The temperature sensor detects this temperature gradient and sends an electrical signal to the electronic circuit. The electronic circuit analyzes the electrical signal and detects any changes in temperature that may indicate clump formation. If clump formation is detected, the microcontroller actuates a heating element installed with the box 105 to heat the chambers 104 to reduce a viscosity of the material to enable uniform mixing.

[0035] The heating element used herein is preferably a copper coil that generates heat when an electric current passes through the coil. When an electric current runs through a copper wire the electrons come across the resistive forces of the medium’s material, releasing energy that is expended in the form of heat energy. The copper coil is properly insulated to prevent any heat loss and also direct the generated heat toward the chambers 104. The heating element begins to generate heat and as the heating element warms up, it heats the chambers 104, which results in reducing a viscosity of the material to allow uniform mixing.

[0036] Multiple hollow cuboidal stencil 110 arranged beneath the box 105 to receive the mortar with the help of a tubes installed with second flow control valves to prepare a cuboidal sample by imparting the mortar with cuboidal shape of the stencil 110, wherein lateral walls of the stencil 110 are assembled with a base of the stencil 110 via hinges 111 to allow the user to access the sample from the stencil 110 as per requirement.

[0037] A water tank 112 installed inside the housing 101, which is responsible for storing and dispensing water onto the sample. The tank 112 connected to an articulated nozzle 113 that sprays water onto the sample. The water tank 112 consists of several internal components, including a water reservoir, a water pump, a valve arrangement, and an articulated nozzle 113. The water reservoir is the main compartment of the tank 112 that stores water. The reservoir is typically made of a food-grade material, such as stainless steel or polypropylene. The water pump is responsible for pressurizing the water in the reservoir and supplying it to the articulated nozzle 113. The pump is typically a small, electrically-driven pump that is designed for low-flow applications. The valve arrangement controls the flow of water from the reservoir to the articulated nozzle 113. The valve arrangement typically consists of a solenoid valve or a pneumatic valve that is controlled by the device's microcontroller.

[0038] The articulated nozzle 113 is a movable nozzle 113 that sprays water onto the sample. The nozzle 113 is typically made of a stainless steel or polypropylene material and is designed to withstand the water pressure and flow rate. When microcontroller detects that the sample is solidified via an ultrasonic sensor, it activates the water pump to pressurize the water in the reservoir. The valve arrangement then opens, allowing the pressurized water to flow through the articulated nozzle 113. The articulated nozzle 113 sprays water onto the sample, which is then absorbed by the sample. A weight sensors embedded in the stencils 110 measure the weight of the sample before and after water absorption. The microcontroller calculates the porosity of the sample based on the weight measurements and the amount of water absorbed. The water tank 112 plays a crucial role in determining the porosity of the sample by providing a controlled amount of water for absorption. The articulated nozzle 113 ensures that the water is sprayed evenly onto the sample, while the weight sensors provide accurate measurements of the sample's weight before and after water absorption.

[0039] An articulated L-shaped arm 114 is a mechanical component disposed within the housing 101. The arm 114 is designed to be movable and flexible, allowing it to impact onto the samples with varying forces. The arm 114 is shaped like an "L", with one end attached to the housing 101 and the other end featuring a pneumatic pusher 115. The pneumatic pusher 115 uses compressed air to generate a force that is applied to the samples. The articulated L-shaped arm 114 is designed to work in conjunction with the imaging unit 109 to detect defects in the samples. The arm 114 apply varying forces to the samples, and the imaging unit 109 captures images of the samples before and after the force is applied. By analyzing the images, the microcontroller detects any defects or damage caused by the applied force. The force at which damage is detected is recorded in a database linked with the microcontroller.

[0040] A weight sensor installed in the chambers 104 for monitoring weight of the raw material in the chambers 104 to allow the microcontroller to actuate generate a notification over the computing unit in order to alert the user about refilling the chambers 104. The weight sensor is typically a load cell or strain gauge sensor. The materials exert a downward force to the weight sensor due to their weight. The weight sensor detects this force and converts it into an electrical signal, typically in the form of voltage variations. The raw electrical signal is weak and noisy. Therefore, it goes through signal conditioning circuitry to amplify, stabilize, and filter the signal. This conditioned signal is then sent to the microcontroller and the microcontroller continuously monitors the weight of the raw materials.

[0041] A holographic projection unit 116 embedded in the housing 101 to project an image onto a region of the sample having defect for a reference of user. On actuation of holographic projection unit 116 by the microcontroller, the light source emits various combination of lights towards the lens which is further portrayed onto a region of the sample with defects to project the virtual images for the reference of the user.

[0042] The present invention works best in following manner, where the cuboidal housing 101 as disclosed in the invention is developed to be positioned over a ground surface and the process begins by storing raw materials, including marble powder, marble chips, cement, sand, and water, in multiple chambers 104 disposed within the cuboidal housing 101. The motorized omnidirectional wheels 103 attached to the telescopic rods 102 facilitate the locomotion of the housing 101. When the raw materials are loaded, the weight sensor embedded in the chambers 104 detects the weight of the raw material and sends a signal to the microcontroller. The microcontroller then actuates the connecting pipes 106 configured with first flow control valves 107 to supply the raw materials to the cylindrical mixing box 105. The motorized four-paddle blade 108 mounted within the box 105 mixes the raw materials into a mortar. During the mixing process, the artificial intelligence-based imaging unit 109 captures images of the mixture and sends them to the microcontroller. The microcontroller analyzes the images and detects any clump formation or bubble formation during mixing. If clump formation is detected, the microcontroller actuates the heating element embedded in the box 105 to heat the chambers 104, reducing the material's viscosity for uniform mixing. If bubble formation is detected, the microcontroller actuates the vibration unit installed in the box 105 to remove dissolved air from the material. Once the mixture is uniform and free of clumps and bubbles, the microcontroller actuates the tubes configured with second flow control valves to supply the mortar to the hollow cuboidal stencils 110. The stencils 110 impart a cuboidal shape to the mortar, creating a cuboidal sample. The lateral walls of the stencils 110 are attached to the base of the stencil 110 by means of hinges 111, enabling easy removal of the sample. Once the sample is solidified, the ultrasonic sensor embedded in the housing 101 detects the solidification and sends a signal to the microcontroller. The microcontroller then actuates the water tank 112 to spray water onto the sample through the articulated nozzle 113. The weight sensors embedded in the stencils 110 detect the weight of the water absorbed by the sample, and the microcontroller calculates the porosity of the sample based on the weight measurements. The articulated L-shaped arm 114 disposed within the housing 101 then impacts onto the sample with varying forces to detect any defects. The imaging unit 109 captures images of the sample during the impact test, and the microcontroller analyzes the images to detect any defects. The force at which damage occurs is recorded in a database linked with the microcontroller. Finally, the holographic projection unit 116 projects an image onto the defective region of the sample, providing a reference for the user. The user can then analyze the sample and take corrective action to improve the quality of the sample.

[0043] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A mortar sample preparation and testing device, comprising:

i) a cuboidal housing 101 having four perpendicularly installed telescopic rods 102 with motorized omnidirectional wheels 103 at the ends, attached underneath said housing 101, for a locomotion of said housing 101;
ii) a plurality of chambers 104 disposed in said housing 101 for storing raw material including marble powder, marble chips, cement, sand, water;
iii) a cylindrical mixing box 105 disposed within said housing 101 for receiving said raw material from said chambers 104 by means of connecting pipes 106 configured with first flow control valves 107, to mix said raw material in said box 105 to create a mortar;
iv) a motorized four-paddle blade 108 mounted within said box 105 for missing said raw material in said box 105;
v) an artificial intelligence-based imaging unit 109, installed in said housing 101 and integrated with a processor for recording and processing images in a vicinity of said housing 101, in synchronisation with a temperature sensor embedded in said box 105, to detect a clump formation during mixing to trigger a microcontroller to actuate a heating element embedded in said box 105 to heat said chambers 104 to reduce a viscosity of said material to enable uniform mixing, if said detected temperature is below a threshold temperature;
vi) a plurality of hollow cuboidal stencil 110, located underneath said box 105 for receiving said mortar via a tube configured with second flow control valves, to impart said mortar with cuboidal shape of said stencil 110 to prepare a cuboidal sample, wherein lateral walls of said stencil 110 are attached to a base of said stencil 110 by means of hinges 111 to enable a removal of said sample from said stencil 110;
vii) a water tank 112 incorporated within said housing 101 having an articulated nozzle 113 connected with said tank 112 to spray water onto said sample when an ultrasonic sensor embedded in said housing 101 detects said sample to be solidified, to determine porosity of said sample as per water absorbed detected by weight sensors embedded in said stencils 110; and
viii) an articulated L-shaped arm 114 disposed within said housing 101 and having a pneumatic pusher 115 at an end to impact onto said samples with varying forces to detect defects caused by means of said imaging unit 109, to record said force at which damage is detected, in a database linked with said microcontroller.

2) The device as claimed in claim 1, wherein a vibration unit installed in said box 105 is actuated to vibrate said material to remove dissolved air when said imaging unit 109 detects bubbles being formed during mixture.

3) The device as claimed in claim 1, wherein a weight sensor embedded in said chambers 104 detects a weight of said raw material in said chambers 104 to trigger said microcontroller to actuate said wireless communication unit to push an alert to said computing unit regarding refilling said chambers 104.

4) The device as claimed in claim 1, wherein a holographic projection unit 116 installed in said housing 101 projects an image onto a region of said sample having defect for a reference of user.