Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated bolt joint inspection and maintenance device that is capable of streamlining the process of bolt joint maintenance by automating the inspection process to detect and assess potential faults, performing automated tightening or loosening of bolts as needed, thereby enables early detection and prevention of potential hazards, saves time and labor.

BACKGROUND OF THE INVENTION

[0002] Bolt joint maintenance is a critical aspect of ensuring the structural integrity and safety of various infrastructure, including bridges, buildings, and industrial equipment. Bolt joints are subject to wear and tear, corrosion, and other forms of degradation, which can lead to catastrophic failures if left undetected or unaddressed. With the increasing complexity and scale of modern infrastructure, the need for efficient and effective bolt joint maintenance has become more pressing than ever.

[0003] Traditionally, bolt joint maintenance has relied on manual inspection and maintenance techniques. These methods typically involve visual examinations, manual tightening or loosening of bolts, and subjective assessments by experienced technicians. Additionally, traditional methods often rely on scheduled maintenance intervals, which may not account for unexpected wear and tear or sudden changes in environmental conditions.

[0004] CN203769324U discloses the utility model discloses a simple maintenance device for a bolt and a nut of a fastener, relates to the technical field of building engineering construction, and mainly aims at the technical management field of maintenance for the bolt and the nut of the building fastener. The simple maintenance device comprises a machine frame. A transverse transmission shaft is supported on the machine frame through a deep groove ball bearing and a bearing pedestal, one end of the transmission shaft is connected with a first belt wheel, a transverse three-phase asynchronous motor is arranged below the transmission shaft, an output shaft of the three-phase asynchronous motor is connected with a second belt wheel, the second belt wheel and the first belt wheel are in transmission connection through a belt, the end, away from the first belt wheel, of the transmission shaft is fixedly connected with a sleeve, a rocker arm is hinged to the machine frame, and a bolt fixing frame is fixedly connected with the middle of the rocker arm. The simple maintenance device is convenient to operate and high in efficiency.

[0005] US7513514B1 discloses a present invention includes a ball joint assembly having a first stud extending upward from a ball joint housing and a second stud extending from the ball joint housing opposite the first stud. The ball joint assembly is adapted to adjustably connect with a control arm through a slotted connection. The rotational position of the second stud of the ball joint assembly relative to the control arm as well as the linear position of the first stud of the ball joint assembly within the slot can be adjusted to affect the camber and/or caster angles for wheel alignment on motor vehicles.

[0006] Conventionally, there exists many devices that are capable of maintaining bolt joint, however these existing devices fail in providing detailed reports and real-time visual assistance for maintenance operations due to which not only unskilled but the skilled operators also face difficulties in proper execution of maintenance operation, which at last results in reduced shelf life.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of enhancing transparency and accountability so that the user can understand the condition of bolt joints and the accordingly perform the maintenance work.

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 enabling early detection and prevention of potential hazards by detecting and assessing the health of bolt joints in a specified area to identify potential faults or damage in bolt joints, which leads to structural failures or accidents, thereby ensuring safety and reducing the risk of costly repairs.

[0010] Another object of the present invention is to develop a device that is capable of maintaining the structural integrity and stability of bolt joints, which is crucial for the overall health of infrastructure by performing tightening or loosening of bolts as needed for saving time and labor and reducing the risk of human error, thereby ensures consistent and precise maintenance.

[0011] Yet another object of the present invention is to develop a device that is capable of providing detailed reports and real-time visual assistance for maintenance operations to give users a clear understanding of the condition of bolt joints and the maintenance work performed, thereby enables data-driven decision-making, enhances transparency and accountability, and facilitates more efficient maintenance planning and scheduling.

[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 an automated bolt joint inspection and maintenance device that is capable of simplifying the process of bolt joint inspection and maintenance by inspecting and assessing potential faults, auto-adjusting bolts as needed, and providing instant reports and analysis, which leads to swift hazard detection and prevention, time and labor savings, and informed decision-making.

[0014] According to an embodiment of the present invention, an automated bolt joint inspection and maintenance device, comprising a cuboidal body is designed to be positioned near metallic infrastructure, configured with multiple motorized wheels for maneuverability, and accepts user-input inspection area details via a user-interface integrated into a computing unit, upon receiving user commands, a microcontroller linked to the computing unit activates an artificial intelligence-based imaging unit installed on the body, which detects bolt joints within the user-specified area and assesses their health using piezoelectric lead zirconate titanate (PZT) modules, an articulated arm mounted on the body's side wall is integrated with a bolt tightening unit as an end effector, allowing the microcontroller to extend or shorten the arm for precise bolt tightening or loosening, the bolt tightening unit features an adjustable socket and electromagnet, enabling automatic selection and secure attachment of various bolt head sizes based on detected bolt dimensions, a dedicated storage chamber houses multiple bolt heads of different sizes, and the bolt tightening unit automatically selects and retrieves the appropriate bolt head size based on the detected bolt size, as measured by an ultrasonic sensor synced with the imaging unit.

[0015] According to another embodiment of the present invention, the proposed device further comprises of a crack detection sensor installed on the body and synced with the imaging unit detects internal cracks, voids, or material property changes in the bolt joint, the microcontroller generates detailed reports on the computing unit, accessed by authorized users, identifying specific faults or material changes in the bolt joint for analysis and future reference, a holographic projecting unit on the body's upper section projects holographic images in the working area, providing real-time visual assistance to authorized users during bolt joint maintenance operations, a motorized ball-and-socket joint integrated between the body and extendable link enables multi-axis rotational movement of the link, ensuring flexibility and precision in bolt joint maintenance.

[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 an automated bolt joint inspection and maintenance 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 an automated bolt joint inspection and maintenance device that is capable of streamlining the process of bolt joint maintenance by automating inspection, auto-tightening/loosening bolts, and delivering real-time insights, thereby enables proactive hazard prevention, reduced labor hours, and data-driven decisions.

[0022] Referring to Figure 1, an isometric view of an automated bolt joint inspection and maintenance device is illustrated, comprising a cuboidal body 101 configured with multiple motorized wheels 102, an artificial intelligence-based imaging unit 103 installed on the body 101, an extendable link 104 is attached to the body 101, and the link 104 is bifurcated into two parts, each fabricated with a piezoelectric lead zirconate titanate (PZT) module 105, an articulated arm 106 mounted on side wall of the body 101, integrated with a bolt tightening unit 107 as an end effector, a dedicated storage chamber 108 installed on the housing, a holographic projecting unit 109 is mounted on upper section of the body 101, the tightening unit is integrated with an electromagnet 110.

[0023] The device disclosed herein comprises of a cuboidal body 101 developed to be positioned in proximity to a metallic infrastructure. The body 101 is constructed from a combination of materials that provide structural integrity while minimizing weight, allowing the device to operate for extended periods without excessive power consumption. Multiple motorized wheels 102 are strategically positioned beneath said body 101 to offer enhanced mobility and stability.

[0024] The wheels 102 enable the body 101 to traverse different ground surfaces with precision, providing a stable platform for carrying out inspections and maintenance tasks. The motorized wheels 102 are designed to adjust speed and direction autonomously or via user input, ensuring that the body 101 efficiently reach designated inspection areas regardless of the complexity of the environment. Whether the body 101 is moving over flat floors or navigating uneven terrain, the wheels 102 maintain stability and avoid obstacles, facilitating smooth operation in challenging environments.

[0025] The wheels 102 herein are a circular object that revolves on an axle to enable the body 101 to move easily over the ground surface. The hub motor is an electric motor that is integrated into the hub of the wheels 102. The hub motor is comprises of a series of permanent magnets and electromagnet 110ic coils. When the motor is activated, a magnetic field is set up in the coil and when the magnetic field of the coil interacts with the magnetic field of the permanent magnets, a magnetic torque is generated causing the stator of the motor to turn and that provides the rotation motion to the wheels 102 for maneuvering the body 101.

[0026] The user through a user-interface inbuilt in a computing unit associated with the device provide input details regarding designated inspection areas. The computing unit is linked wirelessly with the microcontroller via a communication module which includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module. The user interface serves as a bridge between the user and the microcontroller, allowing for a user-friendly way to input commands regarding designated inspection areas along which the user desires to perform monitoring and inspection of the metallic infrastructure.

[0027] The user interface presents information and options to the user through options or other visual images, where the user interacts by typing commands or selecting options from the user-interface. Upon receiving user’s commands, the microcontroller activates an artificial intelligence-based imaging unit 103 installed on the body 101 and paired with a processor to detect bolt joints present within the user-specified area.

[0028] The imaging unit 103 is equipped with advanced vision module which is capable of detecting bolt joints within the user-specified area. The imaging unit 103 uses high-resolution cameras and modules powered by artificial intelligence to identify bolted connections, assessing both visual integrity and position. The imaging unit 103 is paired with a dedicated processor that analyzes the captured data in real time, ensuring quick detection of any potential issues with the joints. The cameras are paired with artificial intelligence modules that process the visual data in real time. The imaging unit 103 is trained to detect bolt joints by recognizing patterns, shapes, and specific features associated with bolted connections.

[0029] Upon receiving the user’s commands, the microcontroller activates the imaging unit 103, directing it to scan the specified area. The imaging unit 103 autonomously identifies and locates bolt joints, even in complex environments or hard-to-reach locations. The imaging unit 103 works in conjunction with an extendable link 104, which is attached to the main body 101. The extendable link 104 provides the necessary flexibility for body 101 to reach bolted joints in hard-to-access areas, making the inspection process more thorough.

[0030] The link 104 mentioned above basically consist of multiple cylindrical sections with one section sliding inside the other. The sections are basically made of materials that may include but are not limited to metals and lightweight alloys. The link 104 as mentioned herein are powered by a pneumatic unit that utilizes compressed air to extend and retract the link 104. 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 link 104. The piston is attached to the link 104 and its movement is controlled by the flow of compressed air.

[0031] To extend the link 104 the piston activates the air valve to allow compressed air to flow into the chamber 108 behind the piston. As the pressure increases in the chamber 108, the piston pushes the link 104 to the desired length. By controlling the flow of compressed air and the position of the piston, the link 104 length is adjusted. The link 104 is bifurcated into two distinct parts, each equipped with a piezoelectric lead zirconate titanate (PZT) module 105, a material known for its ability to convert mechanical stress into electrical signals. The PZT modules 105 are critical to the device's ability to assess the structural health of the bolt joints. By applying mechanical pressure or vibrations to the bolted connections, the PZT modules 105 detect any changes in the joint’s structural integrity.

[0032] These patches are strategically bonded to two sides of a bolted joint, connected through an electromagnet 110ic unit that facilitates the monitoring and detection of faults. The first PZT patch functions as an actuator, while the second serves as a sensor, providing crucial feedback for real-time structural analysis.

[0033] The actuator PZT patch is activated by an alternating electrical signal, which excites the material to vibrate within a specific frequency range. This vibration propagates through the bolted joint, and the waves' behavior is affected by the structural integrity of the connection. Healthy, secure bolts allow the vibrations to travel uniformly, while issues such as looseness or improper fit disrupt this pattern. The sensor PZT patch detects these fluctuations in the vibration patterns, which indicate potential faults, such as a loose bolt or an unstable connection.

[0034] The piezoelectric module 105 generate electrical signals in response to the vibrations or stress imparted onto the bolt joint. These signals are then analyzed by the microcontroller, which interprets to identify any faults or inconsistencies in the joint. For instance, any damage, looseness, or cracks in the bolt or surrounding structure will produce a distinct signal pattern, allowing the microcontroller to detect potential failures before they become critical. This level of diagnostic capability ensures the microcontroller identify early signs of wear, corrosion, or structural compromise that may not be immediately visible to the human eye.

[0035] Furthermore, motorized hinge joints are provided between the two links, which plays a pivotal role in facilitating precise patch movement on the bolt joint. This allows for dynamic adjustments and better contact with the bolted surface, improving the functionality and accuracy of the monitoring process. Through this combination of PZT technology, electromagnet 110ic monitoring, AI-guided imaging, and dynamic patching, the microcontroller ensures an in-depth and accurate analysis of the bolted joint’s health, providing real-time diagnostic feedback for maintenance and repair decision.

[0036] For precise and accurate placement of the link 104 over the bolt joint, a motorized ball-and-socket joint is integrated between the body 101 and extendable link 104 that is dynamically regulated by the microcontroller to provide multi-axis rotational movement to the link 104. The ball-and-socket joint provides a flexible, 360-degree range of motion, allowing the extendable link 104 to rotate in multiple directions. This movement capability is essential for positioning the PZT patches accurately on either side of a bolted joint, ensuring optimal contact and precise monitoring.

[0037] By adjusting the orientation of the extendable link 104 in real-time, the motorized ball-and-socket joint enables the device to adapt to varying geometries and orientations of the bolt joints within the user-specified inspection zone. The device is further equipped with an articulated arm 106 mounted on the side wall of the body 101, providing an essential function for bolt maintenance tasks. The articulated arm 106 is integrated with a bolt tightening unit 107 as its end effector, designed to both tighten and loosen bolts efficiently during the inspection and maintenance process.

[0038] The articulated arm 106 offers significant flexibility, allowing it to extend and shorten based on specific operational requirements. The extension and retraction of the arm 106 are precisely controlled by the microcontroller. When a bolt joint requires tightening or loosening, the microcontroller activates the arm 106’s movement, adjusting its position to ensure the bolt tightening unit 107 is accurately aligned with the targeted bolt. This ensures the process is performed with high precision and minimal effort.

[0039] The bolt tightening unit 107 at the end of the articulated arm 106 is designed to accommodate a wide range of bolt sizes and types. Whether the task is tightening a loose bolt or loosening a stubborn one, the unit adapts to the required torque and force specifications, ensuring effective maintenance without the risk of damaging the bolt or surrounding structure. The bolt tightening unit 107 it not only conducts inspections but also handles critical maintenance tasks, automating processes that would traditionally require manual labor.

[0040] The combination of the microcontroller’s control over the arm 106’s movement and the versatility of the bolt tightening unit 107 significantly improves the efficiency, speed, and accuracy of bolt joint maintenance. The bolt tightening unit 107 is equipped with an adjustable socket, which is integrated with an electromagnet 110 for the automatic selection and secure attachment of various bolt head sizes. The socket is designed to adapt seamlessly to bolts of different dimensions by detecting the size of the bolt to be operated on.

[0041] The electromagnet 110’s role is to securely hold and attach the appropriate socket to the bolt head, ensuring that the correct tool is selected based on the detected bolt size. This eliminates the need for manual adjustments, increasing efficiency and precision when tightening or loosening bolts. To complement this, the body 101 features a dedicated storage chamber 108 that houses a variety of socket sizes, ensuring that the chamber 108 accommodate bolts of all types and sizes without requiring human intervention.

[0042] The microcontroller works in coordination with the ultrasonic sensor, which is mounted on the body 101 of the device and synced with the imaging unit 103. The ultrasonic sensor scans the bolt dimensions in real time, providing accurate data about the size of the bolt head. This information is then used to automatically select and retrieve the correct socket size from the storage chamber 108.

[0043] The ultrasonic sensor works by emitting high-frequency sound waves and measuring the time it takes for the waves to bounce back from the bolt’s surface. Based on this data, the sensor precisely detect the dimensions of the bolt, including its diameter and head type. Once the size is detected, the microcontroller activates the electromagnet 110 to select and retrieve the matching socket from the storage chamber 108, ensuring that the bolt head is securely attached and ready for tightening or loosening.

[0044] This fully automated process not only streamlines maintenance tasks but also ensures that the correct tools are always used for each specific bolt, improving both efficiency and accuracy during maintenance operations. A crack detection sensor is mounted on the body 101, and integrated with the imaging unit 103, forming a comprehensive device for detecting internal structural issues in bolt joints. The ultrasonic sensor is specifically designed to identify internal cracks, voids, or changes in the material properties of the bolted connection, which are critical indicators of potential failure or degradation that may not be visible on the surface.

[0045] The ultrasonic crack detection sensor works by emitting high-frequency sound waves into the material of the bolt joint. These sound waves travel through the material and are reflected back when they encounter changes in material properties, such as cracks or voids. The sensor analyzes the time it takes for the waves to return, as well as the intensity and pattern of the echoes, to detect any internal flaws. Cracks or material inconsistencies disrupt the sound wave's path, allowing the sensor to identify potential issues. This data is processed by the microcontroller, and results are generated for further analysis and maintenance decision.

[0046] The microcontroller coordinates the operation of the crack detection sensor and ensures the data is synced with the imaging unit 103 for a comprehensive assessment of the bolt joint's condition, wherein a GPS is inbuilt in the microcontroller, which stores the location as well as details of the crack. Once the microcontroller has collected all relevant data on the internal and external conditions of the joint, the microcontroller compiles the findings into a detailed report. This report is generated on a computing unit, which is accessed by an authorized user. The report includes specific information about any faults, including the location and severity of cracks, voids, or changes in material properties. The report also highlight any shifts in structural integrity that requires immediate attention or future monitoring.

[0047] On the upper outer surface of the body 101, a holographic projecting unit 109 is mounted configured to project holographic images in a working area where maintenance work is being carried out, providing real-time visual assistance to the authorized user during bolt joint maintenance operations. The holographic projecting unit 109 is configured to project three-dimensional holographic images into the working area where maintenance is being carried out, offering real-time visual assistance to the authorized user.

[0048] When the device encounters a maintenance task beyond its capabilities, it automatically triggers a notification to dispatch a nearby operator for assistance. Upon the operator's arrival, the holographic projection unit, providing real-time, step-by-step visual guidance to facilitate the maintenance work, ensuring a seamless and efficient repair process.

[0049] The holograms display detailed, interactive schematics, diagrams, or visual guides that align with the specific bolt joint being worked on, providing step-by-step instructions, torque specifications, or even highlighting the exact locations of bolts that require attention. By projecting these holographic images directly into the workspace, the device allows the user to visually overlay important information onto the physical environment.

[0050] In the device discussed above, there is a battery associated with the device that supplies current to all the components that need electric power to perform their functions and operation in an efficient manner. The battery utilized here is generally a dry battery which is made up of Lithium-ion material that gives the device a long-lasting as well as an efficient DC (Direct Current) current which helps every component to function properly in an efficient manner. The device is battery-operated and does not need any electrical voltage to function. Hence the presence of the battery leads to the portability of the device i.e., the user is able to place as well as move the device from one place to another as per the requirements.

[0051] The present invention works best in the following manner, where the cuboidal body 101 positioned in proximity to the metallic infrastructure and the process begins where the user inputs details regarding designated inspection areas using a user-interface integrated into a computing unit associated with the device. The microcontroller linked to the computing unit receives the user's commands and activates an artificial intelligence-based imaging unit 103 installed on the body 101. The imaging unit 103 detects bolt joints present within the user-specified area. The extendable link 104, bifurcated into two parts with PZT module 105s, detects the health of the bolt joint by assessing structural integrity and faults. Based on the assessment, the microcontroller enables extension or shortening of the articulated arm 106, which is integrated with a bolt tightening unit 107. The bolt tightening unit 107 automatically selects and attaches the appropriate bolt head size for tightening or loosening. The crack detection sensor installed on the body 101 detects internal cracks, voids, or material property changes in the bolt joint. The microcontroller generates a detailed report on the computing unit, accessed by an authorized user, identifying specific faults or material changes present in the bolt joint. Additionally, the holographic projecting unit 109 provides real-time visual assistance to the authorized user during bolt joint maintenance operations. The motorized ball-and-socket joint provides multi-axis rotational movement to the extendable link 104, ensuring flexibility and precision in bolt joint maintenance. This flow of working enables the automated bolt joint inspection and maintenance device to efficiently and effectively inspect and maintain bolt joints, ensuring the structural integrity and safety of infrastructure.

[0052] 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) An automated bolt joint inspection and maintenance device, comprising:

i) a cuboidal body 101 developed to be positioned in proximity to a metallic infrastructure, configured with multiple motorized wheels 102 to maneuver said body 101 over a ground surface, wherein a user via a user-interface inbuilt in a computing unit inputs details regarding designated inspection areas;
ii) a microcontroller linked with said computing unit upon receiving said user’s commands activates an artificial intelligence-based imaging unit 103 installed on said body 101 and paired with a processor to detect bolt joints present within said user-specified area, wherein an extendable link 104 is attached to said body 101, and said link 104 is bifurcated into two parts, each fabricated with a piezoelectric lead zirconate titanate (PZT) module 105 to detect health of said bolt joint by detecting structural integrity and faults in said joint;
iii) an articulated arm 106 mounted on side wall of said body 101, integrated with a bolt tightening unit 107 as an end effector, wherein said microcontroller enables extension and shortening of said articulated arm 106 based on specific requirements for tightening or loosening of bolt via said bolt tightening unit 107; and
iv) a crack detection sensor installed on said body 101 and synced with said imaging unit 103 to detect to detect internal cracks, voids, or changes in material properties of said bolt joint, wherein said microcontroller is further configured to generate a detailed report on a computing unit accessed by an authorized user based on collected data, identifying specific faults or material changes present in bolt joint for analysis and future reference.

2) The device as claimed in claim 1, wherein said bolt tightening unit 107 includes an adjustable socket integrated with an electromagnet 110, enabling automatic selection and secure attachment of different bolt head sizes for tightening or loosening based on detected bolt dimensions.

3) The device as claimed in claim 1, wherein a dedicated storage chamber 108 houses multiple bolt heads of various sizes, and said bolt tightening unit 107 automatically selects and retrieves appropriate bolt head size based on detected size of bolt to be operated on, as detected by an ultrasonic sensor mounted on said body 101 and synced with said imaging unit 103.

4) The device as claimed in claim 1, wherein a holographic projecting unit 109 is mounted on upper section of said body 101, configured to project holographic images in a working area where maintenance work is being carried out, providing real-time visual assistance to said authorized user during bolt joint maintenance operations.

5) The device as claimed in claim 1, wherein one of PZT module 105 function as a sensor and other function as an actuator that generates vibrations when an electrical signal is applied, and said sensor is configured to detect any changes in vibration patterns as vibrations travel through said bolt joint.

6) The device as claimed in claim 1, wherein a motorized ball-and-socket joint is integrated between said body 101 and extendable link 104, dynamically regulated by said microcontroller to provide multi-axis rotational movement to said extendable link 104.