US20250084595A1 - Systems and methods for adjusting crown to remediate road mat anomalies - Google Patents
Systems and methods for adjusting crown to remediate road mat anomalies Download PDFInfo
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- US20250084595A1 US20250084595A1 US18/243,537 US202318243537A US2025084595A1 US 20250084595 A1 US20250084595 A1 US 20250084595A1 US 202318243537 A US202318243537 A US 202318243537A US 2025084595 A1 US2025084595 A1 US 2025084595A1
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Classifications
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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C19/00—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving
- E01C19/48—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for laying-down the materials and consolidating them, or finishing the surface, e.g. slip forms therefor, forming kerbs or gutters in a continuous operation in situ
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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C19/00—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving
- E01C19/004—Devices for guiding or controlling the machines along a predetermined path
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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C23/00—Auxiliary devices or arrangements for constructing, repairing, reconditioning, or taking-up road or like surfaces
- E01C23/01—Devices or auxiliary means for setting-out or checking the configuration of new surfacing, e.g. templates, screed or reference line supports; Applications of apparatus for measuring, indicating, or recording the surface configuration of existing surfacing, e.g. profilographs
Definitions
- This disclosure relates generally, but not by way of limitation, to work machines for constructing, repairing, reconditioning, stabilizing, or taking-up road or like surfaces.
- the finished mat should have a uniform/consistent cross-mat texture which does not show irregularities in the finished mat texture/composition.
- One such irregularity is known as segregation, which occurs when larger/coarse aggregates separate from smaller aggregates and are visible in the asphalt mat being laid behind the paving machine.
- striping An indication of poor cross-mat texture is referred to as striping. Segregation or other mat texture irregularities can cause visible stripes in the finished asphalt mat.
- the striping is due to a difference in texture/composition across the mat, including, for example, portions including a reflective (shiny) tight texture/composition and adjacent portions having a dull/less reflective and more open texture/composition.
- These stripes can be at various locations behind the screed, including aligned with the centerline of the paving machines screed system, or aligned with the screed outer bearing supports, as examples. These stripes are very visible and can cause long term issues with the quality of the finished mat.
- the open texture areas can allow more water ingression leading to premature mat failures, e.g., potholes. Additionally, consistent mat texture is important to the paving machine operating crew for several reasons, including because it can affect bonus compensation tied to mat quality.
- U.S. Pat. No. 11,127,135, entitled “SYSTEM AND METHOD FOR CORRECTING PAVING MAT DEFECTS” discloses a method that includes receiving sensor data indicative of a paved surface, and identifying a defect associated with the paved surface based at least in part on the sensor data. The method also includes determining that the defect is of a defect type based on determining that a value associated with the defect is within a value range associated with the defect type. The method further includes generating a command associated with the defect that, when executed by a machine, at least partially remedies the defect.
- asphalt mat striping can occur at various locations behind the paving machine screed, including aligned with the centerline of the paving machines screed system, or aligned with the screed outer bearing supports. At each location at which striping occurs, adjustments to the configuration/set up of the paving machine and/or the screed system of the machine can remediate the striping in the mat.
- example systems and methods according to this disclosure can be employed to detect and remediate centerline striping (asphalt striping occurring at or near the forward-to-backward centerline of the paving machine and screed system).
- centerline striping can occur when the asphalt aggregate being fed to the screed system becomes stagnant behind the auger drive box in front of the screed. At this location, the larger aggregates tend to get trapped in the stagnant material and do not feed under the screed. Only the small aggregates get fed under this center area of the screed which leads to this visible centerline stripe containing a different texture than the rest of the mat.
- a paving machine includes a machine frame, a screed system, a mat striping sensor, and a controller.
- the screed system is connected to the frame and includes a mat crown system.
- the mat striping sensor is connected to the paving machine and configured to detect anomalies in an asphalt mat laid by the screed system.
- the controller is communicatively connected to the mat striping sensor and the mat crown system and configured to control the mat crown system to adjust a crown of the asphalt mat in response to the mat striping sensor detecting one or more anomalies in the asphalt mat.
- FIG. 1 is an elevation view schematically depicting an example system including a paving machine and a material transfer machine.
- FIG. 2 is a plan view of an asphalt mat with centerline striping.
- FIGS. 3 A- 3 C are elevation views schematically depicting a screed system in different configurations.
- FIGS. 4 A and 4 B schematically depict portions of an adjustable screed system.
- FIG. 5 is a flowchart depicting an example method for adjusting the crown of an asphalt mat to remediate anomalies in the mat.
- FIG. 1 is a perspective view depicting example a paving machine 100 which is used, for example, to deposit asphalt, concrete, or other materials on a work surface associated with a worksite.
- Paving machine 100 includes tractor 102 , frame 104 , ground-engaging elements 106 , hopper 108 , conveyor 110 , auger assembly 112 , tow arms 114 , screed system 116 , and operator station 118 .
- Paving machine 100 also includes controller(s) 120 incorporated into or communicatively connected to the machine and one or more mat striping sensors 130 .
- Striping sensor(s) 130 of paving machine 100 are connected to the machine (e.g., to frame 104 and/or operator station 118 ) and configured to detect anomalies in asphalt mat 124 laid by screed system 116 .
- Controller 120 is communicatively connected to mat striping sensor(s) 130 and a mat crown system of screed system 116 .
- Controller(s) 120 is configured to control the mat crown system to adjust a crown of asphalt mat 124 in response to mat striping sensor(s) 130 detecting one or more anomalies in the asphalt mat.
- Controller(s) 120 can, for example, control the mat crown system to incrementally increase the crown of asphalt mat 124 up to a threshold crown or until such adjustment remedies the anomalies in the mat.
- Tractor 102 of paving machine 100 is supported on and conveyed via ground-engaging elements 106 .
- Tractor 102 includes frame 104 , as well as a power source for driving ground-engaging elements 106 .
- ground engaging elements 106 are depicted as continuous tracks, other example work machines according to this disclosure may include other types of ground engaging elements, for example, wheels.
- Paving machine 100 and other work machines in accordance with this disclosure can include different types of power sources, including, e.g. an internal combustion engine operating on fossil or hybrid fuels, or an electrically operated drive powered by alternate energy sources.
- Paving machine 100 includes hopper 108 for storing paving material 122 , e.g. asphalt aggregate material employed by paving machine to produce asphalt mat 124 .
- Paving machine 100 also includes conveyor 110 for conveying paving material 122 from hopper 108 to other downstream components of paving machine 100 .
- paving machine 100 includes auger assembly 112 which receives paving material 122 supplied via conveyor system 110 , and distributes paving material 122 onto paving surface 126 .
- Auger assembly 114 can include one more augers.
- auger assembly 114 includes a main, single auger extending laterally across a majority of the width of paving machine 100 .
- auger assembly 114 includes a pair of augers on either side of a forward-to-backward centerline of paving machine 100 .
- the two side-by-side augers are driven together and operatively connected via an auger bearing or other coupling.
- the two side-by-side augers are driven independently and auger assembly 114 includes a gear box arranged on or near the centerline of paving machine 100 in front of screed system 116 .
- paving machine 100 may be susceptible to laying down mat 124 with centerline striping.
- Centerline striping can happen when asphalt being fed into screed system 116 becomes stagnant in front the gear or other drive mechanism actuating the side-by-side augers.
- larger aggregates tend to get trapped in the stagnation zone and are not therefore fed into screed system 116 .
- only relatively smaller aggregates get fed under the central region of screed system 116 , which leads to a visible centerline stripe containing a different texture/composition than the rest of mat 124 .
- Paving machine 100 includes tow arm 114 which couples a height adjustable screed system 116 to tractor portion 102 .
- Screed system 116 is configured to spread and compact paving material 122 into asphalt mat 124 on paving surface 126 .
- Tow arm 116 can be actuated by a hydraulic actuator, an electric actuator, and/or other types of actuators.
- Paving machine 100 also includes operator station 118 connected to tractor 102 .
- Operator station 118 includes console 128 and controls and other components for operating paving machine 100 .
- console 128 can include control interface for controlling various functions of paving machine 100 .
- the control interface can include analog and/or digital input/outputs, and user controls and interfaces, including, e.g. a touchscreen display.
- the control interface can be communicatively connected to controller(s) 120 and configured to receive operator commands that when executed by controller(s) remediate striping detected in mat 124 .
- the control interface can also support other functions, including for example, sharing various operating data with one or more other machines (not shown) operating in consonance with paving machine 100 .
- Mat striping sensors 130 are connected to the roof of operator station 118 and positioned to detect anomalies in asphalt mat 124 .
- Example striping sensors 130 are depicted schematically for illustration only and, in other examples according to this disclosure, can be positioned in additional and/or other locations on paving machine 100 .
- Asphalt mat striping can be detected in various ways and may be indicated by various in various characteristics of asphalt mat 124 .
- striping can be indicated by temperature differences, differences in reflectivity (sections of properly finished asphalt mat will have higher reflectivity than sections including a stripe), and/or differences in density.
- FIG. 2 is a plan view depicting a portion of asphalt matt 124 including centerline stripe 200 .
- stripe 200 is indicated by a lighter shade and less dense section of material relative to the other portions of mat 124 .
- mat striping sensors 130 can include a variety of different types of sensor(s) configured to detect anomalies in asphalt mat 124 .
- striping sensors 130 can include a camera or other image detection/generation apparatus positioned to capture an image of asphalt mat 124 and communicate the data representing such image to controller 120 .
- the camera is a digital camera configured to record and/or transmit digital images and/or video of mat 124 to controller(s) 120 .
- the camera can include an infrared sensor, a thermal camera, or other like device configured to record and/or transmit thermal images of mat 124 .
- the camera provides image data to controller(s), which uses the image data to identify striping in mat 124 .
- Mat striping sensors 130 can also include, for example, infrared or thermal sensor(s) configured to detect variations in temperature laterally across mat 124 , which may be indicative of mat striping.
- Mat striping sensors 130 can also include density sensor(s) configured to detect variations in density of mat 124 , which may be indicative of mat striping.
- Mat striping sensors 130 can include photoelectric sensor(s) configured to detect variations in the reflectivity of mat 124 , again, indicative of mat striping.
- controller(s) 120 can be included in or separate from paving machine 102 .
- controller(s) 120 is depicted as communicatively connected to paving machine 100 via communication device 132 , which can be, for example, a transceiver. Examples according to this disclosure may include multiple controllers working in conjunction with each other to execute functions attributed to controller(s) 120 .
- FIG. 1 also depicts controller(s) 120 on board paving machine 100 .
- controller(s) 120 can be part of or included in an electronic control unit ECU of paving machine 100 .
- Controller(s) 120 or other controllers, ECUs, etc. included in examples according to this disclosure can be configured to communicate with one another and with other components of paving machine 100 (e.g., striping sensors 130 ) via various wired or wireless communications technologies and components using various public and/or proprietary standards and/or protocols.
- Examples of transport mediums and protocols for electronic communication between components of machine 300 include Ethernet, Transmission Control Protocol/Internet Protocol (TCP/IP), IEEE 802.11 or Bluetooth, or other standard or proprietary transport mediums and communication protocols.
- controller 120 can be included in an ECU of paving machine 100 .
- An electronic control unit (ECU) can be an embedded system that controls various aspects of machine operation. Types of ECUs include Electronic/Engine Control Module, Powertrain Control Module, Transmission Control Module, Brake Control Module, Suspension Control Module, among other examples.
- ECUs can also include an Implement Control Module associated with one or more implements connected to and operable from the machine.
- Example machine 100 may include, for example, an Engine Control Module (ECM), an Implement Control Module (ICM), a Transmission Control Module (TCM), and a Brake Control Module (BCM). These electronic modules/units can be communicatively connected and configured to send and receive data, sensor or other digital and/or analog signals, and other information between the various ECUs of machine 100 . Additionally, functions attributed to an ECU or controller(S) 120 , can be distributed among multiple devices.
- ECM Engine Control Module
- ICM Implement Control Module
- TCM Transmission Control Module
- BCM Brake Control Module
- Controller(s) 120 can include software, hardware, and combinations of hardware and software configured to execute a number of functions attributed to the components in the disclosed examples.
- Such controllers in examples according to this disclosure can be an analog, digital, or combination analog and digital controller including a number of components.
- the controller(s) can include integrated circuit boards or ICB(s), printed circuit boards PCB(s), processor(s), data storage devices, switches, relays, etcetera.
- Examples of processors can include any one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or equivalent discrete or integrated logic circuitry.
- DSP digital signal processor
- ASIC application specific integrated circuit
- FPGA field-programmable gate array
- Controller(s) 120 , ECUs and other electronic controls in examples according to this disclosure can include storage media to store and/or retrieve data or other information, for example, signals from sensors.
- non-volatile storage devices include magnetic hard discs, optical discs, floppy discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.
- volatile storage devices include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile storage devices.
- the data storage devices can be used to store program instructions for execution by processor(s) of, for example, controller 124 .
- the device(s) are configured to detect anomalies in mat 124 , including detecting mat striping. As screed system 116 of paving machine 100 lays down mat 124 , striping sensors 130 detect one or more characteristics of the mat texture/composition laterally across the finished mat and communicate information/data associated with such detection to controller(s) 120 .
- screed system 116 includes a mat crown system configured to change the crown of asphalt mat 124 laid down by screed system 116 of paving machine 100 .
- the mat crown system of screed system 116 is communicatively connected to controller(s) 120 .
- Controller 120 is configured to control the mat crown system to adjust a crown of asphalt mat 124 in response to the mat striping sensor(s) detecting one or more anomalies in the asphalt mat. For example, in response to mat striping sensor(s) detecting one more anomalies indicative of mat striping, controller 120 controls the mat crown system of screed system 116 to incrementally increase the crown of mat 124 .
- FIGS. 3 A- 3 C schematically depict an adjustable screed system 116 of paving machine 100 .
- Screed system 116 is depicted in three respective states, including neutral or zero crown in FIG. 3 A , positive crown in FIG. 3 B , and negative crown in FIG. 3 C .
- FIGS. 4 A and 4 B schematically depict portions of adjustable screed system 116 .
- screed system 116 includes a single screed plate 400 spanning the width of screed system 116 and mat crown system 402 including crown mechanism 404 .
- Crown mechanism 404 includes links 406 and 408 and piston 410 .
- Links 406 and 408 are fixedly connected to screed plate 400 and pivotally connected to opposing ends of piston 410 .
- piston 410 can be actuated (e.g., hydraulically, electro-magnetically, etc.) to extend and thereby push the upper ends of links 406 and 408 away from each other and cause screed plate to bend from a planer state into a convex state.
- piston 410 in this manner will cause screed system 116 to produce an asphalt mat with a positive crown.
- piston 410 can also be actuated to pull the upper ends of links 406 and 408 closer to each other and cause screed plate to bend from a planer state into a concave state to produce a negative crown.
- screed system 116 includes side-by-side, pivotally connected screed plates 412 and 414 spanning the width of screed system 116 .
- Screed system also includes mat crown system 402 including crown mechanism 404 .
- Crown mechanism 404 includes links 406 and 408 and piston 410 .
- Link 406 is fixedly connected to screed plate 412 and pivotally connected to one end of piston 410 .
- Link 408 is fixedly connected to screed plate 414 and pivotally connected to the other end of piston 410 opposite the end to which link 406 is connected. As depicted in FIG.
- piston 410 can be actuated (e.g., hydraulically, electro-magnetically, etc.) to extend and thereby push the upper ends of links 406 and 408 away from each other and cause screed plates 412 and 414 to pivot from a planer arrangement relative to one another into a convex arrangement. Actuating piston 410 in this manner will cause screed system 116 to produce an asphalt mat with a positive crown. Although not depicted, piston 410 can also be actuated to pull the upper ends of links 406 and 408 closer to each other and cause screed plates 412 and 414 to pivot from a planer arrangement relative to one another into a concave arrangement to produce a negative crown.
- actuated e.g., hydraulically, electro-magnetically, etc.
- screed plate 400 bends and screed plates 412 and 414 pivot about a forward-to-backward centerline 416 of paving machine 100 to which screed system 116 is connected.
- a screed system of a paving machine can include a variety of other mat crown systems and associated crown mechanisms that adjust the configuration of the screed plate(s) and thereby change the crown of the mat produced by screed system.
- FIG. 5 is a flowchart depicting example method 500 for adjusting the crown of an asphalt mat to remediate anomalies in the mat.
- Example method 500 includes laying an asphalt mat using a paving machine ( 502 ), detecting one more anomalies in the asphalt mat using one or more mat striping sensors connected to the paving machine ( 504 ), and adjusting a crown of the asphalt mat in response to detecting the one or more anomalies ( 506 ).
- paving machine 100 lays asphalt mat 124 on paving surface 126 .
- asphalt aggregate 122 is delivered to the work site and loaded into hopper 108 of paving machine 100 by a material transfer vehicle.
- Asphalt aggregate 122 is feed from hopper 108 to auger assembly 112 by conveyor 110 .
- Auger assembly 112 feeds asphalt aggregate 122 to screed assembly 116 , which spreads and compacts the aggregate to lay down asphalt mat 124 .
- auger assembly 112 includes a pair of augers on either side: of a forward-to-backward centerline of paving machine 100 .
- the two side-by-side augers of auger assembly 112 are driven together or independently and operatively connected via, e.g., a bearing or a gear box arranged on or near the centerline of paving machine 100 in front of screed system 116 .
- mat striping sensors 130 detect the variation in the characteristics of mat 124 , i.e. the centerline stripe and communicate data or other information indicative of the stripe to controller(s) 120 .
- Controller(s) 120 receive the data from mat striping sensors 130 and cause mat crown system 402 to adjust the crown of asphalt mat 124 in response thereto. For example, controller(s) 120 control mat crown system 402 to produce a positive crown in mat 124 . In such circumstances, for example, mat crown system 402 actuates piston 410 to push links 406 and 408 away from each other (laterally outward), which causes screed plates 412 and 414 to pivot about centerline 416 from a planer state into a convex state.
- controller(s) control mat crown system 402 to incrementally increase the crown in asphalt mat 124 .
- the requirements of a particular job for which asphalt mat 124 is being laid down can include a threshold on the amount of positive crown of the mat.
- the threshold beyond which the positive crown of asphalt mat cannot go is 1 ⁇ 8 inches (3.175 millimeters).
- controller(s) control mat crown system 402 to increase the crown in asphalt mat 124 in increments of 1 millimeter (0.039 inches).
- controller(s) 120 controls mat crown system 402 to increase the crown of asphalt mat 124 until mat striping sensors 130 cease to detect the centerline strip in the asphalt mat, and, thereafter, the controller is configured to control the mat crown system to maintain the crown of the asphalt mat.
- controller(s) 120 can be configured to control mat crown system 402 to incrementally increase the crown of asphalt mat 124 up to and including a threshold positive crown, e.g., 1 ⁇ 8 inch. In the event, the stripe in asphalt mat 124 is not remediated when the crown reaches 1 ⁇ 8 inch, additional measures may need to be taken to address the anomaly in the mat.
- a threshold positive crown e.g. 1 ⁇ 8 inch.
- the increments by which mat crown system 402 adjusts the crown of asphalt mat 124 and the threshold crown beyond which the mat crown system will not go can be programmatically adjusted or can be user configured.
- an operator employing the control interface e.g., a touchscreen interface at console 128 of paving machine 100 can select different increments by which to adjust the crown of asphalt mat 124 and/or a threshold crown value beyond which the crown will not be adjusted.
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Abstract
A paving machine includes a machine frame, a screed system, a mat striping sensor, and a controller. The screed system is connected to the frame and includes a mat crown system. The mat striping sensor is connected to the paving machine and configured to detect anomalies in an asphalt mat laid by the screed system. The controller is communicatively connected to the mat striping sensor and the mat crown system and configured to control the mat crown system to adjust a crown of the asphalt mat in response to the mat striping sensor detecting one or more anomalies in the asphalt mat.
Description
- This disclosure relates generally, but not by way of limitation, to work machines for constructing, repairing, reconditioning, stabilizing, or taking-up road or like surfaces.
- When laying a new asphalt road with a paver, there are numerous mat anomalies and/or defects that can occur without a properly setup machine. One important characteristic of asphalt mat quality is the cross-mat texture/composition. The finished mat should have a uniform/consistent cross-mat texture which does not show irregularities in the finished mat texture/composition. One such irregularity is known as segregation, which occurs when larger/coarse aggregates separate from smaller aggregates and are visible in the asphalt mat being laid behind the paving machine.
- An indication of poor cross-mat texture is referred to as striping. Segregation or other mat texture irregularities can cause visible stripes in the finished asphalt mat. The striping is due to a difference in texture/composition across the mat, including, for example, portions including a reflective (shiny) tight texture/composition and adjacent portions having a dull/less reflective and more open texture/composition. These stripes can be at various locations behind the screed, including aligned with the centerline of the paving machines screed system, or aligned with the screed outer bearing supports, as examples. These stripes are very visible and can cause long term issues with the quality of the finished mat. The open texture areas can allow more water ingression leading to premature mat failures, e.g., potholes. Additionally, consistent mat texture is important to the paving machine operating crew for several reasons, including because it can affect bonus compensation tied to mat quality.
- U.S. Pat. No. 11,127,135, entitled “SYSTEM AND METHOD FOR CORRECTING PAVING MAT DEFECTS” discloses a method that includes receiving sensor data indicative of a paved surface, and identifying a defect associated with the paved surface based at least in part on the sensor data. The method also includes determining that the defect is of a defect type based on determining that a value associated with the defect is within a value range associated with the defect type. The method further includes generating a command associated with the defect that, when executed by a machine, at least partially remedies the defect.
- As noted, asphalt mat striping can occur at various locations behind the paving machine screed, including aligned with the centerline of the paving machines screed system, or aligned with the screed outer bearing supports. At each location at which striping occurs, adjustments to the configuration/set up of the paving machine and/or the screed system of the machine can remediate the striping in the mat.
- The present inventor(s) have recognized, inter alia, systems and methods for automatically detecting and remediating anomalies in an asphalt mat, including striping. For example, example systems and methods according to this disclosure can be employed to detect and remediate centerline striping (asphalt striping occurring at or near the forward-to-backward centerline of the paving machine and screed system). Centerline striping can occur when the asphalt aggregate being fed to the screed system becomes stagnant behind the auger drive box in front of the screed. At this location, the larger aggregates tend to get trapped in the stagnant material and do not feed under the screed. Only the small aggregates get fed under this center area of the screed which leads to this visible centerline stripe containing a different texture than the rest of the mat.
- In an example, a paving machine includes a machine frame, a screed system, a mat striping sensor, and a controller. The screed system is connected to the frame and includes a mat crown system. The mat striping sensor is connected to the paving machine and configured to detect anomalies in an asphalt mat laid by the screed system. The controller is communicatively connected to the mat striping sensor and the mat crown system and configured to control the mat crown system to adjust a crown of the asphalt mat in response to the mat striping sensor detecting one or more anomalies in the asphalt mat.
- These and other examples and features of the present devices, systems, and methods will be set forth in part in the following Detailed Description. This overview is intended to provide a summary of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about the present patent application.
- In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
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FIG. 1 is an elevation view schematically depicting an example system including a paving machine and a material transfer machine. -
FIG. 2 is a plan view of an asphalt mat with centerline striping. -
FIGS. 3A-3C are elevation views schematically depicting a screed system in different configurations. -
FIGS. 4A and 4B schematically depict portions of an adjustable screed system. -
FIG. 5 is a flowchart depicting an example method for adjusting the crown of an asphalt mat to remediate anomalies in the mat. -
FIG. 1 is a perspective view depicting example apaving machine 100 which is used, for example, to deposit asphalt, concrete, or other materials on a work surface associated with a worksite.Paving machine 100 includestractor 102,frame 104, ground-engaging elements 106,hopper 108,conveyor 110,auger assembly 112,tow arms 114,screed system 116, andoperator station 118.Paving machine 100 also includes controller(s) 120 incorporated into or communicatively connected to the machine and one or moremat striping sensors 130. - Striping sensor(s) 130 of
paving machine 100 are connected to the machine (e.g., toframe 104 and/or operator station 118) and configured to detect anomalies inasphalt mat 124 laid byscreed system 116.Controller 120 is communicatively connected to mat striping sensor(s) 130 and a mat crown system of screedsystem 116. Controller(s) 120 is configured to control the mat crown system to adjust a crown ofasphalt mat 124 in response to mat striping sensor(s) 130 detecting one or more anomalies in the asphalt mat. Controller(s) 120 can, for example, control the mat crown system to incrementally increase the crown ofasphalt mat 124 up to a threshold crown or until such adjustment remedies the anomalies in the mat. - Tractor 102 of
paving machine 100 is supported on and conveyed via ground-engaging elements 106. Tractor 102 includesframe 104, as well as a power source for driving ground-engaging elements 106. Although groundengaging elements 106 are depicted as continuous tracks, other example work machines according to this disclosure may include other types of ground engaging elements, for example, wheels. Pavingmachine 100 and other work machines in accordance with this disclosure can include different types of power sources, including, e.g. an internal combustion engine operating on fossil or hybrid fuels, or an electrically operated drive powered by alternate energy sources. -
Paving machine 100 includeshopper 108 for storingpaving material 122, e.g. asphalt aggregate material employed by paving machine to produceasphalt mat 124.Paving machine 100 also includesconveyor 110 for conveyingpaving material 122 fromhopper 108 to other downstream components ofpaving machine 100. For example,paving machine 100 includesauger assembly 112 which receivespaving material 122 supplied viaconveyor system 110, and distributespaving material 122 ontopaving surface 126. - Auger
assembly 114 can include one more augers. In examples,auger assembly 114 includes a main, single auger extending laterally across a majority of the width ofpaving machine 100. In other examples,auger assembly 114 includes a pair of augers on either side of a forward-to-backward centerline ofpaving machine 100. In an example, the two side-by-side augers are driven together and operatively connected via an auger bearing or other coupling. In another example, the two side-by-side augers are driven independently andauger assembly 114 includes a gear box arranged on or near the centerline ofpaving machine 100 in front of screedsystem 116. - In examples in which
auger assembly 114 includes two independently driven side-by-side augers and a central gear box, pavingmachine 100 may be susceptible to laying downmat 124 with centerline striping. Centerline striping can happen when asphalt being fed intoscreed system 116 becomes stagnant in front the gear or other drive mechanism actuating the side-by-side augers. At this location in front of the gear box, larger aggregates tend to get trapped in the stagnation zone and are not therefore fed intoscreed system 116. As a result, only relatively smaller aggregates get fed under the central region ofscreed system 116, which leads to a visible centerline stripe containing a different texture/composition than the rest ofmat 124. - Paving
machine 100 includestow arm 114 which couples a heightadjustable screed system 116 totractor portion 102.Screed system 116 is configured to spread andcompact paving material 122 intoasphalt mat 124 on pavingsurface 126.Tow arm 116 can be actuated by a hydraulic actuator, an electric actuator, and/or other types of actuators. - Paving
machine 100 also includesoperator station 118 connected totractor 102.Operator station 118 includesconsole 128 and controls and other components for operating pavingmachine 100. For example,console 128 can include control interface for controlling various functions of pavingmachine 100. The control interface can include analog and/or digital input/outputs, and user controls and interfaces, including, e.g. a touchscreen display. Additionally, the control interface can be communicatively connected to controller(s) 120 and configured to receive operator commands that when executed by controller(s) remediate striping detected inmat 124. The control interface can also support other functions, including for example, sharing various operating data with one or more other machines (not shown) operating in consonance with pavingmachine 100. -
Mat striping sensors 130 are connected to the roof ofoperator station 118 and positioned to detect anomalies inasphalt mat 124.Example striping sensors 130 are depicted schematically for illustration only and, in other examples according to this disclosure, can be positioned in additional and/or other locations on pavingmachine 100. - Asphalt mat striping can be detected in various ways and may be indicated by various in various characteristics of
asphalt mat 124. For example, striping can be indicated by temperature differences, differences in reflectivity (sections of properly finished asphalt mat will have higher reflectivity than sections including a stripe), and/or differences in density.FIG. 2 is a plan view depicting a portion ofasphalt matt 124 includingcenterline stripe 200. In this schematic representation,stripe 200 is indicated by a lighter shade and less dense section of material relative to the other portions ofmat 124. - Referring again to
FIG. 1 ,mat striping sensors 130 can include a variety of different types of sensor(s) configured to detect anomalies inasphalt mat 124. As depicted inFIG. 1 , for example, stripingsensors 130 can include a camera or other image detection/generation apparatus positioned to capture an image ofasphalt mat 124 and communicate the data representing such image tocontroller 120. In examples, the camera is a digital camera configured to record and/or transmit digital images and/or video ofmat 124 to controller(s) 120. Additionally, the camera can include an infrared sensor, a thermal camera, or other like device configured to record and/or transmit thermal images ofmat 124. In examples, the camera provides image data to controller(s), which uses the image data to identify striping inmat 124. -
Mat striping sensors 130 can also include, for example, infrared or thermal sensor(s) configured to detect variations in temperature laterally acrossmat 124, which may be indicative of mat striping.Mat striping sensors 130 can also include density sensor(s) configured to detect variations in density ofmat 124, which may be indicative of mat striping.Mat striping sensors 130 can include photoelectric sensor(s) configured to detect variations in the reflectivity ofmat 124, again, indicative of mat striping. - As noted, controller(s) 120 can be included in or separate from paving
machine 102. In the example ofFIG. 1 , controller(s) 120 is depicted as communicatively connected to pavingmachine 100 viacommunication device 132, which can be, for example, a transceiver. Examples according to this disclosure may include multiple controllers working in conjunction with each other to execute functions attributed to controller(s) 120. As such,FIG. 1 also depicts controller(s) 120 onboard paving machine 100. In examples, controller(s) 120 can be part of or included in an electronic control unit ECU of pavingmachine 100. - Controller(s) 120 or other controllers, ECUs, etc. included in examples according to this disclosure can be configured to communicate with one another and with other components of paving machine 100 (e.g., striping sensors 130) via various wired or wireless communications technologies and components using various public and/or proprietary standards and/or protocols. Examples of transport mediums and protocols for electronic communication between components of machine 300 include Ethernet, Transmission Control Protocol/Internet Protocol (TCP/IP), IEEE 802.11 or Bluetooth, or other standard or proprietary transport mediums and communication protocols.
- In some examples,
controller 120 can be included in an ECU of pavingmachine 100. An electronic control unit (ECU) can be an embedded system that controls various aspects of machine operation. Types of ECUs include Electronic/Engine Control Module, Powertrain Control Module, Transmission Control Module, Brake Control Module, Suspension Control Module, among other examples. In the case of industrial, construction, and other heavy machinery, example ECUs can also include an Implement Control Module associated with one or more implements connected to and operable from the machine. -
Example machine 100 may include, for example, an Engine Control Module (ECM), an Implement Control Module (ICM), a Transmission Control Module (TCM), and a Brake Control Module (BCM). These electronic modules/units can be communicatively connected and configured to send and receive data, sensor or other digital and/or analog signals, and other information between the various ECUs ofmachine 100. Additionally, functions attributed to an ECU or controller(S) 120, can be distributed among multiple devices. - Controller(s) 120, whether onboard and/or separate from paving
machine 100, can include software, hardware, and combinations of hardware and software configured to execute a number of functions attributed to the components in the disclosed examples. Such controllers in examples according to this disclosure can be an analog, digital, or combination analog and digital controller including a number of components. As examples, the controller(s) can include integrated circuit boards or ICB(s), printed circuit boards PCB(s), processor(s), data storage devices, switches, relays, etcetera. Examples of processors can include any one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or equivalent discrete or integrated logic circuitry. - Controller(s) 120, ECUs and other electronic controls in examples according to this disclosure can include storage media to store and/or retrieve data or other information, for example, signals from sensors. Examples of non-volatile storage devices include magnetic hard discs, optical discs, floppy discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories. Examples of volatile storage devices include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile storage devices. The data storage devices can be used to store program instructions for execution by processor(s) of, for example,
controller 124. - Regardless of the number, location, or type of
striping sensors 130 incorporated into pavingmachine 100, the device(s) are configured to detect anomalies inmat 124, including detecting mat striping. Asscreed system 116 of pavingmachine 100 lays downmat 124, stripingsensors 130 detect one or more characteristics of the mat texture/composition laterally across the finished mat and communicate information/data associated with such detection to controller(s) 120. - As will be described and depicted in more detail with reference to
FIGS. 4A and 4B ,screed system 116 includes a mat crown system configured to change the crown ofasphalt mat 124 laid down byscreed system 116 of pavingmachine 100. The mat crown system ofscreed system 116 is communicatively connected to controller(s) 120.Controller 120 is configured to control the mat crown system to adjust a crown ofasphalt mat 124 in response to the mat striping sensor(s) detecting one or more anomalies in the asphalt mat. For example, in response to mat striping sensor(s) detecting one more anomalies indicative of mat striping,controller 120 controls the mat crown system ofscreed system 116 to incrementally increase the crown ofmat 124. -
FIGS. 3A-3C schematically depict anadjustable screed system 116 of pavingmachine 100.Screed system 116 is depicted in three respective states, including neutral or zero crown inFIG. 3A , positive crown inFIG. 3B , and negative crown inFIG. 3C . -
FIGS. 4A and 4B schematically depict portions ofadjustable screed system 116. InFIG. 4A ,screed system 116 includes asingle screed plate 400 spanning the width ofscreed system 116 andmat crown system 402 includingcrown mechanism 404.Crown mechanism 404 includes 406 and 408 andlinks piston 410. 406 and 408 are fixedly connected to screedLinks plate 400 and pivotally connected to opposing ends ofpiston 410. As depicted inFIG. 4A ,piston 410 can be actuated (e.g., hydraulically, electro-magnetically, etc.) to extend and thereby push the upper ends of 406 and 408 away from each other and cause screed plate to bend from a planer state into a convex state.links Actuating piston 410 in this manner will causescreed system 116 to produce an asphalt mat with a positive crown. Although not depicted,piston 410 can also be actuated to pull the upper ends of 406 and 408 closer to each other and cause screed plate to bend from a planer state into a concave state to produce a negative crown.links - In
FIG. 4B ,screed system 116 includes side-by-side, pivotally connected 412 and 414 spanning the width ofscreed plates screed system 116. Screed system also includesmat crown system 402 includingcrown mechanism 404.Crown mechanism 404 includes 406 and 408 andlinks piston 410.Link 406 is fixedly connected to screedplate 412 and pivotally connected to one end ofpiston 410.Link 408 is fixedly connected to screedplate 414 and pivotally connected to the other end ofpiston 410 opposite the end to which link 406 is connected. As depicted inFIG. 4B ,piston 410 can be actuated (e.g., hydraulically, electro-magnetically, etc.) to extend and thereby push the upper ends of 406 and 408 away from each other and causelinks 412 and 414 to pivot from a planer arrangement relative to one another into a convex arrangement.screed plates Actuating piston 410 in this manner will causescreed system 116 to produce an asphalt mat with a positive crown. Although not depicted,piston 410 can also be actuated to pull the upper ends of 406 and 408 closer to each other and causelinks 412 and 414 to pivot from a planer arrangement relative to one another into a concave arrangement to produce a negative crown.screed plates - As schematically represented in
FIGS. 4A and 4B ,screed plate 400 bends and 412 and 414 pivot about a forward-to-screed plates backward centerline 416 of pavingmachine 100 to whichscreed system 116 is connected. In examples according to this disclosure, a screed system of a paving machine can include a variety of other mat crown systems and associated crown mechanisms that adjust the configuration of the screed plate(s) and thereby change the crown of the mat produced by screed system. -
FIG. 5 is a flowchart depictingexample method 500 for adjusting the crown of an asphalt mat to remediate anomalies in the mat.Example method 500 includes laying an asphalt mat using a paving machine (502), detecting one more anomalies in the asphalt mat using one or more mat striping sensors connected to the paving machine (504), and adjusting a crown of the asphalt mat in response to detecting the one or more anomalies (506). - In an example, paving
machine 100 laysasphalt mat 124 on pavingsurface 126. For example,asphalt aggregate 122 is delivered to the work site and loaded intohopper 108 of pavingmachine 100 by a material transfer vehicle.Asphalt aggregate 122 is feed fromhopper 108 to augerassembly 112 byconveyor 110.Auger assembly 112, in turn, feedsasphalt aggregate 122 to screedassembly 116, which spreads and compacts the aggregate to lay downasphalt mat 124. - As
asphalt mat 124 is being laid by pavingmachine 100, stripingsensors 130 are measuring one or more characteristics of the finished mat behind the paving machine, e.g., laterally sections just behindscreed system 116. In an example,auger assembly 112 includes a pair of augers on either side: of a forward-to-backward centerline of pavingmachine 100. The two side-by-side augers ofauger assembly 112 are driven together or independently and operatively connected via, e.g., a bearing or a gear box arranged on or near the centerline of pavingmachine 100 in front ofscreed system 116. - As paving
machine 100 laysmat 124, asphalt being fed intoscreed system 116 becomes stagnant in front of the gear or other drive mechanism actuating the side-by-side augers, which results in a visible centerline stripe containing a different texture/composition than the rest ofmat 124. In such circumstances, one or more ofmat striping sensors 130 detect the variation in the characteristics ofmat 124, i.e. the centerline stripe and communicate data or other information indicative of the stripe to controller(s) 120. - Controller(s) 120 receive the data from
mat striping sensors 130 and causemat crown system 402 to adjust the crown ofasphalt mat 124 in response thereto. For example, controller(s) 120 controlmat crown system 402 to produce a positive crown inmat 124. In such circumstances, for example,mat crown system 402 actuatespiston 410 to push 406 and 408 away from each other (laterally outward), which causeslinks 412 and 414 to pivot aboutscreed plates centerline 416 from a planer state into a convex state. - In examples, controller(s) control
mat crown system 402 to incrementally increase the crown inasphalt mat 124. In some cases, the requirements of a particular job for whichasphalt mat 124 is being laid down can include a threshold on the amount of positive crown of the mat. In an example, the threshold beyond which the positive crown of asphalt mat cannot go is ⅛ inches (3.175 millimeters). In an example, controller(s) controlmat crown system 402 to increase the crown inasphalt mat 124 in increments of 1 millimeter (0.039 inches). In an example, controller(s) 120 controlsmat crown system 402 to increase the crown ofasphalt mat 124 untilmat striping sensors 130 cease to detect the centerline strip in the asphalt mat, and, thereafter, the controller is configured to control the mat crown system to maintain the crown of the asphalt mat. With the positive crown resulting frommat crown system 402 raising the centerline of 412 and 414, aggregate that may have become stagnant behind the center auger drive box are able to flow easily under the screed plates. This center area ofscreed plates asphalt mat 124 will then be a more consistent mixture of small/large aggregates like the rest of the mat, thus remediating or eliminating the centerline stripe and providing a consistent texture/composition across the finished mat. - Additionally, as noted, in examples, controller(s) 120 can be configured to control
mat crown system 402 to incrementally increase the crown ofasphalt mat 124 up to and including a threshold positive crown, e.g., ⅛ inch. In the event, the stripe inasphalt mat 124 is not remediated when the crown reaches ⅛ inch, additional measures may need to be taken to address the anomaly in the mat. - In examples, the increments by which
mat crown system 402 adjusts the crown ofasphalt mat 124 and the threshold crown beyond which the mat crown system will not go can be programmatically adjusted or can be user configured. For example, an operator employing the control interface, e.g., a touchscreen interface atconsole 128 of pavingmachine 100 can select different increments by which to adjust the crown ofasphalt mat 124 and/or a threshold crown value beyond which the crown will not be adjusted. - In the foregoing Detailed Description, it can be seen that various features are grouped together in a single example for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed examples require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed example. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate example.
- Note that not all of the activities or elements described above in the general description are required, that a portion of a specific activity or device may not be required, and that one or more further activities may be performed, or elements included, in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which they are performed. Also, the concepts have been described with reference to specific examples. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present disclosure as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present disclosure.
- Benefits, other advantages, and solutions to problems have been described above with regard to specific examples. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims. Moreover, the particular examples disclosed above are illustrative only, as the disclosed subject matter may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. No limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular examples disclosed above may be altered or modified and all such variations are considered within the scope of the disclosed subject matter. Accordingly, the protection sought herein is as set forth in the claims below.
Claims (20)
1. A paving machine comprising:
a machine frame;
a screed system connected to the frame and including a mat crown system;
a mat striping sensor connected to the paving machine and configured to detect anomalies in an asphalt mat laid by the screed system; and
a controller communicatively connected to the mat striping sensor and the mat crown system and configured to control the mat crown system to adjust a crown of the asphalt mat in response to the mat striping sensor detecting one or more anomalies in the asphalt mat.
2. The paving machine of claim 1 , wherein the controller is configured to control the mat crown system to produce a positive crown of the asphalt mat in response to the mat striping sensor detecting one or more anomalies in the asphalt mat.
3. The paving machine of claim 2 , wherein the controller is configured to control the mat crown system to incrementally increase the crown of the asphalt mat in response to the mat striping sensor detecting one or more anomalies in the asphalt mat.
4. The paving machine of claim 3 , wherein the controller is configured to control the mat crown system to increase the crown of the asphalt mat until the mat striping sensor ceases to detect the one or more anomalies in the asphalt mat, and, thereafter, the controller is configured to control the mat crown system to maintain the crown of the asphalt mat.
5. The paving machine of claim 3 , wherein the controller is configured to control the mat crown system to incrementally increase the crown of the asphalt mat in increments approximately equal to one millimeter (0.03937 inches).
6. The paving machine of claim 3 , wherein the controller is configured to control the mat crown system to incrementally increase the crown of the asphalt mat up to and including a threshold positive crown.
7. The paving machine of claim 6 , wherein the threshold positive crown is approximately equal to 0.125 inches (3.175 millimeters).
8. The paving machine of claim 1 , wherein the mat striping sensor is configured to detect variation in one more characteristics of the asphalt mat.
9. The paving machine of claim 8 , wherein the mat striping sensor comprises an infrared sensor configured to detect variation in temperature of the asphalt mat.
10. The paving machine of claim 8 , wherein the mat striping sensor comprises a density sensor configured to detect variation in density of the asphalt mat.
11. The paving machine of claim 8 , wherein the mat striping sensor is a photoelectric sensor configured to detect variation in reflectivity of the asphalt mat.
12. The paving machine of claim 8 , wherein the mat striping senor comprises a camera configured to capture image data of a portion of the asphalt mat indicative of mat striping.
13. The paving machine of claim 1 , wherein the screed system comprises at least one screed plate and the mat crown system comprises a crown mechanism configured to move the at least one screed plate between a planer condition in which the screed plate is substantially planer, a convex condition in which the at least one screed plate is convex, and a concave condition in which the at least one screed plate is concave.
14. The paving machine of claim 13 , wherein the screed system comprises first and second screed plates pivotally connected at and configured to pivot about a forward-to-backward centerline of the paving machine.
15. The paving machine of claim 14 , wherein:
the controller is configured to control the mat crown system to produce a positive crown of the asphalt mat in response to the mat striping sensor detecting one or more anomalies in the asphalt mat; and
the crown mechanism of the mat crown system produces the positive crown of the asphalt mat by pivoting the first and second screed plates about the forward-to-backward centerline of the paving machine.
16. A paving machine comprising:
a machine frame;
a screed system connected to the frame and including a mat crown system;
one or more mat striping sensors connected to the paving machine and configured to detect striping in an asphalt mat laid by the screed system; and
a controller communicatively connected to the one or more mat striping sensors and the mat crown system and configured to control the mat crown system to increase a crown of the asphalt mat in response to the one or more mat striping sensors detecting striping in the asphalt mat.
17. A method comprising:
laying an asphalt mat using a paving machine;
detecting one or more anomalies in the asphalt mat using one or more mat striping sensors connected to the paving machine; and
adjusting a crown of the asphalt mat in response to detecting the one or more anomalies.
18. The method of claim 17 , wherein detecting the one or more anomalies comprises detecting variation in at least one of temperature, density, and reflectivity in the asphalt mat.
19. The method of claim 17 , wherein detecting the one or more anomalies comprises detecting striping in the asphalt mat.
20. The method of claim 17 , wherein adjusting the crown of the asphalt mat comprises incrementally increasing the crown of the asphalt mat up to and including a threshold positive crown or until the one or more mat striping sensors cease to detect the one or more anomalies.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US18/243,537 US20250084595A1 (en) | 2023-09-07 | 2023-09-07 | Systems and methods for adjusting crown to remediate road mat anomalies |
| DE102024124784.3A DE102024124784A1 (en) | 2023-09-07 | 2024-08-29 | Roof profile adjustment systems and methods to correct road surface anomalies |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US18/243,537 US20250084595A1 (en) | 2023-09-07 | 2023-09-07 | Systems and methods for adjusting crown to remediate road mat anomalies |
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| US20250084595A1 true US20250084595A1 (en) | 2025-03-13 |
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| US18/243,537 Pending US20250084595A1 (en) | 2023-09-07 | 2023-09-07 | Systems and methods for adjusting crown to remediate road mat anomalies |
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| US11127135B1 (en) | 2020-03-23 | 2021-09-21 | Caterpillar Paving Products Inc. | System and method for correcting paving mat defects |
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- 2023-09-07 US US18/243,537 patent/US20250084595A1/en active Pending
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