Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated bio-brick manufacturing device that efficiently converts agro-industrial waste into bio-bricks with ensuring, enhanced durability, and consistent quality, while minimizing material wastage and reducing manual effort to achieve reliable, sustainable, and high-performance bio-bricks.

BACKGROUND OF THE INVENTION

[0002] The demand for sustainable and eco-friendly construction materials has led to the need for a device that efficiently convert agro-industrial waste into high-quality bio-bricks. Conventional manual and semi-automatic methods require significant human effort, time, and precision, often resulting in inconsistent brick size, shape, and strength. Users face challenges such as uneven mixing, improper compaction, inaccurate patterning, and variable moisture content, which compromise structural integrity and durability. Additionally, manual handling increases the risk of errors, material wastage, and safety hazards. An automated device is therefore required to streamline the entire production process, ensure uniform quality, enable real-time monitoring, reduce human intervention, and enhance efficiency and reliability.

[0003] Existing automated bio-brick manufacturing devices, such as those utilizing hydraulic presses or vibration-based molding systems, have made strides in mechanizing the production process. However, the existing inventions often face limitations in achieving uniform material mixing, precise shaping, and consistent quality control. For instance, some machines leave depressions on the brick surfaces, compromising structural integrity. Additionally, challenges like clogging of output ports and the need for regular maintenance can disrupt production efficiency. While these devices contribute to labor reduction and energy efficiency, they still require significant manual oversight and lack real-time adaptability to varying material properties, leading to potential inconsistencies in the final product. Therefore, there is a need for more advanced systems that offer precise control over each stage of the bio-brick manufacturing process, ensuring uniform quality and reducing dependency on manual intervention.

[0004] Conventionally, many devices are available in the market for manufacturing bricks. However, the cited inventions lack the ability to integrate all key stages of bio-brick production, including uniform material processing, precise mixing, accurate compaction, patterning, drying, baking, and quality assessment, into one device, resulting in inconsistent brick quality, increased material wastage, higher labor dependency, and limited adaptability to varying agro-industrial waste compositions.

[0005] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is required to be capable of performing end-to-end bio-brick manufacturing with real-time monitoring and adaptive control of processing parameters, ensuring uniform quality, improved structural integrity, reduced human intervention, enhanced efficiency, and reliable production of bio-bricks suitable for diverse construction applications.

OBJECTS OF THE INVENTION

[0006] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0007] An object of the present invention is to develop a device that enables manufacturing of bricks from agro-industrial waste with improved strength and durability.

[0008] Another object of the present invention is to develop a device that ensures uniform processing, thorough mixing, and accurate shaping of materials for producing bio-bricks with consistent quality and reliable performance.

[0009] Yet another object of the present invention is to develop a device that reduce errors in production by enabling accurate monitoring and adjustment of key manufacturing parameters in real time.

[0010] 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

[0011] The present invention relates to an automated bio-brick manufacturing device that enables efficient conversion of agro-industrial waste into bio-bricks , while ensuring uniform processing, thorough mixing, and accurate shaping of materials to produce bio-bricks with consistent quality and reliable performance in the manufacturing of bio-bricks.

[0012] According to an aspect of the present invention, an automated bio-brick manufacturing device, includes a housing integrated with a plurality of storage chambers to hold agro-industrial wastes and binding agents, a user-input interface comprising a microphone and display unit to receive user commands and specifications, a chopping unit integrated within each storage chamber triggered by a microcontroller to process agro-waste into uniform particles with solenoid valves located at the base to discharge chopped material downstream, a mixing container with a motorized stirrer connected to a storage box containing a binding agent for forming a homogeneous mixture, a torque rheological sensor installed within the container to detect binding strength, viscosity and shear strength with an AI unit dynamically adjusting composition ratios, an electronic nozzle mounted at the base of the mixing container to pour the blended mixture into selected moulds.

[0013] According to another aspect of the present invention, the device herein further includes a mould handling arrangement integrated with a mould storage unit including a mechanical linkage arm with a motorized ball-and-socket joint, a dispensing pin, and a sensor suite comprising position, force and proximity sensors for precise mould handling, a pressing arrangement including an L-shaped hydraulic actuator, a rectangular compaction plate, pressure sensor and material density sensor to ensure proper binding and levelling, a patterning arrangement comprising L-shaped frames, vertically oriented linear actuators, interchangeable pattern bases and synchronized sensors for tactile pattern application, a drying arrangement including a drying vessel with hot air blowers, thermal and humidity sensors, and a front-end transfer linkage unit for uniform moisture removal, a baking arrangement comprising a baking unit with heating units and transfer conveyor belt for uniform firing, and a quality assessment arrangement comprising vision sensors, laser profilers, vibration unit with accelerometers and strain gauges, a pneumatic actuator with hammer tool, and integrated force and acoustic sensors for structural evaluation of the bio-bricks.

[0014] 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

[0015] 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 bio-brick manufacturing device.

DETAILED DESCRIPTION OF THE INVENTION

[0016] 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.

[0017] 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.

[0018] 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.

[0019] The present invention relates to an automated bio-brick manufacturing device that enables efficient conversion of agro-industrial waste into bio-bricks with improved strength and durability, while reducing production errors by providing accurate real-time monitoring and adjustment of key manufacturing parameters, ensuring consistent quality, reliable performance, and enhanced efficiency throughout the bio-brick manufacturing process.

[0020] Referring to Figure 1, an isometric view of an automated bio-brick manufacturing device is illustrated, comprising a housing 101 integrated with a plurality of storage chambers 102, a chopping unit 103 integrated within each storage chamber 102, solenoid valves 104 are located at the base of the chambers 102, a mixing container 105 with a motorized stirrer 106, installed inside the housing 101, a storage box 107 containing a binding agent is connected to the container 105, a mould handling arrangement integrated with a mould storage unit 129, includes a mechanical linkage arm 108 mounted on a side of the mould storage unit 129, a dispensing pin 109 installed at a tip of the linkage arm 108, a motorized conveyor belt 110 provided inside the housing 101, a pressing arrangement integrated downstream the mixing container 105, includes a L-shaped hydraulic actuator 111 integrated with a rectangular compaction plate 112 connected to the actuator via a motorized pivot joint 113, a patterning arrangement provided in continuation to the pressing arrangement, includes a plurality of L-shaped frames 114 installed along the sides of the conveyor belt 110, each frame 114 equipped with a vertically oriented linear actuator 115, an interchangeable pattern base 116 mounted at the bottom of each actuator 115, a drying arrangement integrated inside the housing 101, includes a drying vessel 117 comprising a plurality of hot air blowers 118, a front-end transfer linkage unit 119 positioned outside the drying vessel 117, equipped with a rectangular transfer plate 120 mounted via a motorized hinge 121, a baking arrangement integrated with the housing 101, includes a baking unit 122 positioned in continuation with a drying vessel 117, the baking unit 122 is internally lined with a plurality of heating units 123, a quality assessment arrangement integrated in continuation with the baking arrangement, includes a rectangular unit 124, a vibration unit 125 embedded within the rectangular unit 124 and a pneumatic actuator 126 mounted within the rectangular unit 124 and connected to a hammer tool 127 via a universal joint 128.

[0021] The device disclosed in the present invention includes a housing 101 equipped with a plurality of storage chambers 102 designed to securely hold agro-industrial wastes and binding agents, ensuring organized storage and discharge of materials. The structured arrangement facilitates controlled handling, prevents contamination, and enables smooth transfer of raw components for subsequent processing into bio-bricks.

[0022] A user-input interface comprising a microphone and display unit is arranged on the housing 101 to receive user commands and specifications for brick manufacturing. In a preferred embodiment of the present invention, the user is enabled to provide voice command via the microphone. The microphone turns the sound energy emitted by the user into electrical energy. The sound waves created by the user carry energy towards the microphone. Inside the microphone, a diaphragm, made of plastic, is present and moves back and forth when the sound wave hits the diaphragm. The coil attached to the diaphragm also moves in same way. The magnetic field produced by the permanent magnet cuts through the coil. As the coil moves, the electric current flows. The electric current from coil flows to an amplifier which convert the sound into electrical signal. An inbuilt microcontroller of the device is linked to the microphone recognize the voice and perform the operations.

[0023] In another embodiment of the present invention, the user accesses the display unit to provide input commands. When the user touches the surface of the display unit to enter the input details, then an internal circuitry of the display unit senses the touches of the displayed option and synchronically, the internal circuitry converts the physical touch into the form of electric signal. The microcontroller processes the received signal from the display unit in order to process the signal and determine the user selection and store the user response to a linked database for further associated functions.

[0024] A chopping unit 103 is integrated within each of the storage chambers 102 to process agro-waste. Based on the input specification given by the user, the chopping units 103 are actuated by the microcontroller for chopping the stored waste into uniform particles. When actuated, the chopping units 103 employ sharp rotating blades driven by a motorized shaft to chop large pieces of waste into uniform fine particles. The design ensures efficient size reduction for better mixing.

[0025] A plurality of solenoid valves 104 are installed at the base of the chambers 102 to discharge the chopped material downstream. Post chopping the waste material, the microcontroller actuates the valves 104 for dispensing the chopped waste. When signaled by the microcontroller, an electric current energizes the solenoid coil, generating a magnetic field that pulls or pushes the valve plunger. This action opens the valve orifice, allowing the processed material to flow downward in a controlled manner. The discharge rate is managed by varying the valve’s opening duration and frequency, ensuring precise quantities of chopped waste are delivered downstream.

[0026] A mixing container 105 with a motorized stirrer 106 is installed within the housing 101 to receive the chopped materials. A storage box 107 containing a binding agent is connected to the container 105 to form a homogeneous mixture. As the processed agro-waste and the binding material is dispended into the container 105, the microcontroller actuates the motorized stirrer 106 for mixing the received material into homogeneous mixture. The motorized stirrer 106 operates by using an electric motor to drive a rotating shaft, which is equipped with a paddle. The motor's rotational force is transmitted through the shaft to the paddle, which grinds the agro-waste and binding material.

[0027] A torque rheological sensor embedded within the container 105 detects binding strength, viscosity, and shear strength, enabling an AI unit linked with the microcontroller to dynamically adjust composition ratios. The torque rheological sensor operates by continuously monitoring the resistance encountered by the stirrer 106 while mixing agro-industrial waste with the binding agent. As the stirrer 106 rotates, the rheological sensor measures the torque required to maintain motion, which directly correlates with mixture viscosity and shear strength. Higher resistance indicates increased viscosity or improper blending, while lower resistance suggests insufficient binding strength.

[0028] These measurements are converted into real-time data signals transmitted to the AI unit. The AI unit consist includes machine learning protocols for analyzing the parameters, compares them against predefined thresholds saved in a database, and dynamically adjusts the composition ratios by regulating the input of binding agents or waste materials.

[0029] A mould handling arrangement integrated with a mould storage unit 129 arranged within the housing 101, organizes, selects, and transports moulds of varying sizes and shapes based on the inputs given by the user. The mould handling arrangement includes a mechanical linkage arm 108 with a motorized ball-and-socket joint for multi-axis movement, a dispensing pin 109 for releasing the bottom-most mould onto a motorized conveyor belt 110.

[0030] In synchronization with operation of the stirrer 106, the microcontroller actuates the dispensing pin 109 to release the selected mould from the mould storage unit 129. The dispensing is powered by a pneumatic actuator that is pneumatically powered by a pneumatic unit. The 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 pin 109. The microcontroller controls the pneumatic valves to regulate the airflow and pressure, providing smooth and precise positioning of the pin 109.

[0031] As the mould is released from the storage unit 129, the microcontroller actuates the mechanical linkage arm 108 to position the mould over the conveyor belt 110. The mechanical linkage arm 108 contains an end effector and several segments that are attached together by motorized joints also referred to as axes. Each joints of the segments contains a step motor that rotates and allows the mechanical linkage arm 108 to complete a specific motion in translating the equipped end effector. The end effector further comprises of a pair of jaws hinged with each other by means of a bi-directional step motor. On actuation the step motor rotates and enables the opening/closing of the jaws of the effector for releasing/gripping the mould over the conveyor belt 110.

[0032] A sensor suite comprising position, force, and proximity sensors is installed within the housing 101 to detect alignment, collision avoidance, and secure handling of the mould. The position sensor used herein is an angle sensor that detects the alignment of the mould placed over the conveyor belt 110.

[0033] The angle sensor used herein works through a reflective surface placed on the mould. An optical encoder consists of a light emitter and a detector. As the mould moves, the reflective surface alters the angle at which light reflects back to the detector. The encoder measures these changes in light patterns, converting them into electrical signals that represent the mould’s angular position. The microcontroller processes these signals to determine the mould’s exact alignment with the surface of the conveyor belt 110.

[0034] The force sensor consists of components such as strain gauges to measure force through changes in electrical resistance when deformed due to applied pressure. As the mechanical linkage arm 108 grips the mould, the force sensor captures the pressure applied and converts it into an electrical signal. This signal is then transmitted to the microcontroller, which interprets the force exerted by the mechanical linkage arm 108 on the mould. In case, the determined force exceeds the pre-fed threshold saved in the database, the microcontroller regulates the mechanical linkage arm 108 for secure handling of the mould.

[0035] The proximity sensor used herein is a capacitive proximity sensor that detects the presence or absence of the mould within its vicinity without physical contact. The proximity sensors detect changes in capacitance caused by the presence of the mould near the sensor's surface. The proximity sensor operates by generating an electrostatic field from an electrode. When the mould comes in contact with this field, it alters the capacitance between the sensor and the mould due to differences in the dielectric constants of materials. The sensor detects the change in capacitance and determines the presence or absence of mould.

[0036] An electronic nozzle mounted at the base of the mixing container 105 pours the blended mixture into selected moulds. Upon confirming the presence and alignment of the mould, the microcontroller actuates the nozzle to dispense blended mixture into the mould. The electronic nozzle comprises of a gate and a magnetic coil which uses electricity from microcontroller to generate the force to control the opening/closing of gate to control the flow of mixture through a small aperture of the nozzle, allowing for precise control of the flow of the mixture on the mould.

[0037] A pressing arrangement is positioned downstream of the mixing container 105 to compacts the poured mixture within the mould for achieving optimal shape and binding strength. The pressing arrangement, includes an L-shaped hydraulic actuator 111 integrated with a rectangular compaction plate 112 connected via a motorized pivot joint 113 to perform vertical and angular adjustments.

[0038] Upon pouring the mixture into the mould, the microcontroller actuates the hydraulic actuator 111 to extend the plate 112 for compacting the mixture. The hydraulic actuator 111 is hydraulically powered by a hydraulic unit. The hydraulic unit comprises of a hydraulic pump, a hydraulic reservoir, a hydraulic fluid, hydraulic valves, and hydraulic cylinders. The hydraulic actuator 111 utilizes pressurized fluid supplied by the hydraulic unit to create strong linear force, which drives the extension and retraction of the compaction plate 112. The microcontroller controls hydraulic valves to modulate fluid flow and pressure, ensuring controlled and stable movement of the compaction plate 112.

[0039] The pivot joint 113 is actuated by the microcontroller to adjust the orientation of the compaction plate 112 as required. The pivot joint 113 works by allowing rotational movement of the compaction plate 112 around a single fixed axis, enabling connected parts to rotate relative to each other like a hinge. The pivot joint 113 consists of a pin inserted through aligned holes in two components, forming a secure connection while permitting one part to turn or pivot around the pin. This design provides controlled, limited movement, allowing the joint to support loads while enabling angular motion to the compaction plate 112.

[0040] A pressure sensor and material density sensor integrated with the plate 112 provides real-time feedback to modulate compression force and ensure uniform levelling and reduced air pockets. The pressure sensor used here is a capacitive pressure sensor that works by measuring changes in capacitance. The pressure consists of two conductive members separated by a small gap. When pressure is applied, the gap between the member is changed, altering the capacitance. The sensor detects this change and converts it into an electrical signal that relates to the amount of pressure. This signal is then sent to the microcontroller to be processed to give a precise pressure reading.

[0041] The material density sensor works by evaluating the compacted mixture inside the mould after pressing. The material density sensor preferably combines force and displacement measurements to calculate density. As the hydraulic actuator 111 lowers the compaction plate 112 onto the mixture, the applied compression force and resulting volume change are measured. The material density sensor detects resistance levels and compares them with reference density values.

[0042] The microcontroller then compares the determined density and pressure against a pre-fed threshold range saved in the database. In case, the determined density and pressure exceeds/recedes the pre-fed threshold range, the microcontroller modulates compression force or mixing ratios accordingly.

[0043] A patterning arrangement mounted in the housing 101, comprises a plurality of L-shaped frames 114 equipped with vertically oriented linear actuator 115 and interchangeable pattern bases 116 to apply various tactile designs including linear grooves, dotted textures, and user-specified patterns based on input commands. Post compacting the mixture, the microcontroller actuates the linear actuator 115 to extend and press the pattern base 116 against the mixture for tracing the required design over the mixture.

[0044] The linear actuator 115 converts the rotational motion into linear motion, allowing for straight-line movement. The actuator preferably consists of a motor, a lead screw, and a sliding component. When the motor is activated, the lead screw is rotated, causing the sliding component to move along a fixed path. The motion is either in one direction (extension) or the opposite (retraction), depending on the requirements. linear actuator 115 is powered by electricity and is used to press the pattern base 116 against the mixture.

[0045] A position and a force sensor are integrated with the conveyor belt 110 for detecting exact brick positioning and monitoring applied pressure. The force sensor herein works in the similar manner as mentioned above. The position sensor is activated by the microcontroller to detect the exact location of the compacted mixture on the conveyor belt 110.

[0046] The position sensor detects the exact location of the compacted mixture on the conveyor belt 110 by continuously monitoring the movement and alignment of the mould. Typically, optical sensors are mounted along the conveyor, emitting a beam of light toward the surface. When the compacted mixture passes through, the sensor records interruptions or reflections to determine its presence and position. This data is relayed to the microcontroller, which synchronizes subsequent operations such as pressing, patterning, or transfer.

[0047] A drying arrangement integrated inside the housing 101 removes moisture from the moulded bio-bricks. The drying arrangement includes a drying vessel 117 with strategically positioned hot air blowers 118. A front-end transfer linkage unit 119 with a rectangular transfer plate 120 mounted via a motorized hinge 121 transfers freshly moulded bricks into the vessel 117.

[0048] Upon pattering the moulded brick, the microcontroller actuates the linkage unit 119 to extend the rectangular plate 120 underneath the moulded brick. In a preferred embodiment of the present invention, the linkage unit 119 is operated through an actuator that is pneumatically powered by a pneumatic unit. The 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 linkage unit 119. The microcontroller controls the pneumatic valves to regulate the airflow and pressure, providing smooth and precise positioning of the linkage unit 119.

[0049] In another embodiment of the present invention, the linkage unit 119 is operated through an actuator that hydraulically powered by a hydraulic unit. The hydraulic unit comprises of a hydraulic pump, a hydraulic reservoir, a hydraulic fluid, hydraulic valves, and hydraulic cylinders. The hydraulic actuator utilizes pressurized fluid supplied by the hydraulic unit to create strong linear force, which drives the extension and retraction of the linkage unit 119. The microcontroller controls hydraulic valves to modulate fluid flow and pressure, ensuring controlled and stable movement of the linkage unit 119.

[0050] Yet in an embodiment of the present invention, the linkage unit 119 is operated through an actuator that is electromechanically powered which convert electrical energy into precise mechanical motion. These actuators typically consist of electric motors coupled with mechanical components such as gears that drive the extension and retraction of the linkage unit 119.

[0051] As the rectangular plate 120 is positioned underneath the moulded brick, the microcontroller re-actuates the linkage unit 119 to retrieve the brick. Upon retrieving the brick, the microcontroller actuates the hinge 121 to flip the moulded brick into the drying vessel 117. The motorized hinge 121 uses motors to control the movement of rectangular plate 120, allowing the rectangular plate 120 to move in a converging or diverging manner. The hinge 121 typically have a mechanical structure that allows for rotation or movement in multiple directions. The motor is connected to this hinge 121 and provides the energy for the movement to adjust the angle or position of the attached rectangular plate. When the motor is activated, the linkages within the hinge 121 move and this movement translates into the rotation or shifting of the plates 120 attached to the hinge 121. The motor makes the plates 120 converge by moving them closer together or diverge by moving them further apart, enabling the transfer of the moulded brick into the drying vessel 117.

[0052] As the brick is transferred into the drying vessel 117, the microcontroller actuates the air blowers 118 for drying the moulded brick. The air blowers 118 work by using a motor to drive a fan, which generates a flow of air. The motor is typically powered by electricity and is connected to a fan blade that spins at high speed. As the fan blades rotate, they create a pressure difference that pulls air into the blower 118 and forces the pulled air out through an outlet. The direction and intensity of the airflow is controlled by the microcontroller.

[0053] A sensor assembly with thermal and humidity sensors is arranged within the drying vessel 117 to regulate airflow intensity and drying duration. The thermal sensor used herein is preferably a temperature sensor to detect the internal temperature of the drying vessel 117. The temperature sensor operates by using a temperature-sensitive element, such as Resistance Temperature Detector (RTD), which changes its electrical resistance with temperature variations. As the temperature rises or falls, the resistance of the element changes accordingly. This change in resistance is converted into an electrical signal by the sensor's circuitry, which then processes the signal to determine the temperature.

[0054] The humidity sensor detects the humidity within the drying vessel 117. The humidity sensor measures humidity by using a hygroscopic conductive material, often a polymer, whose electrical resistance changes with moisture absorption. As humidity levels increase, the conductive material absorbs moisture, causing its resistance to decrease. The sensor measures these changes in resistance and converts them into an electrical signal that represents the relative humidity. The final signal is then sent to the microcontroller.

[0055] The microcontroller compares the determined humidity and temperature against a pre-fed threshold saved in the database. In case, the determined temperature and humidity exceeds/recedes the pre-fed pressure reading, the microcontroller regulates the air flow intensity from the air blowers 118 to enhance the drying efficiency.

[0056] A baking arrangement is positioned in continuation with the drying vessel 117. The baking arrangement includes a baking unit 122 internally lined with heating units 123 to provide uniform high-temperature firing. As the moulded brick is dried, the microcontroller actuates the front end transfer linkage to transfer the dried brick over the conveyor belt 110 arranged in continuation of the drying vessel 117.

[0057] The conveyor belt 110 transport dried moulds to the baking unit 122. The conveyor belt 110 works by using two motorized pulleys that loop over a long stretch of thick and durable material. The motor drives the pulley at the same speed and spin in the same. As the pulley turns, it pulls the belt 110 along its path. The belt 110 moves over a series of rollers, which reduce friction and support the belt 110. As the belt 110 moves, the brick placed on the belt 110 is transported from one end to the other.

[0058] Upon transferring the dried brick into the baking unit 122, the microcontroller actuates the heating units 123 to bake the brick. The heating unit 123 is equipped with heating elements like heated plates that generate heat. The heating plates warm up the interior of the baking unit 122, where the brick is located. The heat is transferred to the brick through conduction and convection.

[0059] A pair of sliding gate is installed at entry and exit points of the baking unit 122, allowing smooth entry and exist of the brick from the baking unit 122. Once the dried brick is placed on the conveyor belt 110, the microcontroller actuates the gates open the baking unit 122, allowing entry of the brick into the baking unit 122.

[0060] The sliding gate opens using an electric motor that drives a rolling assembly. When activated by the microcontroller, electric current powers the tubular motor housed within the gate drum. The motor turns a gear box, which rotates the winding shaft, causing the gate to roll upward around the drum. As the gate rolls upwards, limit switches detect when the gate is fully opened and halt the motor to prevent over-rotation.

[0061] A quality assessment arrangement is integrated downstream of the baking unit 122 to evaluate structural integrity and dimensional accuracy of the bio-bricks. The quality assessment arrangement, comprises a rectangular unit 124 with vision sensors and laser profilers for non-destructive inspection.

[0062] The quality assessment arrangement employs vision sensors and laser profilers to perform non-destructive inspection of bio-bricks after baking. Vision sensors capture high-resolution images of each brick as it passes through the unit, using advanced image processing protocols to detect surface defects, cracks, chips, and dimensional irregularities. Simultaneously, laser profilers project laser beams across the brick surface and measure the reflected signals to generate precise 3D profiles. This allows accurate evaluation of dimensional conformity, surface flatness, and edge alignment. Together, these components ensure comprehensive assessment, enabling the microcontroller to identify defective bricks, maintain consistent quality standards, and reduce manual inspection efforts.

[0063] A vibration unit 125 is embedded within the rectangular unit 124 for generating controlled mechanical vibrations. Upon evaluating the structural integrity of the brick, the microcontroller actuates the vibration unit 125 to generate mechanical vibrations. The vibration unit 125 comprises of an electric motor and an unbalanced weight. The weight is connected to the rotor of the motor. The rotation of the rotor of the motor due to the electric current causes the rotation of the unbalanced weight generating vibrations. The vibration from the vibration unit 125 is translated to brick.

[0064] The vibration unit 125 is operatively connected to integrated accelerometers and strain gauges configured to measure the brick's response and assess impact resistance or falling strength.

[0065] The vibration unit 125 works by subjecting baked bio-bricks to controlled mechanical vibrations, while accelerometers and strain gauges monitor their response. Accelerometers detect changes in acceleration when the brick vibrates, converting mechanical motion into electrical signals that reflect its stability, rigidity, and resistance to dynamic forces. Strain gauges, attached to the unit, measure minute deformations on the brick’s surface by detecting changes in electrical resistance as the material stretches or compresses. Together, these components provide accurate data on the brick’s elasticity, impact resistance, and structural durability. This enables the microcontroller to assess falling strength and identify weak or defective bricks without destructive testing.

[0066] A pneumatic actuator 126 is connected to a hammer tool 127 via a universal joint 128 to apply controlled tapping force in multiple directions. The pneumatic actuator 126 operates by using compressed air to generate linear motion. When pressurized air enters the actuator chamber 102, it pushes the piston, creating a precise forward or backward stroke. This motion is transferred to the hammer tool 127 for applying force. The hammer tool 127 delivers controlled tapping impact onto the bio-brick surface, simulating external stress conditions.

[0067] The universal joint 128 connects the actuator and hammer tool 127, allowing flexible multi-directional movement without misalignment. The universal joint 128 ensures the tapping force can be applied at different angles and orientations while maintaining consistent contact. Together, these components provide controlled, repeatable impact testing to evaluate internal strength and bonding consistency of the bio-bricks.

[0068] A force sensor and an acoustic sensor is integrated with the hammer tool 127 for monitoring brick response to stress and determining internal strength and bonding consistency. The force sensor integrated with the hammer tool 127 works by converting the applied tapping force into electrical signals. When the hammer strikes the bio-brick, the sensor detects the magnitude of impact and transmits real-time data to the control unit for analysis of stress resistance.

[0069] The acoustic sensor functions by capturing sound waves generated during impact. Cracks, voids, or weak bonding inside the brick alter the sound frequency and amplitude. The sensor records these acoustic emissions, which are processed to identify internal defects and bonding consistency. Together, the force sensor quantifies external stress while the acoustic sensor evaluates internal responses, ensuring accurate quality assessment.

[0070] Moreover, a battery 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 known as a cathode and an anode. A voltage is generated between the anode and cathode via oxidation/reduction and thus produces the electrical energy to provide to the device.

[0071] The present invention works best in the following manner, where the agro-industrial wastes and binding agents are stored in the housing 101 within the plurality of storage chambers 102. The user provides commands and specifications for brick manufacturing through the user-input interface comprising the microphone and display unit. The chopping unit 103 integrated within each storage chamber 102 is triggered by the microcontroller to process the agro-waste into uniform particles, and solenoid valves 104 located at the base of the chambers 102 discharge the chopped material into the mixing container 105. The motorized stirrer 106 inside the container 105 blends the chopped material with the binding agent supplied from the connected storage box 107. The torque rheological sensor detects binding strength, viscosity, and shear strength of the mixture, and the AI unit dynamically adjusts composition ratios accordingly. Once the homogeneous mixture is formed, the electronic nozzle mounted at the base of the mixing container 105 pours the mixture into selected moulds organized, selected, and transported by the mould handling arrangement integrated with the mould storage unit 129. The pressing arrangement compacts the mixture within the mould to achieve optimal shape and binding strength. The patterning arrangement then imprints tactile surface patterns. The moulded bio-bricks pass through the drying arrangement to remove moisture and proceed to the baking arrangement where controlled heat is applied for solidifying and strengthening. Finally, the quality assessment arrangement evaluates the structural integrity and dimensional accuracy of the bio-bricks before packaging or dispatch.

[0072] 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. , C , C , Claims:1) An automated bio-brick manufacturing device, comprising:
i) a housing 101 integrated with a plurality of storage chambers 102 configured to hold agro-industrial wastes and binding agents;
ii) a chopping unit 103 integrated within each storage chamber 102, triggered by a microcontroller to process agro-waste into uniform particles, and solenoid valves 104 are located at the base of the chambers 102 to discharge the chopped material downstream;
iii) a mixing container 105 with a motorized stirrer 106, installed inside the housing 101 to receive the chopped materials, wherein a storage box 107 containing a binding agent is connected to the container 105 for mixing with the chopped materials to form a homogeneous mixture;
iv) a mould handling arrangement integrated with a mould storage unit 129 of the housing 101, configured to organize, select, and transport moulds of varying sizes and shapes for bio-brick production;
v) a pressing arrangement integrated downstream the mixing container 105 to compact poured blended mixture within the mould to achieve optimal shape and binding strength;
vi) a patterning arrangement provided in continuation to the pressing arrangement to imprint tactile surface patterns onto the molds;
vii) a drying arrangement integrated inside the housing 101 to remove moisture from moulded bio-bricks prior to baking;
viii) a baking arrangement integrated with the housing 101 configured to apply heat for solidifying and strengthening the moulded bio-bricks; and
ix) a quality assessment arrangement integrated in continuation with the baking arrangement to evaluate the structural integrity and dimensional accuracy of bio-bricks before packaging or dispatch.

2) The device as claimed in claim 1, wherein a user-input interface comprising a microphone and display unit is installed with the housing 101 to receive user commands and specifications related to brick manufacturing.

3) The device as claimed in claim 1, wherein a torque rheological sensor is installed within the container 105 for detecting binding strength, viscosity, and shear strength of the mixture, and wherein based on detected values, the AI unit dynamically adjusts composition ratios.

4) The device as claimed in claim 1, wherein the mould handling arrangement includes:
a) a mechanical linkage arm 108 mounted on a side of the mould storage unit 129, configured with a motorized ball-and-socket joint for providing multi-axis movement,
b) a dispensing pin 109 installed at a tip of the linkage arm 108 and configured to operate in a retractable back-and-forth motion to selectively release a bottom-most mould onto a motorized conveyor belt 110 provided inside the housing 101, and
c) a sensor suite comprising a position sensor, force sensor, and proximity sensor, integrated with the linkage arm 108 for ensuring precise alignment, collision avoidance, and secure mould handling.

5) The device as claimed in claim 1, wherein an electronic nozzle mounted at the base of the mixing container 105 for pouring the blended mixture into the selected moulds.

6) The device as claimed in claim 1, wherein the pressing arrangement includes:
a) a L-shaped hydraulic actuator 111 integrated with a rectangular compaction plate 112 connected to the actuator via a motorized pivot joint 113, to perform vertical motion and angular adjustments, and
b) a pressure sensor and a material density sensor integrated with the plate 112, real-time sensor feedback is analyzed for modulating compression force to ensure proper binding, reduced air pockets, and uniform levelling of the bio-brick surface.

7) The device as claimed in claim 1, wherein the patterning arrangement includes:
a) a plurality of L-shaped frames 114 installed along the sides of the conveyor belt 110, each frame 114 equipped with a vertically oriented linear actuator 115 for enabling precise vertical motion,
b) an interchangeable pattern base 116 mounted at the bottom of each actuator, configured to apply various tactile designs including linear grooves, dotted textures, and user-specified patterns based on input commands, and
c) a position and a force sensor integrated with the conveyor belt 110 for detecting exact brick positioning and monitoring applied pressure, respectively, and synchronizing actuator movement for accurate and consistent pattern application.

8) The device as claimed in claim 1, wherein the drying arrangement includes:
a) a drying vessel 117 comprising a plurality of hot air blowers 118 strategically positioned to circulate controlled heated air for uniform moisture removal from the bio-bricks,
b) a sensor assembly including a thermal sensor and a humidity sensor installed within the vessel 117, to continuously monitor internal temperature and humidity, and to dynamically regulate airflow intensity and drying duration accordingly, and
c) a front-end transfer linkage unit 119 positioned outside the drying vessel 117, equipped with a rectangular transfer plate 120 mounted via a motorized hinge 121, configured to perform tilting and lifting actions for transferring freshly moulded bricks into the vessel 117.

9) The device as claimed in claim 1, wherein the baking arrangement comprises of:
a) a baking unit 122 positioned in continuation with a drying vessel 117, the baking unit 122 is internally lined with a plurality of heating units 123 configured to generate consistent high-temperature heat for uniform brick firing, and
b) the transfer conveyor belt 110 linking the drying vessel 117 to the baking unit 122 for transporting dried moulds into the baking zone.

10) The device as claimed in claim 1, wherein the quality assessment arrangement comprises of:
a) a rectangular unit 124 integrated with a sensor array comprising vision sensors and laser profilers configured for non-destructive inspection of surface cracks, dimensional deviations, and shape conformity of the bio-bricks,
b) a vibration unit 125 embedded within the rectangular unit 124 for generating controlled mechanical vibrations, wherein the rectangular unit 124 is operatively connected to integrated accelerometers and strain gauges configured to measure the brick's response and assess impact resistance or falling strength,
c) a pneumatic actuator 126 mounted within the rectangular unit 124 and connected to a hammer tool 127 via a universal joint 128, the actuator 126 being configured to apply controlled tapping force in multiple directions, and
d) a force sensor and an acoustic sensor integrated with the hammer tool 127 for monitoring brick response to stress and determining internal strength and bonding consistency.