Description:FIELD OF THE INVENTION

[0001] The present invention relates to a roof crack filling device that is capable of detecting and repairing roof cracks for improving structural durability, repair accuracy, operational efficiency, and surface restoration with reduced manual intervention.

BACKGROUND OF THE INVENTION

[0002] Roof surfaces of residential, commercial, and industrial structures are continuously exposed to environmental stress, thermal expansion, moisture infiltration, ultraviolet radiation, and structural vibrations, which gradually result in the formation of cracks, gaps, and surface deteriorations. Such cracks reduce the structural integrity and waterproofing capability of the roof, allowing penetration of water and contaminants into underlying layers, thereby accelerating corrosion, weakening reinforcement structures, and increasing maintenance requirements. In large buildings and elevated roof structures, manual inspection and repair procedures are often difficult, time-consuming, and hazardous due to accessibility limitations and inconsistent surface conditions. Inadequate crack preparation, uneven application of repair materials, and improper finishing frequently lead to weak bonding and recurring failures after repair operations. Additionally, varying crack dimensions and structural conditions require different repair approaches and material compositions, making conventional repair methods highly dependent on operator skill and judgment, which often results in inconsistent repair quality and increased operational costs.

[0003] Traditionally, roof crack repair activities have been carried out using manual inspection tools and hand-operated filling instruments that require workers to individually identify cracks, clean damaged regions, prepare surfaces, apply reinforcement materials, and manually fill repair compounds onto the affected portions. Such conventional approaches are labor-intensive and generally lack precision in assessing crack depth, continuity, and severity prior to repair execution. Manual preparation methods often fail to achieve uniform surface conditioning, while uncontrolled mixing and application of repair materials may result in improper consistency, insufficient penetration, and poor adhesion with the surrounding structure. Existing repair devices also provide limited monitoring and quality control during execution, making it difficult to maintain consistent repair standards across large roof areas. Furthermore, conventional techniques typically do not support automated regulation, operational adjustment, or remote monitoring capabilities, thereby reducing efficiency and increasing the possibility of repair defects, material wastage, delayed maintenance, and repeated structural deterioration over time.

[0004] CN110374353B discloses a repairing robot for preventing leakage of a roof, which comprises a box body, wherein a gear cavity is arranged in the box body, cleaning disc shafts are symmetrically and rotatably arranged between the gear cavity and the bottom surface of the box body in a front-back mode, the cleaning discs are fixedly arranged on the bottom surfaces of the cleaning disc shafts, the front cleaning discs and the rear cleaning discs can clean garbage on cracks on the roof when rotating, an adjusting motor is started, the adjusting motor drives a threaded shaft to rotate, the threaded shaft rotates to drive a threaded sliding block to slide towards the left side, the threaded sliding block can pull a pull rod to enable the cleaning discs to rotate around a universal joint, the cleaning discs and the surface of the roof can be prevented from being contacted and interfered with each other, house fillers can be directly squeezed into the cracks, the extruded fillers can be scraped, a large amount of manual labor is reduced, the roof of a house can be conveniently repaired, the garbage and sundries around the cracks can be collected after being cleaned, the rainproof effect of repair is increased.

[0005] JP2021028462A discloses a repair robot for roof leak prevention is provided with a box body. A gear space is provided in the box body; a cleaning board shaft is mounted symmetrically and rotatably between the gear space and the bottom surface of the box body; a cleaning board is fixedly attached to the bottom surface of the cleaning board shaft, so that the front and rear cleaning boards can clean the dust on the roof when rotating; the cleaning board shaft is coupled with a transmission device that can drive the operation of the cleaning board; a gear rack space is provided on the right side of the gear space; a rack rod is slidably mounted between the gear rack space and the bottom surface of the box body; a hinge connecting rod is attached to the rack rod with a hinge; a suction box for further processing dust cleaned by the cleaning board is attached to the hinge connecting rod with a hinge; a rearranging mechanism is connected to the suction box; and a slide pillar is symmetrically and fixedly attached to the bottom surface of the box body.

[0006] Conventionally, many devices used for roof crack repair rely heavily on manual inspection, surface preparation, and repair execution procedures, which often result in inconsistent repair quality, inaccurate crack assessment, increased labor requirements, delayed maintenance operations, and insufficient restoration efficiency, particularly in large-scale or difficult-to-access roof structures.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of detecting, preparing, reinforcing, and repairing roof cracks with improved precision, controlled material application, enhanced operational efficiency, monitoring capability, and reduced dependency on manual intervention.

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 detects and repairs cracks formed on roof surfaces with improved repair precision and structural restoration efficiency.

[0010] Another object of the present invention is to develop a device that minimizes manual intervention during roof crack repairing operations, while enhancing operational safety and consistency of repair quality.

[0011] Yet another object of the present invention is to develop a device that enables monitoring of roof craks, adaptive repair execution, and controlled application of repair materials for improving durability and long-term performance of repaired roof structures.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a roof crack filling device that is capable of detecting and repairing cracks formed on roof surfaces through automated repair operations, thereby improving structural stability, enhancing repair precision, reducing manual effort, and enabling efficient restoration of damaged roof portions under varying operating conditions.

[0014] According to an aspect of the present invention, a roof crack filling device, comprises of a housing, a plurality of motorized omnidirectional wheels and an IMU (inertial measurement unit) sensor, are attached to the housing and configured to provide controlled mobility and navigation to the housing, a crack detection unit installed on the housing and comprising a UPV (ultrasonic pulse velocity) sensor for measuring crack depth and continuity, and a fiber optic sensor for detecting strain and bonding strength to identify crack location, severity and integrity, a first articulated arm coupled to a chisel bit and a second articulated arm coupled to a spring loaded hammering tool, and each arm mounted on a linear slider installed on the housing, configured to prepare the crack surfaces through peening, chasing and spalling, a robotic arm coupled to a motorized cleaning brush is mounted on the linear slider and configured to clean debris from the crack areas prior to the execution of repairing and crack filling operations, a motorized metal mesh sheet dispensing roller mounted on an exterior surface of the housing and configured to controllably dispense the mesh sheet, a telescopic arm coupled to a clamping unit, mounted on a linear guide rail installed on the housing and configured to retrieve and position the dispensed mesh sheet over the prepared crack surface, a motorized blade is mounted on the housing via an extendable linkage and configured to sever the mesh sheet from the roller.

[0015] According to another aspect of the present invention, the device further comprises of a plurality of storage compartments positioned in the housing, each connected to a delivery conduit with a dispensing valve and configured to store and dispense controlled quantities of cement, sand, epoxy resin, sodium silicate, polymer slurries and PCMs (phase change materials) based on detected crack severity and integrity, a mixing chamber positioned within the housing and configured to receive the dispensed materials from the storage compartments and thoroughly bend to form a mixture of optimal consistency, the mixing chamber is equipped with a motorized mixing blade and a viscosity sensor configured to monitor the continuously monitor the viscosity of the mixture and enable a microcontroller embedded in the housing to dynamically regulate the blending parameters including blade speed and mixing duration, a delivery channel connected to the mixing chamber and coupled to a dispensing nozzle, extending outward from the housing, configured to controllably dispense the prepared mixture onto the cracks, a gauging trowel coupled to a scissor-based extension linkage mounted on the linear slider installed on the housing and configured to level and finish the filled cracks, an imaging unit is installed on the housing and configured to monitor the operations and enable the microcontroller to dynamically adjust the operational parameters analyzed imaging data, a communication module is integrated with the microcontroller, configured to establish wireless connectivity with a computing unit, inbuilt with a user interface, enabling remote monitoring and control of operations.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a roof crack filling device.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to a roof crack filling device that is capable of detecting, preparing, reinforcing, and repairing cracks formed on roof surfaces through controlled repair operations, thereby enhancing structural durability, improving crack sealing efficiency, minimizing manual intervention, and enabling precise surface restoration with optimized repair quality under varying structural conditions.

[0022] Referring to Figure 1, an isometric view of a roof crack filling device is illustrated, comprising a housing 101, a linear slider 102 installed on the housing 101, a first articulated arm 103 coupled to a chisel bit 104 mounted on the slider 102, a second articulated arm 105 coupled to a spring loaded hammering tool 106 mounted on the slider 102, a motorized metal mesh sheet dispensing roller 107 mounted on an exterior surface of the housing 101, a telescopic arm 108 coupled to a clamping unit 109 mounted on a linear guide rail 110 installed on the housing 101, a plurality of storage compartments 111 connected to a delivery conduit 112 with a dispensing valve 113 positioned on the housing 101, a mixing chamber 114 positioned within the housing 101, a delivery channel 115 connected to the mixing chamber 114 coupled to a dispensing nozzle 116 extending outward from the housing 101, a gauging trowel 117 coupled to a scissor-based extension linkage 118 mounted on the slider 102, a plurality of motorized omnidirectional wheels 119 attached to the housing 101, a robotic arm 120 coupled to a motorized cleaning brush 121 mounted on the linear slider 102, a motorized blade 122 mounted on the housing 101 via an extendable linkage 123, a motorized mixing blade 124 integrated in the mixing chamber 114, a water storage reservoir 125 connected to a dispensing tube 126 coupled with a spraying nozzle 127 extending outward from the housing 101, an imaging unit 128 installed on the housing 101.

[0023] The device disclosed herein comprises of a housing 101 to accommodate and support operational components of the device. The housing 101 is configured as a rigid enclosed framework structured to support and protect the operational assemblies of the device during crack repair operations on roof surfaces. The housing 101 is preferably fabricated from corrosion-resistant high-strength materials including but not limited to, stainless steel, reinforced aluminum alloy, and industrial composite materials to withstand harsh outdoor environments, mechanical stress, moisture exposure, temperature variations, and prolonged construction-site operating conditions.

[0024] A plurality of motorized omnidirectional wheels 119 and an IMU (inertial measurement unit) sensor are attached to the housing 101 to provide controlled mobility and navigation to the housing 101. Upon activation by a microcontroller associated with the device, the IMU sensor internally operates by combining measurements obtained from embedded accelerometers for detecting linear acceleration and tilt, gyroscopes for detecting angular velocity and rotational orientation, and optionally magnetometers for detecting directional orientation relative to earth’s magnetic field to continuously detect acceleration, angular velocity, orientation, tilt, and directional movement of the housing 101. The sensor converts the detected physical motion into electrical signals and transmits corresponding positional and navigational data to the microcontroller for real-time processing. The microcontroller analyzes the received data to regulate movement stability, directional alignment, navigation accuracy, and controlled mobility of the housing 101 during roof crack repair operations.

[0025] Based on the data from the IMU sensor, the microcontroller actuates the omnidirectional wheels 119 to provide mobility to the housing 101. The omnidirectional wheels 119 internally operate through independently driven motorized wheel assemblies equipped with multiple peripheral rollers mounted around the wheel 119 circumference at angular orientations. Upon receiving movement commands, the motors rotate the wheels 119 at controlled speeds and directions, while the peripheral rollers enable simultaneous longitudinal, lateral, diagonal, and rotational movement without requiring directional turning of the housing 101. The coordinated operation of the wheel motors enables precise maneuverability, stable navigation, position correction, and smooth mobility of the devices.

[0026] A crack detection unit is installed on the housing 101 and comprising a UPV (ultrasonic pulse velocity) sensor for measuring crack depth and continuity, and a fiber optic sensor for detecting strain and bonding strength to identify crack location, severity and integrity. The UPV sensor internally operates by generating ultrasonic pulse waves through a transmitting transducer directed toward the roof surface. The transmitted pulses travel through the structural material and are received by a receiving transducer after passing across the crack region. Internal signal processing circuitry measures the pulse travel time, attenuation, and transmission characteristics to determine crack depth, continuity, and internal structural defects. The processed data is transmitted to the microcontroller for analyzing crack severity and regulating subsequent repair operations accordingly.

[0027] The fiber optic sensor internally operates by transmitting light signals through optical fibers positioned to detect strain, deformation, and bonding variations around crack regions. Structural stress and material displacement alter the intensity, phase, wavelength, or reflection characteristics of the transmitted light within the fiber. Internal photodetectors and signal conditioning circuitry analyze these optical variations and convert them into electrical signals corresponding to crack integrity and bonding strength. The generated sensing data is transmitted to the microcontroller for evaluating crack conditions and controlling repair operations.

[0028] A first articulated arm 103 is coupled to a chisel bit 104 is mounted on a linear slider 102 to prepare crack surfaces through controlled peening, chasing, and material removal operations. The first articulated arm 103 internally operates through interconnected movable joint sections driven by motorized actuators and rotational linkages that enable multi-directional movement and positional adjustment of the chisel bit 104. Internal drive means coordinate angular motion, extension, and controlled force application for accurately aligning the chisel bit 104 with the detected crack surface. The articulated joints enable flexible movement across varying roof contours while maintaining operational precision during crack preparation procedures including peening, chasing, and spalling operations prior to filling.

[0029] The chisel bit 104 operates by applying concentrated mechanical impact and cutting force onto the crack surface for removing weakened material portions, widening narrow cracks, and preparing the surface for effective filling operations. The chisel bit 104 further assists in cleaning irregular crack edges, improving surface adhesion, and creating a structurally suitable bonding region for receiving reinforcement materials and repair mixtures during crack rehabilitation procedures.

[0030] The linear slider 102 internally operates through a guided rail comprising sliding carriages, bearings, and motor-driven translation assemblies configured to provide controlled linear movement of the first articulated arm 103 with the chisel bit 104 along predetermined paths. Internal drive means including lead screws to enable smooth positional displacement with high accuracy and stability. The linear slider 102 coordinates directional movement and alignment of the first articulated arm 103 with the bit 104 for performing crack preparation operations across different regions of the roof surface.

[0031] Further, a second articulated arm 105 coupled to a spring loaded hammering tool 106 are mounted on the linear slider 102 to prepare the crack surfaces through peening, chasing and spalling. The second articulated arm 105 works internally in the similar manner as the first articulated arm 103 operates. The spring loaded hammering tool 106 internally operates through a reciprocating impact means comprising a spring-biased striking member driven by motorized actuation. During operation, internal compression of the spring stores mechanical energy which is subsequently released to generate repeated controlled hammering impacts onto the crack surface. The cyclic impact action enables effective peening, chasing, and spalling of deteriorated roof material. The hammering intensity and operational frequency are regulated to achieve controlled surface preparation without causing excessive structural damage.

[0032] A robotic arm 120 coupled to a motorized cleaning brush 121 is mounted on the linear slider 102 to clean debris from the crack areas prior to the execution of repairing and crack filling operations. The robotic arm 120 internally operates through interconnected articulated segments driven by servo motors, rotational joints, and positional control actuators configured to provide multi-axis movement and controlled brush positioning. Internal motion control means coordinate angular displacement, extension, elevation, and directional alignment for accurately positioning the cleaning brush 121 relative to the crack regions. The robotic arm 120 enables flexible movement across varying roof geometries, while maintaining operational precision and stability during automated cleaning and crack preparation procedures.

[0033] The motorized cleaning brush 121 internally operates through a rotary drive means comprising an electric motor coupled to a shaft supporting multiple abrasive bristles. Upon activation, the motor rotates the brush at controlled speeds to dislodge dust, debris, loose particles, and deteriorated material accumulated around the crack regions. Internal speed regulation means enable controlled brushing intensity according to surface conditions. The rotation of the cleaning brush 121 enhances crack cleanliness and surface preparation to improve bonding efficiency and filling effectiveness during repair operations.

[0034] A motorized metal mesh sheet dispensing roller 107 is mounted on an exterior surface of the housing 101 to controllably dispense the mesh sheet. The mesh sheet dispensing roller 107 internally operates through a rotational drive assembly comprising a powered spindle, motorized rollers, tension regulating elements, and feed control means configured to dispense the mesh sheet in a controlled manner. Upon activation, the motor rotates the roller to gradually unwind the mesh sheet while maintaining uniform tension and alignment during dispensing. Internal feed regulation means control dispensing speed and positioning accuracy to ensure proper reinforcement coverage over the prepared crack surfaces during repair operations.

[0035] A telescopic arm 108 coupled to a clamping unit 109, is mounted on a linear guide rail 110 that is installed on the housing 101 to retrieve and position the dispensed mesh sheet over the prepared crack surface. The linear guide rail 110 works internally in the similar manner as the linear slider 102 operates. The telescopic arm 108 is operated by a pneumatic unit that internally functions through multiple extendable arm sections interconnected with pneumatic cylinders, pressurized air conduits, valves, and actuator chambers. Upon receiving operational commands, compressed air is selectively directed into the pneumatic cylinders to generate controlled extension and retraction of the telescopic sections. Internal pressure regulation means enable smooth movement, positional stability, and controlled gripping operations. The pneumatic actuation enables efficient handling, retrieval, and placement of the mesh sheet over the prepared crack surfaces via the clamping unit 109.

[0036] The clamping unit 109 internally operates through movable gripping members driven by actuator means configured to securely engage and hold the dispensed mesh sheet during retrieval and positioning operations. Internal force transmission assemblies regulate gripping pressure to prevent slippage or deformation of the mesh sheet while enabling controlled release after placement. The clamping unit 109 attached on the telescopic arm 108 to maintain accurate positioning of the reinforcement mesh over the prepared crack surface during crack rehabilitation procedures.

[0037] Further, a motorized blade 122 is mounted on the housing 101 via an extendable linkage 123 to sever the mesh sheet from the roller 107. The extendable linkage 123 works internally in the similar manner as the telescopic arm 108 operates. The motorized blade 122 internally operates through a rotary cutting unit driven by an electric motor coupled to a transmission assembly. Upon activation, the motor generates controlled rotational cutting motion of the blade 122 for severing the dispensed metal mesh sheet at predetermined lengths. Internal speed regulation and positioning means enable accurate cutting operations, while minimizing deformation or displacement of the mesh sheet. The motorized blade 122 enables automated separation of reinforcement material during crack repair procedures.

[0038] A water storage reservoir 125 is positioned within the housing 101 to store water. The water storage reservoir 125 is configured as a sealed fluid containment chamber positioned within the housing 101 for storing controlled quantities of water utilized during crack preparation and repair operations. The reservoir 125 is preferably fabricated from corrosion-resistant materials that is capable of withstanding prolonged moisture exposure and varying environmental conditions.

[0039] The reservoir 125 is connected to a dispensing tube 126 extending outward from the housing 101 to deliver controlled quantities of water onto the crack prior to execution of repairing and filling operations for enhancing bonding with the prepared mixture. The dispensing tube 126 internally operates through a fluid transfer passage connected between the water storage reservoir 125 and a spraying nozzle 127 for directing controlled water flow toward the prepared crack regions. Internal flow pathways, pressure-regulating sections, and sealing arrangements enable smooth and leakage-resistant transportation of water during operation. The dispensing tube 126 maintains consistent fluid delivery while accommodating controlled regulation of water quantity and flow rate to optimize surface conditioning and bonding preparation prior to crack filling operations.

[0040] The spraying nozzle 127 internally operates through a pressurized fluid discharge means configured to atomize or distribute water into controlled spray patterns over the prepared crack surfaces. Internal flow channels, pressure control passages, and outlet apertures regulate water dispersion intensity, coverage area, and spray direction during operation. The spray nozzle 127 enables uniform wetting of the crack regions to improve surface conditioning and bonding efficiency during crack rehabilitation procedures.

[0041] The spraying nozzle 127 is integrated with a flow sensor and a moisture sensor for detecting the flow of water and moisture content in the prepared cracks. The flow sensor internally operates by detecting the movement and quantity of water passing through the dispensing tube 126 using sensing elements including turbine-based component. As water flows through the sensor, internal sensing circuitry generates corresponding electrical signals proportional to the flow rate and fluid volume. The generated signals are transmitted to the microcontroller for continuously monitoring water delivery conditions and regulating dispensing operations to maintain controlled moisture application during crack preparation procedures.

[0042] The moisture sensor internally operates by detecting the moisture content present within the prepared crack surfaces through electrical property variations including resistance caused by water presence. Internal sensing electrodes and signal conditioning circuitry analyze these variations and generate corresponding electrical signals indicative of surface moisture conditions. The detected moisture data is transmitted to the microcontroller for evaluating surface readiness and regulating water dispensing operations to achieve optimal bonding conditions prior to crack filling and repair procedures.

[0043] A plurality of storage compartments 111 connected to a delivery conduit 112 with a dispensing valve 113 is positioned in the housing 101 to store and dispense controlled quantities of cement, sand, epoxy resin, sodium silicate, polymer slurries and PCMs (phase change materials) based on detected crack severity and integrity via the fiber optic sensor. The compartments 111 are preferably fabricated from, but not limited to, chemically resistant materials and structured to maintain material isolation, prevent contamination, and support controlled dispensing of predetermined material quantities during crack repair and filling operations. The delivery conduit 112 works internally in the similar manner as the dispensing tube 126 operates.

[0044] The dispensing valve 113 internally operates through a controlled flow regulation means comprising movable valve 113 members, actuator assemblies, sealing elements, and flow passages configured to selectively permit or restrict material discharge from the storage compartments 111. Upon receiving operational commands, the actuator adjusts the valve 113 position to regulate dispensing quantity and flow rate of repair materials. Internal sealing arrangements prevent leakage and ensure precise metering of materials according to crack severity and repair requirements during filling operations.

[0045] A mixing chamber 114 is positioned within the housing 101 to receive the dispensed materials from the storage compartments 111 and thoroughly blend to form a mixture of optimal consistency. The mixing chamber 114 is configured as an enclosed blending enclosure positioned within the housing 101 for receiving and combining repair materials dispensed from the storage compartments 111. The mixing chamber 114 is fabricated from wear-resistant and chemically resistant materials capable of withstanding continuous mixing operations and exposure to abrasive and reactive repair substances.

[0046] The mixing chamber 114 is equipped with a motorized mixing blade 124 and a viscosity sensor to continuously monitor the viscosity of the mixture and enable the microcontroller to dynamically regulate the blending parameters including blade 124 speed and mixing duration. The motorized mixing blade 124 internally operates through a rotary agitation means driven by an electric motor coupled to a rotating shaft positioned within the mixing chamber 114. Upon activation, the motor rotates the blade 124 at controlled speeds to continuously agitate, shear, and blend the dispensed repair materials into a substantially homogeneous mixture. Internal speed control means enable adjustment of rotational velocity according to material properties and viscosity conditions, thereby improving mixture consistency and ensuring proper preparation of the repair composition prior to dispensing operations.

[0047] The viscosity sensor internally operates by detecting the resistance characteristics and flow behavior of the repair mixture present within the mixing chamber 114 using mechanical, rotational, vibrational, or pressure-responsive sensing elements. Internal sensing circuitry analyzes variations in fluid movement, shear resistance, or flow consistency and converts the detected parameters into electrical signals indicative of mixture viscosity. The generated data is transmitted to the microcontroller for continuously monitoring mixture consistency and dynamically regulating blending parameters including mixing speed and mixing duration.

[0048] A delivery channel 115 is connected to the mixing chamber 114 and coupled to a dispensing nozzle 116, extending outward from the housing 101 to controllably dispense the prepared mixture onto the cracks. The delivery channel 115 is similar as the dispensing tube 126. The dispensing nozzle 116 connected with the channel 115, internally operates through a controlled discharge means comprising internal flow channels, outlet passages, and pressure-regulating sections configured to direct the prepared repair mixture onto the crack surfaces with controlled flow characteristics. The dispensing nozzle 116 regulates dispensing direction, discharge quantity, and application width to ensure accurate filling of the prepared cracks. Internal anti-clogging and flow stabilization features maintain consistent material delivery while minimizing blockage and irregular discharge during automated crack filling and rehabilitation operations.

[0049] A gauging trowel 117 coupled to a scissor-based extension linkage 118 is mounted on the linear slider 102 installed on the housing 101 to level and finish the filled cracks. The gauging trowel 117 internally operates through a surface finishing means configured to spread, compress, smoothen, and level the dispensed repair mixture over the filled crack regions. The trowel 117 maintains controlled contact with the roof surface, while applying regulated finishing pressure to eliminate excess material, improve surface uniformity, and achieve a substantially flat finish. The extension linkage 118 enables accurate alignment and controlled traversal of the trowel 117 during automated surface finishing operations.

[0050] The scissor-based extension linkage 118 internally operates through interconnected pivotally coupled link members arranged in a collapsible scissor configuration driven by actuator means for controlled extension and retraction. Upon activation, the linked members expand or contract in synchronized motion to adjust the positional reach and elevation of the attached gauging trowel 117. Internal pivot joints and force transmission assemblies maintain structural stability and controlled movement while enabling precise positioning and operational flexibility during crack leveling and finishing procedures.

[0051] The gauging trowel 117 is equipped with a laser sensor to monitor the surface levelling, enabling the microcontroller to dynamically regulate the troweling operations for achieving optimal flat finish. The laser sensor internally operates by emitting laser beams toward the repaired roof surface and detecting the reflected signals using optical receiving elements. Internal signal processing circuitry analyzes variations in reflected beam distance, alignment, and surface contour to determine surface flatness, height deviations, and leveling accuracy of the filled crack regions. The processed measurement data is transmitted to the microcontroller for continuously monitoring surface conditions and dynamically regulating the gauging trowel 117 operations to achieve a substantially uniform finished surface.

[0052] An imaging unit 128 is installed on the housing 101 to monitor the operations and enable the microcontroller to dynamically adjust the operational parameters analyzed imaging data. The imaging unit 128 internally operates through optical image acquisition components including image sensors, lenses, illumination elements, and signal processing circuitry configured to capture visual data associated with crack conditions and ongoing repair operations. The acquired image data is converted into digital signals and transmitted to the microcontroller for analysis of crack geometry, surface preparation quality, material application, and finishing conditions. The imaging unit 128 enables continuous visual monitoring and supports dynamic operational adjustments during automated crack repair procedures.

[0053] An AI (artificial intelligence) module is integrated with the microcontroller to analyze the imaging and sensor data using trained machine learning protocols, enabling the microcontroller to accordingly regulate the operational parameters. The AI module internally operates using trained machine learning protocols including convolutional neural network (CNN)-based image analysis models and long short-term memory (LSTM) predictive learning protocols to analyze imaging and sensor data acquired from the imaging unit 128, and sensors. The CNN protocol processes crack geometry, surface conditions, and repair quality from captured images, while the LSTM protocol analyzes sequential sensor data patterns to predict crack severity, material requirements, operational adjustments, and optimal repair parameters, enabling the microcontroller to dynamically regulate device operations.

[0054] A communication module is integrated with the microcontroller to establish wireless connectivity with a computing unit, inbuilt with a user interface, enabling remote monitoring and control of operations. The communication module internally operates through wireless transceiver circuitry including Wi-Fi, Bluetooth, or cellular communication chips that encode, modulate, and transmit operational data received from the microcontroller. The communication module also receives remote control signals from the computing unit, demodulates them, and converts them into digital instructions for execution. Internal protocol handling units manage data packet formatting, encryption, error correction, and signal synchronization to ensure reliable bidirectional communication during real-time monitoring and control of the device.

[0055] The user interface internally operates through a graphical display means integrated within the computing unit, enabling visualization of operational parameters, sensor outputs, and device status in real time. The user interface processes input commands from the user via touch, keyboard, or remote controls and converts them into structured digital instructions. Internal rendering engines display imaging data, alerts, and control menus, while feedback modules ensure synchronization between user actions and device response through the communication module and microcontroller coordination.

[0056] The computing unit internally operates through a processor-based architecture comprising a central processing unit, memory modules, and storage unit configured to execute protocol instructions for device monitoring and control. The computing unit receives real-time data from the communication module, processes imaging and sensor inputs, and executes analytical protocols for operational decision-making. Internal data management means store historical and live operational records, while processing units generate control commands that are transmitted back to the microcontroller for regulating device functions during roof crack repair operations.

[0057] The present invention works best in the following manner, where the housing 101 is first positioned on the roof surface, wherein the crack detection unit installed on the housing 101 analyzes roof crack conditions using the UPV sensor for determining crack depth and continuity and the fiber optic sensor for assessing strain, bonding strength, crack location, severity, and integrity. Based on the analyzed data the microcontroller determines the required repair strategy and actuates the first articulated arm 103 coupled to the chisel bit 104 and the second articulated arm 105 coupled to the spring loaded hammering tool 106, both mounted on the linear slider 102, to perform surface preparation through peening, chasing, and spalling of the cracked region. Thereafter, the motorized metal mesh sheet dispensing roller 107 is activated to dispense the controlled length of metal mesh sheet, which is subsequently retrieved and positioned over the prepared crack surface by the clamping unit 109 on the telescopic arm 108 mounted on the linear guide rail 110. The robotic arm 120 coupled with the motorized cleaning brush 121 is actuated prior to surface preparation to remove dust, debris, and loose particles from the crack region, ensuring the clean and adherent surface for subsequent repair operations.

[0058] In continuation, the plurality of storage compartments 111 dispenses controlled quantities of repair materials including cement, sand, epoxy resin, sodium silicate, polymer slurries, and phase change materials through their respective delivery conduit 112 and the dispensing valve 113 into the mixing chamber 114. The materials are thoroughly blended to form the homogeneous repair mixture of optimal consistency using the motorized mixing blade 124, and the prepared mixture is then transferred through the delivery channel 115 and dispensed via the dispensing nozzle 116 onto the reinforced crack area. The gauging trowel 117 coupled to the scissor-based extension linkage 118 performs leveling and finishing of the filled crack surface under guidance of the laser sensor for achieving the uniform surface profile, while during the entire process the imaging unit 128 continuously monitors operations and provides feedback to the microcontroller. The AI module analyzes imaging and sensor data using trained machine learning protocols to optimize operational parameters. The communication module enables wireless connectivity with the computing unit having the user interface for remote monitoring and control.

[0059] 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) A roof crack filling device, comprising:

i) a housing 101;
ii) a crack detection unit installed on the housing 101 and comprising a UPV (ultrasonic pulse velocity) sensor for measuring crack depth of roof and continuity, and a fiber optic sensor for detecting strain and bonding strength to identify crack location, severity and integrity;
iii) a first articulated arm 103 coupled to a chisel bit 104 and a second articulated arm 105 coupled to a spring loaded hammering tool 106, and each arm 103, 105 mounted on a linear slider 102 installed on the housing 101 for providing positioning adjustment to the arms 103 configured to prepare the crack surfaces through peening, chasing and spalling;
iv) a motorized metal mesh sheet dispensing roller 107 mounted on an exterior surface of the housing 101 and configured to controllably dispense the mesh sheet;
v) a telescopic arm 108 coupled to a clamping unit 109, mounted on a linear guide rail 110 installed on the housing 101 and configured to dynamically adjust the positioning and retrieve and place the dispensed mesh sheet over the prepared crack surface;
vi) a plurality of storage compartments 111 positioned in the housing 101, each connected to a delivery conduit 112 with a dispensing valve 113 and configured to store and dispense controlled quantities of cement, sand, epoxy resin, sodium silicate, polymer slurries and PCMs (phase change materials) based on detected crack severity and integrity;
vii) a mixing chamber 114 positioned within the housing 101 and configured to receive the dispensed materials from the storage compartments 111 and thoroughly blend to form a mixture of optimal consistency;
viii) a delivery channel 115 connected to the mixing chamber 114 and coupled to a dispensing nozzle 116, extending outward from the housing 101, configured to controllably dispense the prepared mixture onto the cracks; and
ix) a gauging trowel 117 coupled to a scissor-based extension linkage 118 mounted on the linear slider 102 installed on the housing 101 and configured to extend and level the filled cracks.

2) The roof crack filling device as claimed in claim 1, wherein a plurality of motorized omnidirectional wheels 119 and an IMU (inertial measurement unit) sensor, are attached to the housing 101 and configured to monitor the movement patterns, and provide controlled mobility and navigation to the housing 101.

3) The roof crack filling device as claimed in claim 1, wherein a robotic arm 120 coupled to a motorized cleaning brush 121 is mounted on the linear slider 102 and configured to clean debris from the crack areas prior to the execution of repairing and crack filling operations.

4) The roof crack filling device as claimed in claim 1, wherein a motorized blade 122 is mounted on the housing 101 via an extendable linkage 123 and configured to sever the mesh sheet from the roller 107.

5) The roof crack filling device as claimed in claim 1, wherein the mixing chamber 114 is equipped with a motorized mixing blade 124 for thoroughly blending the received materials from the storage comaprtments and a viscosity sensor configured to monitor the continuously monitor the viscosity of the mixture and enable a microcontroller embedded in the housing 101 to dynamically regulate the blending parameters including blade 124 speed and mixing duration.

6) The roof crack filling device as claimed in claim 1, wherein a water storage reservoir 125 is positioned within the housing 101 and connected to a dispensing tube 126 extending outward from the housing 101, the tube 126 coupled to a spraying nozzle 127 with a flow sensor and a moisture sensor for detecting the flow of water and moisture content in the prepared cracks, the tube 126 configured to deliver controlled quantities of water onto the crack prior to execution of repairing and filling operations for enhancing bonding with the prepared mixture.

7) The roof crack filling device as claimed in claim 1, wherein the gauging trowel 117 is equipped with a laser sensor configured to monitor the surface levelling, enabling the microcontroller to dynamically regulate the troweling operations for achieving optimal flat finish.

8) The roof crack filling device as claimed in claim 1, wherein an imaging unit 128 is installed on the housing 101 and configured to monitor the operations and enable the microcontroller to dynamically adjust the operational parameters based on analyzed imaging data.

9) The roof crack filling device as claimed in claim 1, wherein an AI (artificial intelligence) module is integrated with the microcontroller and configured to analyze the imaging and sensor data using trained machine learning protocols, enabling the microcontroller to accordingly regulate the operational parameters.

10) The roof crack filling device as claimed in claim 1, wherein a communication module is integrated with the microcontroller, configured to establish wireless connectivity with a computing unit, inbuilt with a user interface, enabling remote monitoring and control of operations.