Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated mortar mixture molding device that is capable of molding and levelling the mortar mixture over a boundary by regulating the shape as per the curvature of the boundary in order to shape the mortar according to user desired thickness.

BACKGROUND OF THE INVENTION

[0002] Mortar mixing and molding devices are essential tools in construction for preparing and applying mortar, a key material in masonry and plastering. These devices include portable mixers that blend cement, sand, and water to the desired consistency, ensuring uniformity and quality of mortar. Molding devices like trowels and floats are used to apply and smooth mortar onto surfaces, ensuring proper adhesion and finish. They facilitate efficient construction processes, reducing labor intensity and improving workmanship. Advances in technology have led to electric and pneumatic mortar mixers, enhancing productivity and precision in mixing operations, crucial for modern construction projects.

[0003] Traditional methods of mortar mixing involve manual labor using shovels or hoes to blend cement, sand, and water on a flat surface. Molding is typically done by hand with trowels or wooden floats to apply and smooth mortar on walls or surfaces. Drawbacks include inconsistent mixing ratios, leading to variations in mortar quality. Manual mixing is labor-intensive and time-consuming, affecting productivity. Hand molding can result in uneven application and finishing, impacting structural integrity and aesthetics. Moreover, traditional methods may not meet modern construction standards for consistency, strength, and durability, necessitating advancements in mechanized mixing and molding technologies.

[0004] WO1990009875A1 discloses horizontally oriented mortar mixing drum fabricated of polyethylene material having an elemental cylindrical segment opening through which mortar materials to be mixed may be deposited into or poured from. A perimeter frame having base elemental frame member, diametric wall frame members and polyethylene grate is provided for enhancing resistance to torsional stress on drum. Wear resistant liner and side panels and cover the interior surface of drum. Paddle shaft is rotatable and axially supported within drum and has paddle stubs attached to and extending radially therefrom. Polyethylene mixing paddles are sleeved onto paddle stubs to complete improved mortar mixing drum assembly. Although WO’875 relates to an improved mortar mixing drum, and in particular to a mortar mixing drum fabricated from polyethylene crosslink with a removable wear resistant plastic liner and paddles, and an elemental perimeter drum frame for rigidity. However the cited prior art lacks in providing assistive means for levelling and molding the mortar mixture over the boundary in an effective manner without manual efforts of the user.

[0005] 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. Though US’714 relates to art of mortar applicators and, more particularly, to an apparatus for applying a layer of mortar to substantially any desired surface. However the cited prior art lacks in providing assistive means for levelling and molding the mortar mixture over the boundary in an effective manner without manual efforts of the user.

[0006] Conventionally, many devices have been developed that are capable of molding the mortar mixture but no such device exists and have been developed that is efficient enough to mold and level the mortar mixture over the boundary by regulating the shape as the curvature of the boundary.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of molding and levelling the mortar mixture over a boundary by regulating the shape as per the curvature of the boundary in order to shape the mortar according to user desired thickness.

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 molding and levelling the boundary of building with mortar mixture in an effective manner.

[0010] Another object of the present invention is to develop a device that is capable of levelling the mortar mixture as per user desired thickness.

[0011] Yet another object of the present invention is to develop a device that is capable of mitigating the time and efforts employed by the user while molding and levelling the mortar over the boundary.

[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 mortar mixture molding device that is capable of effectively molding and levelling the mortar mixture as per user desired thickness over a boundary.

[0014] According to an embodiment of the present invention, an automated mortar mixture molding device comprising of an inverted L-shaped plate positioned over a boundary along which mortar mixture is to be molded, touch interactive display panel installed over the plate to enable a user to provide input regarding thickness of the mortar mixture to be molded, a multi-sectioned container arranged with the plate and stored with cement, sand, aggregates and water, an electronic valve installed with each section of the container dispense a regulated amount of the cement, sand, aggregates and water within the chamber connected with the valves, a motorized stirrer installed in the chamber mix the received cement, sand, aggregates and water in order to make the mortar mixture, an inverted L-shaped telescopic rod installed over top portion of the plate extend and position a flap configured with the rod at a specific distance in accordance with the user-specified thickness as monitored via an ultrasonic senor installed with the flap, a pair of motorized grippers installed with the plate each by means of an inverted L-shaped telescopic bar extend and grip the boundary via the grippers in a secured manner to provide stability to the plate over the boundary, an artificial intelligence based imaging unit installed over the plate and integrated with a laser measurement sensor captures images of the boundary to determines curvature of the boundary, plurality of motorized hinge joints integrated in the flap to regulate shape of the flap in accordance with the detected curvature, a chamber stored with mortar mixture arranged with the plate.

[0015] According to another embodiment of the present invention, the proposed device further comprises of plurality of electronic nozzles linked with the chamber are installed over inner periphery of the plate and to dispense a regulated amount of the mortar mixture within the space, a weight sensor installed in the chamber to monitor weight of the mortar mixture, a speaker installed over the plate to produce a voice command to notify the user regarding refilling of the chamber, a hydraulic pusher mapped beneath top portion of the plate extend and retract in a reciprocatory manner to apply pressure over the dispensed mortar mixture in view of molding the mixture, a motorized ball and socket joint installed between the pusher and plate to provide multidirectional movement to the pusher for enabling even molding of the mixture, a pressure sensor installed with the pusher to monitor pressure applied by the pusher over the mixture, a robotic arm installed over the plate flatten the molded mortar mixture via a trowel configured with the arm, plurality of motorized Omni-directional wheels installed beneath the plate provide translation to the plate over the surface in view of enabling molding of the mortar mixture along with the boundary, a vibration unit installed with the pusher produce vibrations to aid in appropriate molding of the mortar mixture and a battery is associated with the device for powering up electrical and electronically operated components associated with the device.

[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 a perspective view of an automated mortar mixture molding 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 mortar mixture device that is capable of accurately molding any dimension of boundary with mortar mixture as well as levelling without manual efforts of the user.

[0022] Referring to Figure 1, a perspective view of an automated mortar mixture molding device is illustrated, comprising an inverted L-shaped plate 101 positioned over a boundary, touch interactive display panel 102 installed over the plate 101, an inverted L-shaped telescopic rod 103 installed over top portion of the plate 101, a flap 104 configured with the rod 103, an artificial intelligence based imaging unit 105 installed over the plate 101, a chamber stored with arranged with the plate 101 and linked with plurality of electronic nozzles 108, a hydraulic pusher 109 mapped beneath top portion of the plate 101, robotic arm 110 installed over the plate 101, a trowel configured with the arm 110, a multi-sectioned container 107 arranged with the plate 101 installed with, an electronic, a pair of motorized grippers 106 installed with the plate 101 each by means of an inverted L-shaped telescopic bar.

[0023] The proposed device deals with molding of mortar mixture into different shapes and comprises of inverted L-shaped plate 101 positioned over a boundary, wherein the plate 101 is preferably made portable integrated with various components associated with the device, developed to be positioned on a boundary where the mortar mixture is to be molded. The plate 101 is made up of any material selected from but not limited to metal or plastic that ensures rigidity of the plate 101 for longevity of the device. The user then access and presses a switch button arranged on the plate 101 to activate the device for further processes.

[0024] The switch button when pressed by the user, opens up an electrical circuit and allows currents to flow for powering an associated microcontroller of the device for operating of all the linked components for performing their respective functions upon actuation. The microcontroller mentioned herein mentioned herein, is preferably an Arduino microcontroller. The Arduino microcontroller used herein controls the overall functionality of the components linked to it. The Arduino microcontroller is an open-source programming platform. The microcontroller receives the data from various
electronic units and generates a command signal for further processing.

[0025] Post activation of the device, the user accesses a touch interactive display panel 102 installed over the plate 101 to enter details of thickness of mortar mixture that is to be molded. When the user touches the surface of the touch interactive display panel 102 to enter the input details of thickness of mortar mixture that is to be molded, then an internal circuitry of the touch interactive display panel 102 senses the touches of the displayed option and synchronically, the internal circuitry converts the physical touch into the form of electric signal. Further, the touch interactive display panel 102 transmits the signal to the microcontroller.

[0026] The microcontroller processes the received signal from the display panel 102 in order to process the signal and determine the user selection and store the user response to the linked database. The plate 101 is configured with a multi-sectioned container 107 that stores cement, sand, aggregates and water for making the mortar mixture. In order to make the mortar mixture, first the microcontroller actuates an electronic valve 107 installed with each section of the container 107 to dispense the required amount of components for making mortar.

[0027] The electronic valve 107 is used to control flow of substance of chamber by varying the size of the flow passage as directed by a signal from the microcontroller. This enables the direct control of flow rate and the consequential control of process quantities such as pressure, temperature, and liquid level while dispensing the mixture inside a chamber arranged with the plate 101.

[0028] The chamber is further configured with a weight sensor that monitor the weight of the mortar mixture in the chamber . The weight sensor used herein is a kind of a transducer. The weight sensor depends on the conversion of a load into an electronic signal. The signal is a change in voltage or current otherwise a frequency on the basis of load and the signal is sent to the microcontroller for processing in order to monitor weight of the mortar mixture in the chamber .

[0029] In the case the detected weight of the mortar mixture in the chamber recedes a threshold limit then the microcontroller actuates the speaker for notifying the user to refill the chamber . The speaker works by taking the input signal from the microcontroller, it then processes and amplifies the received signal through a series of equipment in a specific order within the speaker, and then sends the output signal in form of audio notification through the speaker for alerting the user regarding refilling of the chamber .

[0030] The dispensed cement, sand, aggregates and water is further mixed by a motorized stirrer 107 installed with the chamber that on actuation mixes the dispensed mix to form mortar mixture. The motorized stirrer 107 operates by using an electric motor to rotate a shaft or paddle immersed in the mixture of the mortar. The rotating action of the stirrer 107 creates turbulence and mixes the contents in order to make mortar mixture.

[0031] Post formation of mortar mixture, the microcontroller actuates an inverted L-shaped telescopic rod 103 installed over top portion of the plate 101 to extend in order to position an adjoined flap 104 at a specific distance as per the given thickness that is specified by the user over the display panel 102. At the time of placement of the flap 104 the distance for the positioning is monitored by an ultrasonic sensor installed with the flap 104. The ultrasonic sensor consists of a transducer that functions as both a transmitter and a receiver. The transducer typically contains a piezoelectric crystal or a similar material. The sensor sends an electromagnetic wave that bounces off the surface of the boundary and the travel time is used to determine the distance of the flap 104 and boundary. The sensor measures the ultrasonic sound waves and converts the reflected sound into an electrical signal and sends the signal to the microcontroller.

[0032] On the basis of the desired distance that is to be maintained for molding the mortar mixture the flap 104 is positioned at the desired distance. Post positioning of the flap 104, an artificial intelligence based imaging unit 105 installed over the plate 101 captures images of the boundary by working in sync with a laser measurement sensor. The imaging unit 105 captures images using an image capturing arrangement including a set of lenses that captures multiple images of the boundary, and the captured images are stored within memory of the imaging unit 105 in form of an optical data.

[0033] The imaging unit 105 also comprises of a processor that is integrated with artificial intelligence protocols, such that the processor processes the optical data and extracts the required data from the captured images. While the laser measurement sensor used herein, is a measurement value recorder working with laser technology and turning the physical measured value into an analog electric signal. The laser measurement sensor is conceived for contactless measurement which is based on the triangulation principle. Triangulation used for determining measurement by angle calculation where the sensor projects a laser spot on the boundary.

[0034] The reflected light falls incident onto a receiving unit at a certain angle depending on the distance and these received lights are converted into signals and sent to the microcontroller. The microcontroller then processes the received signals in order to determine the curvature of the boundary for positioning of the flap 104 accordingly.

[0035] In order to aid the positioning of the flap 104 as per the curvature of the boundary, the microcontroller actuates plurality of motorized hinge joints integrated in the flap 104 to regulate the shape of the flap 104. The motorized hinge is a piece of metal that joins the flap 104 together and allows it to be opened or closed by revolving along the longitudinal axis whose operation is governed by a DC motor that further regulates the shape of the flap 104 as per the curvature of the boundary.

[0036] The microcontroller then actuates plurality of electronic nozzles 108 linked with the chamber arranged on the inner periphery to dispense the mortar mixture in an effective manner within the space of the boundary where flap 104 is laid. The electronic nozzles 108 also works same as the electronic valve 107 mentioned above. Simultaneous to the dispensing of the nozzle the microcontroller actuates a pair of motorized grippers 106 installed with the plate 101 each by means of an inverted L-shaped telescopic bar to extend in order to grip the boundary using the grippers 106 for providing stability to the plate 101 over the boundary.

[0037] The telescopic rod 103 mentioned above and telescopic bar mentioned herein comprise of a pneumatic arrangement that includes including a pneumatic cylinder, air compressor, air valve 113, cylinder and piston. The valve 107 is an air valve 107 that allows entry/exit of compressed air from the compressor. Furthermore, the valve 107 opens and the compressed air enters inside the cylinder thereby increasing the air pressure of the cylinder. The piston is connected to the cylinder and due to the increase in the air pressure, the piston extends. For the retraction of the piston, air is released from the cylinder to the air compressor via the valve 113. Thus, providing the required extension/retraction of the rod 103 and bar to perform their respective functions.

[0038] As the bar extends the gripper grip the boundary in a secured manner. The motorized grippers 106 comprise, motor controllers, arm 110, end effector and sensors. All these parts are configured with the microcontroller. The elbow is at the middle section of the arm 110 that allows the upper part of the arm 110 to move the lower section independently. Lastly, the wrist is at the tip of the upper arm 110 and attached to the end effector which is further attached with the grippers 106. The grippers 106 comprise an electric motor and a controller. The controller provides a signal relating to the force, position, or the speed required of the gripping. The grippers 106 receive the signal and its motor carries out the gripping of the boundary for stability.

[0039] Post dispensing of the mortar mixture, the microcontroller actuates a hydraulic pusher 109 mapped beneath top portion of the plate 101 to extend and retract in a to and fro motion to apply an accurate pressure for molding the mixture on the boundary. The hydraulic pusher 109 comprise of a hydraulic arrangement consisting of a hydraulic cylinder, hydraulic compressor, hydraulic valve 107 and piston that work in collaboration for providing the required extension/retraction to the pusher 109 The microcontroller actuates the valve 107 to allow passage of hydraulic fluid from the compressor within the cylinder, the hydraulic fluid further develops pressure against the piston and results in pushing and extending the piston.

[0040] The piston is connected with the pusher 109 and due to applied pressure the pusher 109 extends and similarly, the microcontroller retracts the pusher 109 by closing the valve 107 resulting in retraction of the piston. The microcontroller regulates the extension/retraction of the pusher 109 for levelling the mortar mixture in an efficient manner. The movement of the pusher 109 is aided by means of a motorized ball and socket joint that provides multidirectional movement to the pusher 109 for effective shaping.

[0041] The motorized ball and socket joint provides a 360-degree rotation to the pusher 109 for aiding the molding of the mixture to turn at a desired angle. The ball and socket joint is a coupling consisting of a ball joint securely locked within a socket joint, where the ball joint is able to move in a 360-dgree rotation within the socket thus, providing the required rotational motion to the pusher 109. The ball and socket joint is powered by a DC (direct current) motor that is actuated by the microcontroller thus providing multidirectional movement to the pusher 109 for effective shaping.

[0042] The microcontroller further actuates a vibration unit installed with the pusher 109 in order to produce vibrations to aid in appropriate shaping. The vibrational unit subjecting the pusher 109 to the action of moving or causing to move back and forth or from side to side very quickly leading to controlled and reproducible mechanical vibration for molding the mortar.

[0043] In addition, a pressure sensor installed with the pusher 109 monitors the pressure that is applied by the pusher 109. The pressure sensor comprises of a sensing element known as diaphragm that experiences a force exerted by the pusher 109 on the mortar mixture while shaping. This force leads to deflection in the diaphragm that is measured by the sensor and converted into an electrical signal which is sent to the microcontroller for determining the pressure. In case the detected pressure exceeds/recedes a threshold value then the microcontroller accordingly regulates the pressure that is applied by the pusher 109.

[0044] The microcontroller then actuates a robotic arm 110 installed over the plate 101 to flatten the molded mortar mixture using a trowel that is configured with the arm 110. The robotic arm 110 comprises, motor controllers, arm 110, end effector and sensors. All these parts are configured with the microcontroller. The elbow is at the middle section of the arm 110 that allows the upper part of the arm 110 to move the lower section independently. Lastly, the wrist is at the tip of the upper arm 110 and attached to the end effector thereby the end effector works as a hand for levelling the mortar mixture using the trowel.

[0045] During the time of levelling of the mortar mixture, the microcontroller continuously actuates a plurality of motorized Omni-directional wheels are installed beneath the plate 101 to move the plate 101 over the boundary for effective molding of the mortar over the boundary. The Omni-directional wheels have small discs or rollers around the circumference of the wheel that are powered by a direct current (DC) motor, enabling the wheels to move in required direction, which provide the plate 101 with the required movement for levelling of the mortar.

[0046] A battery (not shown in figure) is associated with the device to supply power to electrically powered components which are employed herein. The battery is comprised of a pair of electrodes named as a cathode and an anode. The battery uses a chemical reaction of oxidation/reduction to do work on charge and produce a voltage between their anode and cathode and thus produces electrical energy that is used to do work in the device.

[0047] The proposed device works well in following manner, where the inverted L-shaped plate 101 positioned over the boundary along which mortar mixture that is to be molded and have the touch interactive display panel 102 that allows the user to provide input regarding thickness of the mortar mixture to be molded. Then the inverted L-shaped telescopic rod 103 extend and position the flap 104 at the specific distance in accordance with the user-specified thickness as monitored via the ultrasonic senor Further, the artificial intelligence based imaging unit 105 integrated with the laser measurement sensor captures images of the boundary based on which, the microcontroller determines curvature of the boundary accordingly the plurality of motorized hinge joints integrated in the flap 104 regulate shape of the flap 104 in accordance with the detected curvature. Then the electronic nozzles 108 dispense the regulated amount of the mortar mixture within the space and the hydraulic pusher 109 extend and retract in the reciprocatory manner to apply pressure over the dispensed mortar mixture in view of molding the mixture. Further, the motorized ball and socket joint provide multidirectional movement to the pusher 109 for enabling even molding of the mixture and simultaneously the robotic arm 110 flatten the molded mortar mixture via the trowel configured with the arm 110. Lastly, the plurality of motorized Omni-directional wheels provide translation to the plate 101 over the surface in view of enabling molding of the mortar mixture along with the boundary.

[0048] 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 mortar mixture molding device, comprising:

i) An inverted L-shaped plate 101 positioned over a boundary along which mortar mixture is to be molded, wherein a touch interactive display panel 102 installed over said plate 101 to enable a user to provide input regarding thickness of said mortar mixture to be molded;
ii) an inverted L-shaped telescopic rod 103 installed over top portion of said plate 101 and actuated by said microcontroller to extend and position a flap 104 configured with said rod 103 at a specific distance in accordance with said user-specified thickness as monitored via an ultrasonic senor installed with said flap 104, wherein positioning of said flap 104 creates a space in which said mortar mixture is to be poured;
iii) an artificial intelligence based imaging unit 105 installed over said plate 101 and integrated with a laser measurement sensor for capturing and processing images of said boundary based on which, a microcontroller linked with said processor determines curvature of said boundary based on which said microcontroller actuates plurality of motorized hinge joints integrated in said flap 104 to regulate shape of said flap 104 in accordance with said detected curvature;
iv) a chamber stored with mortar mixture arranged with said plate 101, wherein plurality of electronic nozzles 108 linked with said chamber are installed over inner periphery of said plate 101 and actuated by said microcontroller to dispense a regulated amount of said mortar mixture within said space;
v) a hydraulic pusher 109 mapped beneath top portion of said plate 101 and actuated by said microcontroller to extend and retract in a reciprocating manner to apply pressure over said dispensed mortar mixture in view of molding said mixture, wherein a motorized ball and socket joint is installed between said pusher 109 and plate 101 to provide multidirectional movement to said pusher 109 for enabling even molding of said mixture; and
vi) a robotic arm 110 installed over said plate 101 and actuated by said microcontroller to flatten said molded mortar mixture via a trowel configured with said arm 110, wherein plurality of motorized Omni-directional wheels are installed beneath said plate 101 and actuated by said microcontroller to provide translation to said plate 101 over said surface in view of enabling molding of said mortar mixture along with said boundary.

2) The device as claimed in claim 1, wherein a vibration unit is installed with said pusher 109 and actuated by said microcontroller to produce vibrations to aid in appropriate molding of said mortar mixture.

3) The device as claimed in claim 1, wherein a pressure sensor is installed with said pusher 109 to monitor pressure applied by said pusher 109 over said mixture and in case said monitored pressure exceeds/recedes a threshold value, said microcontroller directs said pusher 109 to regulate said applied pressure.

4) The device as claimed in claim 1, wherein a weight sensor is installed in said chamber to monitor weight of said mortar mixture and in case said monitored weight recedes a threshold limit, said microcontroller actuates a speaker installed over said plate 101 to produce a voice command to notify said user regarding refilling of said chamber .

5) The device as claimed in claim 1, wherein a multi-sectioned container 107 is arranged with said plate 101 and stored with cement, sand, aggregates and water.

6) The device as claimed in claim 1 and 5, wherein an electronic valve 107 is installed with each section of said container 107 and actuated by said microcontroller to dispense a regulated amount of said cement, sand, aggregates and water within said chamber connected with said valve 113s.

7) The device as claimed in claim 1 and 6, wherein a motorized stirrer 107 is installed in said chamber and actuated by said microcontroller to mix said received cement, sand, aggregates and water in order to make said mortar mixture.

8) The device as claimed in claim 1, wherein a pair of motorized grippers 106 are installed with said plate 101 each by means of an inverted L-shaped telescopic bar that are actuated by said microcontroller to extend and grip said boundary via said grippers 106 in a secured manner to provide stability to said plate 101 over said boundary.

9) The device as claimed in claim 1, wherein a battery is associated with said device for powering up electrical and electronically operated components associated with said device.