Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated insulation tape wrapping device that is capable of accurately detecting and aligning the wire for the wrapping insulation tape over the wire. Further, the device is also capable of continuously monitoring the current flowing through the wire and providing real-time alerts in case leakage is detected.

BACKGROUND OF THE INVENTION

[0002] The need of insulation wrapping is important for improving efficiency in industries that require insulation for pipes, wires, or equipment. This method uses machines to quickly and accurately wrap insulation material around items, saving time and labor costs compared to manual methods. Automated methods ensure consistent quality and uniformity in the wrapping process, reducing errors and waste. They also enhance safety by minimizing human contact with potentially hazardous materials. With faster production speeds, automated insulation wrapping helps businesses meet demand more effectively while maintaining high-quality standards.

[0003] Traditional insulation wrapping methods typically involve manual labor, where workers wrap insulation materials around pipes or equipment by hand. While this method allows for flexibility in handling different sizes and shapes and has several limitations. These methods are time-consuming and labor-intensive, leading to higher costs. Workers are also make mistakes, resulting in inconsistent wrapping quality. Additionally, manual wrapping increases the risk of worker fatigue and injuries. As a result, traditional methods are less efficient compared to automated system.

[0004] CN111931662A discloses a insulation film wrapping machine, which comprises: the multi-station turntable comprises a multi-station turntable, a front film coating device, a side film coating device and a corner adhesive tape sticking device, wherein the front film coating device, the side film coating device and the corner adhesive tape sticking device are arranged on the periphery of the multi-station turntable; the front film wrapping device is used for wrapping the bottom surface and the upper surface of a product with an insulating film, the side film wrapping device is used for wrapping two side surfaces of the product with the insulating film and fixing the two side surfaces with adhesive tapes, and the corner adhesive tape sticking device is used for sticking the adhesive tapes to the insulating film at the corner of the product and enabling the adhesive tapes to be flat. The automatic film wrapping machine can automatically wrap the insulating film and automatically stick the adhesive tape to the product, the insulating film and the adhesive tape are smooth and stable, and the film wrapping efficiency and quality of the product are effectively improved.

[0005] CN104681211A discloses a transmission line cable insulated rubber automatic wrapping device. The transmission line cable insulated rubber automatic wrapping device comprises a travelling mechanism, a lifting mechanism and a conveying wrapping mechanism, wherein the travelling mechanism mainly comprises a rubber coated pulley, and drives the pulley to roll through the power provided by a motor, thereby realizing a travelling function of the device on an overhead line; the lifting device realizes the ascending and descending of the conveying wrapping mechanism through a movable pulley and a rope, and accomplishes the connection between the travelling mechanism and the wrapping mechanism; the wrapping mechanism belongs to a core mechanism of a whole robot, and realizes the conveying and wrapping of insulated rubber through the matching of a connecting rod and a pulley. The transmission line cable insulated rubber automatic wrapping device perfectly combines mechanical devices and electromechanical control, ensures that a travelling device is separated from a lifting device, realizes lifting through cables, guarantees the operation stability and reliability, and can flexibly and independently accomplish the operation of wrapping insulated sheath for transmission lines.

[0006] Conventionally, many methods are available in the market for insulating wrapping but these often lack advanced real-time monitoring features, leading to delayed detection of issues like leakage. They are also struggle with wire positioning, resulting in inconsistent insulation wrapping and higher operational costs.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to be capable of automatically wrapping an insulation tape over a wire, ensuring proper alignment and continuously monitors electrical flow, providing real-time alerts for leakage, enhancing safety.

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 automatically positioning and securing the wire for wrapping an insulation tape, ensuring proper orientation and accommodation during the process.

[0010] Another object of the present invention is to develop a device that is capable of continuously monitoring the current flowing through the wire and provide real-time alerts in case leakage is detected, enhancing safety.

[0011] Yet another object of the present invention is to develop a device that is capable of wirelessly communicating for real-time monitoring, allowing the device to provide timely updates and alerts to a remote unit.

[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 insulation tape wrapping device that is capable of monitoring the wire allowing the device to detect any abnormalities and automatically insulating the wire preventing further damage of wire.

[0014] According to an embodiment of the present invention, an automated insulation tape wrapping device, comprises of a housing positioned over a ground surface in proximity to a wire that is wrapped with an insulation tape, a plurality of motorized wheels arranged beneath the housing to provide translation to the housing over the surface, an artificial intelligence based imaging unit installed over the housing and integrated with a proximity sensor for capturing and processing images of the wire, a microcontroller linked with the imaging unit to determines distance of the wire from the housing, a pneumatic scissor arrangement installed over the housing to extend in accordance with the detected distance and position a platform configured with the arrangement in parallel to the wire, a robotic arm installed over the platform to position a pair of C-shaped members configured with the arm around the wire, a motorized hinge joint that actuates to orient the members around the wire to accommodate the wire within the members and a motorized roller wrapped with an insulation tape installed over one of the member to unwrap the tape.

[0015] According to another embodiment of the present invention, the proposed device further comprises of a motorized gripper is configured with inner periphery of the members that grips free end of the unwrapped tape, a motorized sliding unit installed over inner periphery of the members to provide translation to the gripper around the wire in view of wrapping the tape around the wire, an electromagnetic unit installed over ends of the members to attach the ends with each other, a clamp meter is configured with the platform via a robotic link to monitor current flowing through the wire, a computing unit accessed by a concerned authority to inform the authority regarding the detected current leakage, a communication module is integrated to establish a wireless connection between the computing and the microcontroller, a pneumatic cutter is installed with the roller to extend and cut the tape 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 an isometric view of an automated insulation tape wrapping 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 insulation tape wrapping device that is capable of capturing images of the wire for any disruptions and monitoring the flow of current in the wire and providing real-time alerts in case of any disruption is detected in the wire.

[0022] Referring to Figure 1, an isometric view of an automated insulation tape wrapping device is illustrated, comprising a housing 101 positioned over a ground surface, plurality of motorized wheels 102 arranged beneath housing 101, an artificial intelligence based imaging unit 103 installed over housing 101, a pneumatic scissor 104 arrangement installed over housing 101, a robotic arm 105 installed over platform 106, a pair of C-shaped members 107 configured with arm 105, a motorized roller 108 installed over one of member, a motorized gripper 109 is configured with inner periphery of members 107, a motorized sliding unit 110 installed over inner periphery of members 107, a clamp meter 111 is configured with platform 106 via a robotic link 112, a pneumatic cutter 113 is installed with roller 108 and an electromagnetic unit 114 installed over ends of the members 107.

[0023] The device disclosed herein includes a housing 101 positioned over a ground surface in proximity to a wire that is to be wrapped with an insulation tape. The housing 101 present herein is a protective enclosure that contains and supports various components and safeguards the internal parts from external elements. Beneath the housing 101 plurality of motorized wheels 102 are arranged to provide translation to the housing 101 over the surface as per requirement. The motorized wheels 102 consist of a pair of wheels 102 connected to a motor through a shaft. The motor rotates in either a clockwise or counterclockwise direction, driving the wheels 102 movement via the shaft.

[0024] To activate the device, the user must manually press a push button installed on the platform. Upon pressing the button, the circuits within the device gets close, allowing electric current to flow through the sensors. The flow of electricity powers the device, activating the sensor and other components. The button essentially acts as an on/off switch, enabling the device to function by initiating the electrical circuit, which triggers the sensor and activates the associated components for operation. A push button has an outer casing and an inner mechanism, including a spring and metal contacts. When the button is pressed, it pushes down on the spring-loaded mechanism inside. In the default state, the internal contacts are apart, so the circuit is open and no electricity flows. Pressing the button makes the contacts touch each other, closing the circuit and allowing electricity to flow. When the button is released, the spring pushes it back to its original position.

[0025] The housing 101 is installed with an artificial intelligence based imaging unit 103 integrated with a processor captures and processes images of the wire. The imaging unit is also integrated with a proximity sensor for determining distance of the wire from the housing. The artificial intelligence-based imaging unit 103 integrated with the processor comprises a high-resolution camera which captures multiple images of the wire. The artificial intelligence based imaging unit paired with a process carries out a sequence of image processing operations including pre-processing, feature extraction, and classification over the images and utilizes artificial intelligence and machine learning protocols over the captured images and send the signal to the microcontroller for further processing. Further, the proximity sensor works with the help of a high-frequency oscillator and an amplifier. The capacitance of the loop varies when the wires approach the sensor's detection surface, causing the high-frequency oscillator to vibrate. Amplifiers transform the oscillation and stop states into electrical signals, which are then turned into binary switching signals and sent to the microcontroller for further processing. The microcontroller upon receiving the signals from both the imaging unit 103 and the proximity sensor further processes the signal and determines the presence and distance of the wire from the housing 101.

[0026] A pneumatic scissor 104 arrangement is installed over the housing 101 to extend in accordance with the detected distance for position a platform configured with the arrangement in parallel to the wire. The scissor 104 lift arrangement comprises of bars linked in a scissor 104 like arrangement that is powered by a pneumatic unit including an air compressor, air cylinders, air valves and piston which works in collaboration to aid in extension and retraction of the arrangement. The pneumatic unit is operated by the microcontroller, such that the microcontroller actuates valve to allow passage of compressed air from the compressor within the cylinder, the compressed air further develops pressure against the piston and results in pushing and extending the piston. The piston is connected with the bars and due to applied pressure the arrangement extends and similarly, the microcontroller retracts the arrangement by closing the valve resulting in retraction of the piston. Thus, the microcontroller regulates the extension/retraction of the arrangement in order to position a platform 106 configured with the arrangement in parallel to the wire. The platform 106 present herein is rectangular in shape, providing stability and a solid base that is likely constructed from sturdy materials capable of withstanding outdoor conditions. The platform 106 is coated with insulation materials to prevent direct electrical contact between the device and the wire.

[0027] A robotic arm 105 is installed over the platform 106 to position a pair of C-shaped members 107 configured with the arm 105 around the wire. The robotic arm 105 is powered by a motor that moves by turning electrical energy into a spinning motion. Upon actuated by the microcontroller the electricity flows through the motor and a magnetic field is created that pushes against magnets inside the motor, making the rotor inside the motor spin. This spinning motion is then passed through a shaft through gears to move the robotic arm 105 for positioning the pair of C-shaped members 107 around the wire.

[0028] Additionally, the members 107 are configured by means of a motorized hinge joint. The motorized hinged joints comprises an electric motor with a hinge mechanism that allows controlled rotation between the members 107. Upon actuation by the microcontroller, the motor rotates the shaft, causing the hinge to pivot and move the members 107. The motor is connected to the hinge through gears, belts, or linkages, transmitting rotational force to facilitate movement of the hinge joint allowing for precise control over the angle of rotation, enabling to orient the members 107 around the wire to accommodate the wire within the members 107.

[0029] An electromagnetic unit 114 is installed over ends of the members 107 to attach the ends with each other. The electromagnetic unit 114 operates by using an electromagnetic field to attach the ends of the members 107 with each other. Upon actuation by the microcontroller, power is supplied power to the electromagnetic unit 114. When the current is passed through the unit, a magnetic field gets created around the unit. Thus attaching the ends of the members 107 with each other after the wire is accommodated within the members 107.

[0030] Further, a motorized roller 108 wrapped with an insulation tape is installed over one of the member to rotate on axis to unwrap the tape. The motorized roller 108 operates by utilizing an integrated electric motor to drive the roller’s 108rotation to unwrap the tape over the wire.

[0031] Upon actuation by the microcontroller, the motor rotates and turns the roller 108 to rotate on the axis to unwrap the tape which is gripped by a motorized gripper 109 configured with the inner periphery of the members 107 that grips the free end of the unwrapped tape.

[0032] The motorized gripper 109 operates as a robotic hand that is designed to grasp the free end of the tape effectively. The gripper 109 typically incorporates a motorized mechanism that controls the opening and closing of the jaws of the gripper 109. The motor generates the necessary force to move the gripper’s 109fingers for the opening and closing of the jaws with precision. This motorized action is often controlled by the microcontroller for the smooth and precise gripping of the free end of the unwrapped tape.

[0033] Furthermore, a motorized sliding unit 110 is installed over inner periphery of the members 107 to provide translation to the gripper 109 around the wire in view of wrapping the tape around the wire. Upon actuation of the sliding unit by the microcontroller, the motor moves the slider in an automated way for a smooth and controlled transitional motion of the gripper 109 around the wire to wrap the insulation tape around the wire.

[0034] Herein, a pneumatic cutter 113 is installed with the roller 108 to extend and cut the tape after unwrapped over the wire. The pneumatic cutter 113 is powered by a pneumatic unit that includes an air compressor, air cylinder, air valves, and piston which works in collaboration to aid in extension and retraction of the cutter 113. The microcontroller controls the pneumatic unit by actuating a valve that allows compressed air from the compressor to enter the cylinder. This pressurized air pushes against the cutter 113, causing the cutter 113 to extend and cut the tape after the wrapping is completed.

[0035] Also, a clamp meter 111 is configured with the platform 106 via a robotic link 112 to monitor the current flowing through the wire. The clamp meter 111 works by utilizing a magnetic field to measure the current flowing through the wire without the need to physically disconnect the wiring. The clamp meter 111 has a hinged jaw that opens to clamp around the wire. Inside the clamp, there is a current transformer that detects the magnetic field generated by the current flowing through the wire. The clamp meter 111 detects this magnetic field and converts it into an electrical signal. The meter 111 then processes this signal and in case a leakage of current is detected, the microcontroller sends an alert notification to a computing unit accessed by a concerned authority to inform the authority regarding the detected current leakage.

[0036] Also, in case the microcontroller by means of the imaging unit 103 identifies sparking from the wire, the microcontroller sends a relative notification to the computing unit. The computing unit used herein includes but not limited to mobile phones, computers, and tablet. Further, a communication module is also integrated with the microcontroller which includes but not limited to Wi-Fi (Wireless Fidelity) and GSM (Global System for Mobile Communications) module. The Wi-Fi module allows the device to connect wirelessly to the computing unit using internet. The Wi-Fi module scans for available networks and connects to the chosen one using the correct credentials. The module transmits and receives data via radio waves, converting digital data into radio signals and vice versa and follows networking protocols like TCP/IP to ensure proper data transmission. The Wi-Fi communication module integrated within the microcontroller establishes a wireless connection with the computing unit to send the notification regarding the sparking from the wire.

[0037] . The robotic link 112 used herein which holds the clamp meter 111 is made of several segments that are attached together by joints also referred to as axes. Each joint of the segments contains a step motor that rotates and allows the robotic link 112 to complete a specific motion of the link 112. Upon actuation of the robotic link 112 by the microcontroller, the motor drives the movement of the link 112 to position the clamp near the wire.

[0038] Lastly, a battery is installed in the device and connected to the microcontroller to provide power to all electrically-driven components present in the device that require electricity for their proper functioning. The battery used herein is a lithium-ion dry battery, which DC (Direct Current) power, ensuring each components operates effectively.

[0039] The present invention works best in the following manner where, the housing 101 is positioned over the ground surface in proximity to the wire that is to be wrapped with the insulation tape. The plurality of motorized wheels 102 are arranged beneath the housing 101 to provide translation to the housing 101 over the surface. The artificial intelligence-based imaging unit 103 is installed over the housing 101 and integrated with the proximity sensor to determine distance of the wire from the housing 101. The pneumatic scissor 104 arrangement is installed over the housing 101 to extend in accordance with the detected distance and position the platform 106 configured with the arrangement in parallel to the wire. The robotic arm 105 is installed over the platform 106 to position the pair of C-shaped members 107 which are configured with the arms 105 by means of the motorized hinge joint to orient the members 107 around the wire to accommodate the wire within the members 107. Upon accommodation of the wire within the members 107, the electromagnetic unit 114 is installed over end of the members 107 to attach the ends with each other. The motorized roller 108 is wrapped with the insulation tape installed over one of the member to rotate on axis to unwrap the tape and the motorized gripper 109 which is configured with inner periphery of the members 107 grips free end of the unwrapped tape. The motorized sliding unit 110 is installed over inner periphery of the members 107 provides translation to the gripper 109 around the wire for wrapping the tape around the wire. The pneumatic cutter 113 is installed with the roller 108 to extend and cut the tape upon wrapping of the wire. Further, the clamp meter 111 is configured with the platform 106 via the robotic link 112 to monitor current flowing through the wire and in case leakage of current is detected, an alert notification is sent to the computing unit. The communication module is integrated with the microcontroller to establish wireless connection between the computing and the microcontroller and also in case the microcontroller by means of the imaging unit 103 identifies sparking from the wire, the microcontroller sends a relative notification to the computing unit.

[0040] 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 insulation tape wrapping device, comprising:

i) a housing 101 positioned over a ground surface in proximity to a wire that is to be wrapped with an insulation tape, wherein plurality of motorized wheels 102 arranged beneath said housing 101 that actuates to provide translation to said housing 101 over said surface as per requirement;
ii) an artificial intelligence based imaging unit 103 installed over said housing 101 and integrated with a proximity sensor for detecting distance of said wire from said housing 101;
iii) a pneumatic scissor 104 arrangement installed over said housing 101 and actuated by an inbuilt microcontroller to extend in accordance with said detected distance and position a platform 106 configured with said arrangement in parallel to said wire;
iv) a robotic arm 105 installed over said platform 106 and directed by said microcontroller to position a pair of C-shaped members 107 configured with said arm 105 around said wire, wherein said members 107 are configured with said arm 105 each by means of a motorized hinge joint that actuates to orient said members 107 around said wire to accommodate said wire within said members 107;
v) a motorized roller 108 wrapped with an insulation tape installed over one of said member that is actuated by said microcontroller to rotate on axis to unwrap said tape, wherein a motorized gripper 109 is configured with inner periphery of said members 107 that grips free end of said unwrapped tape; and
vi) a motorized sliding unit 110 installed over inner periphery of said members 107 and actuated by said microcontroller to provide translation to said gripper 109 around said wire in view of wrapping said tape around said wire, thereby wrapping said insulation over said wire.

2) The device as claimed in claim 1, wherein upon accommodation of said wire within said members 107, said microcontroller actuates an electromagnetic unit 114 installed over ends of said members 107 to attach said ends with each other.

3) The device as claimed in claim 1, wherein a clamp meter 111 is configured with said platform 106 via a robotic link 112 to monitor current flowing through said wire and in case leakage of current is detected, said microcontroller sends and alert notification to a computing unit accessed by a concerned authority to inform said authority regrading said detected current leakage.

4) The device as claimed in claim 1 and 3, wherein a communication module is integrated with said microcontroller to establish a wireless connection between said computing and said microcontroller.

5) The device as claimed in claim 1, wherein in case said microcontroller by means of said imaging unit 103 identifies sparking from said wire, said microcontroller sends a relative notification to said computing unit.

6) The device as claimed in claim 1, wherein a pneumatic cutter 113 is installed with said roller 108 that is actuated by said microcontroller upon wrapping of said wire, to extend and cut said tape.

7) 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.