Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated orthopedic insoles manufacturing device that is capable of detecting foot size and contours of the user’s foot, and automatically manufactures customized orthopedic insoles for catering different needs of the user, thereby enhancing overall foot function and mobility of the user.

BACKGROUND OF THE INVENTION

[0002] Orthopedic insoles, also known as orthotics or orthotic inserts, are specialized shoe inserts designed to provide support, correct alignment, and improve the function of the feet and lower extremities. They are commonly prescribed by orthopedic specialists, podiatrists, and physical therapists to address various foot and lower limb conditions, as well as to enhance comfort and prevent future problem. By providing additional support to the arches, heels, and other parts of the foot, orthopedic insoles can alleviate stress on the joints and muscles. This is particularly beneficial for individuals with flat feet or high arches.

[0003] Traditionally, orthopedic insoles were handcrafted by orthopedic shoemakers or cobblers. They were made by shaping materials such as leather, cork, or felt to match the contours of a patient’s foot. Quality and consistency varied based on the skill and experience of the cobbler, leading to potential inconsistencies in fit and effectiveness. Techniques using plaster casting or positive molds became common. Plaster was used to create a mold of the patient’s foot, which was then used to shape orthopedic insoles. Plaster casting was messy and uncomfortable for patients, requiring them to keep still while the plaster dried. Foam impression boxes, introduced later, involved patients standing or stepping into boxes filled with foam that hardened to create a mold of the foot. While less messy than plaster, foam impressions could still be imprecise, especially in capturing subtle foot contours and dynamic movements.

[0004] KR102479812B1 discloses a device includes: a portable housing; a heater unit for selectively heating the insole or heel cap of the shoe insert to increase the flexibility of the shoe insert; at least one alignment device to assist in positioning and orienting the individual's foot prior to conforming the insole or heel cap to the plantar surface of the individual's foot; and a vacuum system for selectively applying a vacuum around the individual's foot to conform the insole or heel cap to the plantar surface of the individual's foot prior to setting the insole or heel cap. Related methods of manufacturing custom insoles, insoles and other shoe inserts are also provided. Although, KR’812 is capable of manufacturing custom insoles with minimal human intervention. However, the cited device is incapable of detecting foot size and contours of the user’s foot, in order to manufacture customized orthopedic insoles for catering different needs of the user.

[0005] CN214386339U discloses a utility model relates to an insole turn-over device which comprises a bearing assembly, a turning assembly and a turning assembly. The turn-over assembly comprises a mounting rack and a turn-over frame; the material suction assembly comprises an adapter plate, a supporting rod, a connecting rod, a swing rod, an air nozzle and an air cylinder. The end, away from the swing rod, of the air cylinder is used for being hinged to the end, away from the air tap, of the swing rod, and the air cylinder is used for driving the end, provided with the air tap, of the swing rod to be close to or away from the adapter plate. The lifting supporting block can stretch out of the top face of the conveying belt in a protruding mode and then is arranged between the two adapter plates in a penetrating mode, and the air nozzle is used for sucking insoles. The insole turn-over device is simple in structure and convenient to use, the insoles are sucked through the suction assembly, then the insoles can be turned over automatically through turning over of the turning-over frame, and the production efficiency of the insoles is improved. Though, CN’399 is capable of efficiently producing insoles of various sizes. However, the cited utility model is incapable of trimming extra rubber supports of the insoles in an automated manner in view of providing the user with a finished and good quality of insoles.

[0006] Conventionally, many devices are available in the market that are capable of manufacturing orthopedic insoles of various shapes and sizes. However, ensuring the fit and comfort of manufactured orthotics still requires skilled assessment and sometimes adjustments.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of creating highly accurate models of the foot, capturing both static and dynamic aspects of foot biomechanics, in view of manufacturing orthopedic insoles in accordance with foot contours of the user in real time.

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 detecting foot size and contours of the user’s foot, and automatically manufactures customized orthopedic insoles for catering different needs of the user and aiding in providing better support and comfortable walking experience.

[0010] Another object of the present invention is to develop a device that is capable of trimming extra rubber supports of the insoles in an automated manner in view of providing the user with a finished and good quality of insoles.

[0011] Yet another object of the present invention is to develop a device that is capable of trimming extra rubber supports protruding from the curves of the user’s foot, thereby facilitating real-time customization for manufacturing a custom-fit insole in accordance with unique contours of the user’s foot.

[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 orthopedic insoles manufacturing device that is capable of manufacturing customized orthopedic insoles in accordance with contours and size of user’s feet. Additionally, the proposed device is capable of trimming extra rubber supports of the insoles in an automated manner in view of providing the user with a finished and good quality of insoles.

[0014] According to an embodiment of the present invention, an automated orthopedic insoles manufacturing device, comprises of a cuboidal body developed to positioned on a fixed horizontal surface, motorized slidable opening configured on body for allowing user to accommodate foot inside body, an artificial intelligence-based imaging unit installed on the body to determine dimensions and contours of the user’s foot, a multi-sectioned chamber configured on the body, each section stored with various sizes and shapes of insoles, a robotic arm configured inside body to grip and position the sole over a rectangular plate carved with horizontal grooves inside the body, plurality of hydraulically operated plungers configured in between base of the body and plate for pushing the rubber support upward, in view of obtaining a curve under the feet of the user and a motorized cutting unit configured in on the plate to trim off extra rubber supports.

[0015] 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

[0016] 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 orthopedic insoles manufacturing device.

DETAILED DESCRIPTION OF THE INVENTION

[0017] 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.

[0018] 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.

[0019] 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.

[0020] The present invention relates to an automated orthopedic insoles manufacturing device that is capable of trimming extra rubber supports protruding from the curves of the user’s foot, thereby facilitating real-time customization for manufacturing a custom-fit insole in accordance with unique contours of the user’s foot.

[0021] Referring to Figure 1, an isometric view of an automated orthopedic insoles manufacturing device is illustrated, comprising a cuboidal body 101 developed to positioned on a fixed horizontal surface, motorized slidable opening 102 configured on body 101, an artificial intelligence-based imaging unit 103 installed on the body 101, a multi-sectioned chamber 104 configured on the body 101, a robotic arm 105 configured inside body 101, a rectangular plate 106 carved with horizontal grooves 107 inside the body 101, plurality of hydraulically operated plungers 108 configured in between base of the body 101 and plate 106, a motorized cutting unit 109 configured in on the plate 106 and a container 110 mounted inside the body 101.

[0022] The device disclosed herein comprises of a cuboidal body 101 developed to be positioned on a fixed horizontal surface. The body 101 is constructed from sturdy and robust material which includes, but is not limited to stainless steel, aluminum, and high-grade engineered plastics like polycarbonate or reinforced nylon. These materials offer strength and rigidity to the body 101 making it resistant to mechanical stress and pressure. The surface of the body 101 is coated with material like Teflon or other low-friction coatings to improve wear resistance and reduce friction.

[0023] Vibration-dampening materials are integrated into the body 101 to minimize noise and shaking of the body 101 during operations, thereby enhancing user comfort and machine longevity. For allowing accommodation of the foot inside the body 101, a motorized slidable opening 102 is configured on the body 101. A motor integrated within the slidable opening 102 provides the mechanical power necessary to drive the movement of the slidable opening 102. The rotational motion of the motor is transmitted to the slidable opening 102 mechanism through gears, pulleys, or direct linkage. This movement causes the slidable opening 102 to slide or retract open, creating the desired access space.

[0024] An artificial intelligence-based imaging unit 103 is configured on the body 101 for capturing multiple images of the surroundings. The imaging unit 103 consists of multiple high-resolution cameras for capturing multiple images from different angles and perspectives and providing comprehensive coverage of the surroundings. The imaging unit 103 captures multiple images of the surroundings from various angles simultaneously. Before analysis, the captured image goes through pre-processing steps to enhance image quality which includes adjusting brightness and contrast and removing any distortions. The processed images are then sent to the processor linked with the imaging unit 103. The processor processes the captured images of the surroundings by means of an artificial intelligence protocol encrypted within the microcontroller for detecting the dimensions and contours of the user’s foot.

[0025] The microcontroller uses artificial intelligence protocol like Convolution Neural Network (CNN) for detecting distinctive patterns or characteristics in the image like the length, breadth, and thickness of the user’s foot. Once potential features are detected, the microcontroller localizes them by identifying their positions within the image. This involves finding their coordinates or regions of interest where these features are located. The microcontroller also uses techniques like object recognition, edge detection, and shape analysis to accurately detect the dimensions and contours of the user’s foot.

[0026] Based on the detected dimensions of the user’s foot, the microcontroller scrutinizes a database linked with the microcontroller for determining the size and shape of untreated sole that is to be utilized for making orthopedic insoles for the user. A multi-sectioned chamber 104 is arranged on the body 101 and each section is stored with insoles fabricated with rubber mounting of various shapes and sizes. After determining the size and shape of the untreated sole requirement, the microcontroller in sync with the imaging 103 unit actuates a robotic arm 105 arranged inside the body 101 to grip an optimum size of untreated sole from a specific section of multi-sectioned chamber 104 and position the gripped sole over a rectangular plate 106 installed inside the body 101.

[0027] The robotic arm 105 is equipped with multiple joints and actuators that allows the robotic arm 105 to move in multiple dimensions and orient the sole with great precision in manner that the rubber supports of the sole are affixed over the horizontal grooves 107 fabricated over the plate 106. Once the robotic arm 105 positions the sole over the plate 106, the microcontroller activates an ultrasonic sensor configured on the plate 106 for detecting placement of the user’s foot over the plate 106.

[0028] The ultrasonic sensor works by emitting ultrasonic waves and then measuring the time taken by these waves to bounce back after hitting the surface of the user’s foot. The ultrasonic sensor includes two main parts viz. transmitter, and a receiver. The transmitter sends a short ultrasonic pulse towards the surface of user’s foot which propagates through the air at the speed of sound and reflects back as an echo to the transmitter as the pulse hits the user’s foot. The transmitter then detects the reflected eco from the surface of user’s foot. The determined data is then sent to the microcontroller in a signal form, based on which the microcontroller detects the presence of user’s foot over the plate 106.

[0029] Upon detection of user’s foot portion over the plate 106, the microcontroller actuates plurality of hydraulically operated plungers 108 configured between the base of the body 101 and the plate 106 to extend in upward direction, in view of pushing the rubber support towards the user’s foot portion. The hydraulically operated plunger consists of a sturdy metal rod with a pointed tip and is connected to a cylinder. The cylinder contains piston that moves back and forth within it. This movement is controlled by a hydraulic pump that pressurizes hydraulic fluid. When the user’s foot is oriented in upright in the specified point, the microcontroller sends a signal to the hydraulic pump to pressurize the hydraulic fluid, causing the piston inside the cylinder to extend and retract.

[0030] As the piston extends and retracts in a repetitive manner, the rubber support is pressed over the user’s foot portion, driving the rubber support towards the user’s foot. The pressure applied by the rubber supports over the user’s foot portion is precisely monitored by a pressure sensor embedded in the plate 106. The pressure sensor is in direct contact with the hydraulic fluid and utilizes a sensing element which may include but not limited to a strain gauge nor a piezoelectric crystal, which deforms in response to the applied pressure. This deformation generates an electrical signal that is proportional to the pressure of the hydraulic fluid. The microcontroller continuously monitors the pressure sensor reading to assess the resistance encountered by the user’s foot. Any sudden spikes or drops in pressure indicate obstructions or changes in the pressure exerted by the rubber supports on the user’s foot portion.

[0031] For instance, the microcontroller sends a signal to the plunger to provide a series of repetitive thumping movement when the pressure sensor detects pressure applied by insoles under the user’s feet recedes a threshold value, and accordingly the microcontroller actuates the plungers 108 to push the rubber supports towards the user feet with an optimum amount of force, thereby facilitating precise customization of insoles for catering foot of different shapes and sizes.

[0032] As the plunger pushes the rubber supports under the user’s foot, and curved insole design is obtained, extra rubber supports extends out from the groove of the plate 106. A laser sensor is installed on the body 101 for detecting the extra runner supports protruding downward from the grooves 107. The laser sensor emits a laser beam which is usually in the form of a focused, collimated light beam that hits the rubber supports surface, it gets reflected back towards the sensors. The time it takes for the laser beam to travel from the sensor to the ground and back is measured. The sensor precisely measures the time it takes for the laser beam to travel to the rubber supports surface and return.

[0033] Using the speed of light as a constant, the sensor calculates the distance between itself and the rubber supports surface. The laser sensor collects a significant amount of data by scanning the entire surface of the rubber supports and forms a 3D point cloud, which represents the shape of the rubber supports. The laser sensor sends the data to the microcontroller which processes the acquired data and detects the length of the rubber supports protruding out of the grooves 107.

[0034] In order to trim the extra rubber supports, the microcontroller actuates a motorized cutting unit 109 configured on the body 101 to trim off the extra rubber supports. The cutting unit 109 comprises of a cutter and a motor. The motor is the key component that converts electrical energy into mechanical energy to provide movement to the cutting unit 109. Upon actuation of the cutting unit 109 by the microcontroller, the motor starts rotating the cutting unit 109 in a clockwise/ anti-clockwise direction by imparting the rotational motion to the cutting unit 109, thereby trimming off the extra runner supports extending out from the grooves 107, and thereby manufacturing customized orthopedic insoles for correcting foot alignment and providing better support and alignment for the user’s feet, and enhancing overall foot function and mobility.

[0035] The cutting unit 109 is integrated with a tactile sensor for detecting the hardness of the rubber supports prior cutting of the extra rubber supports. The tactile sensor employs various sensing units, such as resistive, capacitive, or piezoelectric, to detect changes in pressure or force applied to the sensor. The tactile sensor is designed with a flexible and deformable structure to conform to the contours of the rubber supports. This flexibility allows the sensor to make effective contact with the surface, ensuring accurate readings. Multiple sensing elements are arranged in an array to provide spatial information about the applied pressure across the sensor surface by the rubber supports.

[0036] This array allows for more detailed and nuanced readings, especially on irregular surfaces. The microcontroller converts this force into an electrical signal, typically resistance or capacitance, which is proportional to the applied force. The raw data collected by the sensor is processed by the microcontroller to extract meaningful information about the hardness of the rubber supports. Based on the detected hardness of the rubber supports, the microcontroller actuates the cutting unit 109 for trimming the extra rubber supports with ease, ensuring structural integrity of the manufactured insoles.

[0037] After successful trimming of the extra rubber supports, the microcontroller actuates the robotic grippers for gripping the manufactured insole and position the insole inside a container 110 mounted on the body 101. The robotic gripper typically consists of two opposing arms or fingers that mimic a human hand-gripping motion. These arms are usually made of durable materials like metal or plastic to provide strength and flexibility. The robotic gripper design incorporates springs to securely hold the manufactured insole and position the manufactured insole inside the container 110. Electric motors and servo motors are used to control the robotic gripper's movement. These motors provide the necessary force and precision to manipulate and position the manufactured insole. The motors are connected to the gripper arms through an arrangement of gears and linkages, allowing for controlled positioning of the manufactured insole inside the container 110.

[0038] In view of maintaining a storage log of the untreated insoles stored inside the multi-sectioned chamber 104, an IR (Infrared) counter is embedded within each sections of the multi-sectioned chamber 104 for counting number of the untreated insoles stored within the chamber 104. The IR counter includes an IR emitter and a corresponding receiver placed opposite each other, creating a beam path. Infrared beams are emitted across the chamber 104 and when the chamber 104 is empty, the infrared beams travel freely from the emitter to the receiver. However, when an untreated sole is present in the beam path, it interrupts the flow of infrared light. The receiver detects the interruption in light caused by the untreated sole and this interruption is translated into an electrical signal.

[0039] The electrical signal triggers a counting mechanism, decrementing the count each time an untreated sole is detected. Based on the detected counting, when the counted number of untreated sole recedes a threshold number, the microcontroller sends an alert notification on a computing unit accessed by the user for notifying the user to re-fill untreated sole in the chamber 104. The microcontroller is wirelessly linked with the computing unit via a communication module which includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module.

[0040] A battery is associated with the device that supplies current to all the components that need electric power to perform their functions and operation in an efficient manner. The battery utilized here is generally a dry battery which is made up of Lithium-ion material that gives the device a long-lasting as well as an efficient DC (Direct Current) current which helps every component to function properly in an efficient manner. The device is battery-operated and does not need any electrical voltage to function. Hence the presence of the battery leads to the portability of the device i.e., the user is able to place as well as move the device from one place to another as per the requirements.

[0041] The present invention works best in the following manner, where the body 101 as disclosed in the invention is positioned on the fixed horizontal surface and user through the slidable opening 102 accommodates foot inside the foot. The imaging unit 103 detects the dimensions and contours of the user’s foot, based on which the microcontroller determines a size and shape of untreated sole that is to be utilized for making orthopedic insoles for the user. Upon detection, the microcontroller actuates the robotic arm 105 for gripping a specific size of untreated sole from the multi-sectioned chamber 104 and position over the plate 106 in a manner that the rubber supports affixed with the grooves 107. The ultrasonic sensor detects placement of the user’s foot over the plate 106, after successful placement of the user’s foot, the microcontroller actuates the plungers 108 for pushing the rubber support upward, in view of obtaining a curve under the feet of the user, and facilitating in making a custom-fit insole in accordance with unique contours of the user’s foot. The laser sensor detects extra rubber supports protruding downward from the groves, and accordingly the microcontroller actuate the cutting unit 109 for removing the extra rubber support. Upon successful trimming of the extra protruded rubber support, the microcontroller actuates the robotic grippers for gripping the manufactured insole and position the insole inside the container 110 mounted on the body 101.

[0042] 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 individuals skilled in the art upon reference to the description of the invention. , Claims:1) An automated orthopedic insoles manufacturing device, comprising:

i) a cuboidal body 101 developed to positioned on a fixed horizontal surface, wherein motorized slidable opening 102 is configured on said body 101 that is actuated by an inbuilt microcontroller for allowing said user to accommodate foot inside said body 101;
ii) an artificial intelligence-based imaging unit 103 installed on said body 101 and paired with a processor for capturing and processing multiple images of surroundings, respectively, to determine dimensions and contours of said user’s foot, wherein based on which said microcontroller determines a size and shape of untreated sole that is to be utilized for making orthopedic insoles for said user;
iii) a multi-sectioned chamber 104 configured on said body 101, each section stored with various sizes and shapes of insoles with rubber supporting mounting integrated on said insole, wherein based on said determined size and shape of untreated sole, said microcontroller actuates a robotic arm 105 configured inside said body 101 to grip and position said sole over a rectangular plate 106 carved with horizontal grooves 107, and said robotic arm 105 positions said insole in a manner that said rubber supports affixed with said grooves 107;
iv) an ultrasonic sensor installed on said plate 106 for detecting placement of said user’s foot over said plate 106, wherein after successful placement of said user’s foot, said microcontroller actuates plurality of hydraulically operated plungers 108 configured in between base of said body 101 and plate 106 for pushing said rubber support upward, in view of obtaining a curve under the feet of said user, and facilitating in making a custom-fit insole in accordance with unique contours of said user’s foot;
v) a pressure sensor integrated with said plate 106 for detecting pressure applied by said rubber supports on said user’s foot while said plungers 108 pushes said insole under said user’s feet, and in case said detected pressure recedes a threshold value, said microcontroller actuates said plungers 108 to push said rubber support towards said user’s foot with an optimum amount of force in order create precise insoles; and
vi) a motorized cutting unit 109 configured in on said plate 106, wherein said microcontroller actuates said cutting unit 109 to trim off extra rubber supports which is affixed in horizontal grooves 107, once curve is obtained on said insole, thereby making customized orthopedic insoles for correcting foot alignment and providing better support and alignment for said user’s feet, and enhancing overall foot function and mobility.

2) The device as claimed in claim 1, wherein a laser sensor is configured on said body 101 for detecting extra rubber supports protruding downward from said groves, and accordingly said microcontroller actuate said cutting unit 109 for removing said extra rubber support.

3) The device as claimed in claim 1, wherein upon successful trimming of said extra protruded rubber support, said microcontroller actuates said robotic grippers for gripping said manufactured insole and position said insole inside a container 110 mounted on said body 101.

4) The device as claimed in claim 1, wherein a tactile sensor is arranged on said cutting unit 109 for detecting hardness of said rubber supports, in accordance to which said microcontroller regulates operation of said cutting unit 109 to cut said rubber supports without causing any damage to said insoles.

5) The device as claimed in claim 1, wherein an IR (Infrared) counter is embedded within each sections of said multi-sectioned chamber 104 for counting number of said untreated insoles stored within said chamber 104s, and as soon as said counted number recedes a threshold number, said microcontroller sends an alert on a computing unit for notifying said user to re-fill said untreated insoles in said chamber 104s.

6) The device as claimed in claim 1, wherein said microcontroller is wirelessly linked with said computing unit via a communication module which includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module.

7) The device as claimed in claim 1, wherein a battery is associated with said device for powering up electrical and electronically operated components associated with said device.