Description:FIELD OF THE INVENTION

[0001] The present invention relates to an autonomous monitoring and maintenance device for bolted joints that is capable of independently inspecting bolted joints of the railway track by utilizing advanced artificial intelligence techniques to efficiently detect looseness or damage in bolts, and carrying out maintenance by adjusting the tightness accordingly.

BACKGROUND OF THE INVENTION

[0002] Maintaining the bolted joints of railway tracks is critical to ensuring the safety, stability, and longevity of railway infrastructure. Bolted joints are essential components that hold the rails together, connecting them to the underlying ties or base plates. Over time, these joints experience significant stress from constant vibrations, thermal expansion and contraction, heavy train loads, and environmental factors such as moisture and temperature fluctuations. This continuous strain can lead to the loosening of bolts, causing joint instability, rail misalignment, or even track displacement. Loosened or damaged bolts can result in dangerous conditions like derailments, increased wear on track components, and higher maintenance costs. Routine inspection and maintenance are therefore necessary to detect early signs of bolt failure, such as looseness, corrosion, or fatigue, before they lead to more severe issues. Traditional maintenance methods often involve manual inspections, which are time-consuming, labor-intensive, and prone to human error. Advanced technologies, such as automated inspection systems that monitor vibration patterns, gap measurements, and bolt integrity, are becoming increasingly vital. These systems can provide real-time data, enabling prompt identification and repair of faulty bolts, thus reducing downtime, enhancing safety, and improving the overall efficiency of track maintenance operations.

[0003] Maintenance of bolted joints in railway tracks is crucial for ensuring the stability and safety of the rail network. The primary equipment used for this purpose includes torque wrenches, impact wrenches, spanners, track alignment tools, and bolt tensioning devices. These tools help tighten or loosen bolts, align the tracks, and maintain the correct tension to prevent track misalignment or wear. Torque wrenches are used to apply a specific amount of force to the bolts, while impact wrenches can quickly remove or install fasteners. Tensioning devices are employed to ensure uniform pressure across bolts, reducing the risk of track displacement. Despite the effectiveness, bolted joints have several drawbacks. Over time, they are subject to loosening due to vibrations from passing trains, which can compromise track integrity and safety. Regular maintenance is required to re-tighten bolts, which can be time-consuming and labor-intensive. Additionally, bolts can corrode, especially in harsh weather conditions, leading to rust and weakening of the joint. This necessitates periodic inspection and replacement, which increases maintenance costs. Finally, the process of tightening or loosening bolts requires precise measurements to avoid over-tightening or under-tightening, both of which can lead to premature failure or increased wear on components.

[0004] WO2015057921A1 discloses a track connector that bridges between two railroad track rails in line to lay a railroad track without need to bolt the rails together with joint bars. It has a short piece of the rail as a bridging rail with a joint bar welded or bolted central to each side and extending out beyond the ends of the bridging rail to form a two pronged fork at each end each to secure a rail end between the prongs of the joint bars at that end in line with the track. It can be a single piece or pieces bolted together spanning a distance between rail ends, saving the drilling and bolting of rails together with joint bars.

[0005] GB2420142A discloses a method of installing railway rail track comprises a first step of pre-forming a section of rail track, by connecting a pair of railway rails to a plurality of rail foundations, spaced along the length of the rails, by means of rail fasteners which are respectively removably attached to the rail foundations, before the rail foundations, with attached rails, are placed in the location in which the section of rail track is to be used, and a second step of joining together successive sections of rail track. The first step includes a sub-step of connecting the rails to the rail foundations immediately adjacent to each end of each section of rail track using removable rail fasteners of a first type, different to a second type used elsewhere on the rail track section, the rail foundations being designed for use with the second type of rail fastener and the first type of rail fastener being adapted for use with such rail foundations, and the second type of rail fastener comprising an elastic member for supporting a rail under its head, the elastic member itself being supported by support means having an upper section for bearing against the elastic member and a lower section comprising a stem which, when the support means are use in, extends into a slot in the rail foundation for removably attaching the support means to the rail foundation. The second step includes a sub-step of initially joining together successive sections of rail track by means of a joining member which extends along the web of each rail so as to span the interface between abutting rails, the first and second types of rail fastener having a contact part which is in contact with the foot or web of the rail, the extent of the contact part of the first type of rail fastener being less than that of the contact part of the second type of rail fastener, such that the joining member can be accommodated between the contact parts of rail fasteners of the first type. The method further comprises a third step of removing the removable rail fasteners of the first type from the rail foundations, after the rails of successive track sections have been joined, and a fourth step of attaching to the rail foundations, in place of the first type of rail fasteners, rail fasteners of the second type. A method of temporarily repairing a damaged rail in railway track is also disclosed.

[0006] Conventionally, many devices have been developed for railway tracks maintenance, however the devices mentioned in the prior arts have limitations pertaining to repair defective bolts by securely cutting and replacement with new bolts.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to autonomously examine railway infrastructure and maintain bolted joints of the railway track wherever required by the integration of cutting-edge artificial intelligence, to detect bolt looseness or damage and adjust the tightness accordingly. Additionally, the developed device further features capability to repair defective bolts by securely cutting and replacing in an efficient manner.

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 inspecting railway infrastructure autonomously and carries maintenance of bolted joints of railway track as and when required.

[0010] Another object of the present invention is to develop a device that is capable of incorporating advanced artificial intelligent technique for efficient operation in investigating looseness or damage in bolts of bolted joints and provides a means for carrying out tightening the bolts.

[0011] Yet another object of the present invention is to develop a device that is capable of repairing defective bolts of bolted joints by cutting and replacing the bolt in a secured manner.

[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 autonomous monitoring and maintenance device for bolted joints that is designed to inspect railway infrastructure in self-sufficient manner and handle maintenance of bolted joints of the track as required using advanced artificial intelligent techniques.

[0014] According to an embodiment of the present invention, an autonomous monitoring and maintenance device for bolted joints, comprises of a cuboidal body developed to be positioned in proximity to a railway track, configured with multiple motorized wheels to maneuver the body over a ground surface, a laser-based sensor is installed over the body to determine level of the surface and sends acquired data to a microcontroller linked with the laser-based sensor that in turn activates a telescopically operated bar attached in between each of the wheels and body to stabilize the body over the surface, a user interface installed within a computing unit associated with the device for enabling the user to input details regarding designated inspection areas, upon receiving the user’s commands, the microcontroller activates an artificial intelligence-based imaging unit installed on the body and paired with a processor to detect objects or specific bolted joints in proximity.

[0015] According to another embodiment of the present invention, the proposed device comprises of an extendable rod attached to the body through a primary motorized ball-and-socket joint, the extendable rod is configured to hold a plate, plurality of piezoelectric patches (PZT) are affixed to surface of the plate, one of PZT patch functions as a sensor and the other functions as an actuator that generate vibrations when an electrical signal is applied, and the sensor is configured to detect any changes in vibration patterns as vibrations travel through the bolted joint, the microcontroller analyzes Electro-mechanical Impedance (EMI) by comparing detected vibration signals across different frequency ranges, using Root Mean Square Deviation (RMSD) technique to identify significant deviations that indicate looseness or damage in bolts.

[0016] According to another embodiment of the present invention, the proposed device further comprises of an ultrasonic sensor configured with the body and synced with the imaging unit to detect a gap between nut and bolt, upon detecting looseness, the microcontroller automatically tightens the bolt using a holding unit that is connected to a pneumatic link mounted on the body via a secondary motorized ball-and-socket joint, a rpm (revolution per minute) sensor embedded with the holding unit continuously monitors rotation of holding unit during bolt-tightening or loosening operation, and a cutting blade attached with the body to precisely cut the defective bolt, ensuring that damaged or defective bolt is safely and efficiently removed.

[0017] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of an autonomous monitoring and maintenance device for bolted joints.

DETAILED DESCRIPTION OF THE INVENTION

[0019] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0020] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0021] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0022] The present invention relates to an autonomous monitoring and maintenance device for bolted joints configured with rail tracks by utilizing advanced artificial intelligence techniques for detecting any sort of looseness or damage in the bolts and accordingly is equipped with multiple means for tightening the loosened bolts along with carrying out maintenance work on the damaged bolts.

[0023] Referring to Figure 1, an isometric view of an autonomous monitoring and maintenance device for bolted joints is illustrated, comprises of a cuboidal body 101 having multiple motorized wheels 102, a telescopically operated bar 103 attached in between each of the wheels 102 and body 101, an artificial intelligence-based imaging unit 104 installed on the body 101, an extendable rod 105 attached to the body 101 through a primary motorized ball-and-socket joint 106, the extendable rod 105 is configured to hold a plate 107.

[0024] Figure 1 further illustrates a holding unit 108 connected to a pneumatic link 109 mounted on the body 101 via a secondary motorized ball-and-socket joint 110, a cutting blade 111 attached with the body 101, a collecting chamber 112 mounted on the body 101, a clamp mechanism 113 attached to an extendable pole 114, connected to the body 101 via a tertiary motorized ball-and-socket joint 115.

[0025] The proposed invention includes a body 101 preferably in portable cuboidal shape incorporating various components associated with the device, developed to be positioned proximity to a railway track. The body 101 is configured in a way such that comprise plurality of motorized wheels 102 positioned underneath the body 101 for translation of the body 101 over a ground surface as per requirement. Each of the wheels 102 are connected with the body 101 by means of telescopically operated bar 103 which are pneumatically powered by a pneumatic arrangement associated with the device. The pneumatic arrangement constitutes extension/retraction of the bar 103 such that elevate the height of the body 101 as per requirement. The body 101 is made up of any material selected from but not limited to metal or alloy that ensures rigidity of the body 101 for longevity of the device.

[0026] A user is required to access and presses a switch button arranged on the body 101 to activate the device for associated processes of the device. The switch button when pressed by the user, opens up an electrical circuit and allows currents to flow for powering an associated microcontroller of the device for operating of all the linked components for performing their respective functions upon actuation.

[0027] The microcontroller, mentioned herein, is preferably an Arduino microcontroller. The Arduino microcontroller used herein controls the overall functionality of the components linked to it. The Arduino microcontroller is an open-source programming platform.

[0028] After the activation of the device, the user accesses a user interface which is installed in a computing unit linked with the microcontroller wirelessly by means of a communication module. The user interface enables the user to provide input regarding designated inspection areas. The communication module includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module.

[0029] Upon receiving of the user input, the microcontroller generates a command to activate an artificial intelligence-based imaging unit 104 integrated on the body 101 for capturing multiple images in a vicinity of the body 101 to detect objects or specific bolted joints in proximity. The imaging unit 104 incorporates a processor that is encrypted with an artificial intelligence protocol. The artificial intelligence protocol operates by following a set of predefined instructions to process data and perform tasks autonomously. Initially, data is collected and input into a database, which then employs protocol to analyze and interpret the captured images. The processor of the imaging unit 104 via the artificial intelligence protocol processes the captured images and sent the signal to the microcontroller.

[0030] In accordance to the detected objects or specified bolted joints, the microcontroller then powers an associated direct current (DC) motor connected with the wheels 102. The wheels 102 have small discs or rollers around the circumference of the wheel that are powered by the motor, enabling the wheels 102 to move in required direction, which provide the body 101 with the required movement for maneuvering over the surface.

[0031] The level of the surface is determined by a laser-based sensor installed over the body 101. The laser-based sensor, used herein, is a type of point sensor which detects the level of the surface by measuring the amount of infrared light that is reflected back from the surface of the ground into a photodiode associated with the sensor. The level sensor detects the level of the surface and sends to the microcontroller in the form of electrical signal to the microcontroller. The microcontroller then processes the signal of the detected level.

[0032] In accordance to the level of the surface, the height of the body 101 is regulated by the microcontroller by actuating the pneumatic arrangement to extend/retract the bars. The microcontroller actuates an air compressor and air valve associated with the pneumatic arrangement consisting of an air cylinder, air valve and piston which works in collaboration to aid in extension and retraction of the bars. The air valve allows entry/exit of compressed air from the compressor. Then, the valve opens and the compressed air enters inside the cylinder thereby increasing the air pressure of the cylinder. The piston is connected to the bars 103 and due to the increase in the air pressure, the piston extends. For the retraction of the piston, air is released from the cylinder to the air compressor via the valve. Thus, providing the required extension/retraction of the bars 103 for adjusting the height of the body 101. All the pneumatically operated components associated with the device comprises of the same type of pneumatic arrangement.

[0033] The body 101 is attached with an extendable rod 105 through a primary motorized ball-and-socket joint. The rod 105 is arranged in such a fashion that holds a plate 107 which is integrated with plurality of piezoelectric patches (PZT) on the surface of the plate 107. The rod 105 is powered by the pneumatic arrangement associated with the device providing extension/retraction of the rod 105 as per requirement. The working of the rod 105 is similar to the working of the bars 103 as mentioned above, for positioning the plate 107 in proximity to the bolted joint.

[0034] The articulated movement of the rod 105 for positioning the rod 105 is provided by the actuation of the primary motorized ball-and-socket joint. the ball and socket joint provides a 360-degree rotation to the rod 105 for aiding the rod 105 to turn at a desired angle. The ball and socket joint are a coupling consisting of a ball joint securely locked within a socket joint, where the ball joint is able to move in a 360-dgree rotation within the socket thus, providing the required rotational motion to the rod. The ball and socket joint are powered by a DC (direct current) motor that is actuated by the microcontroller thus providing multidirectional movement to the rod, thereby aids in efficient positioning of the plate 107 in proximity to the bolted joint.

[0035] One of the PZT patch functions as a sensor while the other PZT patches functions as an actuator that generate vibrations when an electrical signal is applied. The Piezoelectric patches work by converting mechanical stress or pressure into electrical signals. The patches generate a small electrical charge when deformed or subjected to vibrations. This property makes the PZT patches ideal for detecting changes in vibration patterns in the bolted joints. As vibrations occur, the piezoelectric material in the patch deforms, generating electrical signals that are proportional to the frequency and intensity of the vibrations. By monitoring these electrical signals, any changes in the vibration patterns such as shifts in frequency, amplitude, or rhythm is detected. These changes indicate issues like structural defects or mechanical faults in the bolted joint being monitored.

[0036] The microcontroller analyzes the Electro-mechanical Impedance (EMI) by comparing detected vibration signals across different frequency ranges, using Root Mean Square Deviation (RMSD) technique in order to identify significant deviations that indicate looseness or damage in bolts. The microcontroller compares detected vibration frequencies to a database linked with the microcontroller, enabling to assess condition of bolted joints and identify whether they are in good condition or require maintenance.

[0037] The imaging unit 104 works in sync with an ultrasonic sensor configured with the body 101 detect a gap between nut and bolt. The ultrasonic sensor disclosed herein, consists of an emitter and a receiver that acts as a transducer. The emitter emits ultrasonic sound waves towards nut and bolt. Then, the radiation strike to the nut and bolt and reflect back which are captured by the receiver. The signal is sent to the microcontroller. The microcontroller processes the received signal from the ultrasonic sensor and on the basis of time lapse in between the sent and received radiations, the microcontroller detects a gap between nut and bolt.

[0038] The body 101 is equipped with a pneumatic link 109 integrated with a holding unit 108 via a secondary motorized ball-and-socket joint. The link 109 is powered by the pneumatic arrangement associated with the device such that provides extension/retraction of the link 109 for positioning the holding unit 108 as per requirement. In accordance to the detected looseness, the microcontroller automatically tightens the bolt by actuating the pneumatic arrangement for translating the link 109 to position the holding unit 108 in contact with the bolt.

[0039] The microcontroller then actuates the holding unit 108 to grip the bolt. The holding unit 108 is integrated with a twisting mechanism that is used to rotate the bolt and tighten or loosen the bolt as required. The articulated movement to the holding unit 108 while operating the nut is provided by the secondary motorized ball-and-socket joint. The working of the secondary motorized ball-and-socket joint 110 is similar to the working of the primary motorized ball-and-socket joint 106 as mentioned above.

[0040] The holding unit 108 is embedded with a rpm (revolution per minute) sensor for continuously monitoring rotation of holding unit 108 during bolt-tightening or loosening operation. The rpm sensor converts mechanical motion into electric pulses with or without direct contact when the holding unit 108 rotates. The resultant output signals are then fed to a digital counter, totalizer, tachometer, or linked with the microcontroller.

[0041] In case the rpm sensor detects the holding unit 108 rotates without tightening the bolt, the microcontroller automatically activates a cutting blade 111 attached with the body 101 to precisely cut the bolt. The microcontroller transmits electric signal to the motor of the blade 111 and the electromotive force induced by the currents flow into the inductive coil of the motor of the blade rotates the output shaft onto which blade 111 is connected. Thus, rotation of the output shaft of the motor, rotates the connected blade 111 by which blade 111 cuts the defective bolt when comes in contact with the defective bolt, ensuring that damaged or defective bolt is safely and efficiently removed.

[0042] The body 101 is mounted with a collecting chamber 112 which stores a variety of bolts in different types and sizes. The collection chamber 112 ensures appropriate replacement bolts are readily available for use during maintenance operation. The body 101 is attached with an extendable pole 114 via a tertiary motorized ball-and-socket joint. The body 101 is integrated with a clamp mechanism 113. The pole 114 is powered by the pneumatic arrangement associated with the device such that provides extension/retraction of the pole 114 in view of positioning the clamp mechanism 113 in proximity to the bolted joint.

[0043] The multi-directional movement of the pole 114 is provided by the actuation of the tertiary motorized ball-and-socket joint 115 which works similar to the working of the tertiary motorized ball-and-socket joint 115 as mentioned above. In relation to provide replacement to the defective bolt, the microcontroller actuates the clamp mechanism 113 to retrieve and select correct bolt from the collecting chamber 112, ensuring a proper fit.

[0044] The microcontroller sends real-time alerts to both user and a control unit via the communication module, thereby notifies the user regarding critical events in relation to the operation of the bolted joints as well as updates on \ progress of ongoing inspections or maintenance tasks.

[0045] A battery (not shown in figure) is associated with the device to supply power to electrically powered components which are employed herein. The battery is comprised of a pair of electrodes named as a cathode and an anode. The battery uses a chemical reaction of oxidation/reduction to do work on charge and produce a voltage between their anode and cathode and thus produces electrical energy that is used to do work in the device.

[0046] The present invention works best in the following manner, where the cuboidal body 101 as disclosed in the invention is equipped with motorized wheels 102, is stabilized using telescopic bars 103 controlled by the microcontroller that responds to data from the laser-based sensor detecting surface levels. The user interface allows the operator to define inspection zones, prompting the microcontroller to activate the imaging unit 104 for detecting specific objects or bolted joints. The extendable rod 105 with piezoelectric patches is used to monitor the vibration patterns of bolted joints, enabling the detection of looseness or damage through electro-mechanical impedance (EMI) analysis. Additionally, the ultrasonic sensor identifies gaps between nuts and bolts, and upon detecting looseness, the microcontroller activates the pneumatic holding unit 108 to tighten the bolt. If the bolt is not tightened, the rpm sensor triggers the operation of the cutting blade 111 to remove the defective bolt. The collecting chamber 112 ensures the availability of appropriate replacement bolts, and the clamp mechanism 113 retrieves the correct one for installation. The device also features the twisting mechanism for precise bolt rotation, and the microcontroller, connected to the communication module, provides real-time alerts and progress updates to users and control units.

[0047] 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 autonomous monitoring and maintenance device for bolted joints, comprising:

i) a cuboidal body 101 developed to be positioned in proximity to a railway track, configured with multiple motorized wheels 102 to maneuver said body 101 over a ground surface, wherein a laser-based sensor is installed over said body 101 to determine level of said surface and sends acquired data to a microcontroller linked with said laser-based sensor that in turn activates a telescopically operated bar 103 attached in between each of said wheels 102 and body 101 to stabilize said body 101 over said surface;
ii) a user interface installed in a computing unit associated with said device for enabling said user to input details regarding designated inspection areas, wherein upon receiving said user’s commands, said microcontroller activates an artificial intelligence-based imaging unit 104 installed on said body 101 and paired with a processor to detect objects or specific bolted joints in proximity,
iii) an extendable rod 105 attached to said body 101 through a primary motorized ball-and-socket joint, said extendable rod 105 is configured to hold a plate 107, wherein plurality of piezoelectric patches (PZT) are affixed to surface of said plate 107, one of PZT patch functions as a sensor and the other functions as an actuator that generate vibrations when an electrical signal is applied, and said sensor is configured to detect any changes in vibration patterns as vibrations travel through said bolted joint;
iv) said microcontroller analyzes Electro-mechanical Impedance (EMI) by comparing detected vibration signals across different frequency ranges, using Root Mean Square Deviation (RMSD) technique to identify significant deviations that indicate looseness or damage in bolts;
v) an ultrasonic sensor configured with said body 101 and synced with said imaging unit 104 to detect a gap between nut and bolt, wherein upon detecting looseness, said microcontroller automatically tightens said bolt using a holding unit 108 that is connected to a pneumatic link 109 mounted on said body 101 via a secondary motorized ball-and-socket joint; and
vi) a RPM (revolution per minute) sensor embedded with said holding unit 108 continuously monitors rotation of holding unit 108 during bolt-tightening or loosening operation, wherein upon detecting holding unit 108 rotates without tightening said bolt, said microcontroller automatically activates a cutting blade 111 attached with said body 101 to precisely cut said defective bolt, ensuring that damaged or defective bolt is safely and efficiently removed.

2) The device as claimed in claim 1, wherein a collecting chamber 112 mounted on said body 101 stores a variety of bolts in different types and sizes, ensuring that appropriate replacement bolts are readily available for use during maintenance operation.

3) The device as claimed in claim 1, wherein a clamp mechanism 113 is attached to an extendable pole 114, which is connected to said body 101 via a tertiary motorized ball-and-socket joint 115 that are actuated by said microcontroller in work in collaboration to retrieve and select correct bolt from said collecting chamber 112, ensuring a proper fit.

4) The device as claimed in claim 1, wherein a twisting mechanism is integrated within said holding unit 108 that is used to rotate said bolt and tighten or loosen said bolt as required.

5) The device as claimed in claim 1, wherein said microcontroller compares detected vibration frequencies to a database linked with said microcontroller, enabling to assess condition of bolted joints and identify whether they are in good condition or require maintenance.

6) The device as claimed in claim 1, wherein said microcontroller is equipped with a communication module, configured to send real-time alerts to both user and a control unit, to notify regarding critical events as well as updates on progress of ongoing inspections or maintenance tasks.