Description:FIELD OF THE INVENTION

[0001] The present invention relates to a mold formation device for moulding operation that is capable of streamlining the process of creating intricate shapes and designs, making it more accessible and manageable for user, thereby reducing the need for manual labor and expertise.

BACKGROUND OF THE INVENTION

[0002] Molding is a crucial step in various industries, including metal casting, plastic injection molding, and concrete formwork, where precise and accurate mold creation is essential for producing high-quality end products. Molding is a fundamental and pivotal step in numerous manufacturing and construction industries, playing a critical role in shaping and producing components that meet exact specifications. This process is integral across various fields, including metal casting, plastic injection molding, and concrete formwork, each of which relies on precise and accurate mold creation to ensure the production of high-quality end products.

[0003] Traditionally, the process of mold formation involves manual labor and is often characterized by its labor-intensive nature. This process typically requires significant human intervention to level sand or other molding materials, precisely position and form molds, and ensure the proper finishing of the molded objects. Furthermore, conventional methods are prone to inconsistencies and inaccuracies, which leads to defects in the final product and inefficiencies in the production process.

[0004] US6354561B1 discloses the invention relates to an adjustable casting mold with a plurality of axially displaceable molding pins. Each molding pin has a self-locking threaded mechanism by way of which the molding pin is supported on a carrier plate. The carrier plates on which in each case a plurality of adjustable molding pins are mounted are, in turn, connected to a molding-box housing member to be adjustable in a different manner perpendicular to the mold parting surface. Though, US’561 provides a molding-box housing member to be adjustable in a different manner perpendicular to the mold parting surface. However, the above cited disclosure is incapable of creating complex shapes and designs by increasing precision and accuracy in mold formation.

[0005] US2007054033A1 discloses a master mold for an offset process is disclosed which enables formation of electrodes with a complex pattern or a very-fine pattern. A pattern formation method using the master mold is also disclosed. The master mold includes a plate having a predetermined thickness, and an intaglio pattern formed in a surface of the plate. The intaglio pattern has a cross-section having a surface inclined in a transfer direction of a material to be transferred. Though, US’033 is capable of providing a master mold for an offset process. However, the above cited disclosure is incapable of preventing damage or errors during the mold creation process by detecting potential issues.

[0006] Conventionally, there exists many devices that are capable of manufacturing an object through a moulding operation, however these existing devices fail in preventing damage or errors during the creation process by monitoring those issues. In addition, these existing devices are also incapable of providing accurate surface finishing of the object.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is need to be capable of creating complex shapes and designs on an object through a moulding operation without causing any damage while entire process. Furthermore, the developed device required to be potent enough of providing precise levelling and finishing.

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 simplifying the process of creating complex shapes and designs by increasing precision and accuracy in mold formation, thereby reducing manual labor and increases efficiency.

[0010] Another object of the present invention is to develop a device that is capable of preventing damage or errors during the mold creation process by detecting potential issues and alert the user or adjust the process accordingly.

[0011] Yet another object of the present invention is to develop a device that is capable of ensuring accurate leveling and surface finishing of the sand and object for providing precise control over the mold formation process.

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

SUMMARY OF THE INVENTION

[0013] The present invention relates to a mold formation device for moulding operation that is capable of enabling a user to create complex shapes and designs with ease and precision by automating the mold formation process, reducing manual labor and increasing efficiency.

[0014] According to an embodiment of the present invention, a mold formation device for moulding operation, comprising a housing developed to be positioned on a ground surface and having a container stored with sand, a computing unit installed with a user-friendly interface installed with the housing to enable the user to input commands and specifications for the object they desired to create, an artificial intelligence-based imaging unit mounted on the housing to capture multiple images of the container from various angles to detect the exact location and orientation of the container, multiple motorized omnidirectional wheels configured underneath the housing to allow the housing to move freely in any direction, a laser sensor positioned on the plate to detect the levelling of the sand in the container and a first robotic arm arranged with the housing to maneuver a plate configured with the arm over the sand.

[0015] According to another embodiment of the present invention, the proposed device further comprises of an L-shaped telescopically operated rod installed on the body and arranged to a vertical bar having multiple pneumatic pins to tilt and adjust the position of the pins via a motorized hinge for creating a structure, which matches the user-defined shape, a speaker is mounted on the housing to generate voice alerts to notify the user to fill the mold with liquid molten material, a pair of telescopically operated grippers assembled with the housing to grip and position the formed object out from the sand, a second robotic arm is configured on the housing and embedded with a motorized scrubber to maneuver the scrubber across the entire surface of the object, an inductive proximity sensor arranged on the housing, working in synchronization with the imaging unit to detect the material of the container, a vibrating unit equipped with each of the grippers to remove excess sand from the object's surface and a battery is associated with the device to supply power to electrically powered components which are employed herein.

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

BRIEF DESCRIPTION OF THE DRAWINGS

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

DETAILED DESCRIPTION OF THE INVENTION

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

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

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

[0021] The present invention relates to a mold formation device for moulding operation that is capable of providing a comprehensive, automated, and user-friendly solution to create complex shapes and designs with ease without requiring much human effort from the user.

[0022] Referring to Figure 1, an isometric view of a mold formation device for moulding operation is illustrated, comprising a housing 101 developed to be positioned on a ground surface and having a container 102 stored with sand, an artificial intelligence-based imaging unit 103 mounted on housing 101, multiple motorized omnidirectional wheels 104 configured underneath housing 101, a first robotic arm 105 arranged with housing 101 to maneuver a plate 106 configured with arm, an L-shaped telescopically operated rod 107 installed on body and arranged to a vertical bar 108 having multiple pneumatic pins 109, a motorized hinge attached with pins 109, a speaker 110 mounted on housing 101, a pair of telescopically operated grippers 111 assembled with housing 101, a second robotic arm 112 configured on housing 101 and embedded with a motorized scrubber 113.

[0023] The device disclosed herein, comprises of a housing 101 that is positioned on a ground surface. The housing 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 housing 101 making it resistant to mechanical stress and pressure. The surface of the housing 101 is coated with material like Teflon or other low-friction coatings to improve wear resistance and reduce friction.

[0024] The housing 101 is placed with a container 102 filled with sand that provides a stable foundation for the device to operate. The housing 101 is equipped with a computing unit installed with a user-friendly interface, allowing users to input commands and specifications for the object they desired to create. The computing unit is wirelessly connected to the device, enabling seamless communication and control.

[0025] The user-interface is designed to be intuitive, making it easy for users to input the desired shape and dimensions of the object they want to manufacture. The computing unit is linked wirelessly with the microcontroller via a communication module which includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module. The user interface serves as a bridge between the user and the microcontroller, allowing for a user-friendly way to input commands.

[0026] Once the user inputs their specifications, the computing unit processes the information and sends commands to the microcontroller linked with the computing unit to begin the moulding operation. The microcontroller interpreting user inputs and activates an artificial intelligence-based imaging unit 103, which is mounted on the housing 101 to capture multiple images of the container 102 from various angles, using artificial intelligence and machine learning protocols to detect the exact location and orientation of the container 102.

[0027] The artificial intelligence based imaging unit 103 is constructed with a camera lens and a processor, wherein the camera lens is adapted to capture a series of images of the container 102. The processor carries out a sequence of image processing operations including pre-processing, feature extraction, and classification. The image captured by the imaging unit 103 is real-time images of the container 102. The artificial intelligence based imaging unit 103 transmits the captured image signal in the form of digital bits to the microcontroller. The microcontroller upon receiving the image signals compares the received image signal with the pre-fed data stored in a database and constantly determines exact location of the container 102.

[0028] The microcontroller uses this data from the imaging unit 103 to precisely position the housing 101 in close proximity to the container 102. For positioning the housing 101 near to the container 102, the microcontroller actuates multiple motorized omnidirectional wheels 104 configured underneath the housing 101 to allow the housing 101 to move freely in any direction, enabling precise maneuvering and positioning. The microcontroller controls the wheels 104 to gently and accurately position the housing 101 in proximity to the container 102, ensuring optimal alignment for the moulding operation.

[0029] Post successful reception of the commands, the microcontroller activates a laser sensor positioned on the plate 106 to detect the levelling of the sand in the container 102. The laser sensor works in synchronization with the imaging unit 103 to accurately measure the sand's surface level, ensuring precise detection. The laser sensor activates and emits a focused and narrow beam toward the mouth portion of the container 102. When the laser beam strikes the surface of the container 102, it gets reflected back towards the sensor. The receiver of the laser sensor captures the reflected light and employs a time-of-flight measurement principle to determine the levelling of the sand in the container 102.

[0030] When the microcontroller receives the levelling data, then the microcontroller actuates a first robotic arm 105 arranged with the housing 101 to maneuver a plate 106 configured with the arm over the sand for ensuring a perfectly levelled base for the moulding operation. The robotic arm is equipped with multiple joints and actuators that allows the first robotic arm 105 to move in multiple dimensions and orient the plate 106 with great precision for moving the plate 106 over the sand for perfect surface levelling of the sand.

[0031] The first robotic arm 105 operates through a combination of motors, sensors, and controllers. The first robotic arm 105 typically consists of multiple joints that allow for various degrees of freedom, mimicking the movements of a human arm. The microcontroller interprets input commands, translating them into specific movements. Motors drive the joints, while sensors provide feedback on position and force.

[0032] An L-shaped telescopically operated rod 107 is installed on the body arranged to a vertical bar 108 having multiple pneumatic pins 109 that is actuated by the microcontroller, to get extend or retract in synchronization with multiple motorized hinges that connect the pins 109 to the bar 108. The synchronized movement allows the pins 109 to tilt and adjust their position, enabling the formation of a structure that matches the user-defined shape and dimensions.

[0033] The pins 109 as mentioned herein are powered by a pneumatic unit that utilizes compressed air to extend and retract the pins 109. The process begins with an air compressor which compresses atmospheric air to a higher pressure. The air cylinder of the pneumatic unit contains a piston that moves back and forth within the cylinder. The cylinder is connected to one end of the pins 109. The piston is attached to the pins 109 and its movement is controlled by the flow of compressed air.

[0034] To extend the pins 109 the piston activates the air valve to allow compressed air to flow into the chamber behind the piston. As the pressure increases in the chamber, the piston pushes the pins 109 to the desired length. Synchronously, the hinges consist of a pair of leaf that are connected with each other via a rod, wherein the rod 107 is coupled with a motor that is interlinked with the microcontroller for tilting the pins 109 to create a structure of the user-defined shape and dimensions.

[0035] As the pins 109 move and tilt, the pins 109 create a precise outline of the desired shape, which is then inserted into the sand. The microcontroller extends the telescopically operated rod, carefully placing the structure into the sand. The rod's precise movement ensures that the structure is positioned accurately, without disturbing the surrounding sand. The extensions of the rod 107is mentioned herein is powered by a pneumatic unit that utilizes the compressed air to extend and retract the rod 107for positioning the structure into the sand.

[0036] Once the structure is inserted, the microcontroller actuates the rod 107to retract, pulling the structure out of the sand, which creates a precise mold in the sand, matching the user-defined shape and dimensions. The mold is now ready for the next stage of the process, where the liquid molten material poured in to create the final object.

[0037] A speaker 110 is mounted on the housing 101, which is activated by the microcontroller to generate voice alerts to notify the user to fill the mold with liquid molten material, signaling the next stage of the object formation process. The speaker 110 is capable of producing clear and natural sound and is capable of adjusting its volume based on ambient noise levels. The speaker 110 consists of audio information, which is in the form of recorded voice, synthesized voice, or other sounds, generated or stored as digital data.

[0038] This data is often in the form of an audio file. The digital audio data is sent to a digital-to-analog converter (DAC). The DAC converts the digital data into analog electrical signals. The analog signal is often weak and needs to be amplified. An amplifier boosts the strength to a level so that the speaker 110 drives it effectively. The amplified audio signal is then sent to the speaker 110. The core of the speaker 110 is an electromagnet attached to a flexible cone. These sound waves travel through the air as pressure waves and are picked by the user’s ear.

[0039] Simultaneously, the microcontroller having a timer that tracks the time elapsed since the mold was created. Once the tracked time matches a predetermined threshold duration, the microcontroller initiates the next step in the process, which ensures that the liquid molten material has sufficient time to cool and solidify, allowing the object to take shape. As the timer reaches the threshold, the microcontroller actuates a pair of telescopically operated grippers 111 assembled with the housing 101 to grip and position the formed object out from the sand, thereby ensures that the object is carefully extracted from the sand, without causing damage or distortion. The gripper 111 mentioned herein is powered by a pneumatic unit that utilizes the compressed air to extend and retract the gripper for gripping the formed object and take it out from the sand.

[0040] A second robotic arm 112 is configured on the housing 101 and embedded with a motorized scrubber 113. The second robotic arm 112 actuated by the microcontroller to maneuver the scrubber 113 across the entire surface of the object. The scrubber’s 113 gentle yet firm touch ensures a thorough surface finishing, removing any imperfections or residue from the object's surface.

[0041] As the second robotic arm 112 moves the scrubber 113 across the object's surface, the scrubber 113 follows a precise path determined by the microcontroller, which ensures that every area of the object is thoroughly cleaned and polished, resulting in a flawless finish. The motorized scrubber’s 113 adjustable speed and pressure allow for customized surface finishing, catering to the specific needs of various materials and objects.

[0042] An inductive proximity sensor arranged on the housing 101, working in synchronization with the imaging unit 103 to detect the material of the container 102. The sensor uses electromagnetic fields to detect the presence and properties of the material, providing accurate and reliable data to the microcontroller. When the sensor detects that the material of the container 102 corresponds to a soft material, the microcontroller actuates the speaker 110 giving warning to the user to change the container 102, thereby prevents potential issues, such as undesired expansion of the container 102 or damage to the container 102, during the insertion of the structure into the sand.

[0043] Upon the extraction of the object from the sand, the microcontroller activates a vibrating unit equipped with each of the grippers 111, which generates precise vibrational sensations, carefully calibrated to remove excess sand from the object's surface. The vibrations gently dislodge sand particles, ensuring a clean and smooth finish on the object. As the grippers 111 hold the object, the vibrating unit's controlled vibrations prevent damage or scratching of the object's surface. The vibrations are precisely tuned to match the object's material properties, ensuring effective sand removal without compromising the object's integrity.

[0044] A battery is associated with the device to supply power to electrically powered components which are employed herein. The battery is comprised of a pair of electrode named as a cathode and an anode. The battery use 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.

[0045] The present invention works best in following manner, where the housing 101 developed to be positioned on the ground surface and having the container 102 stored with sand, the computing unit enable the user to input commands and specifications for the object they desired to create, the artificial intelligence-based imaging unit 103 captures multiple images of the container 102 from various angles to detect the exact location and orientation of the container 102, multiple motorized omnidirectional wheels 104 allows the housing 101 to move freely in any direction, the laser sensor detects the levelling of the sand in the container 102. Further, the first robotic arm 105 maneuvers the plate 106 over the sand, the L-shaped telescopically operated rod 107 having the vertical bar 108 and multiple pneumatic pins 109 to tilt and adjust the position of the pins 109 via the hinge for creating the structure, which matches the user-defined shape, the speaker 110 to generate voice alerts to notify the user to fill the mold with liquid molten material. Simultaneously, the pair of telescopically operated grippers 111 grips and positions the formed object out from the sand, the second robotic arm 112 maneuver the scrubber 113 across the entire surface of the object, the inductive proximity sensor detects the material of the container 102, the vibrating unit removes excess sand from the object's surface and the battery supplies power to electrically powered components which are employed herein.

[0046] 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) A mold formation device for moulding operation, comprising:

i) a housing 101 positioned on a ground surface placed with a container 102 stored with sand, wherein a computing unit installed with a user-interface is wirelessly associated with said device for enabling a user to give input commands regarding shape and dimensions of an object to be manufactured through a moulding operation;
ii) a microcontroller wirelessly linked with said computing unit that processes said input commands and activates an artificial intelligence-based imaging unit 103 paired with a processor mounted on said housing 101 for capturing and processing multiple images of said container 102, respectively, for detecting exact location of said container 102, wherein said microcontroller actuates plurality of motorized omnidirectional wheels 104 configured underneath said housing 101 for maneuvering and positioning said housing 101 in proximity to said container 102;
iii) a first robotic arm 105 arranged with said housing 101 and equipped with a plate 106, wherein said microcontroller via a laser sensor positioned on said plate 106 in sync with said imaging unit 103 detects levelling of said sand in said container 102, in accordance to which said microcontroller actuates said first robotic arm 105 for maneuvering said plate 106 over said sand in order to level surface of said sand;
iv) an L-shaped telescopically operated rod 107installed with said body and attached with a vertical bar 108 equipped with plurality of pneumatic pins 109, wherein said microcontroller actuates said pins 109 to extend/retract in synchronization with actuation of plurality of motorized hinges incorporated between said pins 109 and bar 108 for tilting said pins 109 in manner to form a structure of said user-defined shape and dimensions, followed by actuation of said rod 107to extend for inserting said structure in said sand and pulling said structure out for forming a mold in said sand;
v) a speaker 110 mounted on said housing 101 that is activated by said microcontroller for generating voice alerts to notify said user to fill liquid molten material in said mold to allow formation of said object, wherein a timer is integrated within said microcontroller for tracking time, and as soon as said tracked time matches a threshold time duration, said microcontroller actuates a pair of telescopically operated grippers 111 assembled with said housing 101 to work in collaboration for gripping and positioning said formed object out from said sand; and
vi) a second robotic arm 112 configured on said housing 101 and equipped with a motorized scrubber 113, wherein said microcontroller actuates said second robotic arm 112 for maneuvering said scrubber 113 on entire surface of said object to provide surface finishing to said object.

2) The device as claimed in claim 1, wherein an inductive proximity sensor is arranged on said housing 101 that works in synchronization with said imaging unit 103 for detecting material of said container 102, and in case said detected material corresponds to soft material, said microcontroller activates said speaker 110 for notifying said user to change said container 102 to prevent undesired expansion of said container 102 or damage to said container 102 during insertion of said structure within said sand.

3) The device as claimed in claim 1, wherein upon poisoning out of said object from said sand, said microcontroller activates a vibrating unit equipped with each of said grippers 111 to generate vibrational sensations in view of removing sand from said object.

4) 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.

5) The device as claimed in claim 1, wherein said L-shaped telescopically operated rod, pneumatic pins 109, and telescopically operated grippers 111 are powered by a pneumatic unit that includes an air compressor, air cylinder, air valves and piston which works in collaboration to aid in extension and retraction of said rod, pins 109, and grippers 111.

6) The device as claimed in claim 1, wherein a battery is associated with said device for supplying power to electrical and electronically operated components associated with said device.