Material roll control in a slipform paving process

Abstract

A slipform paver includes a machine frame, a plurality of ground engagement wheels or tracks, and height-adjustable front and rear lifting columns supporting the machine frame from the ground engagement wheels or tracks. The lifting columns are adjustable to adjust the longitudinal tilt of the machine frame in the paving direction. A slipform die, supported from the machine frame, is used to mold a mass of concrete into a formed, uncured concrete slab as the paver moves forward in the paving direction. A swing beam, supported from the machine frame behind the slipform die, engages on the upper surface of the formed, uncured concrete slab and swings laterally in the paving direction to smooth the upper surface. A roll size sensor is configured to detect the size of uncured concrete rolls generated in front of the swing beam.

Description

Technical Field

[0001] This invention relates to a slipform paver and a method for controlling the slipform paver. Background Technology

[0002] One phenomenon encountered during the slipform paving of concrete structures is that when a swing beam is used behind the slipform mold, a "roll" of unhardened concrete material forms immediately in front of the swing beam.

[0003] Improved equipment and methods are needed to monitor and control this unhardened concrete material in "rolls". Summary of the Invention

[0004] In one embodiment, a slipform paver includes: a machine frame, a plurality of ground engagement wheels or tracks, and height-adjustable front and rear lift columns supporting the machine frame from the ground engagement wheels or tracks, the lift columns being adjustable to adjust the longitudinal tilt of the machine frame in the paving direction. A slipform die, supported from the machine frame, is used to mold a mass of concrete into a formed, uncured concrete slab as the paver moves forward in the paving direction. A swing beam, supported from the machine frame behind the slipform die, engages on the upper surface of the formed, uncured concrete slab and swings laterally in the paving direction to smooth the upper surface. A roll size sensor is configured to detect the size of uncured concrete rolls generated in front of the swing beam.

[0005] In another embodiment, the roll size sensor can be configured to detect parameters corresponding to the cross-sectional dimensions of the roll.

[0006] In any of the above embodiments, the roll size sensor can be a roll height sensor, and the parameter can be the vertical distance from the machine frame to the top of the roll, or the roll size sensor can be a roll width sensor, and the parameter can be the horizontal distance from the machine frame to the side of the roll.

[0007] In any of the above embodiments, the roll size sensor may include at least two discrete roll height sensors spaced apart across the width of the machine frame, or the roll size sensor may include at least two discrete roll width sensors spaced apart across the width of the machine frame.

[0008] In any of the above embodiments, the roll size sensor may include at least one scanning laser sensor configured to scan the exterior of the roll across a continuous portion of the machine frame width.

[0009] In any of the above embodiments, the machine may include a controller configured to receive sensor signals from a roll size sensor and generate command signals to an actuator to adjust the longitudinal tilt of the machine.

[0010] In any of the above embodiments, the controller may also be configured to determine the size of the roll as an average size over a time interval.

[0011] In any of the above embodiments, the controller may also be configured to predict the size of the roll based at least in part on the rate of change of the sensor signal.

[0012] In any of the above embodiments, the controller may also be configured to lower the front end of the machine frame relative to the rear end to reduce the size of the roll, and raise the front end of the machine frame relative to the rear end to increase the size of the roll.

[0013] In any of the above embodiments, the controller may also be configured to adjust the longitudinal tilt of the machine frame by adjusting the front and rear lifting columns, thereby tilting the machine frame about the axis of rotation of the rear edge of the adjacent swing beam, so that the height of the upper surface of the unhardened concrete slab formed behind the swing beam remains unchanged.

[0014] In any of the above embodiments, the controller may also be configured to adjust the longitudinal tilt of the machine frame by simultaneously adjusting the front and rear lifting columns.

[0015] In any of the above embodiments, the controller may be configured to: (a) monitor sensor signals from the size sensor; (b) determine, at least in part, based on the sensor signals, the current or predicted deviation of the size of the unhardened concrete roll from the desired size; and (c) generate a command signal to adjust the longitudinal tilt of the machine frame in the direction that counteracts the deviation.

[0016] The controller can also be configured to: repeat steps (a) and (b) after step (c), after a hysteresis time sufficient to allow the adjustment in step (c) to cause a change in the roll size; and further adjust the longitudinal tilt of the machine frame in one direction to counteract any further determined current or predicted deviations in the roll size.

[0017] In any of the above embodiments, the lag time interval may be based on the time required for the paver to travel a specific distance in the paving direction.

[0018] In any of the above embodiments, the machine may further include a concrete supply height sensor and an expansion sensor, the concrete supply height sensor being arranged to detect the height of a pile of concrete in front of the slipform mold, and the expansion sensor being arranged to detect the height of a formed, unhardened concrete slab behind the slipform mold, wherein the controller is further configured to generate command signals based at least in part on signals from the concrete supply height sensor and / or the expansion sensor.

[0019] In any of the above embodiments, the machine may further include a front chord sensor, a front sensor actuator, a rear chord sensor, a rear sensor actuator, and a controller. The front sensor actuator is arranged to adjust the vertical position of the front chord sensor relative to the machine frame, the rear sensor actuator is arranged to adjust the vertical position of the rear chord sensor relative to the machine frame, and the controller is configured to receive a roll size sensor signal from the roll size sensor and send command signals to the front and rear sensor actuators to cause adjustment of the longitudinal tilt of the machine frame.

[0020] In any of the above embodiments, the machine may further include a front sensor actuator position sensor and a rear sensor actuator position sensor, the front sensor actuator position sensor being arranged to generate a position signal indicating the position of the front chord sensor, and the rear sensor actuator position sensor being arranged to generate a position signal indicating the position of the rear chord sensor.

[0021] In any of the above embodiments, the front sensor actuator and the rear sensor actuator can be a front hydraulic smart cylinder and a rear hydraulic smart cylinder, and the position sensor of the front sensor actuator and the position sensor of the rear sensor actuator can be integrated into the front hydraulic smart cylinder and the rear hydraulic smart cylinder, respectively.

[0022] In any of the above embodiments, the front sensor actuator and the rear sensor actuator can be a front rotary spindle and a rear rotary spindle powered by a rotary motor, and the position sensors of the front sensor actuator and the rear sensor actuator can be rotary position sensors.

[0023] A method for controlling a slipform paver constructed according to any of the above embodiments may include the following steps: (a) monitoring at least one parameter with at least one sensor, the parameter indicating the current or predicted size of an uncured concrete roll produced in front of the swing beam, and generating at least one sensor signal representing the at least one parameter; (b) determining, at least in part, based on the at least one sensor signal, a deviation between the current or predicted size of the uncured concrete roll and the desired size using a controller, and generating a corresponding command signal; and (c) in response to the command signal, automatically adjusting the longitudinal tilt of the machine frame in a direction that counteracts the deviation.

[0024] In the above method, at least one parameter may correspond to the cross-sectional size of the roll.

[0025] In any of the methods described above, the cross-sectional dimensions may include the height of the roll or the width of the roll.

[0026] In any of the above methods, step (a) may also include monitoring the average size over a time interval as the size of the roll.

[0027] In any of the above methods, step (a) may also include monitoring the size of the roll at at least two locations across the width of the paver.

[0028] In any of the above methods, step (c) may further include lowering the front end of the machine frame relative to the rear end to reduce the size of the roll, and raising the front end of the machine frame relative to the rear end to increase the size of the roll.

[0029] In any of the above methods, step (c) may further include adjusting the longitudinal tilt of the machine frame by adjusting the front and rear lifting columns, thereby tilting the machine frame about the axis of rotation of the adjacent rear edge of the swing beam, so that the height of the upper surface of the unhardened concrete slab formed behind the swing beam remains unchanged.

[0030] In any of the above methods, step (b) may also include determining the predicted size based at least in part on the rate of change of the at least one parameter.

[0031] Any of the above methods may further include: after step (c), after a hysteresis time interval sufficient to allow the adjustment of step (c) to result in a change in the roll size, repeating steps (a) and (b), and further adjusting the longitudinal tilt of the machine frame in one direction to counteract any further determined current or predicted deviations in the roll size.

[0032] In any of the methods described above, the lag time interval can be based on the time required for the paver to travel a specific distance in the paving direction.

[0033] In any of the above methods, at least one parameter may include the height of the pile of concrete immediately in front of the slipform mold.

[0034] In any of the above methods, at least one parameter may include the height of the unhardened concrete slab formed immediately behind the slipform mold.

[0035] Many objects, features and advantages of the present invention will readily become apparent to those skilled in the art when the following description is read in conjunction with the accompanying drawings. Attached Figure Description

[0036] Figure 1 This is a side view of a slipform paver.

[0037] Figure 2 yes Figure 1 A schematic side view of a slipform paver, excluding the pin bar inserter.

[0038] Figure 3 This is a schematic diagram of a front sensor actuator in the form of a hydraulic intelligent cylinder and a portion of a front chord sensor that engages with a chord.

[0039] Figure 4 This is a schematic diagram of a front sensor actuator in the form of a hydraulically powered rotating spindle and a portion of a front chord sensor that engages with a chord.

[0040] Figure 5 This is a schematic diagram of an "intelligent" hydraulic cylinder.

[0041] Figure 6 This is a schematic diagram of the control system.

[0042] Figure 7A This is a schematic plan view of an expansion sensor, which takes the form of three discrete ultrasonic sensors distributed across the width of the machine.

[0043] Figure 7B This is a schematic plan view of an expansion sensor, which takes the form of a centrally located laser scanner that performs continuous partial scans across the width of the machine. Detailed Implementation

[0044] The embodiments of this disclosure described below are not intended to be exhaustive or to limit this disclosure to the precise forms disclosed in the following detailed description. Rather, the embodiments were chosen and described so that those skilled in the art can appreciate and understand the principles and practice of this disclosure.

[0045] Now refer to the attached diagram, especially the reference... Figure 1 The figure shows a slipform paver, generally indicated by reference numeral 10. The machine 10 is configured to move across the ground 14 in the paving direction 12 for spreading, leveling and finishing concrete into a finished concrete structure 16 having a generally upward-exposed concrete surface 18 and terminating at a transverse concrete side such as 20.

[0046] The slipform paver 10 includes a main frame 22 and a slipform paver mold 24 supported by the main frame 22. A left mold assembly and a right mold assembly 26 are connected to the slipform paver mold 24 to close the slipform paver mold 24 on the left and right sides, thereby forming transverse concrete sides such as 20 of the finished concrete structure 16. Figure 1 The slipform paver 10 shown is an embedded slipform paver device.

[0047] The main frame 22 is supported from the ground by multiple ground engagement units, such as 30, which in the illustrated embodiment are tracked ground engagement units 30. Wheeled ground engagement units may also be used. Each ground engagement unit 30 is connected to the main frame 22 via a lifting column, such as 32, which is attached to a swing arm, such as 34. An operator station 36 is located on the main frame 22. A plow or spreader device 38 is supported from the main frame 22 at the front of the slipform paver mold 24. A spreading auger may be used instead of the plow 38. A pin bar inserter device 40 may be provided at the rear of the slipform paver mold 24. A swing beam 42 and / or a super-smooth device 44 may be provided at the rear of the pin bar inserter device 40. If the pin bar inserter device 40 is not used, the swing beam 42 and / or the super-smooth device 44 may be provided at the rear of the slipform paver mold 24.

[0048] It will be understood that many slipform pavers do not include the pin bar inserter device 40. Figure 2 Further schematic diagrams show a slipform paver 10 without the pin bar inserter device 40. It should also be understood that some slipform pavers do not include the swing beam 42.

[0049] Figure 2 The slide paver 10 is schematically shown, including the swing beam 42 but excluding the pin bar inserter 40. It should be understood that the pin bar inserter 40 may be placed between the slide mold 24 and the swing beam 42.

[0050] exist Figure 2 In the diagram, the lifting columns 32 are designated as front lifting columns 32F and rear lifting columns 32R, respectively. The tracks 30 are designated as front tracks 30F and rear tracks 30R, respectively. It should be understood that there are two front lifting columns 32F on the left and right sides of the machine 10, which support the machine frame 22 from the two front tracks 30F. Similarly, there are two rear lifting columns 32R, which support the machine frame 22 from the two rear tracks 30R. Figure 1 and Figure 2 In the illustration, the slipform paver 10 is shown as a four-tracked machine, having a front track ground engagement unit 30 and a rear track ground engagement unit 30 on each of the left and right sides of the machine. It should be understood that the various features disclosed herein also apply to two-tracked pavers, such as, for example, the Wirtgen model SP 62i, which has a long track on each of the left and right sides of the machine frame, and a front riser and a rear riser on each side of the machine frame, the front and rear risers supporting the machine frame from each of the two tracks.

[0051] Each rising column is constructed as a telescopic component and may include a hydraulic smart cylinder actuator, such as... Figure 2 The actuators 46F and 46R are shown in the diagram. The extension and retraction of actuators 46F and / or 46R causes the extension and retraction of lifting columns 32F and 32R, and can raise or lower the machine frame 22 relative to the ground 14 and / or adjust the longitudinal and / or lateral tilt of the machine frame 22 relative to the ground 14. Each hydraulic smart cylinder may include an integrated extension sensor, such as 48F and 48R, to allow precise monitoring and control of the extension of the lifting column 32. Alternatively, the lifting column may include a conventional hydraulic cylinder and a separately associated extension sensor.

[0052] Figure 1 The plow or spreader device 38 marked in the middle Figure 2 The device is schematically shown as a spiral drill-type distributor 38.

[0053] Behind the auger-type distributor assembly 38 is a height-adjustable concrete supply gate 50. The gate 50 is supported from the machine frame 22 by one or more gate actuators 52 for adjusting the height of the gate 50 relative to the machine frame 22. The gate actuator 52 can also be configured as a hydraulic smart cylinder with an integrated extension sensor 54 to allow precise monitoring and control of the height extension of the gate 50. Alternatively, the gate actuator 52 may include a conventional hydraulic cylinder and may have a separate associated extension sensor.

[0054] Between the gate 50 and the slipform mold 24 are multiple vibrators 56, which are configured to be immersed in the pile of concrete that forms the slab 16 therefrom, so as to help compact the concrete as the slipform mold 24 moves over the pile of concrete.

[0055] During paving, a heap of concrete material 16A is dumped onto the ground 14 in front of the paver 10. This is typically accomplished by a series of dump trucks (not shown) that dump their wet concrete loads onto the ground, thus the supply of concrete material 16A occurs in a series of sequential material dumps. Alternatively, the heap of concrete can be supplied by a side feeder, shuttle, aggregate spreader, or other known concrete supply device. Material 16A is spread laterally across the width of the paver 10 via a spreader device 38. The height of the concrete supply gate 50 is adjusted to control the amount of concrete material 16B directly in front of the slipform slab 24. By means of a vibrator 56, the concrete material is consolidated and semi-liquefied, and the slipform slab 24 moves across the concrete material 16B to form it into a concrete slab 16. Immediately following the slipform slab 24, there may be some expansion in the height of the newly formed slab in area 16C. The expansion of the concrete slab results in an increase in the height of the slab, such as... Figure 2As shown by dimension 91, this dimension 91 is the increased height of the slab above the bottom edge 90 of the mold 24. The concrete material roll 16D can be formed immediately before the swing beam 42.

[0056] The swing beam 42, supported from the machine frame 22 behind the slipform mold 24, is used to engage the upper surface 18 of the formed, unhardened concrete slab 16 and swing laterally to the paving direction 12 to smooth the upper surface 18. The upper surface 18 can be further smoothed by the action of the super-smoother 44, a large automatic smoothing trowel that moves laterally across the width of the slab 16 while reciprocating forward and backward.

[0057] The direction of the paver 10 and the height of the formed concrete slab 16 can be controlled using a slope control system. One such slope control system is a chord-type slope control system, in which a chord 58 is constructed near the planned location of the concrete slab. Such a chord 58 can be constructed by a surveyor before the paving operation, placing the chord at a known geographical location and a known height. The machine 10 can then use the chord 58 as a physical reference to guide its path relative to the ground 14 and control its height in order to control the height of the upper surface 18 of the formed concrete slab 16.

[0058] Although the paver 10 is described primarily in the context of a chord-type slope control system in this disclosure, it should be understood that some aspects of the improved paver 10 disclosed herein can be used with other types of slope control systems, such as satellite-based slope control systems (GPS or GNSS), total station-type slope control systems, or hybrid combinations of satellite-based and total station-type slope control systems. Figure 2 In this context, the satellite-based slope control system is schematically indicated by receivers 302 and 304 on satellite 300 and machine 10, respectively. Receivers 302 and 304 can be satellite signal receivers. Furthermore, in... Figure 2 In the diagram, the two total station laser transmitters are schematically represented as 310A and 310B, and in this case, the receivers 302 and 304 can be total station reflectors / receivers of known types.

[0059] Machine 10 may include a front chord sensor 60F and a rear chord sensor 60R. Although machine 10 may have a front chord sensor 60F and a rear chord sensor 60R on each side (left and right), it should be understood that in some cases, a chord 58 may be constructed only on one side of machine 10. In this case, the height of the opposite side of machine 10 may be controlled via a lateral slope sensor that detects the lateral slope of the machine frame 22 relative to gravity.

[0060] Each of the front chord sensor 60F and the rear chord sensor 60R can be as follows: Figure 3 The known configuration is schematically shown in the diagram. The front chord sensor 60F and the rear chord sensor 60R can be supported from the machine frame 22 by front sensor actuator 62F and rear sensor actuator 62R, respectively. Actuators 62F and 62R are configured to adjust the vertical position of the front chord sensor 60F and the rear chord sensor 60R relative to the machine frame 22, respectively.

[0061] A front sensor actuator position sensor 64F may be associated with a front sensor actuator 62F and configured to generate a position signal representing the vertical position of the front chord sensor 60F relative to the machine frame 22. A rear sensor actuator position sensor 64R may be associated with a rear sensor actuator 62R and configured to generate a position signal representing the vertical position of the rear chord sensor 60R relative to the machine frame 22.

[0062] In one embodiment, the front sensor actuator 62F and the rear sensor actuator 62R may be a front hydraulic smart cylinder 62F and a rear hydraulic smart cylinder 62R, and the front sensor actuator position sensor 64F and the rear sensor actuator position sensor 64R may be integrated into the front hydraulic smart cylinder 62F and the rear hydraulic smart cylinder 62R, respectively. Optionally, actuators 62F and 62R may include conventional hydraulic cylinders and may have separate associated extension sensors.

[0063] In another embodiment, the front sensor actuator 62F and the rear sensor actuator 62R can be a front rotary spindle and a rear rotary spindle powered by a rotary motor, and the front sensor actuator position sensor 64F and the rear sensor actuator position sensor 64R can be rotary position sensors.

[0064] Figure 3A front chord sensor 60F, supported by a front sensor actuator 62F, is schematically shown as a hydraulic smart cylinder 62F. It should be understood that other chord sensors and associated sensor actuators can be constructed similarly. Sensor 60F includes a rod 66 that engages with chord 58. The sensor rod 66 can be biased to travel along the underside of chord 58. Any change in the height of the machine frame 22 relative to chord 58 will cause the rod 66 to rotate about sensor axis 67 and generate a sensor signal that can be used as a basis for adjusting the position of the associated lifting column actuator to maintain the desired height of the machine frame 22 relative to chord 58. Sensor 60F will typically be initially set such that the rod 66 is in a “zero” position, where the machine frame 22 is at the desired height relative to chord 58. The “zero” position is preferably a horizontal position of the rod 66. Then, if the lever 66 rotates up or down, corresponding adjustments can be made at the lifting column position to maintain the desired height of the machine frame 22 relative to the chord 58, and thus obtain the desired height of the concrete slab 16 relative to the chord 58. If it is necessary to adjust the height of the machine frame 22 and the concrete slab 16 relative to the chord 58, this can be accomplished by adjusting the vertical position of the sensor 60F relative to the machine frame 22 using the front sensor actuator 62F. Because the sensor actuator 62F is constructed as a hydraulic smart cylinder with an integrated extension sensor 64F, this allows for precise monitoring and control of the extension of the height of the front chord sensor 60F.

[0065] Figure 4 It is similar to Figure 3 The diagram is shown, but the front sensor actuator 62F is shown as a rotating spindle. The front sensor actuator position sensor 64F is shown as a rotation counter or angle sensor that counts the rotation of the spindle, which corresponds to the change in the vertical position of the front chord sensor 60F. Figure 4 The sensor actuator 62F includes a spindle 92 driven by a rotary motor 94, which can be a hydraulic motor or an electric motor 94. The spindle 92 is supported by a spindle housing 96, which is supported from the machine frame 22. A nut 98 is threadedly received around the spindle 92 and is vertically movable relative to the machine frame 22 when guided by a guide 100. A front chord sensor 60F is mounted on the nut 98. When the spindle 92 is rotated by the motor 94, the nut 98 and the attached sensor 60F move vertically up and down depending on the direction of rotation of the spindle 92. A rotation counter 64F counts the rotations of the spindle 92 and generates a signal corresponding to the movement of the front chord sensor 60F.

[0066] As will be understood by those skilled in the art, the string sensors 60F and 60R can be hydraulic sensors that cause movement of the lever 66 to move a hydraulic valve and direct hydraulic fluid flow to the associated lifting column actuator 46. Alternatively, the string sensors 60F and 60R can be electronic sensors that generate electrical signals used by the controller to produce command signals for various electromechanical actuators.

[0067] Hydraulic "intelligent" cylinder

[0068] As previously mentioned, many of the actuators disclosed herein can be “smart” hydraulic cylinders with integrated extended sensors associated with them.

[0069] exist Figure 5 The diagram shows a representative construction of this “smart” hydraulic cylinder, and details of the “smart” hydraulic sensor actuator 62F will be described by way of example. Figure 5 This can also refer to the internal configuration of any other actuator described herein (when these actuators are implemented as “smart” cylinders). In the illustrated embodiment, actuator 62F includes an integrated sensor 64F configured to provide a signal corresponding to the extension of piston portion 68 relative to cylinder member 70 of actuator 62F.

[0070] Sensor 64F includes a position sensor electronics housing 72 and a position sensor coil element 74. The piston portion 68 of actuator 62F includes a piston 76 and a rod 78. The piston 76 and rod 78 have a hole 80 defined therein, within which the position sensor coil element 74 is received.

[0071] The actuator 62F is configured to provide a signal at connector 82 indicating the position of piston 76 relative to position sensor coil element 74.

[0072] This type of intelligent cylinder can operate based on several different physical principles. Examples of such intelligent cylinders include, but are not limited to, magnetostrictive sensing, magnetoresistive sensing, resistance (potentiometer) sensing, Hall effect sensing, sensing using a linearly variable differential transformer, and sensing using a linearly variable inductor transducer.

[0073] control system

[0074] like Figure 6 As schematically shown, machine 10 includes a control system 200, which includes a controller 202. Controller 202 may be part of the machine control system of slipform paver 10 or it may be a separate control module. Controller 202 may, for example, be mounted in a control panel located at operator station 36. Controller 202 is configured to receive input signals from various sensors. Figure 6The signals transmitted from various sensors to controller 202 are schematically indicated by the lines connecting the sensors to the controller, with arrows indicating the signal flow from the sensors to controller 202.

[0075] For example, extension signals from extension sensors 48F and 48R of the lifting column actuator cylinders 46F and 46R will be received by controller 202, enabling the controller to monitor and control the extension of the lifting columns 32F and 32R. Extension signals from sensor actuator position sensors 64F and 64R will be received by controller 202, enabling controller 202 to monitor and control the vertical position of the front chord sensor 60F and the rear chord sensor 60R. Extension signals from extension sensor 54 of the gate actuator 52 will be received by controller 202, enabling the controller to monitor and control the extension of the gate actuator 52, and thus monitor and control the height of the gate 50.

[0076] Similarly, controller 202 will generate control signals for controlling the operation of the various actuators described above, and these control signals will... Figure 6 The diagram schematically indicates the connection between the controller 202 and various actuators, with arrows indicating the flow of command signals from the controller 202 to the corresponding actuator. It should be understood that, in order to control a hydraulic cylinder-type actuator, the controller 202 sends an electrical signal to an electromechanical control valve (not shown) that controls the flow of hydraulic fluid to and from the hydraulic cylinder.

[0077] exist Figure 6 For ease of explanation, only the actuators suitable for the left-hand side of machine 10 are shown. It should be understood that the actuators suitable for the right-hand side of machine 10 can be the same as those on the left-hand side. Therefore, Figure 6 The adjustable left front sensor actuator 62F, left front lifting column actuator 46F, left gate actuator 52, left rear sensor actuator 62R, and left rear lifting column actuator 46R are schematically shown.

[0078] It should be understood that when adjusting the longitudinal tilt 84, the left front sensor actuator and the right front sensor actuator will generally be adjusted in the same manner, and the left rear sensor actuator and the right rear sensor actuator will be adjusted in the same manner. However, it should also be understood that if a lateral tilt of the machine frame 22 is desired, the left and right sensor actuators can be adjusted differently from each other, and the front and rear sensor actuators on the same side can be adjusted in the same manner.

[0079] Controller 202 includes or is associated with processor 204, computer-readable medium 206, database 208, and control panel 210 or input / output module having display 212. Input / output devices 214, such as keyboards, joysticks, or other user interfaces, are provided to allow an operator to input commands to the controller. It should be understood that the controller 202 described herein may be a single controller having all the described functions, or it may include multiple controllers, wherein the functions are distributed among the multiple controllers.

[0080] The various operations, steps, or algorithms described in conjunction with controller 202 can be directly embodied in hardware, computer program product 216 (such as a software module executed by processor 204), or a combination of both. Computer program product 216 can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, removable disk, or any other form of computer-readable medium 206 known in the art. Exemplary computer-readable medium 206 can be coupled to processor 204, allowing the processor to read information from and write information to the memory / storage medium. Alternatively, the medium can be integrated into the processor. The processor and medium can reside in an application-specific integrated circuit (ASIC). The ASIC can reside in the user terminal. Alternatively, the processor and medium can reside as discrete components in the user terminal.

[0081] As used herein, the term "processor" can refer to a processing device and / or logic for at least a general or special purpose, as would be understood by those skilled in the art, including but not limited to microprocessors, microcontrollers, state machines, etc. A processor can also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors combined with a DSP core, or any other such configuration.

[0082] In some embodiments, data storage in computer-readable medium 206 and / or database 208 may include database services, cloud databases, etc. In various embodiments, the computing network may include a cloud server and, in some implementations, may be part of a cloud application, wherein various functionalities as disclosed herein are inherently distributed among the computing network and other distributed computing devices. Any or all distributed computing devices may be implemented as at least one of an in-vehicle controller, server device, desktop computer, laptop computer, smartphone, or any other electronic device capable of executing instructions. The processor of the device (such as a microprocessor) may be a general-purpose hardware processor, a special-purpose hardware processor, or a combination thereof.

[0083] Specifically, the controller 202 can be programmed to receive extension signals from each extension sensor of each hydraulic smart cylinder and send control signals to control the extension of those hydraulic smart cylinders, at least in part, in response to the corresponding extension signals.

[0084] Longitudinal tilt controlled by intelligent string sensor actuator

[0085] As further described below, for various operating modes of the paver 10 that can be implemented by the control system 200, it is sometimes desirable to adjust the longitudinal tilt of the paver 10 to affect the flow of concrete material at locations 16A, 16B, 16C, and 16D when the paver 10 moves over the concrete material to form a concrete slab 16.

[0086] The controller 202 will implement the desired change in the longitudinal tilt of the machine frame 22 relative to the ground 14 by sending command signals to the front sensor actuator 62F and the rear sensor actuator 62R, resulting in the adjustment of the longitudinal tilt of the machine frame 22. The longitudinal tilt of the machine frame 22 is... Figure 2 The angle 84 is schematically represented in the diagram. The angle 84 can be determined by the controller 202 based on, for example, the measured extensions of the front and rear rising columns, which will establish a longitudinal tilt relative to a reference such as the ground or a chord reference.

[0087] This adjustment of the longitudinal tilt can be achieved as follows. Adjusting the vertical position of the front chord sensor 60F and / or the rear chord sensor 60R via the front sensor actuator 62F and the rear sensor actuator 62R will sequentially generate control signals from the front chord sensor 60F and / or the rear chord sensor 60R. Based on these control signals, the slope control system will cause adjustment of the extension of the corresponding lifting column actuators 46F and 46R so that the rod 66 of each chord sensor 60F and 60R returns to its “zero” position. Therefore, for example, if it is desired to raise the front of the machine frame 22 relative to the rear of the machine frame 22, the controller 202 can send a command signal to the front sensor actuator 62F to extend the actuator 62F. This will cause the rod 66 of sensor 60F to deflect upwards while it remains in contact with the chord 58, thereby generating a control signal that will cause the rod 66 of the front chord sensor 60F to extend until the rod 66 of the front chord sensor 60F deflects back to its “zero” position. As explained further below, controller 202 can determine appropriate adjustments to the vertical positions of chord sensors 60F and 60R based on the geometry of machine 10 to result in any desired changes in the longitudinal tilt 84 of machine frame 22.

[0088] For example, in addition to adjusting the tilt angle 84, it may be desirable to control a predetermined axis of rotation about which the machine frame rotates as the longitudinal tilt changes, such that the height of the upper surface 18 of the unhardened concrete slab 16 formed at and after the predetermined axis of rotation remains constant. This can be achieved by adjusting the front and rear lifting columns. Preferably, this control of the front and rear lifting columns allows for simultaneous adjustment of both. However, the front and rear lifting columns can also be adjusted sequentially or in alternating steps, provided that the adjustment of both is completed within a sufficiently short time interval so as not to produce significant discontinuities in the paved surface 18.

[0089] For example, in Figure 2 The illustrated embodiment includes a swing beam 42 that follows the sliding mold 24, the rear edge of the bottom of the swing beam 42 defining the height of the upper surface 18 of the slab 16. Therefore, when adjusted as... Figure 2 When the machine shown is tilted longitudinally at an angle of 84, the predetermined axis of rotation will be perpendicular to the rear edge of the bottom of the swing beam 42. Figure 2 The attached drawing shows the axis 88 extending from the plane. On the other hand, if the swing beam 42 is omitted from the paver 10, the rear edge of the slipform 24 will determine the height of the upper surface 18 of the slab 16. Therefore, in this case, when adjusting the longitudinal tilt 84, the predetermined axis of rotation will be perpendicular to the rear edge of the bottom of the slipform 24. Figure 2 The attached diagram extends along the axis 90.

[0090] As noted, the controller 202 can be configured, through appropriate programming, to determine the proper adjustment of the vertical positions of the front chord sensor 60F and the rear chord sensor 60R, thereby achieving a desired change in the longitudinal tilt angle 84, and inducing this change by rotation of the machine frame about a predetermined axis of rotation (such as axis 88 at the rear edge of the swing beam 42 or axis 90 at the rear edge of the sliding mold 24). This can be accomplished by configuring the controller 202 to adjust the ratio of the vertical adjustment of the front chord sensor 60F to the vertical adjustment of the rear chord sensor 60R as a function of the ratio of the horizontal distance of the front chord sensor 60F from the axis of rotation to the horizontal distance of the rear chord sensor 60F from the axis of rotation, thereby adjusting the longitudinal tilt of the machine frame.

[0091] For example, such as Figure 2As shown, the horizontal distance of the front chord sensor 60F from the rotation axis 88 is shown as LF, and the horizontal distance of the rear chord sensor 60F from the rotation axis 88 is shown as LR. For the relatively small tilt angles involved in the operation of the paver 10, the ratio of the vertical adjustment of the front sensor 60F to the vertical adjustment of the rear sensor 60R is essentially the same as the ratio LF / LR. Furthermore, the correlation ratio of the vertical adjustments of the front riser actuator 46F and the rear riser actuator 46R can similarly be determined by knowing the corresponding horizontal distances of the risers from the rotation axis. Therefore, by knowing the distances LF and LR, the controller can determine the desired change in the vertical position of the chord sensors 60F and 60R to achieve the desired change in the extension / retraction of the riser actuators 46F and 46R, thereby achieving the desired change in the longitudinal tilt 84 about the predetermined rotation axis 88. It should be noted that the changes in the vertical position of the chord sensors 60F and 60R can be in opposite directions, i.e., one upward and one downward, to achieve the desired rotation about the predetermined rotation axis 88.

[0092] A method for controlling the slipform paver 10, the slipform paver 10 including a front chord sensor 60F and a rear chord sensor 60R, as well as a front sensor actuator 62F and a rear sensor actuator 62R, the method may include the following steps:

[0093] (a) Using controller 202 to determine the desired change in the longitudinal tilt angle 84 of machine frame 22; and

[0094] (b) Send command signals from controller 202 to one or more sensor actuators 62F and 62R to adjust the vertical position of one or more string sensors 60F and 60R to achieve a desired change in longitudinal tilt.

[0095] The method may also include using controller 202 to receive position signals from front sensor actuator position sensor 64F and rear sensor actuator position sensor 64R, and generating command signals based at least in part on the position signals.

[0096] Step (b) may also include adjusting the longitudinal tilt 84 of the machine frame 22 by adjusting both the front lifting column 32F and the rear lifting column 32R, so that the machine frame 22 tilts about a predetermined axis of rotation (e.g., 88 or 90) so that the height of the upper surface 18 of the unhardened concrete slab 16 formed behind the axis of rotation remains unchanged.

[0097] Step (b) may also include adjusting the longitudinal tilt 84 of the machine frame 22 by simultaneously adjusting both the front lifting column 32F and the rear lifting column 32R.

[0098] Step (b) may further include: adjusting the ratio of the vertical adjustment of the front chord sensor to the vertical adjustment of the rear chord sensor to a function of the ratio of the horizontal distance LF of the front chord sensor 60F from the axis of rotation to the horizontal distance LR of the rear chord sensor 60R from the axis of rotation, thereby adjusting the longitudinal tilt 84 of the machine frame 22.

[0099] If the machine also includes at least one machine operating parameter sensor, such as the expansion sensor 220 discussed below, which is configured to sense at least one machine operating parameter and generate a sensor signal corresponding to at least one machine operating parameter, the method may further include using a controller to receive the sensor signal and generate a command signal based at least in part on the sensor signal from the at least one machine operating parameter sensor.

[0100] Expansion sensor

[0101] One phenomenon that must be addressed when operating the slipform paver 10 is the expansion of the concrete layer 16 in the region 16C behind the slipform paver mold 24. In embodiments of the machine 10, an expansion sensor 220 may be provided to detect the expansion of the unhardened concrete slab 16 formed behind the slipform mold 24 relative to the machine frame 22. The expansion sensor 220 generates an expansion signal, which is received by the controller 202. In some embodiments, the controller 202 may generate a command signal to one or more of the aforementioned actuators in response to the expansion signal to adjust at least one operating parameter of the paver 10. As further described below, the operating parameters may include a longitudinal tilt angle 84, the travel speed or forward speed of the paver 10 during paving, the vibration speed or frequency of the vibrator 56, and the height of the concrete gate 50.

[0102] In such Figure 2 In one embodiment seen, the expansion sensor 220 may be a non-contact distance sensor, such as an ultrasonic sensor or a laser sensor, which is supported from the slipform paver mold 24 or machine frame 22 and points to the surface 18 of the concrete slab 16 behind the slipform paver mold 24 to measure the vertical distance from a fixed position on the mold 24 or machine frame 22 to the surface 18.

[0103] Although only a single expansion sensor 220 is shown in the schematic diagram, it should be understood that multiple expansion sensors 220 can be placed across the width of the slipform paver 10. Figure 7AAs schematically illustrated, preferably, the expansion sensor 220 includes at least two spaced-apart height sensors 220A, 220B, and 220C spanning the width 224 of the slab 16 and / or machine frame 22. The expansion of concrete across the width of the concrete slab may be uneven, and therefore it may be desirable to allow for variable adjustment of operating parameters across the width of the concrete slab. Furthermore, it should be understood that in rare cases, the “expansion” of the concrete slab may even be negative, i.e., the concrete slab may shrink, which can also be accommodated by the system described above.

[0104] In such Figure 7B In another embodiment schematically indicated in the plan view, the expansion sensor 220 may include at least one scanning sensor 220S, such as a laser scanner, configured to scan the height of the unhardened concrete slab 16 formed behind the slipform mold 24 across a continuous portion 222 of the width 224 of the machine frame 22. Various sensor technologies can be used for the expansion sensor 220 and other sensors disclosed herein. The improvements disclosed herein do not rely on any particular sensor technology used to measure the identified distance. As previously mentioned, ultrasonic sensors can be used for point measurements. LED or laser sensors can also be used for point measurements. Regarding scanning sensors, laser scanners can be used. Other scanning sensors may include PMD cameras or LiDAR (Light Detection and Ranging) systems.

[0105] It will be understood that the expansion of the concrete slab 16 in region 16C can vary over relatively short time intervals, and therefore the height of the upper surface 18 in region 16C can preferably be determined as an average height over the time interval, so that it does not adjust in response to short-term events. For example, the average height can be determined over a time interval ranging from about 0 seconds to about 240 seconds, optionally from about 10 seconds to 180 seconds, and even more optionally from about 10 seconds to 60 seconds.

[0106] It will also be understood that the expansion of concrete slabs can be attributed to many different factors, some of which are relatively short-term and some of which are relatively long-term.

[0107] Among the relatively short-term factors, for example, there might be a load of concrete material dumped by a truck at location 16A that is substantially different from the material previously supplied. Material supply is typically provided by a fleet of concrete mixer trucks carrying material from a common source, but sometimes, due to uncontrollable events, errors, or delivery delays, loads of concrete material that are too wet or too dry may be dumped. Other short-term events may include variations in the forward speed of paver 10.

[0108] In the category of relatively long-term factors, a change in the tilt angle 84 will correspondingly alter the angle of the bottom of the slipform mold 24. If the angle 84 increases, causing the front edge of the mold 24 to rise relative to the rear edge, this increases the amount of concrete “flowing” beneath the mold as it advances, thereby increasing the expansion at position 16C.

[0109] Similarly, if the gate 50 is raised, this will increase the height of the concrete in area 16B directly in front of the mold 24, which will also cause an increase in expansion in area 16C behind the mold.

[0110] The expansion changes in region 16C tend to occur rather slowly. Controller 202 can be configured to identify certain possible patterns of expansion change and to predict the height of the unhardened concrete slab formed behind slipform mold 24 in region 16C, based at least in part on the rate of change of the expansion sensor signal from expansion sensor 220.

[0111] It should be understood that in typical paving operations, the ultimate goal is operational consistency, enabling the establishment and maintenance of favorable paving results throughout the paving operation. Therefore, the “desired” expansion during a particular operation can be maintained at a level consistent with the expansion present when the paver was first assembled and set up for that operation.

[0112] The controller 202 can also be configured to generate command signals to automatically adjust various operating parameters in response to expansion measured or predicted at position 16C, thereby correcting for undesirable expansion. The controller 202 can send command signals to the forward drive of the paver 10 to increase or decrease the forward speed, thereby decreasing or increasing the expansion at region 16C, respectively. The controller 202 can send command signals to the vibrator 56 to increase or decrease the vibrator speed, thereby increasing or decreasing the expansion at region 16C, respectively. The controller 202 can send command signals to the gate actuator 52 to raise or lower the gate 50, thereby increasing or decreasing the expansion at region 16C, respectively.

[0113] As described above, the controller 202 can send command signals to the front chord sensor actuator 62F and the rear chord sensor actuator 62R to increase or decrease the longitudinal tilt angle 84, thereby increasing or decreasing the expansion at region 16C, respectively.

[0114] Because it may be difficult to determine the primary cause of the observed expansion change, controller 202 can be configured to adjust various effective machine operating parameters in a sequence that is easy to implement or quick to implement. For example, controller 202 can be configured to adjust various machine parameters in response to an observed increase in expansion by adjusting them in a sequence to a point where the selected parameters are not yet at their maximum or minimum values:

[0115] 1. The vibration frequency or velocity of vibrator 56;

[0116] 2. The forward speed of paver 10;

[0117] 3. The height of the concrete supply gate 50; and

[0118] 4. The longitudinal tilt of machine 10 is 84 degrees.

[0119] The method of operating the above-described slipform paver 10, which includes the expansion sensor 220, may include the following steps:

[0120] (a) The expansion of the unhardened concrete slab 16 formed behind the slipform mold 24 is monitored using at least one expansion sensor 220, and at least one sensor signal corresponding to the expansion is generated.

[0121] (b) Based at least in part on a sensor signal, the controller 202 determines the current or predicted deviation of the expansion from the desired expansion and generates a corresponding command signal; and

[0122] (c) In response to the command signal, automatically adjust at least one operating parameter of the paver in the direction that counteracts the deviation.

[0123] Step (a) may also include monitoring the expansion of the unhardened concrete slab formed behind the slipform mold 24 as the average expansion over a time interval.

[0124] Step (a) may also include monitoring the expansion of the unhardened concrete slab 16 formed behind the slipform mold 24 at at least two, preferably at least three, locations across the width 224 of the paver 10.

[0125] The at least one operating parameter adjusted in step (c) may include the travel speed of the paver 10, the vibrator speed or frequency of the vibrator 56 located in front of the slipform 24, the height of the concrete supply gate 50 in front of the slipform 24, or the longitudinal tilt 84 of the machine 10.

[0126] Step (c) may also include lowering the front end of the machine frame 22 relative to the rear end to reduce the expansion of the unhardened concrete slab 16 formed behind the slipform mold 24 in region 16C, and raising the front end of the machine frame 22 relative to the rear end to increase the expansion of the unhardened concrete slab formed behind the slipform mold 24.

[0127] When the paver 10 includes the swing beam 42, step (c) may further include adjusting the longitudinal tilt 84 of the machine frame 22 by adjusting both the front lift column 32F and the rear lift column 32R, thereby tilting the machine frame 22 about the axis of rotation 88 adjacent to the rear edge of the swing beam 42, so that the height of the upper surface 18 of the unhardened concrete slab 16 formed behind the swing beam 42 remains unchanged. Step (c) may further include adjusting the longitudinal tilt 84 of the machine frame 22 by simultaneously adjusting both the front lift column 32F and the rear lift column 32R.

[0128] When the paver 10 does not include the swing beam 42, step (c) may further include adjusting the longitudinal tilt 84 of the machine frame 22 by adjusting both the front lifting column 32F and the rear lifting column 32R, thereby tilting the machine frame 22 about the axis of rotation 90 of the adjacent slipform mold 24, so that the height of the upper surface 18 of the unhardened concrete slab 16 formed behind the slipform mold 24 remains unchanged. Step (c) may further include adjusting the longitudinal tilt of the machine frame by simultaneously adjusting both the front and rear lifting columns.

[0129] The method may include repeating steps (a) and (b) after step (c) and after a lag time interval sufficient to allow the adjustment in step (c) to cause expansion changes in the unhardened concrete slab 16 formed behind the slipform mold 24, and further adjusting the longitudinal tilt 84 of the machine frame 22 in one direction to counteract any further determined current or predicted deviations in the expansion of the unhardened concrete slab 16 formed behind the slipform mold 24. The lag time interval may be based on the time required for the paver 10 to travel a specified distance in the paving direction 12. For example, the lag time may be sufficient to allow the paver 10 to travel a distance in the range of 0 to 20 m, optionally about 0 to 10 m, and further optionally about 1 to 10 m.

[0130] Material roll control

[0131] Another phenomenon encountered in slipform paving when using a swing beam such as swing beam 42 is the formation of a "coil" 16D of unhardened concrete material immediately in front of the swing beam 42. The coil 16D tends to curl forward away from the swing beam and is typically in the form of a slightly irregular, roughly cylindrical coil of unhardened concrete material. The material within the coil is in motion and, depending on various operating parameters of the paver 10, the coil grows and contracts in its cross-sectional dimensions, particularly in its height. Maintaining the coil 16D at an appropriate size is important for the proper functioning of the swing beam 42.

[0132] One machine parameter affecting the dimensions of roll 16D is the longitudinal inclination 84 of the machine frame 22. It should be noted that when using the swing beam 42, any change in inclination is preferably made by rotating the machine frame about the axis of rotation 88 at the rear edge of the swing beam 42, so that the final height of the upper surface 18 of the slab 16 remains unchanged. If the longitudinal inclination 84 is increased, this will allow more concrete material to pass under the slipform 24 and accumulate before the swing beam 42. Conversely, decreasing the longitudinal inclination 84 will reduce the amount of concrete material passing under the advancing slipform 24, thereby reducing the dimensions of roll 16D.

[0133] The dimensions of coil 16D can be monitored using a coil size sensor 230, which is configured to detect the dimensions of coil 16D in front of the swing beam 42. The coil size sensor 230 can be configured to detect parameters corresponding to the cross-sectional dimensions of coil 16D. It should be understood that the shape of coil 16D is irregular, and such dimensions are irregular and may vary continuously when discussing cross-sectional dimensions such as height or width below. The parameters “corresponding” to such dimensions do not need to be precise quantitative measurements of the actual dimensions, but only approximate representations of these dimensions to some extent.

[0134] exist Figure 2 In one embodiment schematically shown, the roll size sensor 230 is a roll height sensor 230H, and the parameter is the vertical distance 232 from the sensor 230H to the top of the roll 16D. Since the vertical distance from the sensor 230H to the bottom of the swing beam 42 is known, subtracting the distance 232 gives the height 236 of the roll 16D.

[0135] exist Figure 2 In the second embodiment also schematically shown, the roll size sensor is a roll width sensor 230W, and the parameter is the horizontal distance 234 from the sensor 230W to the side of the roll 16D. Since the horizontal distance from the sensor 230W to the front of the swing beam 42 is known, subtracting the distance 234 gives the width 238 of the roll 16D.

[0136] In such Figure 2 In one embodiment shown, both roll size sensors 230H and 230W can be non-contact distance sensors, such as ultrasonic sensors or laser sensors. Although only a single roll size sensor 230H or 230W is shown in the schematic diagram, it should be understood that multiple roll size sensors 220 can be placed across the width 224 of the slipform paver 10, similar to those for... Figure 7AThe method of description. Preferably, each roll size sensor 230H or 230W includes at least two, and more preferably at least three, discrete sensors placed across the width 224 of the machine frame 22. The size and shape of the roll 16D across the width of the concrete slab may not be uniform, and therefore it may be desirable to allow for variable adjustment of operating parameters across the width of the concrete slab.

[0137] In similar Figure 7B In another embodiment for the expansion sensor, the roll size sensor 230H or 230W may include at least one scanning sensor, such as a laser scanner, configured to scan the height or width of the roll 16D across a continuous portion 222 of the width 224 of the machine frame 22. As described above, any suitable sensor technology can be used for the roll control sensor 230H or 230W.

[0138] The controller 202 can be configured to receive sensor signals from roll size sensors 230H and / or 230W, and generate command signals to one or both of the sensor actuators 60F and 60R to adjust the longitudinal tilt 84 of the machine 10.

[0139] If the paver 10 is configured to use a slope control system different from the chord-type slope control system, such as satellite-based systems 300, 302, 304 or total station-type systems 310, 302, 304, then the controller 202 can send command signals directly to the hydraulic actuators 46F and 46R of the lifting columns 32F and 32R without the sensor actuator 62.

[0140] It will be understood that the external shape of the roll 16D may be somewhat irregular, therefore the controller 202 may preferably be configured to determine the height or width of the roll 16D as an average height or width over a time interval, such that it does not adjust in response to brief events. For example, the average height or width may be determined over a time interval ranging from about 0 to 20 minutes, optionally from about 0 to 10 minutes, and further optionally from about 1 to 10 minutes.

[0141] The controller 202 can also be configured to predict the size of the roll 16D based at least in part on the rate of change of sensor signals from the roll size sensors 230H and / or 230W.

[0142] The controller 202 can also be configured to lower the front end of the machine frame 22 to reduce the size of the roll 16D, and raise the front end of the machine frame 22 relative to the rear end to increase the size of the roll 16D.

[0143] The controller 202 can also be configured to adjust the longitudinal tilt 84 of the machine frame 22 by simultaneously adjusting both the front lifting column 32F and the rear lifting column 32R, so that the machine frame 22 tilts about the axis of rotation 88 of the adjacent swing beam 42, so that the height of the upper surface 18 of the unhardened concrete slab 16 formed behind the swing beam 42 remains unchanged.

[0144] For any given paver 10 and a set of operating parameters for the machine and concrete material, the desired size of the roll 16D is generally known, sometimes as a size range. The controller can be configured to: (a) monitor sensor signals from roll size sensors 230H and / or 230W; (b) determine, at least in part, the current or predicted deviation of the roll 16D size from the desired size based on the sensor signals; and (c) generate a command signal to adjust the longitudinal tilt of the machine frame in the direction that counteracts the deviation.

[0145] Following step (c), controller 202 may repeat steps (a) and (b) after a hysteresis time interval sufficient to allow the adjustments of step (c) to result in a change in the dimensions of coil 16D. Controller 202 may then further adjust the longitudinal tilt of machine frame 22 in one direction to counteract any further determined current or predicted deviations in the dimensions of coil 16D. The hysteresis time interval may be based on the time required for paver 10 to travel a specified distance in the paving direction.

[0146] Besides the longitudinal tilt angle 84, other machine operating parameters may affect the dimensions of the roll 16D. One such operating parameter is the height of the pile of concrete material in area 16B in front of the slipform die 24. This height can be detected by a concrete supply height sensor 240. Similar to the expansion sensor 220 and the roll height sensor 230H, the concrete supply height sensor 240 can be an ultrasonic sensor, preferably at least two and more preferably at least three such sensors spanning the width of the slab 16, or a scanning sensor, such as a laser scanner.

[0147] Another such operating parameter is the expansion of the slab in region 16C detected by the expansion sensor 220.

[0148] The controller 202 can monitor signals from the concrete supply height sensor 240 and / or the expansion sensor 220 and generate its command signals to adjust the longitudinal inclination 84, at least in part, based on the predicted effects of these signals and these parameters on the roll size.

[0149] Measuring paving thickness

[0150] The paver 10 can also be configured to allow monitoring and / or control of the thickness of the paving slab 16. For this purpose, the paver 10 may include a front height sensor 102 and a rear height sensor 104.

[0151] The front height sensor 102 can be configured to detect the distance 108 of the ground 14 in front of the concrete slab 16 relative to the machine frame 22 and generate a front height signal. The front height sensor 102 can be positioned in front of the front lifting column 32F, but it can be located at any suitable location above the ground 14 before the intended placement of the unformed pile of concrete material 16A.

[0152] The rear height sensor 104 can be configured to detect the distance 110 between the upper surface 18 of the formed concrete slab 16 and the machine frame 22, and generate a rear height signal. The rear height sensor 104 can be positioned behind the rear lifting column 32R, but it can be located at any suitable location behind the swing beam 42.

[0153] The controller 202 can be configured to receive front height signals and rear height signals from the front height sensor 102 and the rear height sensor 104, and determine the thickness 106 of the concrete slab 16 based at least in part on the front height signals and the rear height signals.

[0154] The front height sensor 102 and / or the rear height sensor 104 can both be ultrasonic sensors. Preferably, each of such a front height sensor and / or rear height sensor includes at least two, more preferably at least three discrete ultrasonic sensors, spaced apart across the width 224 of the blank 16, similar to... Figure 7A The expansion sensor shown is used in this manner.

[0155] In another embodiment, the front height sensor 102 and / or the rear height sensor 104 may each include at least one scanning sensor, such as a scanning laser sensor, configured to scan the ground 14 and / or the slab surface 18 across a continuous portion 222 of the width 224 of the slab, similar to... Figure 7B As shown for the expansion sensor. At least one scanning sensor may include two or more scanning sensors that scan different or overlapping continuous portions of the width 224 of the slab.

[0156] To determine the thickness 106 of the slab 16 at any given location on the ground 14, the controller 202 can be configured to compare a forward height signal corresponding to the given location on the ground 14 with a subsequent rear height signal corresponding to substantially the same given location on the ground. This can be implemented in various ways.

[0157] In one aspect, the controller 202 can be configured to correlate the front height signal and the rear height signal based on the fact that the horizontal distance traveled by the machine 10 is substantially equal to the horizontal distance 108 between the front height sensor 102 and the rear height sensor 104.

[0158] In another aspect, controller 202 can be configured to store data corresponding to the altitude signal in computer memory 206 and associate that data with the position of machine 10 on ground 14. If machine 10 uses, for example... Figure 3 and Figure 4 In one of the schematically illustrated chord slope control systems, the aforementioned correlation can be performed by correlating each height signal with the distance the machine 10 has traveled along chord 58 from its starting position. This distance sensing can be accomplished using a pickup or sensor in the track drive to determine the distance the paver has traveled along the track.

[0159] If machine 10 is using a three-dimensional slope control system based on its position in a reference frame outside the machine 10, such as a satellite-based slope control system 300, 302, 304 or a total station-type slope control system 310, 302, 304, then controller 202 can be configured to associate altitude data with the position of machine 10 in a reference frame outside the machine 10. For example, controller 202 can be configured to associate altitude data with the position of machine 10 based on GPS or GNSS satellite system coordinates.

[0160] For any of the aforementioned techniques, when this disclosure refers to "substantially" identical locations or distances "substantially" equal to the horizontal spacing between sensors, it should be understood that such locations or distances do not need to be exactly the same. On the one hand, depending on the specific type of sensor used, the location seen by the sensor on the ground or the upper surface of the slab is not a mathematical point, but rather a region. It should also be understood that any sensor such as 102 or 104 will have a focal point at the center of that region, or for such... Figure 7B The scanning sensors shown will have a focal line spanning the width of the slab. Furthermore, given the expected approximate uniformity of the ground and the upper surface 18 of the slab 16, some variation in the focal points of the front sensor 102 and the rear sensor 104 can be allowed without adversely affecting the comparison used to determine the slab thickness 106. Therefore, as used in this disclosure, the phrase "substantially the same location" should be understood to include the focal point or focal line of the rear sensor 104, which is within 30 cm of the focal point or focal line of the front sensor 102. Similarly, "substantially" equal to the distance of the horizontal interval between sensors 102 and 104 will be understood to include any distance within positive or negative 30 cm of the horizontal interval between the focal points of the front and rear sensors.

[0161] The controller 202 can also be configured to determine the total volume of the concrete slab 16 formed during the paving operation, and optionally generate a report of that total volume. This volume can be determined by integrating the thickness 106 of the concrete slab over a region of the slab, such as as defined by its length and width 224 in the paving direction 12. Such a report can be used, for example, for billing purposes and to demonstrate compliance with contract specifications. The report can also represent other performance parameters (such as minimum thickness, maximum thickness), or otherwise record the paving thickness 106 as a function of geographical location on the slab 16.

[0162] Additionally, controller 202 can be configured to control the paving thickness 106. Controller 202 can be configured to send command signals to lifting columns 32F and 32R, or to the front sensor actuator 62F and the rear sensor actuator 62R, to automatically adjust the height of the machine frame relative to the ground 14, and thus control the thickness of the concrete slab 16, based at least in part on a comparison of the determined thickness 106 of the slab 16 with the desired thickness of the slab at a given geographic location. In either case, the command signal causes the lifting columns to adjust the height of the machine frame relative to the ground to control the thickness of the concrete slab.

[0163] This method can be described as including the following steps:

[0164] The front height sensor 102 in front of the concrete slab 16 detects the distance 108 from the ground 14 relative to the machine frame 22 and generates a front height signal.

[0165] The distance 110 from the upper surface 18 of the concrete slab 16 relative to the machine frame 22 is detected using a rear height sensor 104, and a rear height signal is generated; and

[0166] The thickness 106 of the concrete slab 16 is determined using the controller 202 based at least in part on the front height signal and the rear height signal.

[0167] The determination step may include comparing a forward altitude signal corresponding to a given location on the ground 14 with a subsequent rear altitude signal corresponding to a substantially identical given location on the ground. As described above, this can be accomplished by associating the forward and rear altitude signals based on a horizontal distance between the machine 10 and the horizontal spacing 108 between the forward and rear altitude signals, which is substantially equal to the distance traveled by the machine 10.

[0168] The method may also include storing data corresponding to the altitude signal in computer memory 206 and associating the data with the position of machine 10 on the ground 14.

[0169] The method may also include the step of automatically generating a report using the controller 202, which represents the total volume of the concrete slab 16 formed during the paving operation.

[0170] The method may also include the following steps:

[0171] The controller 202 compares the determined thickness 106 of the concrete slab 16 with the desired thickness of the concrete slab; and

[0172] Command signals are sent from controller 202 to lifting columns 32F and 32R, or to front sensor actuator 62F and rear sensor actuator 62R, to automatically adjust the height of machine frame 22 relative to ground 14, thereby controlling the thickness 106 of concrete slab 16 at least in part based on this comparison.

[0173] Therefore, it can be seen that the apparatus and methods of this disclosure readily achieve the mentioned objects and advantages, as well as those inherent therein. While certain preferred embodiments of this disclosure have been shown and described for the purposes of this invention, many changes can be made by those skilled in the art to the arrangement and construction of components and steps, and these changes are included within the scope and spirit of this disclosure as defined by the appended claims. Each feature or embodiment of the disclosure may be combined with features or embodiments of any other disclosure.

Claims

1. A slipform paver characterized by, include: Machine frame; Multiple ground-mounted wheels or tracks; Height-adjustable front and rear lifting columns support the machine frame from the ground engagement wheels or tracks, and the lifting columns are adjustable to adjust the longitudinal tilt of the machine frame in the paving direction. Slipform molds, supported from the machine frame, are used to mold piles of concrete into shaped, unhardened concrete slabs as the paver moves forward in the paving direction. A swing beam, supported from the machine frame behind the slipform mold, is used to engage on the upper surface of the formed, unhardened concrete slab and swing laterally in the paving direction to smooth the upper surface. as well as A roll size sensor is configured to detect the size of an unhardened roll of concrete produced in front of the swing beam.

2. The slipform paver according to claim 1, characterized in that, The roll size sensor is configured to detect parameters corresponding to the cross-sectional dimensions of the roll.

3. The slipform paver according to claim 2, characterized in that, The roll size sensor is a roll height sensor, and the parameter is the vertical distance from the machine frame to the top of the roll; or the roll size sensor is a roll width sensor, and the parameter is the horizontal distance from the machine frame to the side of the roll.

4. The slipform paver according to claim 3, characterized in that, The roll size sensor includes at least two separate roll height sensors spaced apart across the width of the machine frame, or the roll size sensor includes at least two separate roll width sensors spaced apart across the width of the machine frame.

5. The slipform paver according to claim 2, characterized in that, The roll size sensor includes a scanning laser sensor configured to scan the exterior of the roll across a continuous portion of the width of the machine frame.

6. The slipform paver of claim 1, wherein, Also includes: The controller is configured to receive sensor signals from the roll size sensor and generate command signals to the actuator to adjust the longitudinal tilt of the machine.

7. The slipform paver according to claim 6, characterized in that, The controller is also configured to determine the size of the roll as an average size over a time interval.

8. The slipform paver according to claim 6, characterized in that, The controller is also configured to predict the size of the roll at least in part based on the rate of change of the sensor signal.

9. The slipform paver according to claim 6, characterized in that, The controller is also configured to lower the front end of the machine frame relative to the rear end to reduce the size of the roll, and is also configured to raise the front end of the machine frame relative to the rear end to increase the size of the roll.

10. The slipform paver according to claim 6, characterized in that, The controller is also configured to adjust the longitudinal tilt of the machine frame by adjusting the front and rear lifting columns, thereby tilting the machine frame about the axis of rotation of the rear edge of the adjacent swing beam, so that the height of the upper surface of the formed, unhardened concrete slab behind the swing beam remains unchanged.

11. The slipform paver according to claim 10, characterized in that, The controller is also configured to adjust the longitudinal tilt of the machine frame by simultaneously adjusting the front and rear lifting columns.

12. The slipform paver of claim 1, wherein, Also includes: The controller is configured to: (a) Monitor sensor signals from the size sensor; (b) Determine, at least in part, the deviation between the current or predicted dimensions of the unhardened concrete roll and the expected dimensions, based on sensor signals; as well as (c) Generate a command signal to adjust the longitudinal tilt of the machine frame in the direction that counteracts the deviation.

13. The slipform paver of claim 12, wherein, The controller is also configured to: After step (c), after a hysteresis time sufficient to allow the adjustment in step (c) to cause a change in the size of the roll, steps (a) and (b) are repeated; and Further adjust the longitudinal tilt of the machine frame in one direction to counteract any further determined current or predicted deviations in the size of the roll.

14. The slipform paver according to claim 13, characterized in that, The lag time interval is based on the time required for the paver to travel a specified distance in the paving direction.

15. The slipform paver according to claim 12, characterized in that, Also includes: A concrete supply height sensor and / or an expansion sensor are provided, wherein the concrete supply height sensor is arranged to detect the height of the pile of concrete in front of the slipform mold, and the expansion sensor is arranged to detect the height of the formed, unhardened concrete slab behind the slipform mold. The controller is also configured to generate command signals based at least in part on signals from the concrete supply height sensor and / or the expansion sensor.

16. The slipform paver of claim 1, wherein, Also includes: Front chord sensor; A front sensor actuator is arranged to adjust the vertical position of the front chord sensor relative to the machine frame. Rear chord sensor; A rear sensor actuator is arranged to adjust the vertical position of the rear chord sensor relative to the machine frame. as well as A controller is configured to receive a roll size sensor signal from the roll size sensor and send a command signal to the front sensor actuator and the rear sensor actuator to cause adjustment of the longitudinal tilt of the machine frame.

17. The slipform paver of claim 16, wherein, Also includes: A front sensor actuator position sensor, which is arranged to generate a position signal representing the position of the front chord sensor; as well as A rear sensor actuator position sensor is arranged to generate a position signal indicating the position of the rear chord sensor.

18. The slipform paver according to claim 17, characterized in that, The front sensor actuator and the rear sensor actuator are the front hydraulic smart cylinder and the rear hydraulic smart cylinder, respectively, and the position sensors of the front sensor actuator and the rear sensor actuator are integrated in the front hydraulic smart cylinder and the rear hydraulic smart cylinder, respectively.

19. The slipform paver according to claim 17, characterized in that, The front sensor actuator and the rear sensor actuator are front and rear rotating spindles powered by a rotary motor, and the position sensors of the front sensor actuator and the rear sensor actuator are rotary position sensors.

20. A method of controlling a slipform paver, characterized by, The machine includes: A machine frame having a front end and a back end; Multiple ground-mounted wheels or tracks; The height-adjustable front and rear lifting columns support the machine frame from the ground engagement wheels or tracks, and the lifting columns are adjustable to adjust the longitudinal tilt of the paver frame in the paving direction. A slipform mold, supported from the machine frame, for molding piles of concrete into shaped, unhardened concrete slabs as the paver moves forward in the paving direction; and A swing beam, supported from the machine frame behind the slipform mold, is used to engage the upper surface of the formed, unhardened concrete slab and swings transversely to the paving direction on the upper surface to smooth the upper surface. The method includes: (a) Using at least one sensor to monitor at least one parameter, the at least one parameter indicating the current or predicted size of an unhardened concrete roll generated in front of the swing beam, and generating at least one sensor signal representing the at least one parameter; (b) Based at least in part on a sensor signal, the controller determines the current or predicted deviation of the dimensions of the unhardened concrete roll from the desired dimensions and generates a corresponding command signal; and (c) In response to the command signal, automatically adjust the longitudinal tilt of the machine frame in the direction that counteracts the deviation.

21. The method according to claim 20, characterized in that, The at least one parameter corresponds to the cross-sectional dimension of the roll.

22. The method according to claim 21, characterized in that, The cross-sectional dimensions include the height of the roll or the width of the roll.

23. The method according to claim 20, characterized in that, Step (a) further includes monitoring the size of the roll as an average size over a time interval.

24. The method according to claim 20, characterized in that, Step (a) further includes monitoring the size of the roll at at least two locations across the width of the paver.

25. The method according to claim 20, characterized in that, Step (c) further includes lowering the front end of the machine frame relative to the rear end to reduce the size of the roll, and raising the front end of the machine frame relative to the rear end to increase the size of the roll.

26. The method according to claim 20, characterized in that, Step (c) further includes adjusting the longitudinal tilt of the machine frame by adjusting the front and rear lifting columns, thereby tilting the machine frame about the axis of rotation of the rear edge of the adjacent swing beam, so that the height of the upper surface of the formed, unhardened concrete slab behind the swing beam remains unchanged.

27. The method according to claim 20, characterized in that, Step (b) further includes determining the predicted size based at least in part on the rate of change of the at least one parameter.

28. The method of claim 20, further comprising: After step (c), after a hysteresis time sufficient to allow the adjustment in step (c) to cause a change in the size of the roll, steps (a) and (b) are repeated; and Further adjust the longitudinal tilt of the machine frame in one direction to counteract any further determined current or predicted deviations in the size of the roll.

29. The method according to claim 28, characterized in that, The lag time interval is based on the time required for the paver to travel a specified distance in the paving direction.

30. The method according to claim 20, characterized in that, The at least one parameter includes the height of the pile of concrete immediately in front of the slipform mold.

31. The method according to claim 20, characterized in that, The at least one parameter includes the height of the formed, unhardened concrete slab immediately following the slipform mold.

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