Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated composite drive shaft manufacturing device designed for the efficient production of customized drive shafts by automatically performing material processing, shaft shaping, and quality assurance in order to allow precise control over the manufacturing process, thereby optimizing the creation of shafts with user-defined dimensions and specifications.

BACKGROUND OF THE INVENTION

[0002] Drive shafts are key parts in vehicles, used to transfer power from the engine to the wheels. In the past, these were mostly made from metal, which made them strong but also heavy, increasing the overall weight of the vehicle. To solve this, composite materials like carbon fiber were introduced, offering strength without the added weight. However, traditional ways of making composite drive shafts were slow and required a lot of manual work. These methods often led to inconsistencies, errors, and took up a lot of time, making quite hard to get the precise, high-quality parts needed for modern vehicles.

[0003] Historically, manufacturing composite drive shafts involved labour-intensive processes, including manual winding and hand lay-up techniques. These methods were time-consuming and prone to human error, often resulting in inconsistencies and defects in the final product. Moreover, these traditional processes lacked precision in ensuring uniformity and required substantial manual labour, making mass production difficult and inefficient. As a result, there was a growing need for more advanced, automated methods of manufacturing composite drive shafts to meet modern automotive demands for high-quality, lightweight components.

[0004] US20030129022A1 discloses about an invention that includes a method of fabricating a driveline assembly including the steps of inserting a first member within a second member, heating the first member to a temperature greater than that of the second member and inserting both members into a die. The inner surface of the die includes an interlocking torque transferring profile. Fluid pressure is applied to the inner diameter of the inner member to expand both members into the profile on the inner surface of the die. The inner and outer members are than removed from the die and cooled such that both members are at a common temperature. Because the inner member was at an elevated temperature, and thereby expanded a greater amount than the outer member, cooling of the members results in a clearance between the members that provides for relative axial movement between the inner and outer members.

[0005] US8459978B2 discloses about an invention that includes a mold for manufacturing a composite drive shaft, most of which, except for opposite ends functioning as power transmission parts, has a tubular shape with a circular cross-section similar to that of a general shaft, and the shape of each end of which is changed so as to realize easy removal of the drive shaft from the mold after molding. Further, the present invention provides a composite drive shaft, which is manufactured using the mold and is configured such that, when a connection joint (metal yoke) is assembled with each end of the drive shaft, the drive shaft can be rotated in an integrated state realized by the connection joints. Thus, the composite drive shaft of the present invention can directly transmit power, instead of a mechanical fastening jointing technique or an adhesive bonding jointing technique, thus efficiently transmitting high torque.

[0006] Conventionally, many devices have been developed that are capable of manufacturing composite drive shafts. However, these devices fail to ensure the production of high-quality shafts that meet user-defined criteria. Additionally, these devices also lack in performing defect detection, vibration reduction, and surface coating, which causes defects and external damage to the shafts.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is able to ensure the production of high-quality shafts to meet user-defined criteria by performing real-time adjustments during various stages of the manufacturing process. In addition, the developed device also ensures quality assurance through integrated defect detection, vibration reduction, and surface coating, thereby ensuring that each shaft is free from defects and protected against external damage.

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 able to facilitate the automated manufacturing of customized drive shafts by enabling precise control over the materials, dimensions, and specifications of the shaft.

[0010] Another object of the present invention is to develop a device that is able to ensure the production of high-quality shafts that meet user-defined criteria by performing real-time adjustments during various stages of the manufacturing process.

[0011] Yet another object of the present invention is to develop a device that is capable of ensuring quality assurance through integrated defect detection, vibration reduction, and surface coating, thereby ensuring that each shaft is free from defects and protected against external damage.

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

SUMMARY OF THE INVENTION

[0013] The present invention relates to an automated composite drive shaft manufacturing device that enable the automated production of customized drive shafts by providing precise control over the materials, dimensions, and specifications throughout the manufacturing process.

[0014] According to an embodiment of the present invention, an automated composite drive shaft manufacturing device comprises of, a housing installed with a chamber with composite materials, a touch enabled screen is arranged on the housing for enabling a user to give input commands regarding dimensions of a drive shaft the user desires to manufacture, along with specifying type of the drive shaft, a microcontroller linked with the screen that processes the input commands and determines an amount of the composite materials to be utilized for manufacturing the shaft of the user-defined dimensions, a motorized iris lid configured with chamber, a container installed underside chamber via a hollow tube integrated between chamber and container, plurality of heating units integrated with chamber container, a motorized iris pore integrated with container, a cylindrical hollow member installed underneath chamber, a hollow expandable die provided inside member pre-installed with integrated within an expansion pulley mechanism, a vibration sensor is integrated with the member to impart vibrational sensation of pre-defined intensity for eliminating bubbles from the molten composite material, an expansion pulley mechanism is integrated with the member to expand and contract the member for attaining user-specified diameter of shaft that is to be manufactured, plurality of Peltier units configured with a conduit arranged around each of the member and filled with a liquid coolant, for cooling the coolant to solidify the liquid composite material to obtain a solid structure, a motorized ball and socket joint integrated with the member, which allows the member to be repositioned after shaft is formed, and deploy the shaft over a conveyor belt arranged with inside the housing, a magna testing unit is arranged with the conveyor belt to inspect the manufactured shaft to detect any cracks or defects in composite material of shaft, and a motorized circular chuck mounted inside the housing, attached via a horizontal link to facilitate rotational movement of the chuck, multiple clamping jaws are attached to the chuck.

[0015] According to another embodiment of the present invention, the proposed device further comprises of, a telescopically operated gripper is provided inside the housing to pick up the shaft from conveyor belt and engage with the clamping jaws, the clamping jaws configured to clamp the shaft securely during further processing, a DCMT cutting tool bit mounted on an L-type telescopic rod, configured to gently remove excess diameter from shaft, a cylindrical hob is mounted on an L-type telescopic bar, to cut splines on the shaft, the DCMT cutting tool and cylindrical hob operates in coordination with ultrasonic sensor and angle sensor embedded inside the housing to monitor and adjust machining process, ensuring accurate cutting and spline formation throughout process, a vessel stored with boron epoxy solution is mounted on the chuck via an L-type telescopic pole, an electronic nozzle connected with the vessel to apply a layer of boron epoxy solution onto the shaft after machining process, providing a shield to shaft from environmental factors such as corrosion, wear, and other forms of degradation.

[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 a perspective view of an automated composite drive shaft manufacturing device.

DETAILED DESCRIPTION OF THE INVENTION

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

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

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

[0021] The present invention relates to an automated composite drive shaft manufacturing device that is able to facilitate the production of high-quality shafts that meet user-defined specifications by enabling real-time adjustments throughout the manufacturing process. Additionally, the device provides a means for defect detection, vibration reduction, and surface coating, in view of ensuring that each shaft is devoid of defects and safeguarded against external damage.

[0022] Referring to Figure 1, a perspective view of an automated composite drive shaft manufacturing device is illustrated, respectively, comprising a housing 101 installed with a chamber 102, a touch enabled screen 103 is arranged on the housing 101, a motorized iris lid 104 configured with the chamber 102, a motorized iris lid 104 configured with chamber 102, a container 116 installed underside chamber via a hollow tube 123 integrated between chamber and container 116, plurality of heating units integrated with chamber, a motorized iris pore integrated with container 116, a cylindrical hollow member 105 installed underneath chamber 102, a hollow expandable die 118 provided inside member 105 pre-installed with an expansion pulley mechanism 117, a motorized ball and socket joint 106 integrated with the member 105, a conveyor belt 107 arranged with inside the housing 101, a magna testing unit 108 is arranged with the conveyor belt 107, a motorized circular chuck 109 mounted inside the housing 101, attached via a horizontal link 110, multiple clamping jaws 111 are attached to the chuck 109, a DCMT cutting tool bit 112 mounted on an L-type telescopic rod 113, that is configured on the chuck 109, a cylindrical hob 114 is mounted on an L-type telescopic bar 115, a telescopically operated gripper 119, is provided inside the housing 101, a vessel 120 is mounted on the chuck 109 via an L-type telescopic pole 121, an electronic nozzle 122 connected with the vessel 120.

[0023] The device disclosed herein comprises a housing 101 that is equipped with a chamber 102 specifically designed to contain composite materials, wherein the chamber 102 is constructed to accommodate the necessary components and materials used in the composite manufacturing process. The chamber 102 is constructed with precision to ensure the secure containment of the composite materials, thereby preventing any contamination or leakage during the operation. The composite materials, which may include a combination of fibers, resins, and other reinforcing agents, are stored and prepared within this chamber 102 for subsequent use in the production of the desired components.

[0024] The housing 101 is installed with a touch enabled screen 103 which facilitates a user in providing touch input command regarding dimensions of a drive shaft the user desires to manufacture, along with specifying type of the drive shaft. The touch interactive display screen 103 as mentioned herein is typically an LCD (Liquid Crystal Display) screen 103 that presents output in a visible form. The screen 103 is equipped with touch-sensitive technology, allowing the user to interact directly with the display using their fingers.

[0025] A touch controller IC (Integrated Circuit) is responsible for processing the analog signals generated when the user inputs details regarding dimensions of a drive shaft the user desires to manufacture, along with specifying type of the drive shaft. A touch controller is typically connected to the microcontroller through various interfaces which may include but are not limited to SPI (Serial Peripheral Interface) or I2C (Inter-Integrated Circuit).

[0026] The microcontroller analyzes the command of the user and accordingly actuates a motorized iris lid 104 configured with said chamber 102 to open for dispensing said determined corresponding amount of materials in a container 116 installed underside the chamber via a hollow tube 123 integrated between the chamber and container 116.

[0027] The iris lid 104 is typically composed of a series of thin, overlapping blades or petals arranged in a circular or hexagonal pattern. The microcontroller sends signals to the motor of the motorized iris lid 104 to regulate the flow of composite material from the chamber. The motor then rotates or moves the iris blades to open the iris lid 104 to the desired position and as the motorized iris lid 104 opens the composite material are dispensed inside the container 116.

[0028] When the determined amount of composite material is dispensed on the container 116 the microcontroller actuates the motor of the motorized iris lid 104 to rotate the blades and close the opening of the lid 104. Plurality of heating units (preferably 2 to 6 in numbers) are integrated with the container 116. The heating units used herein is preferably a copper coil that generates heat when an electric current passes through the coil.

[0029] When an electric current runs through a copper wire the electrons come across the resistive forces of the medium’s material, releasing energy that is expended in the form of heat energy. The copper coil is properly insulated to prevent any heat loss and also direct the generated heat toward the plastic flakes. The heating unit begins to generate heat and as the heating element warms up for melting the composite materials to obtain molten paste of composite materials.

[0030] The container 116 arranged with a motorized iris pore which is directed by the microcontroller to get opened in view of dispensing the determined amount of molten paste of composite materials in a cylindrical hollow member 105 which is installed underneath the chamber 102 inside the housing 101. The iris lid 104 comprises of a ring and a blade with multiple protrusions.

[0031] The ring is fabricated with multiple grooves. The ring is installed with the motor that is actuated by the microcontroller for rotating the ring with a specified speed to regulate the opening and closing of the lid 104 in order to open for dispensing the determined amount of molten paste of composite materials in the cylindrical hollow member 105.

[0032] Based on the user-specified thickness of the drive shaft that is to be manufactured, the microcontroller regulates actuation of an expansion pulley mechanism 117 provided inside a hollow expandable die 118 pre-installed inside the member 105 to expand and contract to manufacture user-specified thickness of drive shaft. This process ensures that the shaft is produced to meet the exact specifications as defined by the user, thereby maintaining accuracy and consistency throughout the manufacturing process. The expansion and contraction of the die 118 are seamlessly controlled to achieve the required shaft diameter with minimal manual intervention, enhancing both efficiency and precision.

[0033] As the composite materials is dispensed over the member 105, the microcontroller eliminates bubbles from the molten composite material by means of a vibration sensor that is integrated with the member 105. The vibration sensor disclosed herein consists of a piezoelectric element, a mass, and a housing 101. The piezoelectric element is a material that generates an electrical charge when subjected to mechanical stress.

[0034] The mass is attached to the piezoelectric element, and as the member 105 vibrates, this mass exerts a force on the piezoelectric element, causing it to deform. This deformation generates an electrical signal proportional to the magnitude and frequency of the vibrations. The housing 101 encases these components and provides a means to mount the sensor on the member 105. The generated electrical signal is then processed by the microcontroller to impart vibrational sensation of pre-defined intensity for eliminating bubbles from the molten composite material.

[0035] The adjustment of the member 105 diameter allows for precise control over the final dimensions of the shaft being manufactured. Synchronously, plurality of Peltier units (preferably 2 to 6 in numbers) that are strategically positioned around the member 105 and connected to a conduit that is filled with a liquid coolant, arranged in a spiral shaped arrangement. Once the molten composite materials are introduced into the member 105, the microcontroller triggers the Peltier units to initiate their cooling process. The Peltier units absorb heat from the surrounding, for causing the liquid coolant inside the conduit to lower in temperature.

[0036] This cooling effect facilitates the solidification of the molten composite material inside the member 105, allowing it to transition from a liquid to a solid state, thereby forming a rigid structure as per the desired specifications. The process ensures controlled solidification, improving the quality and precision of the manufactured shaft.

[0037] When powered, the units create a temperature differential, with one side becoming hot and the other side becoming cold. The cold side of each Peltier unit is attached to the conduit filled with coolant. As the Peltier units absorb heat from the environment, the cold side lowers the temperature of the coolant. The coolant, in turn, cools the molten composite material inside the member 105, solidifying it into a desired shape. The heat is transferred to the opposite side of the Peltier unit, maintaining the necessary temperature control for solidification.

[0038] A motorized ball and socket joint 106, integrated with the member 105, enables the precise repositioning of the formed shaft after it has solidified. Upon activation, the motorized mechanism 117 adjusts the angle and orientation of the member 105, allowing it to move the solidified shaft smoothly. Once the shaft is positioned correctly, the joint deploys it onto a conveyor belt 107, which is situated inside the housing 101. This controlled movement ensures that the shaft is transferred efficiently without causing damage or misalignment, allowing for continuous processing and subsequent operations on the shaft as it moves along the conveyor.

[0039] Upon receiving a signal from the microcontroller, the motorized ball and socket joint 106, allows controlled movement of the member 105. The motor adjusts the ball-and-socket joint 106, repositioning the member 105 along a predetermined axis. This movement allows the member 105 to tilt, rotate, or shift the shaft into a desired position. The joint ensures precise alignment and flexibility, facilitating the transfer of the solidified shaft to its next location, such as over a conveyor belt 107.

[0040] Once the motorized ball and socket joint 106 repositions the shaft, it is deployed onto the conveyor belt 107. The conveyor belt 107, driven by an electric motor, moves the shaft along a set path within the housing 101. The belt 107 operates at a constant speed, ensuring the shaft is consistently transported without disruption. The belt 107 delivers the shaft to the next phase of processing or storage, allowing continuous operation of the manufacturing process.

[0041] A Magna testing unit 108 is incorporated within the housing 101 and strategically positioned along the conveyor belt 107 to inspect the manufactured shaft for the presence of cracks or defects in the composite material. The unit 108 operates by generating a magnetic field that is applied to the shaft as it moves along the conveyor belt 107. The composite material of the shaft, upon being subjected to this magnetic field, induces variations in the magnetic flux if any cracks or defects are present. These flux disturbances are detected by the microcontroller and processes the data to identify the nature and location of any imperfections.

[0042] A motorized circular chuck 109 is mounted inside the housing 101 and is connected via a horizontal link 110, which facilitates the rotational movement of the chuck 109. The chuck 109 is designed to rotate in a controlled manner, enabling it to secure and rotate the shaft during the manufacturing process. Multiple clamping jaws 111 are attached to the chuck 109, which are adjustable to firmly hold the shaft in place during its rotation.

[0043] Prior actuation of the chuck 109 and clamping jaws 111 the microcontroller actuates a telescopically operated gripper 119 which is provided inside the housing 101. The gripper 119 is pneumatically actuated, wherein the pneumatic arrangement of the gripper 119 comprises of a cylinder incorporated with an air piston and the air compressor, wherein the compressor controls discharging of compressed air into the cylinder via air valves which further leads to the extension/retraction of the piston. The piston is attached to the telescopic gripper 119, wherein the extension/retraction of the piston corresponds to the extension/retraction of the gripper 119. The actuated compressor allows extension of the gripper 119 to pick up the shaft from conveyor belt 107 and engage with the clamping jaws 111.

[0044] The motorized circular chuck 109 is activated by a motor, which rotates it via a horizontal link 110. As the chuck 109 rotates, multiple clamping jaws 111 attached to its circumference move inward to grip the shaft securely. The jaws 111 apply even pressure to hold the shaft in place while it is rotated. The chuck 109 rotational movement is controlled by a microcontroller, which adjusts the motor’s speed and direction as needed. The clamping jaws 111 ensure that the shaft remains stable during rotation, allowing precise machining or processing of the shaft without shifting or wobbling.

[0045] Upon activation, the jaws 111 move inward toward the shaft, applying a firm grip around its circumference. As the chuck 109 rotates, the jaws 111 maintain their clamping force, holding the shaft in place to ensure stability during processing. The jaws 111 evenly distribute pressure, preventing slippage or misalignment. During rotation, the jaws 111 remain engaged with the shaft, enabling precise machining or testing while maintaining secure positioning. After the operation, the jaws 111 retract to release the shaft for removal or further handling.

[0046] A DCMT cutting tool bit 112 is securely mounted at the free end of an L-type telescopic rod 113, which is integrated with the chuck 109. This tool bit 112 is designed to perform precision material removal by gently shaving off excess diameter from the surface of the shaft during the manufacturing process. The L-type telescopic rod 113 works in the same manner as of gripper 119 on actuation and allows for the precise positioning of the cutting tool along the shaft's length, ensuring uniformity and accuracy in the reduction of the shaft's diameter. The cutting tool is actuated by a microcontroller, for enabling controlled removal of material from the shaft to meet the user-specified dimensions.

[0047] The DCMT cutting tool bit 112 when activated, the motor extends the telescopic rod 113, bringing the cutting tool bit 112 into contact with the shaft. As the shaft rotates, the cutting tool bit 112 removes excess material by cutting along the shaft’s surface. The cutting tool bit 112 continues to shave off material while the shaft rotates, reducing the diameter incrementally. Once the desired shaft diameter is achieved, the telescopic rod 113 retracts, disengaging the cutting tool bit 112 from the shaft, halting the material removal process.

[0048] A cylindrical hob 114 is mounted on an L-type telescopic bar 115, which is connected to a motor. Upon activation by the microcontroller, the telescopic bar 115 works in the same manner as of gripper 119 and rod 113, and extends or retracts, in view of positioning the hob 114 in alignment with the rotating shaft. As the shaft rotates, the cylindrical hob 114 engages the shaft’s surface, cutting splines into the material. The microcontroller regulates the movement and positioning of the hob 114, for ensuring precise and accurate spline cutting. The telescopic bar 115 ensures the hob 114 maintains the correct alignment and depth throughout the cutting process, and once the operation is complete, the hob 114 retracts.

[0049] The DCMT cutting tool and cylindrical hob 114 operate in coordination with an ultrasonic sensor and an angle sensor embedded within the housing 101 to ensure precision during the machining process. The ultrasonic sensor continuously monitors the distance between the cutting tool or hob 114 and the shaft, for providing real-time feedback on tool position and material consistency. Simultaneously, the angle sensor detects the alignment and angular positioning of the tool or hob 114 relative to the shaft. This data is processed by the microcontroller, which dynamically adjusts the movement and operation of both tools to maintain accurate cutting depth, angle, and spline formation throughout the process.

[0050] The ultrasonic sensor emits high-frequency sound waves towards the shaft surface. These sound waves bounce back after hitting the surface, and the sensor measures the time it takes for the waves to return. Based on the time delay, the sensor calculates the distance between the sensor and the surface. This data is continuously relayed to the microcontroller, which adjusts the position of the cutting tools or hob 114 to maintain the correct distance, thereby ensuring consistent cutting and precise formation of splines.

[0051] The angle sensor detects the rotational angle of the cutting tool or hob 114 relative to the shaft. The angle sensor uses an encoder or similar mechanism 117 to measure the angular position, sending this data to the microcontroller. The microcontroller processes the angle information to adjust the movement of the tool or hob 114, in view of ensuring that the cutting angle remains accurate throughout the machining process, thus maintaining the desired geometry and spline formation.

[0052] A vessel 120 containing a boron epoxy solution is mounted on the chuck 109 via an L-type telescopic pole 121, which allows for precise positioning. An electronic nozzle 122, connected to the vessel 120, is actuated to apply a uniform layer of the boron epoxy solution onto the shaft after the machining process. This application serves to provide a protective coating to the shaft, effectively shielding it from environmental factors such as corrosion, wear, and other forms of degradation. The controlled application of the epoxy solution ensures that the shaft is thoroughly coated, thereby enhancing its durability and resistance to external environmental conditions.

[0053] The electronic nozzle 122 receives the boron epoxy solution from the vessel 120 via a conduit. Upon activation by the microcontroller, the nozzle 122 opens and allows the solution to flow through its tip. The flow of the solution is controlled electronically, adjusting the spray rate and direction based on the desired coating specifications. As the nozzle 122 is moved across the surface of the shaft, the epoxy solution is evenly applied in a controlled manner. The nozzle 122 precise operation ensures that a uniform layer of boron epoxy is applied, forming a protective coating over the shaft for improved durability.

[0054] Moreover, 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.

[0055] The present invention works in the best manner, where the housing 101 installed with the chamber 102 with composite materials. Then the touch enabled screen 103 enables the user to give input commands regarding thickness of the drive shaft the user desires to manufacture, along with specifying type of the drive shaft. Now the microcontroller linked with the screen 103 that processes the input commands and determines the amount of the composite materials to be utilized for manufacturing the shaft of the user-defined dimensions. Synchronously, the microcontroller actuates the iris unit to dispense an optimal amount of composite material inside the container 116, and the microcontroller actuates plurality of heating units to melt the composite materials to obtain molten paste of composite materials. Then the motorized iris pore configured with the container 116 opens for dispensing the determined amount of the materials in the cylindrical hollow member 105 inside the housing 101. Thereafter the vibration sensor imparts vibrational sensation of pre-defined intensity for eliminating bubbles from the molten composite material. Afterwards the expansion pulley mechanism 117 expands and contract the member 105 for attaining user-specified diameter of shaft that is to be manufactured. Now plurality of Peltier units configured with the conduit arranged around each of the member 105 and filled with the liquid coolant. Upon filling of the molten composite materials in the member 105, the microcontroller activates the Peltier units for cooling the coolant to solidify the liquid composite material to obtain the solid structure. Then the motorized ball and socket joint 106 allows the member 105 to be repositioned after shaft is formed, and deploy the shaft over the conveyor belt 107 arranged with inside the housing 101. Thereafter the magna testing unit 108 is arranged with the conveyor belt 107 to inspect the manufactured shaft to detect any cracks or defects in composite material of shaft.

[0056] In continuation, the motorized circular chuck 109 mounted inside the housing 101, attached via the horizontal link 110 to facilitate rotational movement of the chuck 109. Now multiple clamping jaws 111 are attached to the chuck 109. Prior actuation of the clamps the telescopically operated gripper 119 picks up the shaft from conveyor belt 107 and engage with the clamping jaws 111. At the same time the clamping jaws 111 configured to clamp the shaft securely during further processing. Now the DCMT cutting tool bit 112 mounted on the L-type telescopic rod 113, configured to gently remove excess diameter from shaft. Then the cylindrical hob 114 is mounted on the L-type telescopic bar 115, to cut splines on the shaft. Thereafter the DCMT cutting tool and cylindrical hob 114 operates in coordination with ultrasonic sensor and angle sensor embedded inside the housing 101 to monitor and adjust machining process, ensuring accurate cutting and spline formation throughout process. Then the vessel 120 stored with boron epoxy solution is mounted on the chuck 109 via the L-type telescopic pole 121. Moreover, the electronic nozzle 122 connected with the vessel 120 apply the layer of boron epoxy solution onto the shaft after machining process, providing the shield to shaft from environmental factors such as corrosion, wear, and other forms of degradation.

[0057] 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 composite drive shaft manufacturing device, comprising:

i) a housing 101 installed with a chamber 102 to stack composite materials, wherein a touch enabled screen 103 is arranged on said housing 101 for enabling a user to give input commands regarding thickness of a drive shaft said user desires to manufacture, along with specifying type of said drive shaft;
ii) a microcontroller linked with said screen 103 that processes said input commands and determines an amount of said composite materials to be utilized for manufacturing said shaft of said user-defined thickness, and accordingly actuates a motorized iris lid 104 configured with said chamber 102 to open for dispensing said determined corresponding amount of materials in a container 116 installed underside said chamber via a hollow tube 123 integrated between said chamber and container 116;
iii) plurality of heating units are integrated with said chamber container 116, that are activated by said microcontroller for melting said composite materials to obtain molten paste of composite materials, wherein post melting said composite material, said microcontroller actuated a motorized iris pore integrated with said container 116 to open and transfer said molten composite material inside a cylindrical hollow member 105 installed underneath said chamber 102, said member 105 pre-installed with a hollow expandable die 118 integrated within an expansion pulley mechanism 117 provided inside said die 118;
iv) plurality of Peltier units configured with a conduit arranged around each of said member 105 and filled with a liquid coolant, wherein upon filling of said molten composite materials in said member 105, said microcontroller activates said Peltier units for cooling said coolant to solidify said molten composite material to obtain a solid structure;
v) a motorized ball and socket joint 106 integrated with said member 105, which allows said member 105 to be repositioned after shaft is formed, and deploy said shaft over a conveyor belt 107 arranged inside said housing 101, wherein a magna testing unit 108 is arranged with said conveyor belt 107 to inspect said manufactured shaft to detect any cracks or defects in composite material of shaft;
vi) a motorized circular chuck 109 mounted inside said housing 101, attached via a horizontal link 110 to facilitate rotational movement of said chuck 109, wherein multiple clamping jaws 111 are attached to said chuck 109, configured to clamp said shaft securely during further processing; and
vii) a DCMT cutting tool bit 112 mounted on an L-type telescopic rod 113, configured to gently remove excess diameter from shaft, wherein a cylindrical hob 114 is mounted on an L-type telescopic bar 115, that is actuated by said microcontroller to cut splines on the shaft, said DCMT cutting tool and cylindrical hob 114 operates in coordination with ultrasonic sensor and angle sensor embedded inside said housing 101 to monitor and adjust machining process, ensuring accurate cutting and spline formation throughout process.

2) The device as claimed in claim 1, wherein said expansion pulley mechanism 117 is actuated by said microcontroller to expand and contract said die 118 for attaining user-specified thickness of shaft that is to be manufactured.

3) The device as claimed in claim 1, wherein a vibration sensor is integrated with said member 105 that is actuated by said microcontroller to impart vibrational sensation of pre-defined intensity for eliminating bubbles from said molten composite material.

4) The device as claimed in claim 1, wherein a telescopically operated gripper 119 is provided inside said housing 101 that is actuated by said microcontroller to pick up said shaft from conveyor belt 107 and engage with said clamping jaws 111.

5) The device as claimed in claim 1, wherein a vessel 120 stored with boron epoxy solution is mounted on said chuck 109 via an L-type telescopic pole 121, an electronic nozzle 122 connected with said vessel 120 is actuated to apply a layer of boron epoxy solution onto said shaft after machining process, providing a shield to shaft from environmental factors such as corrosion, wear, and other forms of degradation.