US20240368848A1

US20240368848A1 - Systems and methods of segmented anti-slabbing for milling machines

Info

Publication number: US20240368848A1
Application number: US18/309,845
Authority: US
Inventors: Colton Hirman; David Nels Peterson; Timothy J. Sturos
Original assignee: Caterpillar Paving Products Inc
Current assignee: Caterpillar Paving Products Inc
Priority date: 2023-05-01
Filing date: 2023-05-01
Publication date: 2024-11-07
Also published as: DE102024110402A1

Abstract

Anti-slabbing systems and methods for counteracting slabbing of a substrate being cut by a rotary cutter of a milling machine may include a plurality of anti-slab segments biased downwardly and independently vertically movable relative to a frame of the milling machine. The anti-slabbing systems and methods may further include segment biasing mechanisms connecting the anti-slab segments to frame of the milling machine. The segment biasing mechanisms may control a slabbing opposition force applied to uncut material of the substrate underlying the milling machine. The anti-slabbing systems and methods may further include an anti-slabbing mechanism comprising a base plate, plow, and/or skids.

Description

TECHNICAL FIELD

The present disclosure relates generally to the field of cold planing or milling, and more particularly to an anti-slabbing system for a cold planer having a plurality of segments.

BACKGROUND

Road planing or milling is the practice of removing an upper layer of paving material from a traffic bearing substrate forming a road. Paving material used in road construction tends to deteriorate over time as a result of weathering, traffic wear, fatigue, biological processes and still other factors. It is common practice for new “lifts” of paving material to be paved upon older, worn layers. Eventually, however, it becomes impractical to build the road any higher, and some or all of the road needs to be rebuilt. Milling machines (e.g., cold planers) are commonly used to cut old paving material from the traffic bearing substrate to enable the placement of new paving material on top.
A typical cold planer is a self-propelled machine or attachment to a self-propelled machine that includes a cutting mechanism (e.g., milling rotor) configured to remove paving material to some specified depth, rendering a more or less planar surface to serve as a grade upon which a new mat of paving material is to be placed. The process of cold planing tends to be fairly demanding, as substantial energy may be required to cut the relatively hard and dense substrate, then elevate the cut material to a conveyor for off-loading from the cold planer. It will thus be readily understood that the operating environment of cold planers tends to be harsh, and the components of such machines subjected to quite demanding conditions.
Among other challenges, in certain instances the cutting mechanism of a cold planer may break off relatively large slabs of to-be-milled material (e.g., old laid pavement) which the conveyor and other sub-systems have difficulty in handling. Anti-slabbing moldboards may be included on cold planers in front of the milling chamber to provide a counteracting force on the top portion of roadways. Some old roadways may have uneven surfaces such that a solid anti-slabbing moldboard may not be able to apply the counteracting force evenly at all points across the width being milled. Hence, it would be advantageous to provide a system that could adapt to different surface profiles.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various exemplary embodiments and together with the description, serve to explain the principles of the disclosure.

FIG. 1 is a drawing of a side view of a milling machine having an anti-slabbing system, in accordance with some embodiments of the present disclosure;

FIG. 2 is a drawing of a front angle view of the anti-slabbing system within the milling machine of FIG. 1 , in accordance with some embodiments of the present disclosure;

FIG. 3 is a drawing of a front angle view of an anti-slabbing system for a milling machine comprising anti-slab segments, in accordance with some embodiments of the present disclosure; and

FIG. 4 is a drawing of a front angle view of another anti-slabbing system for a milling machine comprising anti-slab segments and an anti-slabbing mechanism, in accordance with some embodiments of the present disclosure.

DETAILED DESCRIPTION

FIG. 1 shows a milling machine 100 with an anti-slabbing system 150. In some embodiments, the milling machine 100 may be a cold planer. The milling machine 100 may include a frame 102 having a front frame end 104 and a back frame end 106. A front set of ground engaging propulsion elements 108 and a back set of ground engaging propulsion elements 110 are coupled to the frame 102. Each of the sets of propulsion elements 108 and 110 may include two parallel ground engaging tracks, although the present disclosure is not thereby limited. An operator control station 112 is coupled to the frame 102 for conventional control and monitoring functions. The operator control station 112 may be configured to house a steering wheel, levers, joysticks, push buttons, and/or other types of user interfaces for controlling various systems of the milling machine 100.
The milling machine 100 may further include a cutting mechanism (e.g., rotor) 114 coupled to the frame 102 and having a housing 116 defining a cutting chamber 120. A set of actuators 118 are provided to raise and lower the housing 116, typically in conjunction with adjustments to a cutting depth of the cutting mechanism 114 in a manner that will be familiar to those skilled in the art. The cutting mechanism 114 includes a rotatable cutter 122 which may rotate in a direction counter to a forward travel direction of the milling machine 100. The cutting mechanism 114 is positioned within the housing 116 and configured to cut material of a substrate (e.g., asphalt, pavement) 190 underlying the milling machine 100. An anti-slabbing system 150 comprising an anti-slabbing mechanism may be coupled to the frame 102 and may include an upwardly oriented base plate 152 extending across a front side 128 of the cutting chamber 120, a forwardly projecting plow 154 for plowing loose material lying upon the substrate 190, and a plurality of skids 156. A primary conveyor 160 is positioned forward of the base plate 152. The primary conveyor 160 may be coupled to and supported upon the base plate 152 for feeding material cut from the substrate 190 via the rotatable cutter 122 to a secondary conveyor 162 projecting forward from the frame 102. A positioning mechanism may be coupled with the secondary conveyor 162, to enable left, right, and potentially up and down position control of the secondary conveyor 162. As will be further apparent from the following description, various design features of the milling machine 100 are contemplated to enable improvements in cutting quality, production efficiency, and other desirable advancements over the state of the art.
In some embodiments, a controller may be in communication with one or more features of milling machine 100. The controller may receive inputs from and send outputs to, for example, user interfaces in the operator control station 112 and/or an interface remote from the milling machine 100. For example, the milling machine 100 may include electrohydraulic and/or hydro mechanical hydraulic systems, and the controller may control electrical switches and/or valves to operate hydraulic cylinders, motors, actuators, and/or electrical elements. The controller may include one or more controllers each associated with one or more components or systems of the milling machine 100. For example, the controller may be in communication with a pump and/or directional control valves, as described in further detail herein.
The milling machine 100 may include a prime mover (e.g., engine, motor) for supplying driving power for driven components (e.g., propulsion elements 108 and 110, rotatable cutter 122, primary conveyor 160, secondary conveyor 162) of the milling machine 100. Further, the prime mover may be coupled to a pump or generator for providing hydraulic, pneumatic, or electrical power to the milling machine 100.
FIG. 2 shows the anti-slabbing system 150 of the milling machine 100 of FIG. 1 . In some embodiments, the anti-slabbing system 150 may be positionable across the front side 128 of the cutting chamber 120. Accordingly, as material is cut from the substrate 190, the rotating motion of the rotatable cutter 122—and optionally additional material feeding mechanisms such as so called “kicker paddles” (not shown)—may tend to urge material cut from the substrate 190 in a forward direction toward the base plate 152. The base plate 152 may include upper, lower, and outboard peripheral edges. The base plate 152 may further define a material transfer opening through which the cut material is fed to reach the primary conveyor 160. The primary conveyor 160 may thus be positioned adjacent the material transfer opening of the base plate 152 and configured to receive cut material passed therethrough from the cutting chamber 120. The base plate 152 may also include a shielding wall adjoining the material transfer opening and extending upwardly between the primary conveyor 160 and the cutting chamber 120. As noted above, the primary conveyor 160 may be coupled to the anti-slabbing mechanism of the anti-slabbing system 150, and in particular may be pivotably mounted to the base plate 152. To this end, the anti-slabbing mechanism of the anti-slabbing system 150 may further include conveyor mounts attached to the base plate 152 and positioned upon outboard sides of the material transfer opening.
In some embodiments, a first and a second actuator mount 158 may also be coupled to the base plate 152 and configured to couple with actuators for adjusting a height of the anti-slabbing mechanism of the anti-slabbing system 150 for transport of and/or while operating the milling machine 100. The anti-slabbing mechanism of the anti-slabbing system 150 may include a first and a second guide rail 159 attached to the base plate 152 adjacent the outboard peripheral edges.
The plow 154 of the anti-slabbing mechanism of the anti-slabbing system 150 may project forward from the base plate 152, as mentioned above, and may include a blade and support arms extending between the base plate 152 and the blade. Elongate ribs may also extend between the base plate 152 and the blade. Transverse plates may extend between the support arms. Additional structural plates may be provided which attach to the transverse plates as well as to the blade. In some embodiments, the plow 154 may extend vertically upwardly a distance which may be equal to or greater than about one-fifth of a height of the base plate 152 as measured from the lower peripheral edge to the vertically uppermost part of the upper peripheral edge. In this way, the blade may push loose material lying upon the substrate 190 downward and to the side, to prevent the material from spilling over the top of the blade and thus contacting an underside of the primary conveyor 160 while operating. The transverse plates may assist in protecting the primary conveyor 160 from material that spills over the blade.
The skids 156 may be arranged in a subsets positioned on outboard sides of the plow 154. Each of the skids 156 may be positioned underneath the base plate 152 and include a downwardly facing lower surface, which together define a common horizontal plane. In some embodiments, the skids 156 may downwardly depend from the base plate 152 and define a substrate contacting footprint of the anti-slabbing mechanism of the anti-slabbing system 150. In this way the anti-slabbing system 150 may apply a slabbing opposition force on uncut material of the substrate 190. Positioning the skids 156 in the manner described herein (e.g., downwardly depending from the lower peripheral edge of the anti-slabbing mechanism) makes the lower surfaces of each of the skids 156 the lowest point in space of the anti-slabbing system 150 when installed for operation on the milling machine 100. In some embodiments, the plow 154 may be positioned within the anti-slabbing system 150 such that a vertical clearance extends between the plow 154 and the substrate 190 when the anti-slabbing mechanism of the anti-slabbing system 150 rests on a flat surface.
In some embodiments, the milling machine 100 may include a plurality of hydraulic lines to control hydraulic cylinders and/or hydraulic motors. The milling machine 100 may include a hydraulic pump for supplying high pressure hydraulic fluid through one or more hydraulic lines to one or more hydraulic cylinders and/or hydraulic motors. Additionally, each hydraulic cylinder and/or motor may include an electrical solenoid and one or more hydraulic valves. The solenoid may receive one or more signals from the controller to control and position/rotation each hydraulic cylinder/motor by configuring the flow of hydraulic fluid through the valves.
The delivery of the hydraulic fluid may be controlled by the controller. In some embodiments, the controller may control the delivery of hydraulic fluid through the hydraulic lines to hydraulic cylinders within the anti-slabbing system 150 to control the amount of slabbing opposition force applied to the uncut material of the substrate 190.
FIGS. 3-4 show various anti-slabbing systems for a milling machine.
As seen in FIG. 3 , in some embodiments, an anti-slabbing system 250 for applying a slabbing opposition force to uncut material of a substrate underlying a milling machine may include a base plate 252 divided into independent anti-slab segments 255. Each anti-slab segment 255 may move vertically relative to a frame of the milling machine independent of the other anti-slab segments 255.
Each of the anti-slab segments 255 of the anti-slabbing system 250 may be connected to the frame of the milling machine via segment biasing mechanisms 257 (e.g., springs, hydraulic cylinders). Each segment biasing mechanism 257 may bias the connected anti-slab segment 255 downward toward the underlying substrate. The downward biasing force applied to the anti-slab segments 255 by the segment biasing mechanisms 257 may be individually and/or collectively adjustable.
In some embodiments, one or more of the plurality of anti-slab segments 255 may include a plow projecting forward from the front face of the anti-slab segment 255. In some embodiments, one or more of the anti-slab segments 255 may include a skid, as described above with respect to the anti-slabbing system 150 of FIGS. 1-2 . Although shown with a plow and skids in FIG. 3 , the anti-slabbing system 250 may comprise only the anti-slab segments 255 and the segment biasing mechanisms 257.
As seen in FIG. 4 , in some embodiments, an anti-slabbing system 350 for applying a slabbing opposition force to uncut material of a substrate underlying a milling machine may include an anti-slabbing mechanism 351 and anti-slab segments 355. The anti-slabbing mechanism 351 may be similar to the anti-slabbing mechanism of the anti-slabbing system 150 of FIGS. 1-2 and may include a base plate 352, a plow 354, and one or more skids 356.
As in the anti-slabbing system 250 of FIG. 3 , each anti-slab segment 355 in the anti-slabbing system 350 may move vertically relative to a frame of the milling machine independent of the other anti-slab segments 355. Further, the anti-slabbing mechanism 351 may additionally move independently of the other anti-slab segments 355. Each of the anti-slab segments 355 of the anti-slabbing system 350 may be connected to the frame of the milling machine via segment biasing mechanisms 357 (e.g., springs, hydraulic cylinders). Additionally, the anti-slabbing mechanism 351 may be connected to the frame of the milling machine via one or more biasing mechanisms. Each segment biasing mechanism 357 may bias the connected anti-slab segment 355 downward toward the underlying substrate. The downward biasing force applied to the anti-slab segments 355 by the segment biasing mechanisms 357 may be individually and/or collectively adjustable. For example, in some embodiments, one or more of the segment biasing mechanisms 357 may be springs with adjustable tensioning. In some embodiments, one or more of the segment biasing mechanisms 357 may be hydraulic cylinders with adjustable pressure, stroke, and/or position.
In some embodiments, one or more of the independent anti-slab segments 355 may be positioned in front of the base plate 352 of the anti-slabbing mechanism 351. In some embodiments, one or more of the anti-slab segments 355 may be positioned to the side of the plow 354 of the anti-slabbing mechanism 351.

INDUSTRIAL APPLICABILITY

The various aspects of the anti-slabbing systems of the present disclosure may be used in any milling machine or other machine to assist in conforming to a transverse profile (e.g., cross-slope) of a substrate to thereby better distribute down pressures for aiding in prevention of the substrate slabbing. In this way, uneven substrate (e.g., road) surfaces may not reduce the effectiveness of the anti-slabbing systems (e.g., moldboards) since direct contact with lower surfaces of the substrate—rather than just the highest surface—is facilitated.
Any number of anti-slab segments are possible within the anti-slabbing systems disclosed herein. A higher number of anti-slab segments may enable more closely conforming to the transverse profile of the underlying substrate.
In some embodiments, a controller of the milling machine may remotely and/or automatically control the downward biasing force of the segment biasing mechanisms on the anti-slab segments. In this way, the slabbing opposition force applied to uncut material of a substrate underlying the milling machine may be manually and/or automatically adjusted to optimize slabbing control. For example, feedback from conveyor systems on a milling machine may indicate the presence and/or absence of slabbing via various sensors (e.g., weight, optical), and in response, the downward biasing force could be increased and/or decreased.
In some embodiments, the downward biasing force of the anti-slabbing system may automatically vary with the speed and/or load of the rotatable cutter of the milling machine. In some embodiments, the downward biasing force of the anti-slabbing system may be automatically set based on the type of substrate input, calculated, and/or sensed.
In some embodiments, although not shown, the anti-slabbing system may include anti-slab segments and an anti-slabbing mechanism, which may further be divided into independently vertically movable sections. In some embodiments, the anti-slabbing system may include multiple rows of independently vertically movable anti-slab segments. Other patterns and/or configurations of the anti-slab segments are possible.
In some embodiments, the anti-slab segments may be added on and/or retrofit onto a milling machine already equipped with a anti-slabbing mechanism.
In some embodiments, the anti-slab segments, segment biasing mechanisms, and/or wear skids may be easily removed and replaced in accordance with wear.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed machine without departing from the scope of the disclosure. Other embodiments of the machine will be apparent to those skilled in the art from consideration of the specification and practice of the anti-slabbing systems for milling machines disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.

Claims

What is claimed is:

1. An anti-slabbing system for a milling machine with a frame and a rotatable cutter housed within a cutting chamber and configured to cut material of a substrate underlying the milling machine, the system comprising:

a plurality of segment biasing mechanisms coupled to the frame of the milling machine; and

a plurality of anti-slab segments, each segment being connected to one of the plurality of segment biasing mechanisms such that each segment is biased downward and independently vertically movable relative to the frame of the milling machine,

wherein the plurality of anti-slab segments is positioned in front of the cutting chamber of the milling machine for applying a slabbing opposition force to uncut material of the substrate as the rotatable cutter cuts material of the substrate.

2. The system of claim 1, further comprising:

an anti-slabbing mechanism coupled to the frame of the milling machine and including an upwardly oriented base plate extending across a front side of the cutting chamber of the milling machine.

3. The system of claim 2, wherein the base plate of the anti-slabbing mechanism is positioned behind the plurality of anti-slab segments.

4. The system of claim 2, wherein the anti-slabbing mechanism further includes a forwardly projecting plow.

5. The system of claim 4, wherein one of the plurality of anti-slab segments is positioned in front of the base plate of the anti-slabbing mechanism and alongside the forwardly projecting plow of the anti-slabbing mechanism.

6. The system of claim 1, wherein one of the plurality of segment biasing mechanisms comprises a spring.

7. The system of claim 1, wherein one of the plurality of anti-slab segments further includes a skid.

8. A milling machine for cutting material of an underlying substrate comprising:

a frame;

a rotatable cutter housed within a cutting chamber; and

an anti-slabbing system including:

a plurality of segment biasing mechanisms coupled to the frame, and

a plurality of anti-slab segments, each segment being connected to one of the plurality of segment biasing mechanisms such that each segment is biased downward and independently vertically movable relative to the frame,

9. The milling machine of claim 8, wherein the anti-slabbing system further includes:

an anti-slabbing mechanism coupled to the frame and comprising an upwardly oriented base plate extending across a front side of the cutting chamber.

10. The milling machine of claim 9, wherein the base plate of the anti-slabbing mechanism is positioned behind the plurality of anti-slab segments.

11. The milling machine of claim 9, wherein the anti-slabbing mechanism further comprises a forwardly projecting plow.

12. The milling machine of claim 11, wherein one of the plurality of anti-slab segments is positioned in front of the base plate of the anti-slabbing mechanism and alongside the forwardly projecting plow of the anti-slabbing mechanism.

13. The milling machine of claim 8, wherein one of the plurality of segment biasing mechanisms comprises a spring.

14. The milling machine of claim 8, wherein one of the plurality of anti-slab segments further includes a skid.

15. A method of applying a slabbing opposition force to uncut material of a substrate underlying a milling machine with a frame and a rotatable cutter housed within a cutting chamber and configured to cut material of the substrate, the method comprising:

downwardly biasing a plurality of anti-slab segments coupled with and independently vertically movable relative to the frame of the milling machine,

wherein the anti-slab segments are positioned in front of the cutting chamber of the milling machine.

16. The method of claim 15, wherein downwardly biasing the plurality of anti-slab segments is accomplished using segment biasing mechanisms coupled to the frame of the milling machine.

17. The method of claim 16, wherein one of the segment biasing mechanisms is a spring.

18. The method of claim 16, wherein one of the segment biasing mechanisms is a hydraulic cylinder.

19. The method of claim 18, wherein the hydraulic cylinder is remotely controlled.

20. The method of claim 15, further comprising:

providing an anti-slabbing mechanism coupled to the frame of the milling machine,

wherein the anti-slabbing mechanism comprises an upwardly oriented base plate extending across a front side of the cutting chamber of the milling machine, and

wherein the base plate of the anti-slabbing mechanism is positioned behind the plurality of anti-slab segments.