Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated maintenance device for plastic extruder machine which enables automated monitoring with predictive analysis to perform self-maintenance for maximizing precision, ensuring greater operational efficiency, reducing downtime and improving the longevity of crucial machine components.

BACKGROUND OF THE INVENTION

[0002] In existing industrial manufacturing practices, extruder machines suffer from several demerits that hinder efficiency and reliability. Maintenance is largely dependent on manual inspection, dismantling and cleaning, which is not only time-consuming but also prone to human error and inconsistency. The lack of fault prediction leads to unexpected breakdowns, causing unplanned downtime, production delays and higher operational costs. In addition, residue and contamination frequently accumulate inside the machine, reducing performance and accelerating component wear. Servicing methods fail to ensure precise lubrication and thorough cleaning, resulting in repetitive maintenance cycles and shortened equipment lifespan. Waste management generated during these processes is also inefficient, leading to poor material handling and environmental concerns. Overall, the dependence on manual processes, absence of real-time monitoring and inability to automate complete maintenance create significant limitations that restrict productivity, reduce accuracy and compromise long-term industrial efficiency.

[0003] Traditional maintenance of extruder machines, operators rely heavily on manual tools such as spanners, wrenches, hammers, brushes, scrapers and cleaning rods to perform inspection, dismantling, fastening, and cleaning tasks. These tools demand extensive physical effort, consume considerable time and are incapable of delivering precision in identifying faults or maintaining alignment. Manual tightening and loosening with wrenches or spanners frequently lead to over-tightening or under-tightening, causing damage or inefficiency in machine operation. Similarly, cleaning with brushes and scrapers fails to remove stubborn debris and residue thoroughly, while lubrication applied manually results in uneven distribution and wastage. The reliance on physical inspection also limits the ability to detect subtle irregularities in vibration, pressure or temperature, leaving machines vulnerable to unnoticed failures. Collectively, the limitations of these traditional tools create inefficiencies, increase maintenance cycles and elevate the risk of unexpected downtime in critical production environments.

[0004] CN2276396Y discloses a multipurpose diagonal wrench. The utility model is characterized in that a screw tap socket, a screw die seat hole and an outer hexagonal spanner are arranged on the handle part of the diagonal wrench without changing the body construction and the face shaping of an ordinary diagonal wrench; an inner hexagonal spanner is formed by one lengthened side on the sliding part between the movable wrench mouth and the fixed wrench mouth. So, the utility model is provided with the functions of a screw tap rack, a screw dies rack and an inner hexagonal spanner on the basis of an ordinary diagonal wrench and a multipurpose diagonal wrench is formed. The utility model has universal use value.

[0005] US7496985B1 discloses a multipurpose cleaning apparatus for cleaning a variety of surfaces which includes an apparatus for removably retaining a reusable cleaning swifter, an apparatus for removably retaining a disposable cleaning cloth, an apparatus for removably retaining a brush and an apparatus for removably retaining a scouring pad. The apparatus comprises a base having two hingeably attached sections which can be rotated to form an angle so that the swifter can be attached, rotated to form a rigid elongated structure to retain the disposable cleaning cloth through locking clasp assemblies, and configured to receive members which retain gripping members to removably retain a cleaning brush and a scouring pad.

[0006] Conventionally, many devices have been developed to assist in plastic extruder machine maintenance and monitoring, but these devices lack the ability to perform real-time fault prediction, precise dismantling, thorough automated cleaning, accurate lubrication and supervised reassembly. These existing devices function in isolation, requiring multiple interventions and fail to integrate predictive analysis with corrective actions. As a result, they increase downtime, reduce accuracy and struggle to ensure consistency in long-term operational efficiency.

[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 predicting failures, executing automated dismantling, performing precise cleaning and lubrication, managing waste effectively and ensuring accurate reassembly to minimizes human error, reduces downtime, extends machine life and enhances efficiency. By combining predictive, preventive and corrective functions, the device delivers consistent reliability, operational safety and higher productivity in industrial environments.

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 performing automated inspection for fault prediction and, in response, carrying out dismantling and cleaning of the machine to ensure higher efficiency and uninterrupted operational performance.

[0010] Another object of the present invention is to develop a device that is capable of continuously monitoring operational parameters, identifying subtle irregularities and preventing unexpected downtime for improving machine reliability, reducing operational risks and extending equipment lifespan through predictive maintenance.

[0011] Another object of the present invention is to develop a device that is capable of automated fastening and dismantling with accurate force control and precise alignment while minimizing human error, enhancing safety and enabling repeatable, time-efficient maintenance procedures for improved productivity in industrial operations.

[0012] Yet another object of the present invention is to develop a device that is capable of performing cleaning and lubrication processes to thoroughly remove residue, prevent contamination, optimize surface conditions and ensure consistent machine performance for decreasing wear and tear, improving efficiency and reducing the frequency of unscheduled servicing or machine shutdowns.

[0013] 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

[0014] The present invention relates to an automated maintenance device for plastic extruder machine which performs real-time detection of operational irregularities and, in response to detected conditions, executes dismantling processes with accuracy and carries out cleaning with thorough precision to enhance productivity, prevent unexpected failures and safeguard machine components against performance decline.

[0015] According to an aspect of the present invention, an automated maintenance device for plastic extruder machine, comprises of an enclosure is adapted to accommodate a plastic extruder machine, an inspection module is installed and configured to detect potential failures by identifying irregularities in vibration, noise, pressure, and temperature patterns of a shaping die and associated turning screw of the extruder machine, the inspection module includes a vibration sensor configured to detect oscillations and vibrations in the shaping die and turning screw to identify mechanical irregularities, an acoustic sensor configured to capture noise patterns for detecting abnormal sounds indicative of component wear or failure, a primary pressure sensor configured to detect pressure variations within the shaping die to ensure operational stability, a primary proximity sensor configured to detect the position and alignment of the shaping die and turning screw, a moisture sensor configured to identify the presence of unwanted liquid and a temperature sensor in sync with a thermal imaging camera configured to monitor temperature variations and generate thermal maps for detecting overheating or thermal anomalies, a machine learning protocol is integrated with the inspection module to analyze sensor data in real-time, predict potential failures and trigger alerts via a communication module to notify a user through a computing unit when parameters exceed predefined thresholds, a motorized fastening tool is installed within the enclosure via an articulated link and configured to fasten or unfasten bolts of the shaping die and turning screw with torque sensor and a primary position sensor integrated to detect application of force during loosening and tightening operations thereby preventing over-tightening or under-tightening of bolts, a gripping module is installed within the enclosure on a multi-axis articulated arm to securely grip and position the bolts in a chamber installed within the enclosure for dismantling of the extruder machine while including a secondary pressure sensor and a secondary proximity sensor to detect fine variations in contact force and spatial position and to regulate precise force control and accurate spatial alignment.

[0016] According to another aspect of the present invention, the device further comprises of a secondary weight sensor is integrated with the chamber to detect and monitor the number of bolts stored and to alert the user to refill the chamber in case the detected weight recedes a threshold limit, a cleaning module is installed within the enclosure and configured to remove debris, residue, and contaminants from the shaping die and turning screw after dismantling to ensure operational efficiency, the cleaning module includes a motorized cleaning tool with interchangeable brushes and blades and a rotary cutter on a dual-axis slider configured to remove debris, residue, and contaminants from the shaping die and turning screw, an encoder integrated with the cleaning module for precise positioning and angle adjustment of the cleaning elements with respect to the shaping die and turning screw, a lubrication unit including a multi-compartment storage unit configured to store multiple lubricants and a plurality of nozzles for controlled dispensing of lubricant based on detected conditions, level and flow sensors integrated with the lubrication unit to monitor lubricant quantity and ensure consistent flow during application and a backflush unit including a water tank having a pump connected with a sprayer via a conduit to dispense water into the extruder machine’s barrel to clear material blockages, a waste storage compartment is installed within the enclosure and connected with a vacuum-based unit to collect solid and semi-solid waste removed during the cleaning process, a primary weight sensor is integrated within the waste storage compartment to monitor and manage the accumulation of waste material and to trigger an alert over the computing unit when the weight exceeds a predefined threshold and an artificial-intelligence based imaging unit is integrated within the enclosure to monitor the entire maintenance operation and upon completion triggers the gripping module to assemble the extruder machine.

[0017] 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

[0018] 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 maintenance device for plastic extruder machine.

DETAILED DESCRIPTION OF THE INVENTION

[0019] 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.

[0020] 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.

[0021] 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.

[0022] The present invention relates to an automated maintenance device for plastic extruder machine which identifies potential faults before malfunction and conducts automated servicing, lubrication and supervised reassembly of machine components with thorough cleaning and proper waste management to deliver consistent maintenance and ensure the longevity of the equipment with reliable operational performance.

[0023] Referring to Figure 1, an isometric view of an automated maintenance device for plastic extruder machine is illustrated, comprising an enclosure 101, an inspection module 102 installed within the enclosure 101 comprising a vibration sensor 102a, an acoustic sensor 102b, a primary pressure sensor 102c, a primary proximity sensor 102d, a moisture sensor 102e, a temperature sensor 102f and a thermal imaging camera 102g, a motorized fastening tool 103 installed within the enclosure 101 via an articulated link 104, a gripping module 105 installed within the enclosure 101 on a multi-axis articulated arm 106.

[0024] Figure 1 further illustrates a chamber 107 installed within the enclosure 101, a motorized cleaning tool 108 with interchangeable brushes 109 and blades 110 installed within the enclosure 101, a rotary cutter 111 on a dual-axis slider 112 installed within the enclosure 101, a multi-compartment storage unit 113 configured with plurality of nozzles 114 installed within the enclosure 101, a water tank 115 provided with a sprayer 116 via a conduit 117 installed within the enclosure 101, a waste storage compartment 118 installed within the enclosure 101 and connected with a vacuum-based unit 119 installed within the enclosure 101 and an artificial-intelligence based imaging unit 120 integrated within the enclosure 101.

[0025] The device disclosed herein comprises of a platform that is configured to secure over a ground surface, serves as a stable base and adapted to accommodate a plastic extruder machine and is made from strong and lightweight materials which includes but not limited to hardened steel, Aluminum alloy, hard fiber and composite material to withstand weight, handle loads and surface irregularities, while providing a reliable foundation.

[0026] A user is required to activate the device manually by pressing a button installed on the platform and linked with an inbuilt microcontroller associated with the device. The button is a type of switch that is internally connected with the device via multiple circuits that upon pressing by the user, the circuits get closed and starts conduction of electricity that tends to activate the device and vice versa.

[0027] An inspection module is installed within the enclosure 101 to detect potential failures by continuously evaluating irregularities of the shaping die and turning screw. The inspection module includes a vibration sensor 102a that identifies oscillations and irregular tremors that indicate misalignment, imbalance or wear in the rotating components, catching early signs of mechanical stress. The vibration sensor 102a detects vibrations by converting motion into electrical signals. The sensor consists of a piezoelectric element which is mounted within the sensor housing and is connected to a seismic mass. When the shaping die and turning screw vibrates due to operation, the seismic mass moves, applying stress to the piezoelectric material. This stress generates an electrical charge proportional to the vibration intensity. The signal is then conditioned and amplified by an onboard circuit and then transmits to the microcontroller to determine mechanical irregularities.

[0028] The inspection module also includes an acoustic sensor 102b listens for abnormal noise patterns such as grinding, rattling, or shifts in sound signatures that point to friction, material buildup or damage. The acoustic sensor 102b works by capturing sound waves generated during operation of the shaping die and turning screw, then translating them into electrical signals for analysis commonly utilizing a high-sensitivity piezoelectric element, the sensor detects pressure fluctuations in the surrounding air caused by motion, friction or impact. These analog signals are filtered to remove background noise and then amplified before being converted into digital form through an onboard processor. The system analyzes frequency ranges, amplitude levels, and sound patterns to differentiate between normal machine operation and abnormal acoustic signatures such as grinding, whining, rattling, or sudden spikes in noise that signify wear, misalignment or part failure.

[0029] The inspection module further includes a primary pressure sensor 102c to track internal pressure fluctuations within the shaping die; deviations signify blockages, leaks, or improper feed rates. The primary pressure sensor 102c works by converting the force exerted by material within the shaping die into measurable electrical signals, ensuring stable extrusion. The deformation is detected by strain gauges bonded to the shaping die, which change their electrical resistance in response to the internal pressure. The change in resistance is then converted into a voltage signal by a Wheatstone bridge circuit and amplified through signal conditioning components. This output is transmitted to the microcontroller to interpret real-time pressure levels. By comparing with a predefined thresholds values to detect blockages, leaks or irregular material flow that might compromise extrusion quality.

[0030] The inspection module furthermore includes a primary proximity sensor 102d monitors the relative position of the shaping die and screw, detecting shifts that might compromise extrusion quality. The primary proximity sensor 102d works by emitting infrared light from an IR LED toward the the shaping die or turning screw and detecting the reflected light using a photodiode or phototransistor. When the shaping die or turning screw enters the sensor’s detection range, the emitted IR light reflects off their surface and is received by the photodetector. The intensity of the reflected light is directly proportional to the shaping die or turning screw distance, the closer an object, the stronger the reflection. This change in light intensity is converted into an electrical signal by the photodetector, which is then amplified and processed by the sensor’s internal circuitry. The resulting signal is sent to the microcontroller, which interprets to determine the position and alignment of the shaping die and turning screw.

[0031] The inspection module furthermore includes a moisture sensor 102e that identifies the presence of unwanted liquids that cause corrosion or affect product consistency. The moisture sensor 102e works by measuring how much infrared light is absorbed and reflected by the surface of the shaping die and turning screw, since water molecules strongly absorb specific infrared wavelengths. The sensor consists of an infrared light source (commonly an IR LED) that directs a controlled beam onto the target surface and a photodiode or photodetector that measures the intensity of reflected light at chosen wavelengths. If moisture is present, the absorption at water-sensitive IR bands increases, reducing the signal received by the detector. Internal electronics then compare this to a dry baseline, using signal conditioning and digital processing to calculate moisture content or detect liquid presence and transmits to the microcontroller to identify presence of unwanted liquids on the shaping die and turning screw.

[0032] The inspection module furthermore includes a temperature sensor 102f synchronized with a thermal imaging camera 102g enables real-time monitoring of heat distribution and the generation of detailed thermal maps, to catch localized overheating or abnormal thermal gradients well before they evolve into equipment damage. The temperatures sensor works by capturing the infrared radiation naturally emitted from the shaping die and turning screw surfaces during operation. The sensor consists of a thermopile with a built in lens or optical filter that collects and focuses the IR radiation onto a sensing element.

[0033] The thermopile absorbs this radiation and produces a voltage through the Seebeck effect, directly proportional to the surface temperature of the monitored components. This analog voltage is amplified, digitized by an analog to digital converter (ADC), and transmitted to a microcontroller for processing. The microcontroller evaluates the measured values against threshold value stored in the database to detect excessive heating, abnormal cooling, or deviations in thermal behavior.

[0034] The thermal imaging camera 102g disclosed above comprises an image capturing module including a set of lenses that focuses incoming infrared energy emitted by the shaping die and turning screw onto a focal plane array (FPA) composed of temperature sensitive elements. These elements convert the infrared radiation into electrical signals proportional to the heat distribution across the machine components. The signals are amplified and processed by an onboard processor, which translates them into thermal image data that visually represent temperature variations and gradients, then the image data are stored in the internal memory of the camera 102g as optical data.

[0035] The thermal imaging camera 102g further incorporates a processor programmed with protocols that, based on predefined instructions, analyze the optical data to extract critical temperature information and generate thermal maps for detecting overheating or thermal anomalies. The extracted data, converted into digital outputs, are transmitted to the microcontroller for real time evaluation, enabling detection of overheating, operational irregularities and accurate tracking of thermal behaviour across the shaping die and screw for predictive maintenance and safe operation.

[0036] A machine learning protocol is integrated with the inspection module continuously analyzing multi-sensor data in real time to predict potential failures before they escalate. Data from the sensors are collected and processed through the machine learning protocol, which has been trained on baseline operation patterns of the extruder’s shaping die and turning screw. By comparing live inputs to these learned models, the protocol detects subtle anomalies such as unusual vibration frequencies, abnormal sound signatures, irregular pressure deviations or thermal inconsistencies that signal impending wear, misalignment, clogging or overheating. The ML protocol identifies evolving patterns and trends, enabling predictive fault detection with higher accuracy. When parameters exceed preset limits or when anomaly patterns are recognized, the microcontroller triggers alert to

[0037] A user interface is installed within the computing unit and is wirelessly linked with the microcontroller, which transmits alert notifications directly to the computing unit. This enables operators to take a proactive approach by performing timely corrective actions for extending the machine’s lifespan and maintaining the extruder in a stable, reliable operating condition. The user interacts with the interface through a touch screen, keyboard or other input methods available on the computing unit. The computing unit mentioned herein includes, but is not limited to smartphone, tablet or laptop that comprises a processor that receives data from the microcontroller, stores, processes and retrieves the output in order to display on the computing unit.

[0038] The wireless communication between the microcontroller and the computing unit is achieved through a communication module that is activated on pressing of the above disclosed push button. The communication module used herein includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module. The communication module used herein is preferably a Wi-Fi module that is a hardware component that enables the microcontroller to connect wirelessly with the computing unit. The Wi-Fi module works by utilizing radio waves to transmit and receive data over short distances. The core functionality relies on the IEEE 802.11 standards, which define the protocols for wireless local area networking (WLAN). Once connected, the module allows the microcontroller to send and receive data through data packets.

[0039] A motorized fastening tool 103 is installed within the enclosure 101 via an articulated link 104 for fastening and unfastening of bolts on the shaping die and turning screw of the extruder machine. The inspection module continuously monitors anomalies such as misalignment, abnormal pressure build up, thermal irregularities or early signs of wear providing the user with diagnostic insights. Once the user evaluates the data and determines that maintenance or adjustments are required, an input command is given for maintenance The microcontroller receives this command and actuates the articulated link 104 to position the fastening tool 103 precisely on the relevant bolt. The articulated link 104 consists of multiple rigid segments connected by pivot joints and equipped with pneumatic unit that includes an air compressor, a cylinder with a piston and solenoid valve. The air compressor generates compressed air, which passes through a solenoid valve and enters into the air cylinder.

[0040] The air pressure inside the cylinder causes the piston to push the link 104 outward, causing multiple segments to adjust their orientation to position over the shaping die and turning screw. Once positioned, the microcontroller actuates the motorized fastening tool 103 to apply controlled torque for unfastening to enable component removal. The motorized fastening tool 103 consists of a drive motor to convert input energy into rotational motion. This motion passes through a set of reduction gears that amplifies torque while regulating speed for effective bolt loosening. The output shaft, equipped with interchangeable sockets, directly engages with bolt heads to transfer torque efficiently for unfastening, allowing component removal.

[0041] A torque sensor and a primary position sensor integrated with the fastening tool 103 form a precision control to ensure that bolts on the shaping die and turning screw are fastened or loosened with optimal accuracy, thereby preventing over tightening or under tightening. The torque sensor works by measuring the twisting force applied to the fastening tool 103 during bolt tightening or loosening. The torque sensor consists of strain gauges bonded to the fastening tool surface. When torque is applied, the fastening tool 103 undergoes minute elastic deformation, causing the strain gauges to change resistance. This change unbalances the Wheatstone bridge, generating a small electrical signal proportional to the applied torque.

[0042] The signal conditioner amplifies and filters this low level signal, improving accuracy and reducing noise, then send to the microcontroller to determine the torque values and compares them against predefined values stored in the database to ensure precise fastening without exceeding tolerances. when a bolt reaches proper fastening point or if resistance deviates from expected values, indicating incomplete tightening. The microcontroller adjusts motor output to regulate force dynamically to overcome static friction without risking component damage.

[0043] The primary position sensor disclosed above works by using a light source, commonly an LED, a reflective or transmissive target surface, a lens and a photodetector. When activated, the LED emits a focused light beam toward the rotating shaft or bolt interface within the fastening tool 103. Depending on the sensor design reflective or transmissive the light is either bounced back from the target surface or interrupted as passes through. The returning or interrupted light is captured by the photodetector, which converts the detected light pattern or intensity into an electrical signal.

[0044] This signal, after conditioning, is analysed by the microcontroller to determine the exact angular displacement and position of the shaft or bolt head during fastening/unfastening. By correlating this positional data with torque values, the microcontroller ensures bolts are tightened or loosened to the correct specification, thereby avoiding over tightening, under tightening or misalignment while safeguarding the operational reliability of the shaping die and turning screw.

[0045] A gripping module 105 is installed within the enclosure 101 on a multi axis articulated arm 106 to secure handling and positioning of bolts during the dismantling of the extruder machine. The griping module used herein preferably a motorized gripper to grip bolts with sufficient clamping force without damaging the bolts. Once the motorized fastening tool 103 has unfastened the bolts from the shaping die and turning screw, the microcontroller actuates the multi axis articulated arm 106 which works by pneumatic unit that works same as above mentioned, to position accurately over the bolts.

[0046] One positioned, the microcontroller actuates the motorized gripper to correctly hold the bolts and carefully transported to a chamber 107 within the enclosure 101, where they are positioned for safe storage and later reassembly. The motorized grippers consist of a DC motor that converts electrical energy into rotational motion. The motor drives a gearbox, which reduces speed while increasing torque, enabling precise control of gripping force. The gear drive connects to a rack-and-pinion arrangement that translates rotational motion into linear movement, allowing gripper jaws to open and close to securely hold bolts by maintaining consistent tension and transferred with care to the chamber 107, where they are arranged for protected storage and subsequent reassembly.

[0047] A secondary pressure sensor and a secondary proximity sensor are integrated with the gripping module 105 that enables safe, controlled and accurate handling of bolts and the shaping die during dismantling of the extruder machine. The secondary pressure sensor operates in similar manner as described above, detecting fine variations in contact force as the gripping module 105 secures bolts and transmitting proportional electrical signals to the microcontroller which ensures that the bolts or die are held firmly enough to prevent slippage, yet not so tightly as to cause deformation or damage.

[0048] The secondary proximity sensor disclose above provides real time spatial awareness by detecting exact distances and positions between the gripping module 105, bolts, and die surfaces. The secondary proximity sensor operates in similar manner as described above, to detect the position and distance between the gripping module 105, the bolts and the shaping die during dismantling for allowing the microcontroller to recognize the exact spatial alignment of each component and dynamically regulates the movement and gripping action of the module. By providing real-time alignment feedback, the sensor ensures that the gripping module 105 approaches, grips and repositions bolts with precision, preventing collisions, misalignments or excessive force application.

[0049] A secondary weight sensor is integrated with the chamber 107 monitors the bolts stored during dismantling and reassembly of the extruder machine. The secondary weight sensor consists of a body with strain gauges, when the weight of the bolts exerts pressure, causes the body deforms slightly, causing the strain gauges to compress. This deformation changes the electrical resistance of the gauges, which is measured using a Wheatstone bridge circuit. The resulting analog signal is proportional to the applied load and is amplified and converted into a digital signal, which is then transmitted to the microcontroller for comparison against a predefined optimal range. If the detected weight falls below or exceeds this threshold, indicating either a shortage or an overfill, an alert is generated to notify the user for replenishment.

[0050] A cleaning module is installed within the enclosure 101 to remove debris, residue and contaminants from the shaping die and turning screw of the extruder machine, ensuring operational efficiency and extending component life. The cleaning module includes a motorized cleaning tool 108 equipped with interchangeable brushes 109, blades 110 to scrub, scrape and cut away hardened residues or stubborn deposits from both the die and screw surfaces. After completion of dismantling, the microcontroller actuates motorized cleaning tool 108 to remove debris and residue from the shaping die and turning screw. The motorized cleaning tool 108 consists of a high torque electric motor that converts electrical energy into rotational motion, transmitted via a drive shaft and supported by bearings to ensure smooth operation. The output shaft is connected to interchangeable brushes 109 and blades 110 secured with a quick change coupling arrangement for fast replacement. A gear assembly is integrated between the motor and output shaft to regulate speed and torque, allowing controlled cleaning force for different materials without damaging the underlying components.

[0051] The cleaning module also includes a rotary cutter 111 mounted on a dual-axis slider 112 configured to remove stubborn debris, hardened residue and contaminants from the shaping die and turning screw with precision and efficiency. After scrubbing and scrapping the residues, the microcontroller actuates the dual-axis slider 112 to allow precise movement of the rotary cutter 111 along both the X and Y axes, enable to reach various points on the shaping die and turning screw surface with controlled motion. The dual-axis slider 112 consists of a carriage that slides along linear tracks, with each axis driven by own servo motor under microcontroller control. The first servo motor drives the lower rail’s carriage along the X axis via a rack and pinion arrangement, providing smooth and accurate horizontal motion.

[0052] Mounted perpendicularly on this carriage is the second rail, which houses the second servo motor that drives the upper carriage along the Y axis, enabling controlled vertical positioning. Together, this dual axis slide allows the rotary cutter 111 to be precisely aligned and maneuvered across the surfaces of the shaping die and turning screw. Once aligned, the microcontroller actuates the rotary cutter 111 for effective cleaning of debris, residue and contaminants. The rotary cutter 111 consists of a high speed electric motor that converts electrical energy into rotational motion, transmitted through a drive shaft supported by durable bearings to ensure smooth, vibration free operation. Mounted on the shaft is a circular cutting blade made from wear resistant materials, capable of scraping or chipping away stubborn buildup without damaging underlying metal surfaces.

[0053] The cleaning module furthermore includes an encoder is integrated to provide precise positioning and accurate angle adjustment of the cleaning elements, such as brushes 109, blades 110 and the rotary cutter 111 with respect to the shaping die and turning screw. The encoder operates as a feedback device that translates the mechanical motion of the motor or dual-axis slider 112 into electrical signals, allowing the microcontroller to continuously track the exact position, angle, and speed of the cleaning components. The encoder consists of a rotating disk or scale, precisely machined with evenly spaced markings, slots or patterns that represent incremental movement. This disk is mounted on a shaft coupled directly to the motor within the cleaning module. As the shaft turns, the disk rotates accordingly and movement is tracked by the internal processing circuitry. Alongside the disk, a stationary housing supports the shaft bearings to maintain smooth, friction controlled rotation and prevent mechanical drift. The encoder generates output in the form of timed pulses corresponding to the passing disk divisions, with the pulse frequency representing speed and the pulse count correlating to position or angle. The output circuitry conditions these signals into clean digital data that is read by the microcontroller, ensuring accurate tool positioning and alignment for cleaning with accurate angle, preventing over scraping, uneven contact or missed sections.

[0054] The cleaning module furthermore includes a backflush unit which provides a thorough flushing operation that clears loosened debris and residual material from the extruder machine’s barrel after hardened residues have been removed the shaping die and turning screw. The backflush unit consists of a water tank 115 equipped with a pump that pressurizes stored water for directing through a conduit 117 to the sprayer 116 for clearing material blockages. The pump consists of a motor, pump chamber, inlet and outlet valves, and connecting tubing, all working together to deliver controlled pressurized flow. The motor drives a diaphragm that creates suction within the pump chamber, drawing water through the inlet valve and then forcing toward the outlet valve under pressure.

[0055] The pressurized flow is directed through the connecting conduit 117 toward a valve for precise regulation. When an electric current is applied to the solenoidal coil wound around a plunger, a magnetic field is generated that pulls the plunger upward, opening the internal valve and allowing pressurized water to pass. This motion ensures that water is dispensed in controlled amounts through the sprayer 116 nozzle into the extruder machine’s barrel. By releasing targeted, pressurized jets, the pump effectively flushes out residual particles, softened debris and blockages, restoring clean internal surfaces and maintaining consistent extrusion performance.

[0056] The cleaning module further includes a lubrication unit developed to reduce friction, wear and overheating of the shaping die and turning screw by dispensing lubricants in a controlled and efficient manner. The unit features a multi compartment storage unit 113, each compartment dedicated to storing different types or grades of lubricants suitable for varying operational conditions. These compartments are connected to a plurality of nozzles 114 positioned to target critical contact surfaces across the die and screw. After the completion of the cleaning operation, the microcontroller evaluates the detected operating conditions such as residual heat, friction levels, or mechanical stress on the shaping die and turning screw, and then actuates the respective nozzle 114 corresponding to the required lubricant type. The nozzle 114 works in similar manner as described above, to dispense a controlled amount of lubricant directly onto targeted surfaces, ensuring uniform coverage while avoiding excess application that attract debris or cause inefficiency.

[0057] The cleaning module furthermore includes a level sensor is integrated with the lubrication unit to continuously monitor the quantity of lubricant available in the storage compartments during application. The level sensor works by measuring changes in capacitance caused by the presence or absence of lubricant within the storage compartment of the lubrication unit. The level sensor consists of two conductive plates separated by a non conductive material (dielectric). When lubricant, which has a higher dielectric constant than air, is present and comes into proximity with or covers the sensing area, the dielectric between the plates changes, resulting in a measurable increase in capacitance. This variation is detected by the sensor circuitry and converted into an electrical signal, which is then processed by the microcontroller to determine the lubricant level by comparing the measured value against predefined thresholds. If the lubricant falls below the minimum limit, the microcontroller triggers a low level alert, notifying the user to refill the compartment.

[0058] The cleaning module includes furthermore a flow sensor integrated with the lubrication unit to monitor and ensure consistent lubricant delivery during application to the shaping die and turning screw. The flow sensor comprises a flow tube with two electrodes placed opposite each other and a pair of electromagnetic coils that generate a perpendicular magnetic field across the lubricant flow path. As the lubricant passes through this field, induces a voltage across the electrodes. The magnitude of this voltage is directly proportional to the lubricant’s flow rate. The electrodes capture this voltage signal and transmit it to the microcontroller, which evaluates whether the lubricant quantity being delivered matches the required application conditions for the shaping die and turning screw. If the flow is detected to be too low, indicating possible blockage or depletion, or too high, suggesting over delivery, the microcontroller adjusts the operation of the lubrication unit’s actuator or dispensing valve to regulate the flow. This ensures precise and uniform lubricant application, preventing both under lubrication that causes wear and overheating, and over lubrication that waste material or attract residue.

[0059] A waste storage compartment 118 is installed within the enclosure 101 integrated with a vacuum-based unit 119 to efficiently collect and contain solid and semi solid waste materials generated during the cleaning of the shaping die and turning screw. After completion of the lubrication operation, the microcontroller actuates the vacuum-based unit 119 to initiate a final cleanup cycle, ensuring that any residual debris, loosened residue or excess lubricant particles are effectively cleared from the working area. The vacuum-based unit 119 consists of a compact waterproof electric motor connected to an impeller pump that generates suction through a suction nozzle. When actuated, the motor rotates the impeller to create negative pressure, producing a steady suction force that pulls in solid debris, semi solid residues and loosened contaminants from the shaping die, turning screw, and surrounding surfaces. The intake pathway directs the waste into a waste storage compartment 118 within the enclosure 101, where fine particles and semi solid matter are trapped to prevent recirculation or contamination of cleaned machine components. The enclosed design ensures that collected residues do not obstruct moving parts or interfere with subsequent extrusion cycles.

[0060] A primary weight sensor is integrated within the waste storage compartment 118 to continuously monitor and manage the accumulation of solid and semi solid waste collected during the extruder’s cleaning operations. The weight sensor works in similar manner as described above, to detect the incremental load applied as debris and residue are deposited into the compartment 118. Once the weight exceeds the allowable limit, the microcontroller triggers an alert via the communication module to the connected computing unit for notifying the operator to empty the compartment 118 before storage capacity is exceeded. This monitoring prevents overflow, ensures hygienic storage of waste and maintains uninterrupted cleaning cycles without manual checking.

[0061] An artificial-intelligence based imaging unit 120 integrated within the enclosure 101 and receives an activation signal from the microcontroller, to monitor the entire maintenance operation of the extruder machine and ensure process accuracy. The artificial-intelligence based imaging unit 120 comprises of an image capturing module including a set of lenses that captures multiple high-resolution images of the entire maintenance operation, then the captured images are stored within memory of the artificial-intelligence based imaging unit 120 in form of an optical data.

[0062] The artificial-intelligence based imaging unit 120 incorporates a processor that is fed with an artificial intelligence protocol which operates by following a set of predefined instructions to process optical data and perform tasks autonomously. Initially, captured images are collected and input into a database, which then employs protocol to analyze and interpret the optical data. The processor of the artificial-intelligence based imaging unit 120 via the artificial intelligence protocol processes the optical data and extracts the required data from the captured images. The extracted data is further converted into digital pulses and bits and transmits to the microcontroller for analysis. Once the artificial-intelligence based imaging unit 120 confirms completion of all maintenance stages, the microcontroller triggers the gripping module 105 to begin the reassembly process by accurately handling and repositioning bolts and components according to their predefined locations. This ensures precision and guarantees that the extruder machine is restored to optimal operational readiness with consistency and efficiency.

[0063] A battery is associated with the device for powering up electrical and electronically operated components associated with the device and supplying a voltage to the components. The battery used herein is preferably a Lithium-ion battery which is a rechargeable unit that demands power supply after getting drained. The battery stores the electric current derived from an external source in the form of chemical energy, which when required by the electronic component of the device, derives the required power from the battery for proper functioning of the device.

[0064] The present invention works best in the following manner, where the enclosure 101 as disclosed in the invention is adapted to accommodate the plastic extruder machine. The inspection module installed within the enclosure 101 includes the vibration sensor 102a to detect oscillations, the acoustic sensor 102b to capture abnormal noise, the primary pressure sensor 102c to monitor pressure variations, the primary proximity sensor 102d to verify alignment, the moisture sensor 102e to detect unwanted liquids, and the temperature sensor 102f in sync with the thermal imaging camera 102g to generate thermal maps and identify overheating or anomalies, supported by the machine learning protocol that analyses sensor data in real time and triggers alerts via the communication module when predefined thresholds are exceeded. Based on inspection results, the motorized fastening tool 103 mounted on the articulated link 104 uses the torque sensor and the primary position sensor to fasten/unfasten bolts precisely, after which the gripping module 105 carried on the multi axis articulated arm 106, integrated with the secondary pressure sensor and the secondary proximity sensor, secures and transfers the bolts to the chamber 107 fitted with the secondary weight sensor.

[0065] In continuation, following dismantling, the cleaning module operates the motorized cleaning tool 108 with interchangeable brushes 109 and blades 110 and the rotary cutter 111 mounted on the dual-axis slider 112, guided by the encoder for accurate positioning. The lubrication unit with the multi compartment storage and plurality of nozzles 114 dispenses controlled lubricant, while the level sensor and flow sensor to monitor lubricant quantity and ensure consistent flow during application, the backflush unit with the pump, water tank 115 and sprayer 116 clears blockages. The waste is drawn into the waste storage compartment 118 by the vacuum-based unit 119, monitored by the primary weight sensor. Overseeing the workflow, the artificial-intelligence based imaging unit 120 monitors each operation and after validating completion, triggers the gripping module 105 to reassemble the extruder machine, ensuring reliable performance with minimized downtime.

[0066] 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 maintenance device for plastic extruder machine, comprising:
i) an enclosure 101, adapted to accommodate a plastic extruder machine;
ii) an inspection module installed within the enclosure 101, configured to detect potential failures by identifying irregularities in vibration, noise, pressure, and temperature patterns of a shaping die and associated turning screw of the extruder machine;
iii) a motorized fastening tool 103 installed within the enclosure 101 via an articulated link 104, configured to fasten/unfasten bolts of the shaping die and turning screw;
iv) a gripping module 105 installed within the enclosure 101 on a multi-axis articulated arm 106, to securely grip and position the bolts in a chamber 107 installed within the enclosure 101 and dismantle the extruder machine; and
v) a cleaning module installed within the enclosure 101, configured to remove debris, residue, and contaminants from the shaping die and turning screw after dismantling to ensure operational efficiency.

2) The device as claimed in claim 1, wherein the inspection module includes:
a. a vibration sensor 102a configured to detect oscillations and vibrations in the shaping die and turning screw to identify mechanical irregularities;
b. an acoustic sensor 102b configured to capture noise patterns for detecting abnormal sounds indicative of component wear or failure;
c. a primary pressure sensor 102c configured to detect pressure variations within the shaping die to ensure operational stability;
d. a primary proximity sensor 102d configured to detect the position and alignment of the shaping die and turning screw;
e. a moisture sensor 102e configured to identify presence of unwanted liquids; and
f. a temperature sensor 102f in sync with a thermal imaging camera 102g configured to monitor temperature variations and generate thermal maps for detecting overheating or thermal anomalies.

3) The device as claimed in claim 2, wherein a machine learning protocol is integrated with the inspection module to analyze sensor data in real-time, predict potential failures by identifying irregularities in vibration, noise, pressure, and temperature patterns, and trigger alerts via a communication module, to notify a user over a computing unit when parameters exceed predefined thresholds.

4) The device as claimed in claim 1, wherein the cleaning module, includes:

a. a motorized cleaning tool 108 with interchangeable brushes 109 and blades 110, and a rotary cutter 111 on a dual-axis slider 112 configured to remove debris, residue, and contaminants from the shaping die and turning screw;
b. an encoder integrated with the cleaning module for precise positioning and angle adjustment of the cleaning elements with respect to the shaping die and turning screw;
c. a lubrication unit including a multi-compartment storage unit 113 configured to store multiple lubricants, and a plurality of nozzles 114 for controlled dispensing of lubricant based on detected conditions;
d. a level and flow sensors integrated with the lubrication unit to monitor lubricant quantity and ensure consistent flow during application; and
e. a backflush unit including a water tank 115 having a pump, provided with a sprayer 116 via a conduit 117 to dispense water into the extruder machine’s barrel to clear material blockages.

5) The device as claimed in claim 1, wherein a waste storage compartment 118 installed within the enclosure 101 and connected with a vacuum-based unit 119 to collect solid and semi-solid waste removed during the cleaning process.

6) The device as claimed in claim 5, wherein a primary weight sensor is integrated within the waste storage compartment 118 to monitor and manage the accumulation of waste material, and to trigger an alert over the computing unit when the weight exceeds a predefined threshold.

7) The device as claimed in claim 1, wherein the gripping module 105 further includes a secondary pressure sensor and a secondary proximity sensor to detect fine variations in contact force and spatial position during dismantling, and to regulate the gripping module 105 to handle and position bolts and the shaping die with precise force control and accurate spatial alignment.

8) The device as claimed in claim 1, wherein a torque sensor and a primary position sensor integrated with the fastening tool 103 to detect application of force during loosening and tightening operations, thereby preventing over-tightening or under-tightening of bolts.

9) The device as claimed in claim 1, wherein a secondary weight sensor is integrated with the chamber 107 to detect and monitor the number of bolts stored, and alert the user to refill the chamber 107 in case the detected weight recedes a threshold limit.

10) The device as claimed in claim 1, wherein an artificial-intelligence based imaging unit 120 integrated within the enclosure 101 to monitor entire maintenance operation and upon completion of the maintenance, triggers the gripping module 105 assemble the extruder machine.