Slipform paver with expansion sensor and method of controlling the slipform paver

Abstract

A slipform paver (10) includes a machine frame, a plurality of ground engaging wheels or tracks (30, 30F, 30R), and height adjustable front and rear lift columns (32, 32F, 32R) supporting the machine frame from the ground engaging wheels or tracks, the lift columns adjustable to adjust a longitudinal inclination of the machine frame in a paving direction (12). A slipform mold (24) is supported by the machine frame for molding a mass of concrete (16A) into a shaped green concrete slab as the paver moves forward in the paving direction. An expansion sensor (220) is arranged to detect an expansion of the formed green concrete slab behind the slipform mold relative to the machine frame. A method of controlling a slipform paver is also disclosed.

Description

[0001] Cross-references

[0002] This application claims priority to U.S. Patent Application Serial No. 17 / 555,568, filed December 20, 2021, the details of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a slipform paver and a method for controlling the slipform paver. Background Technology

[0004] One phenomenon encountered during the slipform paving process of concrete structures is the "expansion" of the concrete material after it has been formed.

[0005] Improved equipment and methods are needed to detect and handle this expansion. Summary of the Invention

[0006] In a first embodiment, the slipform paver includes a machine frame, multiple 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 mold, supported by the machine frame, is used to mold a large quantity of concrete into a formed, unhardened concrete slab as the paver moves forward in the paving direction. Expansion sensors are arranged to detect the expansion of the formed, unhardened concrete slab behind the slipform mold relative to the machine frame.

[0007] The expansion sensor of the first embodiment may include at least two height sensors spaced apart across the width of the machine frame.

[0008] The expansion sensor of the first embodiment may include a scanning sensor configured to scan the height of the unhardened concrete slab formed behind the slipform mold across a continuous portion of the width of the machine frame.

[0009] Any of the above embodiments may further include a controller configured to receive sensor signals from the expansion sensor and generate command signals to the actuator to adjust at least one operating parameter of the paver.

[0010] The controller can be further configured to determine the height of the unhardened concrete slab formed behind the slipform mold as the average height over a time interval.

[0011] The controller can also be configured to predict the height of the unhardened concrete slab formed behind the slipform die, at least in part, based on the rate of change of the sensor signal.

[0012] In any of the above embodiments, at least one operating parameter may include the paver's travel speed, or the vibrator speed of the vibrator located in front of the slipform mold, or the height of the concrete supply gate in front of the slipform mold, or the longitudinal inclination of the machine frame.

[0013] In any of the above embodiments, the at least one operating parameter may include the longitudinal tilt of the machine frame, and the controller may be further configured to lower the front end of the machine frame relative to the rear end of the machine frame in order to reduce the expansion of the unhardened concrete slab formed behind the slipform mold.

[0014] In any of the above embodiments, at least one operating parameter may include the longitudinal tilt of the machine frame. The machine may also include a swing beam supported by the machine frame behind the slipform mold for engaging the upper surface of the formed, unhardened concrete slab and swinging transversely to the paving direction on the upper surface to smooth it. The controller may also be configured to adjust the longitudinal tilt of the machine frame by adjusting both the front and rear lifting columns, thereby tilting the machine frame about a rotation axis adjacent to the rear edge of the swing beam, such that the height of the upper surface of the formed, unhardened concrete slab behind the swing beam remains unchanged. Preferably, the controller is also configured to adjust the longitudinal tilt of the machine frame by simultaneously adjusting both the front and rear lifting columns.

[0015] In any of the above embodiments, at least one operating parameter may include the longitudinal tilt of the machine frame, and the controller may be further configured to adjust the longitudinal tilt of the machine frame by adjusting both the front lifting column and the rear lifting column, thereby tilting the machine frame about the axis of rotation of the rear edge of the adjacent slipform mold, such that the height of the upper surface of the unhardened concrete slab formed behind the slipform mold remains unchanged, and preferably, the controller is also configured to adjust the longitudinal tilt of the machine frame by simultaneously adjusting both the front lifting column and the rear lifting column.

[0016] In any of the above embodiments, the machine may include a front chord sensor, a front sensor actuator, a rear chord sensor, a rear sensor actuator, and a controller, the front sensor actuator being arranged to adjust the vertical position of the front chord sensor relative to the machine frame, the rear sensor actuator being arranged to adjust the vertical position of the rear chord sensor relative to the machine frame, and the controller being configured to receive sensor signals from the expansion sensor and send command signals to the front and rear sensor actuators to cause adjustment of the longitudinal tilt of the machine frame.

[0017] In 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.

[0018] In 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.

[0019] Alternatively, 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 are rotary sensors.

[0020] A method for controlling a slipform paver in any of the above embodiments may include the following steps: (a) monitoring the expansion of an unhardened concrete slab formed behind a slipform mold using at least one expansion sensor and generating at least one sensor signal corresponding to the expansion; (b) determining, at least in part, based on the at least one sensor signal, a current or predicted deviation of the expansion from a desired expansion using a controller and generating a corresponding command signal; and (c) in response to the command signal, automatically adjusting at least one operating parameter of the paver in a direction that counteracts the deviation.

[0021] In another embodiment, a method for controlling a slipform paver is provided. The 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 mold, supported by the machine frame, is used to mold a large quantity of concrete into shaped, unhardened concrete slabs as the paver moves forward in the paving direction. The method includes the following steps:

[0022] (a) Use at least one expansion sensor to monitor the expansion of the unhardened concrete slab formed behind the slipform mold and generate at least one sensor signal corresponding to the expansion.

[0023] (b) Based at least in part on the at least one sensor signal, the controller determines the current or predicted deviation of the expansion from the desired expansion and generates a corresponding command signal; and

[0024] (c) In response to the command signal, automatically adjust at least one operating parameter of the paver in the direction that counteracts the deviation.

[0025] Many objects, features and advantages of the present invention will be readily apparent to those skilled in the art upon reading the following description in conjunction with the accompanying drawings. Attached Figure Description

[0026] Figure 1 This is a side view of a slipform paver.

[0027] Figure 2 yes Figure 1 A schematic side view of a slipform paver, excluding the pin bar inserter.

[0028] Figure 3 This is a schematic diagram of a front sensor actuator in the form of a hydraulic intelligent cylinder, and those parts of the front chord sensor that engage with the chord.

[0029] Figure 4 This is a schematic diagram of a front sensor actuator in the form of a hydraulically powered rotating spindle, and the parts of a front chord sensor that engage with a chord.

[0030] Figure 5 This is a schematic diagram of an "intelligent" hydraulic cylinder.

[0031] Figure 6 This is a schematic diagram of the control system.

[0032] 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.

[0033] Figure 7B This is a schematic plan view of an expansion sensor, which takes the form of a centrally positioned laser scanner that performs continuous partial scanning across the width of the machine. Detailed Implementation

[0034] 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 others skilled in the art can appreciate and understand the principles and practice of this disclosure.

[0035] Now refer to the accompanying drawings, and especially to... Figure 1 The image shows a slipform paver, generally identified by the number 10. The machine 10 is configured to move across the ground surface 14 in the paving direction 12 to spread, level, and finish 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.

[0036] 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 the 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.

[0037] The main frame 22 is supported from the ground surface by a plurality of ground engagement units, such as 30. In the illustrated embodiment, the ground engagement unit 30 is a tracked ground engagement unit 30. Wheeled ground engagement units may also be used. Each of the ground engagement units 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 in 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 behind the slipform paver mold 24. Behind the pin bar inserter device 40, a swing beam 42 and / or a super-smoothing device 44 may be provided. If the pin bar inserter device 40 is not used, the swing beam 42 and / or the super-smoothing device 44 may be provided behind the slipform paver mold 24.

[0038] It should be understood that many slipform pavers do not include the pin bar inserter device 40. Figure 2 Another schematic diagram shows 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.

[0039] 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.

[0040] exist Figure 2 In the diagram, the lifting columns 32 are designated as 32F and 32R for the front and rear lifting columns, respectively. For the front and rear tracks, the tracks 30 are designated as 30F and 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 supporting the machine frame 22 from the two rear tracks 30R. Figure 1 and Figure 2Of the two, the slipform paver 10 is shown as a four-track 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-track 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, with a front riser and a rear riser on each side of the machine frame, supporting the machine frame from each of the two tracks.

[0041] Each rising column is configured 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 surface 14, and / or adjust the longitudinal and / or lateral tilt of the machine frame 22 relative to the ground surface 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.

[0042] Figure 1 The plow or spreader device 38 marked in the middle Figure 2 The diagram schematically shows a screw-driven distributor device 38.

[0043] Following the screw conveyor-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 extension of the gate 50's height. Alternatively, the gate actuator 52 may comprise a conventional hydraulic cylinder and may have a separately associated extension sensor.

[0044] Between the gate 50 and the slipform mold 24 are multiple vibrators 56, which are configured to be immersed in the concrete pile from which the slab 16 is formed, to help compact the concrete as the slipform mold 24 moves over the concrete pile.

[0045] During paving, a large quantity of concrete material 16A is dumped onto the ground surface 14 in front of the paver 10. This is typically accomplished using a series of dump trucks (not shown) that unload their wet concrete loads onto the ground surface, thus the supply of concrete material 16A occurs in a series of sequential material dumps. Alternatively, the concrete stockpile can be supplied by a side feeder, shuttle, spreader-distributor, or other known concrete supply device. Material 16A is paved laterally across the width of the paver 10 via a distributor 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. With the aid 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, some expansion may occur 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 2 As indicated by dimension 91, dimension 91 is an increase in the height of the slab above the bottom edge 90 of the mold 24. Immediately in front of the swing beam 42, a roll 16D of concrete material can be formed.

[0046] The oscillating beam 42, supported by the machine frame 22 behind the slipform mold 24, engages with and oscillates laterally to the paving direction 12 on the upper surface 18 of the formed, unhardened concrete slab 16 to smooth the upper surface 18. The upper surface 18 can be further smoothed by the action of a super-smoother 44, a large, automatic smoothing trowel that moves laterally across the width of the slab 16 while reciprocating forward and backward.

[0047] The direction of the paver 10 and the height of the formed concrete slab 16 can be controlled using a graded control system. One such slope control system is a chord-type slope control system, in which a chord 58 is constructed adjacent to the planned location of the concrete slab. Such a chord 58 can be constructed by a surveyor who places the chord at a known geographical location and height before the paving operation. The machine 10 can then use the chord 58 as a physical reference to both guide the path of the machine 10 and control the height of the machine 10 relative to the ground surface 14, in order to control the height of the upper surface 18 of the formed concrete slab 16.

[0048] Although this disclosure primarily describes the paver 10, it should be understood in the context of a chord-type slope control system 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) or total station-type slope control systems, or a hybrid combination of satellite-based slope control systems and total station-type slope control systems. Figure 2In the diagram, the satellite-based slope control system is schematically shown by satellite 300 and receivers 302 and 304 on machine 10. 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.

[0049] 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) of the machine, it should be understood that in some cases, a chord 58 may be constructed only on one side of machine 10, in which 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.

[0050] 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 the front sensor actuator 62F and the rear sensor actuator 62R, respectively. The 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.

[0051] The front sensor actuator position sensor 64F can be associated with the 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. The rear sensor actuator position sensor 64R can be associated with the 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.

[0052] 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, the actuators 62F and 62R may include conventional hydraulic cylinders and may have separate associated extension sensors.

[0053] 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.

[0054] Figure 3 A 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 will generate a sensor signal that can be used as a basis for adjusting the position of the associated lifting column actuator 46F 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 lever 66 rotates up or down, corresponding adjustments can be made in the lifting column position to maintain the desired height of machine frame 22, and thus maintain the desired height of the resulting concrete slab 16 relative to chord 58. If it is desired to adjust the height of machine frame 22 and concrete slab 16 relative to chord 58, this can be accomplished by adjusting the vertical position of sensor 60F relative to machine frame 22 using front sensor actuator 62F. Because 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 front chord sensor 60F.

[0055] Figure 4 It is similar to Figure 3 The diagram shows a front sensor actuator 62F as the main rotating shaft. The position sensor 64F of the front sensor actuator is shown as a rotation counter or angle sensor, which counts the rotation of the main shaft corresponding 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 may be a hydraulic or electric motor 94. The spindle 92 is supported by a spindle housing 96, which is supported by a machine frame 22. A nut 98 is threadedly received around the spindle 92 and moves vertically relative to the machine frame 22 when guided by a guide 100. A front chord sensor 60F is mounted on the nut 98. As the spindle 92 rotates via the motor 94, the nut 98 and the attached sensor 60F move vertically upwards or downwards 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.

[0056] As will be understood by those skilled in the art, the string sensors 60F and 60R can be hydraulic sensors, such that movement of the rod 66 causes a hydraulic valve to move and directs 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, which are used by the controller to generate command signals to various electromechanical actuators.

[0057] Hydraulic "intelligent" cylinder

[0058] As previously mentioned, many of the actuators disclosed herein can be “smart” hydraulic cylinders with integrated extended sensors associated with them.

[0059] 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 actuators described herein when those 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] control system

[0064] 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. Signals transmitted from the various sensors to controller 202 are... Figure 6The diagram is schematically indicated by the lines connecting the sensor to the controller, with arrows indicating the signal flow from the sensor to the controller 202.

[0065] 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.

[0066] 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 of controller 202 to various actuators, with arrows indicating the flow of command signals from controller 202 to the corresponding actuators. It should be understood that, in order to control a hydraulic cylinder-type actuator, controller 202 sends an electrical signal to an electro-mechanical control valve (not shown) that controls the flow of hydraulic fluid to and from the hydraulic cylinder.

[0067] exist Figure 6 For ease of explanation, only the actuator for the left-hand side of machine 10 is shown in the illustration. It should be understood that the actuator for the right-hand side of machine 10 can be the same as the actuator for 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.

[0068] It should be understood that when adjusting the longitudinal tilt angle 84, both the left front sensor actuator and the right front sensor actuator will typically be adjusted in the same manner, and both 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 cross slope 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.

[0069] Controller 202 includes, or may be associated with, processor 204, computer-readable medium 206, database 208, and input / output module or control panel 210 with display 212. Input / output devices 214, such as keyboards, joysticks, or other user interfaces, are provided to allow a human 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, with the functions distributed among the multiple controllers.

[0070] The various operations, steps, or algorithms described in conjunction with controller 202 can be directly embodied in hardware, computer program product 216 (such as software modules executed by processor 204), or a combination of both. Computer program product 216 may 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 may be coupled to processor 204, allowing the processor to read information from and write information to the memory / storage medium. Alternatively, the medium may be integrated into the processor. The processor and medium may reside in an application-specific integrated circuit (ASIC). The ASIC may reside in the user terminal. Alternatively, the processor and medium may reside as discrete components in the user terminal.

[0071] As used herein, the term "processor" may refer at least to a processing device and / or logic for 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 may 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.

[0072] 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 the various functionalities disclosed herein are inherently distributed between 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, a server device, a desktop computer, a laptop computer, a 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.

[0073] Specifically, the controller 202 can be programmed to receive extension signals from each of the extension sensors of the various hydraulic smart cylinders and to send control signals to control the extension of those hydraulic smart cylinders, at least in part, in response to the corresponding extension signals.

[0074] Longitudinal tilt controlled by intelligent string sensor actuator

[0075] As further described below regarding the 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 as the paver 10 moves over the concrete material to form a concrete slab 16.

[0076] The controller 202 sends command signals to the forward sensor actuator 62F and the rear sensor actuator 62R to achieve the desired change in the longitudinal tilt of the machine frame 22 relative to the ground surface 14, resulting in an 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. Angle 84 can be determined by 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 surface or a chord reference).

[0077] This adjustment of the longitudinal tilt can be achieved as follows. Adjustment of 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, in turn, 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 lift column actuators 46F and 46R so that the lever 66 of each chord sensor 60F and 60R returns to its “zero” position. Thus, 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 lever 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 front lift column actuator 46F to extend until the lever 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.

[0078] For example, in addition to adjusting the tilt angle 84, it may be necessary to control a predetermined axis of rotation (around which the machine frame rotates when the longitudinal tilt changes) so that the height of the upper surface 18 of the formed but not yet hardened concrete slab 16 remains unchanged at and after the predetermined axis of rotation. This can be achieved by adjusting both the front and rear lifting columns. Preferably, this control of both the front and rear lifting columns is performed such that their adjustments occur simultaneously. However, the front and rear lifting columns can also be adjusted sequentially or in alternating steps, as long as the adjustments are completed within a sufficiently short time interval to avoid creating significant discontinuities in the paved surface 18.

[0079] For example, in Figure 2 In the embodiment shown, which includes a swing beam 42 that follows the sliding mold 24, the rear edge of the bottom of the swing beam 42 defines 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 diagram shows the axis 8 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.

[0080] As described above, the controller 202 can be configured via appropriate programming to determine the proper adjustment of the vertical positions of the front chord sensor 60F and the rear chord sensor 60R to achieve a desired change in the longitudinal tilt angle 84, which is caused by the 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 longitudinal tilt of the machine frame, i.e., by adjusting the ratio of the vertical adjustment of the front chord sensor 60F to the vertical adjustment of the rear chord sensor 60R according to 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.

[0081] 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, while 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.

[0082] A method for controlling the aforementioned 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, may include the following steps:

[0083] (a) Using controller 202, determine the desired change in the longitudinal tilt angle 84 of the machine frame 22; and

[0084] (b) Send command signals from controller 202 to one or more sensor actuators 62F and 62R, thereby adjusting the vertical position of one or more string sensors 60F and 60R to achieve the desired longitudinal tilt change.

[0085] 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.

[0086] Step (b) may also include adjusting the longitudinal tilt 84 of the machine frame 22 by adjusting 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) such that the height of the upper surface 18 of the unhardened concrete slab 16 formed behind the axis of rotation remains unchanged.

[0087] Step (b) may also include adjusting the longitudinal tilt 84 of the machine frame 22 by simultaneously adjusting the front lifting column 32F and the rear lifting column 32R.

[0088] Step (b) may also include adjusting the longitudinal tilt 84 of the machine frame 22 by adjusting the ratio of the vertical adjustment of the front chord sensor to the vertical adjustment of the rear chord sensor according to 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.

[0089] Furthermore, 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.

[0090] Expansion sensor

[0091] 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 received by the controller 202. In response to the expansion signal, the controller 202 may generate a command signal to one or more of the aforementioned actuators 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.

[0092] 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, supported by the slipform paver mold 24 or machine frame 22, and pointed at 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.

[0093] Although only a single expansion sensor 220 is shown in the schematic diagram, it should be understood that multiple expansion sensors 220 can be installed across the entire width of the slipform paver 10. Figure 7AAs schematically shown, preferably, the expansion sensor 220 includes at least two, and more preferably at least three, height sensors 220A, 220B, and 220C, which are spaced apart across the width 224 of the machine frame 22 and / or the slab 16. Concrete expansion may be uneven across the entire width of the concrete slab, and therefore it may be desirable to variably adjust the operating parameters across the entire 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, and this can also be accommodated by the aforementioned system.

[0094] exist Figure 7B In another embodiment, schematically shown 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 depend 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 systems.

[0095] It should 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 brief events. For example, the average height can be determined over time intervals ranging from about 0 seconds to about 240 seconds, optionally from about 10 seconds to 180 seconds, and even more preferably from about 10 seconds to 60 seconds.

[0096] It should also be understood that the expansion of concrete slabs can be attributed to many different factors, some of which are relatively short-term and others are relatively long-term.

[0097] Among the relatively short-term factors, for example, there might be a load of concrete material dumped by a truck at location 16A, which is substantially different from the previously supplied material. 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, a load of concrete material that is too wet or too dry may be dumped. Other short-term events might include changes in the forward speed of paver 10.

[0098] 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.

[0099] Similarly, if the gate 50 is raised, this will increase the height of the concrete in the area 16B just in front of the mold 24, which will also cause an increase in expansion in the area 16C behind the mold.

[0100] The expansion changes in region 16C tend to occur rather slowly. Controller 202 can be configured to identify certain possible patterns of expansion change based at least in part on the rate of change of the expansion sensor signal from expansion sensor 220, and to predict the height of the unhardened concrete slab formed behind slipform mold 24 in region 16C.

[0101] 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 set up for that operation.

[0102] 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, in order to correct for unwanted 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.

[0103] As discussed above, the controller 202 can send command signals to the forward and backward chord sensor actuators 62F and 62R to increase or decrease the longitudinal tilt angle 84, thereby increasing or decreasing the expansion at region 16C, respectively.

[0104] 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 respond to an observed expansion increase by adjusting various machine parameters in the following order until the selected parameters are not yet at their maximum or minimum values:

[0105] 1. The vibration frequency or velocity of vibrator 56;

[0106] 2. The forward speed of paver 10;

[0107] 3. The height of the concrete supply gate 50; and

[0108] 4. The longitudinal tilt of machine 10 is 84 degrees.

[0109] The method of operating the above-described slipform paver 10, which includes the expansion sensor 220, may include the following steps:

[0110] (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.

[0111] (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

[0112] (c) In response to the command signal, automatically adjust at least one operating parameter of the paver in the direction that counteracts the deviation.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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.

[0117] Furthermore, when the paver 10 includes a swing beam 42, step (c) may further include adjusting the longitudinal tilt 84 of the machine frame 22 by adjusting the front lifting column 32F and the rear lifting column 32R, thereby tilting the machine frame 22 about the axis of rotation 88 of the adjacent 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 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.

[0118] 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 also include adjusting the longitudinal tilt of the machine frame by simultaneously adjusting both the front and rear lifting columns.

[0119] The method may include: repeating steps (a) and (b) after step (c) and after a lag time interval sufficient to allow the adjustment of step (c) to result in 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 a direction that counteracts any further determined current or predicted deviation of the expansion of the unhardened concrete slab 16 formed behind the slipform mold 24. The lag time interval may be based on the time necessary for the paver 10 to travel a specified distance in the paving direction 12. For example, the lag time may be the time sufficient to allow the paver 10 to advance a distance ranging from 0 to 20 m, optionally from about 0 to 10 m, and further optionally from about 1 to 10 m.

[0120] Volume Control

[0121] Another phenomenon encountered in slipform paving when using a swing beam such as swing beam 42 is the formation of a "roll" 16D of uncured concrete material directly in front of swing beam 42. Roll 16D tends to curl forward away from the swing beam and is typically in the form of a roughly cylindrical roll of uncured concrete material with an somewhat irregular shape. Depending on various operating parameters of the paver 10, the material in the roll is in motion, and the cross-sectional size of the roll (and especially its height) increases and decreases. Maintaining the roll 16D at an appropriate size is important for the proper functioning of swing beam 42.

[0122] One machine parameter affecting the size of roll 16D is the longitudinal tilt angle 84 of the machine frame 22. It should be noted that when using the swing beam 42, any change in tilt angle 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 tilt angle 84 is increased, this will allow more concrete material to pass under the slipform 24 and accumulate in front of the swing beam 42. Conversely, decreasing the longitudinal tilt angle 84 will reduce the amount of concrete material passing under the advancing slipform 24, and thus reduce the size of roll 16D.

[0123] The size of roll 16D can be monitored using roll size sensor 230, which is configured to detect the size of roll 16D in front of swing beam 42. Roll size sensor 230 can be configured to detect parameters corresponding to the cross-sectional dimensions of roll 16D. It should be understood that roll 16D is irregularly shaped, 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 merely approximate such dimensions in some way.

[0124] 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, the height 236 of the roll 16D is obtained by subtracting the distance 232.

[0125] exist Figure 2 In the second embodiment, which is 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, the width 238 of the roll 16D is obtained by subtracting the distance 234.

[0126] In such Figure 2 In one embodiment shown, roll size sensors 230H and 230W can each 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 used in conjunction with... Figure 7AThe described manner is similar, with the roll size sensor 230H or 230W positioned across the width 224 of the slipform paver 10. Preferably, each roll size sensor 230H or 230W comprises at least two, and more preferably at least three, discrete sensors arranged across the width 224 of the machine frame 22. The size and shape of the roll 16D may be non-uniform across the entire width of the concrete slab, and therefore, variable adjustment of operating parameters across the entire width of the concrete slab may be desired.

[0127] In similar Figure 7B In another embodiment of 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 may be used for the roll control sensor 230H or 230W.

[0128] 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.

[0129] If the paver 10 is configured to use a slope control system that is 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.

[0130] It should be understood that the external shape of roll 16D may be somewhat irregular, and therefore controller 202 may preferably be configured to determine the height or width of 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.

[0131] The controller 202 can also be configured to predict the size of roll 16D based at least in part on the rate of change of sensor signals from roll size sensors 230H and / or 230W.

[0132] 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.

[0133] 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.

[0134] For any given paver 10 and a set of operating parameters for the machine and the concrete material, the desired size of roll 16D will generally be known, and sometimes 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.

[0135] Following step (c), controller 202 may repeat steps (a) and (b) after a hysteresis interval sufficient to allow the adjustment in step (c) to result in a change in the size of roll 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 size of roll 16D. The hysteresis interval may be based on the time necessary for paver 10 to travel a specified distance in the paving direction.

[0136] Besides the longitudinal tilt angle 84, other machine operating parameters can affect the size of roll 16D. One such operating parameter is the height of the concrete material pile in front of the slipform mold 24 in region 16B. This height can be detected by the concrete supply height sensor 240. Similar to the expansion sensor 220 and 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 across the width of the slab 16, or a scanning sensor, such as a laser scanner.

[0137] Another such operating parameter is the slab expansion in region 16C, as detected by expansion sensor 220.

[0138] 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 tilt 84 at least in part based on the predicted effects of these signals and these parameters on the roll size.

[0139] Measuring paving thickness

[0140] 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.

[0141] The front height sensor 102 can be configured to detect the distance 108 relative to the machine frame 22 from the ground surface 14 in front of the concrete slab 16 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 position above the ground surface 14 before the intended placement of the unformed concrete material pile 16A.

[0142] The rear height sensor 104 can be configured to detect the distance 110 relative to the upper surface 18 of the formed concrete slab 16 from 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 position behind the swing beam 42.

[0143] The controller 202 can be configured to receive front 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 at least in part based on the front and rear height signals.

[0144] The front and / or rear height sensors 102 and / or 104 can each be ultrasonic sensors. Preferably, each such front and / or rear height sensor includes at least two, and more preferably at least three, discrete ultrasonic sensors, which are configured in a manner similar to... Figure 7A The expansion sensors shown are spaced across the width 224 of the slab 16.

[0145] 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 surface 14 and / or the slab surface 18 across a continuous portion 222 of the width 224 of the slab, similar to... Figure 7B The expansion sensor is shown. 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.

[0146] To determine the thickness 106 of the slab 16 at any given location on the ground surface 14, the controller 202 can be configured to compare a frontal height signal corresponding to the given location on the ground surface 14 with a rearal height signal generated later corresponding to substantially the same given location on the ground surface. This can be achieved in various ways.

[0147] In one aspect, controller 202 can be configured to associate the front height signal and the rear height signal based on the horizontal distance traveled by machine 10 being substantially equal to the horizontal spacing 108 between the front height sensor 102 and the rear height sensor 104.

[0148] On the other hand, controller 202 can be configured to store data corresponding to the altitude signal in computer memory 206 and associate this data with the position of machine 10 on ground surface 14. If machine 10 uses, for example Figure 3 and Figure 4 The chord gradient control system of one of those schematically shown can perform this correlation by associating each height signal with the distance the machine 10 has traveled along chord 58 from its starting position. This distance sensing can be accomplished by a pickup or sensor in the track drive to determine the distance the paver has traveled along the track.

[0149] If machine 10 is using a three-dimensional slope control system based on its position in a reference frame outside of machine 10, such as when using satellite-based slope control systems 300, 302, 304 or total station-type slope control systems 310, 302, 304, then controller 202 can be configured to associate altitude data with the position of machine 10 in a reference frame outside of 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.

[0150] 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 the 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 surface 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, considering the expected overall uniformity of the ground surface 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 is permissible without adversely affecting the comparison used to determine the thickness 106 of the slab. 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.

[0151] 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 the area of ​​the slab, such as the area of ​​the slab as determined 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. Such a 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.

[0152] 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 front sensor actuator 62F and rear sensor actuator 62R, to automatically adjust the height of the machine frame relative to the ground surface 14, at least in part, based on a comparison of the determined thickness 106 of the slab 16 with the desired thickness of the slab at a given geographic location, thereby controlling the thickness of the concrete slab 16. In either case, the command signals cause the lifting columns to adjust the height of the machine frame relative to the ground surface to control the thickness of the concrete slab.

[0153] Such a method can be described as including the following steps:

[0154] • The front height sensor 102 in front of the concrete slab 16 detects the distance 108 from the ground surface 14 relative to the machine frame 22 and generates a front height signal.

[0155] • The rear height sensor 104 detects the distance 110 relative to the upper surface 18 of the concrete slab 16 from the machine frame 22 and generates a rear height signal; and

[0156] • The thickness 106 of the concrete slab 16 is determined using the controller 202 based at least in part on the front and rear height signals.

[0157] The determination step may include comparing a front altitude signal corresponding to a given location on the ground surface 14 with a rear altitude signal subsequently generated corresponding to a substantially identical given location on the ground surface. As described above, this can be accomplished by associating the front and rear altitude signals based on a horizontal distance that is substantially equal to the horizontal spacing 108 between the front and rear altitude signals as the machine 10 travels.

[0158] 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 ground surface 14.

[0159] The method may also include the step of automatically generating a report representing the total volume of the concrete slab 16 formed during the paving operation using the controller 202.

[0160] The method may also include the following steps:

[0161] • The controller 202 compares the determined thickness 106 of the concrete slab 16 with the desired thickness of the concrete slab; and

[0162] • Command signals from controller 202 are sent 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 surface 14, thereby controlling the thickness 106 of concrete slab 16 at least in part based on this comparison.

[0163] Therefore, it can be seen that the apparatus and methods of this disclosure readily achieve the mentioned and inherent objects and advantages. 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, which 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 any other feature or embodiment of the disclosure.

Claims

1. A slipform paver, comprising: Machine frame; Multiple ground-mounted wheels or tracks; The machine frame is supported by a height-adjustable front and rear lifting column, which is supported by the ground engagement wheel or track. The lifting column is adjustable to adjust the longitudinal tilt of the machine frame in the paving direction. A slipform mold, supported by the machine frame, is used to mold a large quantity of concrete into shaped, unhardened concrete slabs as the paver moves forward along the paving direction; as well as An expansion sensor is arranged to detect the expansion of the unhardened concrete slab formed behind the slipform mold relative to the machine frame.

2. The slipform paver according to claim 1, characterized in that: The expansion sensor includes at least two height sensors spaced apart across the width of the machine frame.

3. The slipform paver according to claim 1, characterized in that: The expansion sensor includes a scanning sensor configured to scan the height of the unhardened concrete slab formed behind the slipform mold across a continuous portion of the width of the machine frame.

4. The slipform paver according to claim 1 further includes: A controller configured to receive sensor signals from the expansion sensor and generate command signals to the actuator to adjust at least one operating parameter of the paver.

5. The slipform paver according to claim 4, characterized in that: The controller is further configured to determine the height of the unhardened concrete slab formed behind the slipform mold as an average height over a time interval.

6. The slipform paver according to claim 4, characterized in that: The controller is further configured to predict the height of the unhardened concrete slab formed behind the slipform mold, at least in part, based on the rate of change of the sensor signal.

7. The slipform paver according to claim 4, characterized in that: The at least one operating parameter includes the paver's travel speed.

8. The slipform paver according to claim 4, characterized in that: The at least one operating parameter includes the vibrator speed of the vibrator located in front of the sliding mold.

9. The slipform paver according to claim 4, characterized in that: The at least one operating parameter includes the height of the concrete supply gate in front of the slipform mold.

10. The slipform paver according to claim 4, characterized in that: The at least one operating parameter includes the longitudinal tilt of the machine frame.

11. The slipform paver according to claim 10, characterized in that: The controller is further configured to lower the front end of the machine frame relative to the rear end of the machine frame in order to reduce the expansion of the unhardened concrete slab formed behind the slipform mold.

12. The slipform paver according to claim 10, further comprising: A swing beam, supported by 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 it. and The controller is further configured to adjust the longitudinal tilt of the machine frame by adjusting both the front lifting column and the rear lifting column, thereby tilting the machine frame about a rotation axis adjacent to the 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.

13. The slipform paver according to claim 12, characterized in that: The controller is also configured to adjust the longitudinal tilt of the machine frame by simultaneously adjusting both the front lifting column and the rear lifting column.

14. 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 adjusting both the front lifting column and the rear lifting column, thereby tilting the machine frame about a rotation axis adjacent to the rear edge of the slipform mold, so that the height of the upper surface of the formed, unhardened concrete slab behind the slipform mold remains unchanged.

15. The slipform paver according to claim 14, characterized in that: The controller is also configured to adjust the longitudinal tilt of the machine frame by simultaneously adjusting both the front lifting column and the rear lifting column.

16. The slipform paver according to claim 1, further comprising: Front chord sensor; A front sensor actuator, the front sensor actuator being arranged to adjust the vertical position of the front chord sensor relative to the machine frame; Rear chord sensor; A rear sensor actuator, the rear sensor actuator being arranged to adjust the vertical position of the rear chord sensor relative to the machine frame; and A controller configured to receive sensor signals from the expansion sensor and send command signals 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 according to claim 16, further comprising: A front sensor actuator position sensor, the front sensor actuator position sensor being 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 a front hydraulic intelligent cylinder and a rear hydraulic intelligent cylinder, respectively, and the position sensor of the front sensor actuator and the position sensor of the rear sensor actuator are integrated in the front hydraulic intelligent cylinder and the rear hydraulic intelligent cylinder, respectively.

19. The slipform paver according to claim 17, characterized in that: The front sensor actuator and the rear sensor actuator are 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 are rotary sensors.

20. A method for controlling a slipform paver, the slipform paver comprising: A machine framework with front-end and back-end; Multiple ground-mounted wheels or tracks; Height-adjustable front and rear lifting columns support the machine frame from the ground engagement wheels or tracks. The lifting columns are adjustable to adjust the longitudinal tilt of the paver frame in the paving direction. as well as A slipform mold, supported by the machine frame, is used to mold a large quantity of concrete into shaped, unhardened concrete slabs as the paver moves forward along the paving direction; The method includes: (a) Using at least one expansion sensor to monitor the expansion of the unhardened concrete slab formed behind the slipform mold, and generating at least one sensor signal corresponding to the expansion; (b) Based at least in part on the at least one sensor signal, the controller determines the current or predicted deviation of the expansion from the desired expansion and generates a corresponding command signal; as well as (c) In response to the command signal, automatically adjust at least one operating parameter of the paver in the direction that counteracts the deviation.

21. The method according to claim 20, characterized in that: The at least one expansion sensor detects the height of the unhardened concrete slab formed behind the slipform mold relative to the machine frame.

22. The method according to claim 20, characterized in that: Step (a) further includes monitoring the expansion of the unhardened concrete slab formed behind the slipform mold as an average expansion over a time interval.

23. The method according to claim 20, characterized in that: Step (a) further includes monitoring the expansion of the unhardened concrete slab formed behind the slipform mold at at least three locations across the width of the paver.

24. The method according to claim 20, characterized in that: The at least one operating parameter includes the paver's travel speed.

25. The method according to claim 20, characterized in that: The at least one operating parameter includes the vibrator speed of the vibrator located in front of the sliding mold.

26. The method according to claim 20, characterized in that: The at least one operating parameter includes the height of the concrete supply gate in front of the slipform mold.

27. The method according to claim 20, characterized in that: The at least one operating parameter includes the longitudinal tilt of the machine frame.

28. The method according to claim 27, characterized in that: Step (c) further includes lowering the front end of the machine frame relative to the rear end to reduce the expansion of the unhardened concrete slab formed behind the slipform mold, and raising the front end of the machine frame relative to the rear end to increase the expansion of the unhardened concrete slab formed behind the slipform mold.

29. The method according to claim 27, characterized in that: Step (c) further includes raising the front end of the machine frame relative to the rear end to increase the expansion of the unhardened concrete slab formed behind the slipform mold.

30. The method according to claim 27, characterized in that: The slipform paver also includes a swing beam supported by the machine frame behind the slipform mold for engaging the upper surface of the formed, unhardened concrete slab and swinging transversely to the paving direction on the upper surface to smooth the upper surface. and Step (c) further includes adjusting the longitudinal tilt of the machine frame by adjusting both the front lifting column and the rear lifting column, so that the machine frame tilts about the axis of rotation adjacent to the rear edge of the swing beam, such that the height of the upper surface of the unhardened concrete slab formed behind the swing beam remains unchanged.

31. The method according to claim 30, characterized in that: Step (c) further includes adjusting the longitudinal tilt of the machine frame by simultaneously adjusting both the front lifting column and the rear lifting column.

32. The method according to claim 27, characterized in that: Step (c) further includes adjusting the longitudinal tilt of the machine frame by adjusting both the front lifting column and the rear lifting column, so that the machine frame tilts about the axis of rotation adjacent to the rear edge of the slipform mold, such that the height of the upper surface of the unhardened concrete slab formed behind the slipform mold remains unchanged.

33. The method according to claim 32, characterized in that: Step (c) further includes adjusting the longitudinal tilt of the machine frame by simultaneously adjusting both the front lifting column and the rear lifting column.

34. The method of claim 27, further comprising: After step (c), steps (a) and (b) are repeated after a hysteresis time interval sufficient to allow the adjustment in step (c) to cause expansion changes in the unhardened concrete slab formed behind the slipform mold; and Further adjust the longitudinal tilt of the machine frame in one direction to counteract any further determined current or predicted deviations in the expansion of the unhardened concrete slab formed behind the slipform mold.

35. The method according to claim 34, characterized in that: The lag time interval is based on the time required for the paver to travel a specific distance in the paving direction.

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