Claims:WE CLAIM:
1. A radius extruder device 100 for pelletization, comprising:
• an outer frame (102);
• a main die shell (104) embraced inside the outer frame (102);
• a primary plate (106) fixedly connected to the die shell (104);
• a secondary plate (108) coaxially connected to the primary plate (106);
• a first motor (110a) connected to the secondary plate (108);
• a tubular rod (118) centrally mounted over the secondary plate (108);
• a blade holder (114) fitted over the tubular rod (118) of the secondary plate (108);
• a plurality of cutting blades (116) extending inwardly from the blade holder (114);
• a second motor (110b) connected with the plurality of blades (116);
• a microcontroller (112) fitted over the outer frame (102) and operationally coupled to the first motor (110a) and the second motor (110b);
• a plurality of sensors connected to the microcontroller (112);
• a controller module wirelessly connected to the microcontroller (112),
wherein:
i. the outer frame (102) is configured with an opening to feed input material (die) inside the device for formation of pellets;
ii. the die shell (104) is configured with a plurality of predetermined holes, so as to allow passing of input material (die) through porous material of the die shell (104);
iii. the primary plate (106) and the secondary plate (108) are configured with a plurality of perforations,
iv. the perforations provided on the primary plate (106) are structurally similar to the perforations of the secondary plate (108);
v. the secondary plate (108) is configured to rotate in clockwise and anticlockwise direction over the primary plate (106) in order to change radius of pellets formed through said apertures;
vi. the sensors are configured to determine parallax angle of the secondary plate (108) through input parameters provided by a user via the controller module; and
vii. the microcontroller (112) is configured to receive parameters of parallax angle from a user via the controller module, so as to adjust position of perforations of the secondary plate (108) with respect to perforations of the primary plate (106) in order to control radius and length of the pellets.

2. The device (100) as claimed in claim 1, wherein the die shell (104) is composed of a porous material with the plurality of predetermined holes to allow passing of the plurality of die pellets through the die shell (104).

3. The device (100) as claimed in claim 2, wherein the plurality of holes of the die shell (104) are configured to be geometrically smaller than the diameter of the pellets received from opening provided on the outer frame (102), so as to allow passing of the input material (die) through the porous material.

4. The device (100) as claimed in claim 1, wherein the secondary plate (108) is removably connected to the primary frame (106), so as to clean and ensure replacement of the secondary plate (108) from the device.

5. The device (100) as claimed in claim 1, wherein the outer frame (102) is provided with a plurality of treads on the outer periphery of the frame (102), so as to connect the secondary plate (108) with encasing of the primary plate (106).

6. The device (100) as claimed in claim 1, wherein the plurality of sensors comprises of a rotary sensor, a motion sensor and a smart radii sensor.

7. The device (100) as claimed in claim 1, wherein the plurality of sensors detects parallax angle through input fed by the user via the controller module.

8. The device (100) as claimed in claim 7 and claim 1, wherein the plurality of sensors transmits parallax angle to the microcontroller (112) to detect and adjust position of perforations of the secondary plate (108) with respect to the primary plate (106).

9. The device (100) as claimed in claim 1, wherein the outer frame (102) is mounted with a switching means to switch the radius extruder device ON/ OFF.

10. The device (100) as claimed in claim 1, wherein the microcontroller (112) is configured to transmit command signal to the first motor (110a) and the second motor (110b), so as to rotate the secondary plate (108) and the plurality of blades (116) based on parallax angle detected by the rotary sensor to adjust length of the pellets in predetermined sizes.
, Description:FIELD OF INVENTION
[001] The present invention relates to agricultural or metal industry. Particularly, the present invention relates to a radius extruder device for pelletization which is configured to produce pellets of different dimensions without requirement of changing dyes of material.
BACKGROUND OF THE INVENTION
[002] Globally, sustainability is rated as a crucial purchase criterion for majority of consumers. Renewable energy sources lend themselves well to sustainable development, as these energy resources can be used without threatening the resources of upcoming generations.
[003] The wood pellet industry provides an alternative for a sustainable future as today’s wood pellets are green and environment friendly. Not only are wood pellets friendly and sustainable to the environment, the ash produced by these pellets can be used as a fertilizer for the plants. Further, these energy pellets have a very small carbon footprint as wood pellets absorbs as much carbon as it releases when it is burnt. Therefore, there is a need of different sized pellets made of different materials to be used in different industries
[004] Pellets can be made from a variety of biomass or organic materials including wood chips, bark, sawdust, brush and other by-products of lumber milling and the manufacturing of wood products Pellet fuel is a renewable and cost- efficient alternative for commercial and residential purposes. Therefore, there is a need of different sized pellets to be used in different industries and households.
[005] The concept of changing size of pellets in prior arts has been achieved by changing dyes of the material. Therefore existing machines and processes for production of different sized pellets are costly due to excessive wastage of dye material.
[006] Further, KR0135899B1 discloses an apparatus for producing a pellet-type thermoplastic resin foam, and in particular, a small pellet of thermoplastic resin such as polyethylene (PE), polypropylene (PP), etc. A pellet-type thermoplastic resin foam is produced which can be continuously and inexpensively foamed in a form.
[007] None of the pellet producing apparatus and processes disclosed in the prior arts discloses a cost-effective method of producing pellets of different dimensions. Therefore, keeping in view of the problems associated with the state of the art, there is a requirement of a cost-effective apparatus and method for producing pellets of different dimensions with high accuracy and without requiring different dyes material The present invention is one such solution for producing different sized pellets, which can be used in various industries and households without requiring different dyes material.
OBJECTIVES OF THE INVENTION
[008] The primary objective of the present invention is to provide a radius extruder device for producing pellets of précised sizes and shapes.
[009] Another objective of the present invention is to provide a device for pelletization for various industries.
[0010] Another objective of the present invention is to reduce consumption of input material dye required in formation of different sized pellets.
[0011] Yet another objective of the present invention is to provide an automated, easy to operate and low maintenance device for pelletization.
[0012] Other objects and advantages of the present invention will become apparent from the following description taken in connection with the accompanying illustrations and examples to disclose the aspects of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0013] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0014] Figure 1 illustrates an isometric view of a radius extruder device in exploded configuration.
[0015] Figure 2 illustrates cross sectional view of the radius extruder device.
[0016] Reference Numeral for the various component of the present invention is described herein:
S. No. Components Reference Numerals
1. Outer Frame 102
2. Die Shell 104
3. Primary Die Plate 106
4. Secondary Movable Plate 108
5. First Motor 110a
6. Second Motor 110b
7. Microcontroller 112
8. Blade Holder 114
9. Plurality of Blades 116
10. Tubular Rod 118

SUMMARY OF THE INVENTION
[0017] A radius extruder device for pelletization according to the present invention, includes an outer frame, a die shell, a primary die plate, a secondary plate, a rotary sensor, a single stepped shaft motor, a microcontroller, a blade holder, a plurality of blades and a switching means. The frame of the radius extruder is embodied with a main die shell and a primary plate. The primary die plate is a static plate coupled with a secondary plate. The secondary plate is a movable plate configured with a plurality of perforations, which are similar to the perforations of the primary die plate. The secondary plate/ movable plate moves in clockwise and anticlockwise direction in accordance with the primary plate/ main die plate. Further, the secondary plate is connected with a rotatory distance sensor to detect the displacement in rotary fashion, in either a clockwise or anti-clockwise direction. The secondary plate is controlled by a microcontroller, such as but not limited to Arduino operator, based on the input received from the rotary distance sensor. The primary plate and secondary plate are aligned such that both the plates are positioned over each other. As the secondary plate moves over the primary die plate, the secondary movable plate start covering the primary die plate perforations, thereby leaving only a small opening due to the overlapping of perforations. This way the size of the pellets gets changed without requirement of changing dyes of input material. The module simultaneously sends commands signal to the motor fitted within the blade holder for rotation of the blades to cut the pellets for maintaining length of the pellets.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The following description describes various features and functions of the disclosed system and method with reference to the accompanying figure. In the figure, similar symbols identify similar components, unless context dictates otherwise. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system and method can be arranged and combined in a wide variety of different configurations, all of which are contemplated herein.

[0019] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0020] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0021] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0022] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise

[0023] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0024] The present invention relates to a radius extruder device for pelletization. The proposed device is specifically configured to aim at easing the process of pelletization which involves making granuels out of material input in the device. The device is wirelessly connected with an IoT server which is configured to operate the device in autonomous mode.

[0025] In a preferred embodiment of the present invention, a radius extruder device 100 for pelletization comprises of the following components:
[0026] (a) Die Shell (104): A die shell (104) positioned inside the radius extruder device is a porous material, which is configured with a plurality of predetermined holes. In an exemplary embodiment, the size of the holes are designed to be smaller than the diameter of the pellets so as to allow passing of the input material (die) through the porous material.
[0027] (b) Primary Plate (106): A primary plate is a static plate connected to the main die shell (104). The primary plate 106 is made of materials that are selected from but not limited to, aluminium, steel or any ductile materials. The primary plate 106 is employed with a hole positioned at centre of the plate 106. In preferred embodiment, the primary plate is embraced with a plurality of triangular slots to pass the input material (die) in forward direction.
[0028] (c) Secondary plate 108: A secondary plate of the present invention, is movably/ rotatably connected with the primary plate (106). The secondary plate 108 is attached with the primary plate (106) via threads, which are provided on the outer edge periphery of the outer frame 102. The secondary plate 108 can be attached or detached with the outer frame 102 by sealing or unsealing the encasing of the secondary plate 108 with the threads of the frame 102. The secondary plate is further embraced with a cylindrical rod (118), at the centre, to hold a blade holder in place.
[0029] Further, the secondary plate (108) is connected with a first motor (110a) that provides clockwise and anti-clockwise rotation of the secondary plate (108) over the primary plate (106). The rotation of the secondary plate (108) helps to cover the perforations provided over the primary plate (106).
[0030] (d) Blade Holder 114: A blade holder 114 is a hollow cylindrical casing installed over the tubular rod 118. The blade holder 114 is configured to secure the plurality of the blades 116.
[0031] (e) Blades 116: A plurality of cutting blades 116 extending inwardly from the blade holder 114. The plurality of blades 116 are made up of material such as but not limited to, stainless steel, iron, zinc, aluminium, or any other combination thereof. The blades (116) are twisted radially along a longitudinal axis of the blade.
[0032] (f) Rotary sensor: In a preferred embodiment, a rotary sensor is connected with the cylindrical rod (118) of the secondary plate (108) for controlling the rotation of the plate. The rotary sensor is configured to detect rotational motion angle of the secondary plate (108).
[0033] (g) Motor (110a and 110b): In a preferred embodiment, a first motor (110a) is connected with the secondary plate (108) to provide rotation to the secondary plate (108) and a second motor (110b) (i.e. single stepped shaft motor) is connected with the plurality of blades (116) to provide clockwise or anticlockwise rotation to the blades (116). The first motor (110a) and the second motor (110b) are configured inside the outer frame (102) of the radius extruder device (100).
[0034] Microcontroller (112): In a preferred embodiment of the present invention, a microcontroller (112), such as but not limited to Arduino module (112) is embraced inside the outer frame (102) of the device. The microcontroller (112) manages the operation/ working of the radius extruder device (100). The microcontroller (112) acquires the data/ information from the sensors and transmits the data to the IoT server or a memory module to enable the user to manage and monitor the functioning of the device (100) in real time.
[0035] In an exemplary embodiment, the data from the sensors is transferred to the IoT server using a wireless network configured in the microcontroller (112), such as but not limited to Bluetooth, Wi-Fi and internet.
[0036] Further, the microcontroller is wirelessly connected with a remote/ controller module to enable the user to manage the working of the radius extruder device (100) through a wireless connection.
[0037] (j) Switching Means: A switching means mounted on the outer frame of the device (100) is used to turn the device ON/ OFF. The switching means allows the user to manually operate the device (100) depending upon the need of the user.
[0038] In a preferred embodiment of the present invention, Figure 1 illustrates an isometric view of the radius extruder device (102). The outer frame (102) of the radius extruder device (102) is a tubular structure made up of materials that are selected from but not limited to, plastic, carbon fibre, steel, aluminium, carbon composites, ceramic or any other combination thereof. The distal end of the frame (102) is provided with an opening for receiving a plurality of input materials (such as, dyes), so as to transfer the dyes to the proximal end of the frame (102), where the primary and secondary plates are configured.
[0039] In an exemplary embodiment, the outer frame (102) is provided with a plurality of treads at the proximal end of the frame (102). The treads are designed on the outer edge periphery. The treads are spiral-shaped ridge on the proximal end of the frame (102) used to mesh with a similarly sized screw-type closure to connect the secondary plate with the primary plates’ encasing.
[0040] Figure 2 of the present invention illustrates cross sectional view of the radius extruder device. A die shell (104) positioned inside the radius extruder device is a porous material that is configured with a plurality of predetermined holes. The die shell (104) receives the input material (die) from the distal end of the outer frame (102). The die shell (104) configured with porous material have a plurality of pores. The porosity of the porous material present in the die shell (104) is in a range of 5% to 75%. In a preferred embodiment, the dimensions of the pores is designed with an average diameter less than an average input material diameter, so that the pellets can pass through the porous material during process of pellet formation.
[0041] The primary/ die plate (106) provided in the present invention, is fitted in succession with the die shell (104) inside the outer frame (102). The primary plate (106) is fitted in longitudinal axis inside the frame (102). In a preferred embodiment of the present invention, a plurality of triangular slots are forged within the primary/ die plate (106). Multiple perforations or apertures are formed on outer edges of each of the slots of the primary plate (106). The triangular slots forged within the die plate (106) ensures to pass the die material towards the secondary plate (108) via the primary plate (106). In an exemplary embodiment, the specification of the die plate (106) is described as follows: Plate Diameter: 241 mm, Draft angle of edges of the plate: 6o (degree), Hole diameter in the plate: 10mm.
[0042] In a preferred embodiment in the present invention, the secondary/ movable plate (108) is fitted on the same axis of the primary die plate (106). The secondary plate (108) is attached with the outer frame (102) through a plurality of threads formed over outer edge periphery of the frame (102), as shown in fig 2. The secondary/ movable plate (108) is attached or detached with the frame (102) by sealing or unsealing the encasing of the secondary plate (108), through the threads of the frame (102). The secondary plate (108) is configured with a plurality of perforations that are structurally similar to the perforations provided over the primary plate (106). The removable nature of the secondary plate (108) ensures easy maintenance and replacement of the secondary plate (108). The secondary plate (108) is coaxially aligned with the primary plate (106), such that the perforations are positioned over each other. The secondary plate (108) is propelled through a first motor (110a) to align the perforations of the secondary plate (108) with the perforations of the primary plate (106).
[0043] The secondary plate (108) is centrally attached with a tubular rod (118) such that the rod (118) extends outwardly from the centre of the movable plate 108. The central tubular rod (118) mounted over the secondary plate is configured to hold/ connect with the blade holder (114). The blade holder (114) is designed with a cylindrical hole to secure over the tubular rod (118). The blade holder (114) is configured to secure the plurality of the blades 116 for cutting/ snipping the die material received from the die shell (104).
[0044] The plurality of blades (116) extending inwardly from the blade holder 114 are configured with a cutting edge, which are being twisted radially along a longitudinal axis of the cutting blade between a first portion (i.e. connected with the blade holder 114) and a second portion (i.e. opposite end of the blade) of the cutting blade.
[0045] The cutting edge at the first portion of the cutting blade (116) provides a first angle with respect to the longitudinal axis, and the cutting edge at the second portion of the cutting blade (116) provides a second angle with respect to the longitudinal axis. The first angle and the second angle of the cutting edge indicates the strength of the cutting edge. The angles of the cutting edge is the angle between the cutting face of the cutting tool and the surface of the work back/ blade holder of the device. In an exemplary embodiment, the strength of the cutting edge angles are inversely proportional to the cutting edge strength. The blades (116) are configured for cutting engagement used in the process of pelletization.
[0046] The radius extruder device (100) is further embraced with a second motor (110b). In a preferred embodiment, the second motor (110b) is a single stepped shaft motor (110b) configured to provide clockwise or anticlockwise rotation to the blades (116).
[0047] Further, a plurality of sensors such as but not limited to motion sensors, rotatory sensors and radii sensor, are fitted on the frame (102) of the device (100). The motion sensors are configured to determine rotational motion angle between the cylindrical rod (118) and the blades (116). In an embodiment, a radii sensor is connected with the secondary plate (108) which is configured to change the radius sizes of the movable plate so as to cut/ snip the dye into different pellet diameter.
[0048] The rotary distance sensor is configured to transform mechanical rotary positions into electrical signals. In a preferred embodiment, a rotary sensor is connected with the cylindrical rod (118) of the secondary plate (108) for controlling the rotation of the plate (108). The rotary sensor is configured to send the detected rotational motion angle of the secondary plate (108) to a microcontroller (112). The Arduino module (112) controls the rotation of the secondary plate (108) based on the values received from the rotary distance sensor.
[0049] In an exemplary embodiment, the Arduino module (112) is operably connected with a controller module/ remote, so as to manage the operation/ working of the device (100). The Arduino module is used to actuate the sensors invoked by the user through a remote/ a controller module. The device (100) provided in the present invention, is powered by an external power supply or multiple rechargeable batteries, which is also used to power all the sensors, motors (110a and 110b) and microcontroller (112).
[0050] The microcontroller (112) acquires all the data/ information from the sensors, and thereby monitors and manages the functioning of the device (100). In an exemplary embodiment of the present invention, the Arduino module (112) updates the collected data to the cloud/ database server or a memory module in real time.
[0051] Further, the data updated to the cloud/ database server or memory module implements machine learning/ artificial intelligence operation/ processing, which provides improved suggestions for managing and functioning of the device (100) in autonomous mode. The database used for the acquired data is protected through a firewall, such as but not limited to firebase that encrypts the data and protects it from being damaged.
[0052] In a preferred embodiment of the present invention, the die of the input material passes inside the frame (102) via opening provided on the frame (102). The die passes through the die shell (104). The die shell (104) is composed of a porous material and the dimensions of the pores have an average diameter that is less than an average particle diameter of the pellets, which enables the pellets of the die material to pass through the porous material during process of pellet formation. The plurality of sensors configured in the radius extruder device (100) detects the parallax angle (i.e. rotary motion angle) of the secondary plate (108) through input fed by the user via remote/ controller module. The plurality of sensors further transmits the detected values along with parallax angle to the microcontroller (112) to detect the position of perforations of the secondary plate (108) with respect to the primary plate (106). Based on the input of parallax angle provided by the user, the microcontroller (112) adjust the position of perforations of the secondary plate (108) with respect to perforations of the primary plate (106). As the secondary plate (108) rotates over the primary plate (106), the secondary plate (108) start covering the perforations presented over the primary plate (106). The microcontroller (112) transmits command signal to the first motor (110a) and the second motor (110b), so as to rotate the secondary plate (108) and the plurality of blades (116) based on parameters received from the rotary sensor to adjust length of the pellets in predetermined sizes. The perforations of the secondary plate (108) over the primary plate (106) leaves small openings which lead to extraction of the plurality of die pellets. The die pellets are snipped into varied sizes with the help of plurality of blades (116), which are controlled by the microcontroller (112). The microcontroller (112) helps to snip the pellets in varied sizes as per the need of the user.
[0053] In an embodiment of the present invention, the user feeds the input through a remote/ controller module to adjust diameter of the pellet by managing rotation of the secondary plate (108). The diameter of the pellet is adjusted through the parallax angle received from the user. The parallax angle is analysed by calculating the angle displaced by row of perforations of the secondary plate (108) during rotation of the secondary plate (108) over perforations of the primary plate (106)
[0054] In another embodiment of the present invention, the input material passes through the perforations of the primary plate (106) and the secondary plate (108). Further, due to clockwise and anticlockwise rotation of the secondary plate (108), the secondary plate (108) covers or opens the perforations of the main plate periodically, which results in blocking or allowing excessive material from entering into perforations formed over the secondary plate (108).
[0055] The clockwise and anti-clockwise rotation of the secondary plate (108) helps to produce pellets with different radius without requirement of changing dyes of input material. Further, the microcontroller (112) sends command signal to the motors (110a and 110b) which causes the rotation of the secondary plate (108) and the blades (116) based on detection of pellets by the rotary sensors. The blades (116) are controlled by the microcontroller (112) for adjusting length of the pellets in précised sizes. This way the device (100) controls the production of pellets in autonomous mode.
[0056] In an exemplary embodiment, a switching means fitted over the frame (102) of the device (100) is operably coupled to the microcontroller (112). The switching means is configured to activate and deactivate the device (100). The button allows the user to manually operate the device (100) according to the need of the user.
[0057] The advantages of the present invention includes:
• saving of input material (die) required for pellets forming;
• high autonomous functionality;
• low maintenance required from the user;
• continuous monitoring and increased efficiency of the palletisation process;
• consumes less electricity due to autonomous functionality of the device (100)
[0058] While the present invention has been described with reference to one or more preferred aspects, which aspects have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, such aspects are merely exemplary and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. The scope of the invention, therefore, shall be defined solely by the following claims. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the principles of the invention.