DESC:DESCRIPTION
Technical Field of the invention

The present invention generally relates to automated fresh-crushing and juice vending machines. More particularly, it focuses on improving the storage, conveyance, and feeding of sugarcane stalks, addressing issues such as varying stalk sizes and preventing jamming, to enhance the efficiency and reliability of the juice extraction process.

Background of the invention

Automated sugarcane juice vending machines have emerged as a convenient and efficient solution for providing fresh sugarcane juice in various settings, including malls, restaurants, and public events. These machines offer the advantage of hygienic and automated operations, reducing manual intervention and increasing throughput. Despite these benefits, significant challenges persist in the storage, conveyance, and feeding mechanisms of these systems, limiting their efficiency and reliability. These limitations are particularly pronounced when processing sugarcane stalks of varying diameters, shapes, and curvatures, which are common in real-world scenarios.

A critical problem faced by other sugarcane vending machines is their inability to handle non-uniform sugarcane stalks effectively. Most existing systems are designed for straight, uniformly sized stalks, making them ill-equipped to deal with natural variations in sugarcane. As a result, machines often experience clogging, tangling, or jamming during operation, leading to frequent interruptions and downtime. This not only impacts throughput but also increases maintenance requirements and operational costs. Furthermore, the storage capacities of current systems are often limited, requiring frequent manual intervention to align and feed stalks into the crushing mechanism. Such manual involvement compromises hygiene standards and undermines the automated nature of the machines.

The prior art reveals several attempts to address aspects of sugarcane handling and processing. For instance, Patent IN201921036763 discloses a sugarcane juice vending machine that includes a storage unit with a vibrating motor to facilitate the flow of sugarcane sticks. While this design improves horizontal storage and flow, it lacks the ability to accommodate stalks of varying shapes and sizes, making it prone to jamming and operational delays. Similarly, Patent CN110771908A describes a conveyor system integrated with a cutting mechanism, but it is limited to pre-cut sugarcane billets and does not address the complexities of handling whole stalks. These designs fall short of offering a comprehensive solution to the challenges of sugarcane storage and feeding.

Patent CN111746024A focuses on a cane crusher with extrusion rollers, emphasizing the crushing process rather than addressing the upstream challenges of stalk storage and alignment. In contrast, Patent US4043832 introduces a system for extracting soluble substances from fibrous materials like sugarcane but is geared toward industrial-scale operations and lacks provisions for automated feeding in vending machines. Similarly, US20010002037A1 and US20100307483A1 describe sugarcane processing systems with conveyors and compression rollers, but their designs cater to in-field or large-scale processing rather than compact vending applications.

While these prior art references contribute valuable innovations, they collectively fall short in addressing the operational challenges of modern sugarcane juice vending machines. Key deficiencies include the inability to handle non-uniform stalks, lack of anti-jumbling mechanisms, reliance on manual intervention, and limited adaptability to varying operational scenarios. As a result, existing systems often struggle to achieve high throughput and operational reliability.

Recognizing these limitations, the inventors identified a pressing need for a versatile and efficient solution tailored to automated sugarcane juice vending machines.

Brief Summary of the Invention

A primary object of the present invention is to provide an integrated sugarcane stalk storage and vertical conveyor system for automated fresh-crushing and juice vending machines that significantly improves operational efficiency. The invention is designed to optimize the storage, alignment, and feeding of sugarcane stalks, ensuring a smooth and uninterrupted operation that addresses the limitations of conventional systems.

Another object of the invention is to facilitate the handling of sugarcane stalks with varying diameters and inconsistent shapes. Conventional systems are often unable to process non-uniform stalks effectively, leading to frequent clogs and jams. This invention introduces advanced mechanisms, including angular pickup teeth and anti-collision features, to manage these variations seamlessly.

An additional object of the invention is to minimize manual intervention in the operation of automated vending machines. By incorporating a semi-inclined hopper for gravity-assisted feeding and a high-torque screw feeder with embedded sensors, the system reduces the need for human input, thereby improving hygiene and efficiency.

A further object of the invention is to develop a modular system that ensures high throughput while remaining easy to maintain and adaptable to various machine configurations. The modular design allows for straightforward servicing and part replacement, enabling operators to customize the system based on specific operational requirements.

Another object of the invention is to enhance the overall speed and efficiency of sugarcane juice vending machines. The integrated feed system is engineered to complete the processes of storing, aligning, and crushing sugarcane stalks, ensuring rapid service in high-demand scenarios.

Finally, the invention aims to incorporate a sensor-driven precision feeding mechanism. This ensures that sugarcane stalks are accurately aligned and fed into the crushing unit without overloading or congestion, enhancing the reliability and consistency of the operation.

The present invention provides an integrated sugarcane stalk storage and vertical conveyor system with pusher mechanism, specifically designed to address the operational challenges of automated fresh-crushing and juice vending machines. The system is engineered to handle sugarcane stalks of varying diameters and shapes while maintaining high throughput and reliability.

The invention comprises several key components that work in harmony to optimize the process. A semi-inclined hopper is configured to store and guide sugarcane stalks toward the feeder. Its gravity-assisted design minimizes the need for manual intervention, ensuring a consistent flow of stalks into the system. The hopper is equipped with a stock loading door positioned to allow easy loading without disrupting the operation of the machine.

A vertical conveyor system with angular pickup teeth is incorporated to selectively feed individual stalks. The angular teeth are specifically designed to accommodate stalks of varying diameters and inconsistent shapes, ensuring smooth operation and preventing clogs. The conveyor lifts the stalks from the hopper to the feeding mechanism while maintaining their alignment.

At the heart of the feeding system is a pusher mechanism employing a high-torque screw feeder. This component uses a sensor-driven stepwise movement to push individual stalks into the crushing unit. The embedded sensors monitor the alignment and position of the stalks, ensuring precise feeding and preventing overloading of the crushing mechanism.

A critical innovation of the system is its anti-collision and anti-jumbling mechanism, integrated into the vertical conveyor system. This mechanism prevents tangling and misalignment of stalks during the feeding process, enabling uninterrupted operation. The entire system is managed by an integrated feed system, which synchronizes the operation of all components to complete the processes of storing, aligning, and crushing within a maximum time duration of 10 seconds.

The invention is modular, allowing for easy customization and maintenance. The modular design ensures that individual components can be serviced or replaced without disrupting the overall operation of the system. Additionally, the system is adaptable to different machine configurations, making it suitable for a wide range of vending machine designs.

The invention offers several significant advantages over conventional systems. First, it effectively handles sugarcane stalks of varying diameters and inconsistent shapes, a feature that sets it apart from existing designs. By incorporating angular pickup teeth and a high-torque screw feeder, the system ensures smooth feeding without the risk of clogs or jams.

Another major advantage is the system’s ability to minimize manual intervention. The semi-inclined hopper and automated feeding mechanisms reduce the need for human input, improving hygiene and operational efficiency. This makes the system particularly well-suited for applications where cleanliness and speed are critical.

The anti-collision and anti-jumbling mechanism further enhances the system's reliability. By preventing tangling and misalignment, the mechanism ensures uninterrupted operation, reducing downtime and maintenance requirements. This feature is particularly valuable in high-demand environments where consistent performance is essential.

The invention’s modular design offers significant benefits in terms of maintenance and adaptability. Operators can easily service or replace individual components, ensuring minimal downtime. Additionally, the system can be customized to suit specific operational needs, making it highly versatile.

Finally, the system’s ability to complete the entire process of storing, aligning, and crushing sugarcane stalks within 10 seconds ensures high throughput. This makes the invention ideal for busy environments such as shopping malls, restaurants, and outdoor events, where rapid service is a key requirement.

The invention is primarily designed for use in automated fresh-crushing and juice vending machines. Its ability to handle sugarcane stalks of varying diameters and shapes makes it ideal for applications in environments with high variability in raw materials. The system’s modular design ensures adaptability to different machine configurations, making it suitable for a wide range of vending machine models.

In addition to vending machines, the invention can be applied in other sugarcane processing systems, such as small-scale juice extraction units for restaurants and cafes. Its compact and efficient design makes it well-suited for settings where space and speed are critical considerations.

The invention is also applicable in agricultural processing units that require efficient handling and feeding of sugarcane stalks. By incorporating the anti-collision and anti-jumbling mechanism, the system can improve the reliability and efficiency of such operations.

In industrial settings, the invention can be integrated into larger sugarcane processing lines as a specialized module for storing and feeding stalks. Its ability to minimize jams and downtime makes it a valuable addition to high-capacity processing plants.

Furthermore, the system’s modular design and rapid operation make it ideal for deployment in mobile vending units, such as food trucks. This opens up opportunities for operators to serve fresh sugarcane juice in outdoor or remote locations, expanding the reach and profitability of their business.

Further objects, features, and advantages of the invention will be readily apparent from the following description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings.

Brief Description of the Drawings

The invention will be further understood from the following detailed description of a preferred embodiment taken in conjunction with an appended drawing, in which:

Fig. 1 illustrates an integrated sugarcane stalk storage and vertical conveyor system with high-precision pusher mechanism for automated juice vending machines, in accordance with an exemplary embodiment of the present invention;

Fig. 2 illustrates the vertical conveyor system, in accordance with an exemplary embodiment of the present invention;

Fig. 3 illustrates an exploded view of vertical conveyor system, in accordance with an exemplary embodiment of the present invention.

Detailed Description of the invention

It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

According to an exemplary embodiment of the present invention, an integrated sugarcane stalk storage and vertical conveyor system with pusher mechanism, designed specifically for automated fresh-crushing and juice vending machines is disclosed. The invention introduces a modular, efficient, and reliable system that addresses the challenges of handling sugarcane stalks of varying diameters and inconsistent shapes. The system enhances throughput and operational efficiency by ensuring smooth storage, alignment, and feeding of sugarcane stalks into the crushing unit while minimizing manual intervention and downtime.

In one exemplary embodiment of the present invention, the system comprises a semi-inclined hopper, a vertical conveyor system equipped with angular pickup teeth, a stock loading door, a pusher mechanism utilizing a high-torque screw feeder, and an integrated feed system. The inventive elements and their specific functionalities are described in detail below.

In accordance with an exemplary embodiment of the present invention, the semi-inclined hopper is configured to store sugarcane stalks and guide them toward the feeder. Its design leverages gravity to facilitate the smooth movement of stalks, reducing the need for manual intervention. The inclined angle of the hopper is optimized to ensure consistent flow without jamming. The hopper is further equipped with a stock loading door strategically positioned on its side to allow for easy loading of stalks without disrupting the operation of the system. This design ensures a continuous and uninterrupted supply of stalks to the vertical conveyor system.

In accordance with an exemplary embodiment of the present invention, the vertical conveyor system is a critical component that lifts sugarcane stalks from the hopper to the pusher mechanism. The conveyor is equipped with angular pickup teeth, which are specifically designed to engage individual stalks selectively. These angular teeth are capable of handling sugarcane stalks of varying diameters and non-uniform shapes, ensuring smooth feeding and preventing jams.

The conveyor system operates with a modular design that allows for easy servicing and adaptability to different machine configurations. This modularity ensures that individual components can be replaced or upgraded without requiring a complete overhaul of the system. The vertical orientation of the conveyor saves space and facilitates integration into compact vending machine designs.

An innovative feature of the invention is the integration of an anti-collision and anti-jumbling mechanism within the vertical conveyor system. This mechanism prevents tangling, misalignment, and overlapping of stalks during the feeding process. By maintaining optimal alignment, the mechanism ensures uninterrupted operation and minimizes downtime caused by jams.

The anti-jumbling mechanism works in tandem with the angular pickup teeth, allowing only one stalk to be fed into the pusher mechanism at a time. This coordination significantly enhances the reliability and consistency of the system, especially when handling irregularly shaped stalks.

The pusher mechanism employs a high-torque screw feeder to push sugarcane stalks into the crushing unit. The screw feeder operates with stepwise movement, controlled by an embedded sensor network. These sensors monitor the alignment and position of the stalks in real time, ensuring precise feeding and preventing overloading of the crushing unit.

The stepwise movement of the pusher mechanism is a key innovation, allowing the system to adapt dynamically to variations in stalk dimensions. The high-torque motor driving the screw feeder is capable of adjusting torque automatically based on the resistance detected by the sensors, further enhancing the system's adaptability and reliability.

The integrated feed system coordinates the operation of all components, including the hopper, vertical conveyor system, and pusher mechanism. This synchronization ensures that the entire process of storing, aligning, and feeding sugarcane stalks is completed within a maximum time duration of 10 seconds. By optimizing the interaction between components, the feed system achieves high throughput while maintaining operational stability.

The entire system is designed with modularity in mind, allowing for straightforward maintenance and part replacement. High-quality materials are used for all components, ensuring durability and long operational life even under high-throughput conditions. The modular design also enables customization of the system to suit different vending machine configurations and operational requirements.

The operation begins with sugarcane stalks being loaded into the semi-inclined hopper through the stock loading door. The inclined design of the hopper facilitates gravity-assisted flow, directing the stalks toward the vertical conveyor system. As the stalks reach the conveyor, the angular pickup teeth engage them selectively, lifting one stalk at a time to ensure smooth and uninterrupted feeding.

The anti-collision and anti-jumbling mechanism within the conveyor system prevents tangling and ensures that each stalk is properly aligned as it is transferred to the pusher mechanism. The high-torque screw feeder then pushes the stalks into the crushing unit with precision, guided by the embedded sensors that monitor and adjust the alignment in real time.

The integrated feed system ensures seamless coordination between the hopper, conveyor, and pusher mechanism, completing the entire process within 10 seconds. This high-speed operation enables the vending machine to meet the demands of high-throughput environments such as malls, restaurants, and outdoor events.

Now referring to drawings, Fig. 1, illustrates the integrated sugarcane stalk storage and vertical conveyor system (1), showcasing the arrangement of its key components and their functional roles. The system is specifically designed to improve the storage, alignment, and feeding of sugarcane stalks in automated fresh-crushing and juice vending machines. The major components include a semi-inclined hopper (2), a vertical conveyor system (3) equipped with angular pickup teeth, a stock loading door, a pusher mechanism (4) employing a high-torque screw feeder (), and an integrated feed system that ensures seamless operation.

The semi-inclined hopper (2) serves as the initial storage area for sugarcane stalks. Its gravity-assisted design allows stalks to flow smoothly toward the feeding system without requiring manual intervention. The incline angle of the hopper is optimized to prevent jamming and maintain a consistent feed rate. Positioned on the side of the hopper is the stock loading door, which facilitates the addition of sugarcane stalks during operation. The strategic placement of the door ensures that the loading process does not interfere with the flow of stalks into the vertical conveyor system (3).

The vertical conveyor system (3) is a central component of the invention, designed to lift sugarcane stalks from the hopper (2) to the pusher mechanism (4). The conveyor (3) is equipped with angular pickup teeth that engage and transport individual stalks. These teeth are specifically shaped to handle sugarcane stalks of varying diameters and non-uniform shapes, ensuring smooth operation and preventing jams. The modular design of the conveyor allows for easy servicing and adaptability to different machine configurations.

Integrated within the conveyor system (3) is an anti-collision and anti-jumbling mechanism, which plays a critical role in maintaining the alignment of sugarcane stalks. This mechanism prevents tangling and overlapping of stalks as they are lifted by the angular pickup teeth. By ensuring that only one stalk is fed at a time, the anti-jumbling mechanism enhances the reliability and efficiency of the system, particularly when processing irregularly shaped stalks.

At the end of the conveyor system (3), stalks are transferred to the pusher mechanism (4). This mechanism employs a high-torque screw feeder () that pushes individual stalks into the crushing unit. The screw feeder operates with a stepwise movement controlled by an embedded sensor network. These sensors monitor the alignment and position of the stalks in real time, ensuring precise feeding and preventing overloading of the crushing unit. The high-torque motor driving the screw feeder is capable of adjusting torque based on the resistance detected by the sensors, further enhancing the adaptability and reliability of the mechanism.

The overall operation of the system is managed by the integrated feed system, which synchronizes the activities of the hopper (2), vertical conveyor system (3), and pusher mechanism (4). This coordination ensures that the processes of storing, aligning, and feeding sugarcane stalks are completed seamlessly within a maximum time duration of 10 seconds. The feed system also regulates the interaction between the anti-jumbling mechanism and the angular pickup teeth (106) to optimize the flow of stalks through the system.

In the modular design of the invention, the components are interconnected in a manner that allows for straightforward maintenance and customization. For example, the vertical conveyor system (3) and the pusher mechanism (4) can be easily detached and replaced without disrupting the operation of the hopper (2). This modularity ensures long-term durability and adaptability to various machine configurations.

The operation of the system begins with the sugarcane stalks being loaded into the semi-inclined hopper (2) through the stock loading door. Gravity directs the stalks toward the angular pickup teeth of the vertical conveyor system (3). These teeth lift the stalks individually, preventing jamming and maintaining a consistent flow. The anti-collision mechanism ensures proper alignment as the stalks are transported to the pusher mechanism (4). The high-torque screw feeder () then precisely pushes the stalks into the crushing unit, guided by real-time sensor feedback.

This coordinated process is controlled by the integrated feed system (), which completes the entire cycle of storing, aligning, and crushing sugarcane stalks in under 10 seconds. The system’s efficiency and reliability make it particularly suitable for high-throughput environments such as malls, restaurants, and outdoor events, where rapid and uninterrupted service is essential.

The method of manufacturing the Integrated Sugarcane Stalk Storage and Vertical Conveyor System (1) involves several distinct steps to ensure the production of a robust, reliable, and modular system capable of handling sugarcane stalks of varying diameters and inconsistent shapes. The following paragraphs describe the manufacturing process in detail.

1. Fabrication of the Semi-Inclined Hopper (2):
The semi-inclined hopper (2) is fabricated using high-grade stainless steel sheets to ensure durability and resistance to corrosion. The steel sheets are cut and welded to form the inclined structure, with the incline angle optimized for gravity-assisted feeding of sugarcane stalks. The hopper includes reinforcement ribs for structural stability, especially when handling large quantities of stalks. The stock loading door (108) is then installed on the side of the hopper, using hinges and a locking mechanism to facilitate easy loading while maintaining the integrity of the hopper’s structure.

2. Assembly of the Vertical Conveyor System (3):
The vertical conveyor system (3) is assembled using a modular chain conveyor design. Angular pickup teeth are attached to the conveyor links, with each tooth manufactured from wear-resistant stainless steel or reinforced polymer for durability and precision. The conveyor frame is constructed from lightweight, high-strength aluminum to reduce the overall weight of the system while maintaining rigidity. The modular nature of the conveyor allows for easy replacement of individual links or teeth during maintenance. The anti-collision and anti-jumbling mechanism is integrated into the conveyor system during assembly, consisting of strategically placed rollers and guides to ensure smooth alignment of stalks.

3. Manufacturing the Pusher Mechanism (4):
The pusher mechanism (4) employs a high-torque screw feeder manufactured from hardened steel to withstand the mechanical stresses of feeding sugarcane stalks into the crushing unit. The screw feeder is machined with precise tolerances to ensure smooth operation and accurate stepwise movement. Embedded sensors, such as proximity or optical sensors, are installed along the feeder to monitor the position and alignment of stalks in real time. The high-torque motor is calibrated to provide variable torque based on the resistance detected during operation, ensuring adaptability to varying stalk sizes and conditions.

4. Integration of the Anti-Collision and Anti-Jumbling Mechanism:
The anti-collision and anti-jumbling mechanism is manufactured using angled guides and rolling elements designed to maintain the alignment of sugarcane stalks as they are lifted by the conveyor system. The components are constructed from low-friction materials, such as PTFE-coated steel or engineered plastics, to minimize wear and ensure long-term reliability. These elements are installed within the vertical conveyor system (3) during assembly to prevent tangling or overlapping of stalks.

5. Installation of the Integrated Feed System:
The integrated feed system serves as the control center of the invention, coordinating the operation of all components. The system is built using an electronic control unit (ECU) programmed to synchronize the hopper (102), vertical conveyor system (104), and pusher mechanism (4). The ECU is mounted within a protective enclosure to shield it from environmental factors. Wiring harnesses and sensors are routed through designated channels to maintain a clean and organized assembly.

6. Testing and Quality Assurance:
Once all components are assembled, the entire system undergoes rigorous testing to ensure functionality and reliability. The semi-inclined hopper (2) is tested for its ability to handle varying stalk sizes without jamming, while the vertical conveyor system (3) is evaluated for smooth operation and the effectiveness of the anti-jumbling mechanism. The pusher mechanism (4) is calibrated for precision feeding, with the sensor network validated for real-time monitoring and adjustments. Finally, the integrated feed system is tested to confirm that the entire process of storing, aligning, and crushing stalks can be completed within the specified 10-second duration.

7. Modular Assembly and Customization:
The system is designed for modularity, allowing for customization based on specific operational requirements. During the manufacturing process, individual modules, such as the vertical conveyor or pusher mechanism, can be tailored to suit the dimensions or throughput needs of the vending machine. This modular approach also simplifies maintenance, as individual components can be replaced without disassembling the entire system.

8. Final Assembly and Finishing:
In the final assembly stage, all components are integrated into the system (1) and mounted onto a base frame constructed from powder-coated steel for corrosion resistance. The system is then finished with protective coatings to enhance durability and aesthetics. Any additional accessories, such as protective covers or noise-dampening materials, are installed to meet user requirements and operational standards.

9. Packaging and Shipping:
Once assembled and tested, the system is carefully packaged to prevent damage during transportation. Protective padding and secure fasteners are used to safeguard the angular pickup teeth, pusher mechanism, and other sensitive components. The system is then shipped to the end-user or distributor with detailed installation and operational manuals.

This comprehensive manufacturing process ensures that the integrated sugarcane stalk storage and vertical conveyor system (1) is produced to the highest standards, capable of delivering reliable and efficient performance in various applications. The use of high-quality materials, precision engineering, and rigorous testing guarantees a durable and adaptable product.

Fig. 2 illustrates the vertical conveyor system provides a closer view of the vertical conveyor system (3) of the integrated system, highlighting its angular pickup teeth, anti-collision and anti-jumbling mechanism, and modular design. The conveyor is designed to lift sugarcane stalks efficiently and ensure smooth feeding without jamming, even with stalks of varying diameters and shapes. The modular structure also facilitates easy maintenance and customization.

Figure 3 illustrates the mechanical assembly of a system that incorporates various components essential for its operation. At the core of the system are shaft-1 (1) and shaft-2 (2), which serve as the primary and secondary rotating shafts responsible for transmitting rotational motion throughout the assembly. The chain wheel type-1 (3) and chain type-1 (4) are connected to shaft-1, facilitating motion transfer, while chain wheel type-2 (5) and chain type-2 (6) are linked to shaft-2, enabling further motion transfer within the system.

To ensure smooth rotational movement, bearing type-1 (7) and bearing type-2 (8) support the rotating shafts, minimizing friction. Spacer type-1 (9) and spacer type-2 (10) are included in the assembly to maintain proper alignment by keeping the appropriate distance between components. The motor (11) acts as the power source, driving the system by converting electrical energy into mechanical motion. For added structural integrity, stiffener type-1 (12) and stiffener type-2 (13) provide reinforcement to prevent deformation under stress. The attachment (14) connects various parts within the assembly, ensuring they remain in place. Male hook (15) and female hook (16) allow for secure interconnection, enabling easy attachment or detachment of parts.

The system also includes slat type-1 (17) and slat type-2 (18), which are flat, elongated components that form part of a larger structure or conveyor system. To maintain stability and support, leg type-1 (19) and leg type-2 (20) provide the necessary structure, ensuring the assembly remains steady during operation. Finally, the tensioner flange (21) is used to apply tension to the chain, ensuring smooth and efficient movement by preventing slack. Each of these components works in conjunction to ensure the system functions optimally, providing both stability and efficiency in the mechanical assembly.
,CLAIMS:CLAIMS
I/We Claim:
1. An integrated sugarcane stalk storage and vertical conveyor system (1) for automated fresh-crushing and juice vending machines, comprising:
a semi-inclined hopper (2) configured to store and guide sugarcane stalks toward a feeder;
a vertical conveyor system (3) equipped with angular pickup teeth for selectively feeding individual stalks;
a stock loading door positioned on the side of the semi-inclined hopper (2) to facilitate convenient loading of sugarcane stalks without obstructing the flow;
a pusher mechanism (4) employing a high-torque screw feeder for precise feeding of sugarcane stalks into a crushing unit;
an integrated feed system that synchronizes all components to complete the process of storing, aligning, and crushing sugarcane stalks;
Characterized by,
the vertical conveyor system (3) equipped with the angular pickup teeth being designed to handle sugarcane stalks of varying diameters and inconsistent shapes, ensuring individual stalk feeding and preventing clogs;
an anti-collision and anti-jumbling mechanism integrated within the vertical conveyor system (3) to prevent tangling or misalignment of stalks during operation;
a sensor-driven stepwise movement mechanism embedded within the high-torque screw feeder () to monitor and adjust the alignment of stalks in real time, optimizing feeding accuracy and preventing overloading of the crushing unit;
modular design of the vertical conveyor system (3) to allow easy servicing and adaptability to different machine configurations.

2. The system (1) as claimed in claim 1, wherein the semi-inclined hopper (2) facilitates gravity-assisted flow of sugarcane stalks, reducing manual intervention and ensuring uninterrupted feeding.

3. The system (1) as claimed in claim 1, wherein the angular pickup teeth are constructed from wear-resistant stainless steel to enhance durability and operational life under high throughput conditions.

4. The system (1) as claimed in claim 1, wherein the anti-collision and anti-jumbling mechanism includes angular rolling features and a rearrangement guide to maintain smooth stalk alignment.

5. The system (1) as claimed in claim 1, wherein the sensor-driven mechanism embedded in the pusher mechanism (4) uses proximity sensors to detect and align stalks accurately before feeding into the crushing unit.

6. The system (1) as claimed in claim 1, wherein the stock loading door () is positioned at an angle to minimize loading disruptions and ensure consistent flow into the semi-inclined hopper (2).

7. The system (1) as claimed in claim 1, wherein the integrated feed system is operable at a throughput rate of at least 10 sugarcane stalks per minute, ensuring high efficiency in juice extraction.

8. The system (1) as claimed in claim 1, wherein the high-torque screw feeder is configured to adjust torque automatically based on the resistance detected by the embedded sensors during operation.

9. A method for manufacturing an integrated sugarcane stalk storage and vertical conveyor system (1) as claimed in claim 1, comprising the steps of:
fabricating the semi-inclined hopper (2):
cutting and welding steel sheets to form the hopper structure, ensuring an incline angle optimized for gravity-assisted flow of sugarcane stalks;
assembling the vertical conveyor system (3):
installing angular pickup teeth onto modular conveyor chains and calibrating their movement to handle varying stalk diameters;
incorporating the anti-collision and anti-jumbling mechanism:
positioning angular rolling guides and rearrangement components within the conveyor system to prevent tangling or jamming during operation;
manufacturing the pusher mechanism (4):
installing a high-torque screw feeder () and embedding proximity sensors into its structure to enable real-time monitoring and stepwise movement;
installing the integrated feed system:
synchronizing the hopper (2), conveyor (3), and pusher mechanism (4) via a centralized control module to ensure seamless operation;
testing the complete assembly:
performing throughput and durability tests to ensure the system handles varying sugarcane stalk conditions and operates within the specified time duration.