3D intelligent paving equipment and construction process thereof

Abstract

The present application relates to the field of paving equipment, and discloses a 3D intelligent paving equipment, which comprises a positioning measurement module, a sensor and execution module, a control calculation module, and a high-position mast assembly vertically installed on a paver boom, wherein the top end of the high-position mast assembly is fixed with a 360-degree prism, and an inclination sensor is integrated at the prism installation position, the high-precision inclination sensor is coaxially integrated at the 360-degree prism installation position, and geometric deviation compensation logic is built in the control calculation module, the system acquires the deflection angle in real time, synchronously calculates the elevation and plane displacement correction amount in combination with the mast calibration height, strictly aligns the compensation frequency with the total station sampling frequency, mechanically decouples the high-frequency vibration from the positioning signal, eliminates the phase delay and control step, stably improves the elevation control accuracy from the traditional ±8mm to within ±3mm, and solves the technical bottleneck of the screed adjustment jitter caused by the prism shaking.

Description

Technical Field

[0001] This invention relates to the field of paving equipment, and more particularly to a 3D intelligent paving equipment and its construction process. Background Technology

[0002] Traditional paving construction relies primarily on manual pile driving and the use of steel wire ropes as elevation benchmarks. In this method, the tension of the steel wire ropes and the stability of the pile positions are greatly affected by the environment, and the measurement and layout processes are highly dependent on manual experience, making it difficult to achieve millimeter-level precision in elevation and cross slope control. While some 3D intelligent paving equipment has been introduced, attempting to replace steel wire ropes with GNSS or total stations, the severe high-frequency vibrations of the paver during operation often cause the positioning prism mounted on the paver to sway slightly with the mast, resulting in inaccurate positioning data and consequently errors in screed adjustment. Furthermore, existing 3D paving processes mostly employ single-station control. If the total station is obstructed by vehicles at the construction site, the benchmark station experiences slight displacement due to vibration, or sensor signals abruptly change, the system often fails to identify the anomaly immediately, leading to large-area paving thickness deviations, resulting in expensive material waste or tedious rework.

[0003] Therefore, how to solve mechanical vibration interference, improve the system's redundancy monitoring capabilities, realize dynamic correction of loose paving parameters, and ensure continuous operation under complex working conditions have become urgent technical problems to be solved in the field of intelligent paving technology. Summary of the Invention

[0004] The purpose of this invention is to provide a 3D intelligent paving equipment and its construction process to solve the above problems. The specific technical solution is as follows: A 3D intelligent paving device, comprising: Positioning and measurement module: used to acquire real-time three-dimensional coordinates, including a total station, GNSS receiver, and a 360° prism mounted on the paver; Sensors and actuators: used to sense and adjust the construction posture, including a biaxial slope sensor and a cross slope sensor mounted on the screed, as well as a hydraulic controller; Control calculation module: used to process positioning data and distribute hydraulic commands, and has a built-in closed-loop control system based on a digital model; High-mounted mast assembly: vertically mounted on the paver boom, with the 360° prism fixed at its top, and an tilt sensor integrated at the prism mounting position.

[0005] As an improvement to the above technical solution, the control calculation module has geometric deviation compensation logic, which can obtain the deflection angle of the tilt sensor in real time, and calculate and correct the elevation and planar displacement deviation of the 360° prism caused by the swaying of the mast based on the mast height.

[0006] As an improvement to the above technical solution, the positioning and measurement module supports a multi-station collaborative mode, allowing two or more total stations to simultaneously lock the same 360° prism and feed back multi-path coordinate data to the control calculation module for redundancy verification.

[0007] As an improvement to the above technical solution, the control calculation module also integrates a fault self-diagnosis unit, which is used to monitor the data flow integrity of the sensors in real time. When any sensor signal is interrupted or changes abnormally, the system automatically switches to an emergency safety mode based on historical trajectory calculation.

[0008] A construction process, employing the aforementioned 3D intelligent paving equipment, includes the following steps: S1. Subgrade data mining and modeling: Using measuring equipment to collect three-dimensional data of the subgrade to generate a digital ground model (DTM), and comparing the measured DTM with the design parameters to generate a 3D control benchmark model with thickness pre-compensation function; S2. Mast Dynamic Geometric Compensation: During the paving process, the control system monitors the values ​​of the tilt sensor in real time; when the paver vibrates or travels and causes the mast to deviate from the gravity line, the system corrects the spatial coordinates of the prism in real time according to the tilt angle to obtain the true reference elevation of the screed. S3. Dual-station redundant real-time monitoring: Two total stations are used to simultaneously track and lock the 360° prism, and the control system compares the coordinate difference fed back by the two instruments in real time; when the difference exceeds the set accuracy threshold, the system automatically triggers a construction warning and locks the hydraulic controller attitude. S4. Parameter correction based on measured feedback: The measured subgrade data collected in step S1 is spatially superimposed with the screed elevation trajectory recorded in real time by the paver, the current real-time loose paving thickness is dynamically calculated, and the loose paving coefficient compensation value of subsequent road sections is automatically fine-tuned according to the deviation trend. S5. Continuous station switching and smooth transition: Using a backup total station relay mode, the positioning reference is seamlessly and smoothly switched from the current station to the target station via a data link at the line-of-sight limit, maintaining the continuity of hydraulic system adjustment commands.

[0009] As an improvement to the above technical solution, in step S2, the compensation calculation frequency of the tilt sensor is kept consistent with the sampling frequency of the total station to eliminate the interference of high-frequency mechanical vibration on elevation control.

[0010] As one of the improvements to the above technical solution, in step S3, the accuracy threshold is preset to ±3mm; this step achieves real-time active diagnosis of station stability and signal obstruction risk through redundant coverage of two hardware devices.

[0011] As one of the improvements to the above technical solution, in step S5, for the dual-machine paving condition, multiple pavers establish a data sharing link through the vehicle radio. The system automatically corrects the modeling benchmark of the subsequent pavers based on the measured loose paving data of the leading paver position to ensure the consistency of the flatness at the joint.

[0012] As one of the improvements to the above technical solution, the process also includes a real-time construction data storage step, which uploads positioning coordinates, hydraulic commands and attitude feedback data to the cloud management platform in real time to generate traceable digital construction archives.

[0013] The beneficial effects of this invention are as follows: This invention coaxially integrates a high-precision tilt sensor at the 360° prism mounting position and incorporates geometric deviation compensation logic within the control calculation module. The system acquires the deflection angle in real time and synchronously calculates the elevation and planar displacement corrections based on the mast calibration height, ensuring strict alignment of the compensation frequency with the total station sampling frequency. This design physically decouples high-frequency mechanical vibration from the positioning signal, eliminating phase delay and control step, thus significantly improving the elevation control accuracy from the traditional ±8mm to within ±3mm, overcoming the technical bottleneck of ironing plate adjustment jitter caused by prism swaying.

[0014] Overcoming the shortcomings of existing single-station control modes in lacking anomaly recognition capabilities when faced with base station obstruction, minor vibrations, or signal fluctuations, this invention supports simultaneous tracking of the same prism by dual or more total stations. By comparing multi-path coordinate differences in real time and setting a ±3mm accuracy threshold, it achieves proactive diagnosis of station stability and line-of-sight risks. When the difference continuously exceeds the limit, the system triggers an audible and visual warning within milliseconds, locks the hydraulic controller's attitude, and seamlessly switches to an emergency safety mode based on historical trajectory calculations. This redundant architecture achieves end-to-end fault tolerance from anomaly recognition to attitude protection to smooth degradation, effectively avoiding large-scale paving deviations caused by single-point failures.

[0015] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Of course, implementing any product or method of this application does not necessarily require achieving all of the advantages described above at the same time. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2This is a process flow diagram of the present invention; In the diagram: 100, Positioning and Measurement Module; 101, Total Station; 102, GNSS Receiver; 103, 360° Omnidirectional Reflecting Prism; 200, Sensor and Actuation Module; 201, Dual-Axis Slope Sensor; 202, Cross Slope Sensor; 203, Screed Plate; 204, Hydraulic Controller; 300, Control Calculation Module; 301, Geometric Deviation Compensation Unit; 302, Multi-Station Data Fusion Unit; 303, Fault Self-Diagnosis Unit; 400, High-Position Mast Assembly; 401, Tilt Sensor. Detailed Implementation

[0018] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0020] Please see Figure 1 and Figure 2 In this embodiment of the invention, a 3D intelligent paving device is provided, which mainly includes a positioning and measurement module 100, a sensor and execution module 200, a control and calculation module 300, and a high-level mast assembly 400.

[0021] The positioning and measurement module 100 is used to acquire the real-time three-dimensional spatial coordinates of the equipment, including a high-precision total station 101, a GNSS receiver 102, and a 360° omnidirectional reflecting prism 103 installed on the paver. The total station 101 is set up on stable reference points on both sides of the construction route, and the measurement accuracy is preferably ≤±(1mm+1.5ppm); the GNSS receiver 102 supports RTK / PPK dual-mode positioning and serves as an auxiliary positioning source to form heterogeneous data complementarity with the total station; the 360° omnidirectional reflecting prism 103 is fixed to the top of the high-level mast assembly 400 by a high-rigidity shock-absorbing bracket.

[0022] The high-mounted mast assembly 400 is vertically mounted on the side of the paver's boom and is made of aerospace-grade aluminum alloy. The 360° omnidirectional reflecting prism 103 is fixed to its top. A high-precision MEMS tilt sensor 401 is coaxially integrated inside the prism mounting base. The mast bottom is equipped with a quick-leveling base with a locking mechanism. Zero-position calibration has been performed at the factory using a laser tracker to ensure that the tilt sensor 401's measurement reference coincides with the theoretical gravity line.

[0023] The sensor and execution module 200 is used to sense and adjust the construction posture, including a dual-axis slope sensor 201 and a cross slope sensor 202 rigidly mounted on the frame of the screed 203, as well as a hydraulic controller 204. The dual-axis slope sensor 201 collects the longitudinal tilt angle and the transverse slope angle of the screed in real time, and the hydraulic controller 204 receives PWM proportional valve commands from the control calculation module 300 to independently drive the lifting cylinders and corner cylinders on the left and right sides.

[0024] The control and calculation module 300 adopts an industrial-grade embedded main control platform and has a built-in closed-loop control system based on a digital model. Internally, it is divided into a geometric deviation compensation unit 301, a multi-station data fusion unit 302, and a fault self-diagnosis unit 303. The modules communicate in real-time via a CANFD bus and a gigabit Ethernet network, with a core control cycle of ≤20ms, ensuring high real-time performance in command issuance and attitude response.

[0025] Furthermore, the control calculation module 300 has geometric deviation compensation logic, which can acquire the deflection angle of the tilt sensor 401 in real time, and calculate and correct the elevation and planar displacement deviation of the 360° omnidirectional reflecting prism 103 caused by the swaying of the mast according to the mast height.

[0026] The positioning and measurement module 100 supports a multi-station collaborative mode, allowing two or more total stations 101 to simultaneously lock onto the same 360° omnidirectional reflecting prism 103 and feed back multi-path coordinate data to the control and calculation module 300 for redundancy verification.

[0027] The fault self-diagnosis unit 303 integrated in the control calculation module 300 is used to monitor the integrity of sensor data streams in real time (including heartbeat packet verification, CRC verification, and threshold over-limit judgment). When any sensor signal is interrupted, communication times out, or abnormal transition occurs, the system automatically cuts off the open-loop regulation loop and switches to an emergency safety mode based on historical trajectory and Kalman filtering calculations to maintain basic equipment movement and hydraulic pressure holding. As one of the improvements to the above technical solution, the control calculation module has geometric deviation compensation logic, which can obtain the deflection angle of the tilt sensor in real time and calculate and correct the elevation and planar displacement deviation of the 360° prism caused by mast swaying based on the mast height.

[0028] The present invention also provides a construction process using the above-mentioned 3D intelligent paving equipment, the specific implementation steps of which are as follows: S1. Subgrade Data Mining and Modeling: High-density point cloud data of the subgrade is collected using a 3D laser scanner or a vehicle-mounted mobile measurement system. After denoising, registration, and coordinate system transformation, a measured digital ground model (DTM) is generated. Spatial difference calculations are performed between the measured DTM and the design longitudinal section, cross slope, and structural layer thickness parameters to generate a 3D control reference model with thickness pre-compensation function. The model is divided into 5m×5m grids and stored in the control calculation module 300 as the initial command source for paving elevation and cross slope.

[0029] S2. Mast Dynamic Geometric Compensation: During paving operations, the vibration of the vibrator and the movement of the tracks generate high-frequency mechanical vibrations of 5-50Hz, causing the high-position mast assembly 400 to experience slight periodic oscillations. The control system samples the raw signal from the tilt sensor 401 at 200Hz, and extracts the effective deflection angle θ after a first-order low-pass digital filter with a cutoff frequency of 30Hz. Combined with the vertical projection height L (preset calibration value of the equipment) from the prism rotation center to the screed reference plane, the spatial coordinates are corrected in real time according to the following geometric relationship: ΔH = L·(1-cosθ) ΔX=L·sinθ The corrected prism coordinates are: (X',Y',Z')=(X_raw+ΔX,Y_raw,Z_raw+ΔH). The compensation calculation frequency of the tilt sensor is synchronized with the sampling frequency (20Hz) of the total station 101 to eliminate phase delay, thereby obtaining the true reference elevation of the screed and eliminating the interference of high-frequency mechanical vibration on elevation control.

[0030] S3. Dual-station redundant real-time monitoring: Two total stations, 101A and 101B, simultaneously track and lock onto the 360° omnidirectional reflecting prism 103. The control calculation module 300 compares the coordinate difference D fed back by the two instruments in real time, which is calculated as D = √[(X1-X2)² + (Y1-Y2)² + (Z1-Z2)²]. The preset accuracy threshold is ±3mm. When the difference D exceeds the limit for three consecutive sampling cycles, the system determines it as a slight shift of the base station, strong wind disturbance, or signal obstruction, and immediately triggers a three-level linkage response. 1. Driver's cab audible and visual warning; 2. The hydraulic controller 204 switches to attitude freeze mode to lock the current cylinder opening; 3. Seamlessly downgrade to GNSS+IMU fusion positioning to avoid large-area paving thickness exceeding tolerances. This step achieves real-time proactive diagnosis of station stability and signal risks through dual hardware redundancy coverage.

[0031] S4. Parameter Correction Based on Actual Feedback: The measured subgrade data collected in step S1 is superimposed with the screed elevation trajectory recorded in real time by the paver using a TIN grid space to dynamically calculate the real-time loose paving thickness H_actual of the current section. Compared with the designed loose paving thickness H_design, an adaptive iterative model is used to fine-tune the loose paving coefficient: α_new=α_old×[1+k·(H_design-H_actual) / H_design] where k is the material compaction attenuation coefficient, preferably 0.95 for asphalt mixtures and 1.05 for cement-stabilized crushed stone. The correction value is sent forward to the hydraulic controller 204 in 0.5m steps to achieve closed-loop dynamic correction of the paving thickness and eliminate the cumulative error caused by the traditional fixed loose paving coefficient.

[0032] S5. Continuous Station Switching and Smooth Handover: Employing a backup total station relay mode, at the line-of-sight limit (current station elevation angle > 80° or distance > 500m), the NTRIP data link and dedicated industrial router enable seamless and smooth switching of the positioning reference from the current station to the target station. During the switching transition, a weighted sliding window algorithm is used: control command I(t) = w1·I_current(t) + w2·I_next(t), with weights w1 linearly decreasing from 1 to 0 and w2 increasing from 0 to 1, with a transition time ≤ 2s. This maintains the continuity of hydraulic system adjustment commands and eliminates abrupt changes during station switching. For dual-machine paving operations, multiple pavers establish a V2V data sharing link via a vehicle-mounted 5G radio. The system automatically corrects the modeling reference of subsequent pavers based on the measured loose paving data of the leading paver, ensuring that the flatness difference at longitudinal joints is controlled within 2mm.

[0033] Furthermore, the process also includes a real-time construction data storage step: positioning coordinates, hydraulic commands, attitude feedback, environmental temperature and humidity, and equipment status codes are packaged in real time, encrypted with TLS1.3, and uploaded to the cloud management platform to generate a digital construction archive with timestamps and spatial coordinates, meeting the requirements for full life-cycle traceability of project quality.

[0034] To address the issues in the prior art where the vibration and movement of a paver cause slight mast swaying, leading to distorted positioning data and jitter in screed commands, this invention integrates a high-precision tilt sensor coaxially at the 360° prism mounting position and incorporates geometric deviation compensation logic into the control calculation module. The system acquires the deflection angle in real time and simultaneously calculates elevation and planar displacement corrections based on the mast's calibrated height, ensuring strict alignment of the compensation frequency with the total station's sampling frequency. This design physically decouples high-frequency mechanical vibration from the positioning signal, eliminating phase delay and control steps, thus significantly improving elevation control accuracy from the traditional ±8mm to within ±3mm, overcoming the technical bottleneck of screed adjustment jitter caused by prism swaying.

[0035] Overcoming the shortcomings of existing single-station control modes in lacking anomaly recognition capabilities when faced with base station obstruction, minor vibrations, or signal fluctuations, this invention supports simultaneous tracking of the same prism by dual or more total stations. By comparing multi-path coordinate differences in real time and setting a ±3mm accuracy threshold, it achieves proactive diagnosis of station stability and line-of-sight risks. When the difference continuously exceeds the limit, the system triggers an audible and visual warning within milliseconds, locks the hydraulic controller's attitude, and seamlessly switches to an emergency safety mode based on historical trajectory calculations. This redundant architecture achieves end-to-end fault tolerance from anomaly recognition to attitude protection to smooth degradation, effectively avoiding large-scale paving deviations caused by single-point failures.

[0036] This invention departs from the traditional open-loop operation mode that relies on fixed loose paving coefficients or manual experience. It dynamically calculates the actual loose paving thickness of the current section by spatially superimposing measured DTM pre-compensation modeling of the underlying layer with the real-time elevation trajectory of the screed. The control system uses an adaptive iterative algorithm based on deviation trends to fine-tune the loose paving coefficient compensation value for subsequent road sections, forming a closed-loop control system of measured feedback, parameter correction, and command issuance. This mechanism effectively offsets systematic errors caused by local undulations in the underlying layer, material gradation fluctuations, and changes in environmental temperature and humidity, ensuring that the standard deviation of the paving thickness is stably controlled within ±3mm, and the road surface smoothness IRI value significantly exceeds industry standard requirements.

[0037] To address the challenges of limited visibility leading to interrupted station-changing commands during long-distance construction and the difficulty in controlling the elevation difference at longitudinal joints during dual-paver paving, this invention employs a backup total station relay mode and a weighted sliding window transition algorithm. This achieves a linear and smooth transition of hydraulic adjustment commands during positioning benchmark switching, eliminating abrupt changes. In dual-paver paving operations, multiple pavers establish a V2V shared channel via vehicle-mounted data links. The measured loose-lay data from the leading paver position is used to correct the modeling benchmark for subsequent pavers in real time, ensuring consistency in thickness and flatness at joints from the outset. Combined with real-time cloud storage of construction data, a traceable digital archive is created throughout the entire lifecycle, providing a quantifiable and auditable standardized construction paradigm for high-standard projects such as smart highways and airport runways.

[0038] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

Claims

1. A 3D intelligent paving device, characterized in that, include: Positioning and measurement module: used to acquire real-time three-dimensional coordinates, including a total station, GNSS receiver, and a 360° prism mounted on the paver; Sensors and actuators: used to sense and adjust the construction posture, including a biaxial slope sensor and a cross slope sensor mounted on the screed, as well as a hydraulic controller; Control calculation module: used to process positioning data and distribute hydraulic commands, and has a built-in closed-loop control system based on a digital model; High-mounted mast assembly: vertically mounted on the paver boom, with the 360° prism fixed at its top, and an tilt sensor integrated at the prism mounting position.

2. The 3D intelligent paving equipment according to claim 1, characterized in that: The control calculation module has geometric deviation compensation logic, which can obtain the deflection angle of the tilt sensor in real time, and calculate and correct the elevation and planar displacement deviation of the 360° prism caused by the swaying of the mast based on the mast height.

3. The 3D intelligent paving equipment according to claim 1, characterized in that: The positioning and measurement module supports a multi-station collaborative mode, allowing two or more total stations to simultaneously lock onto the same 360° prism and feed back multi-path coordinate data to the control and calculation module for redundancy verification.

4. The 3D intelligent paving equipment according to claim 1, characterized in that: The control calculation module also integrates a fault self-diagnosis unit, which is used to monitor the data stream integrity of the sensors in real time. When any sensor signal is interrupted or changes abnormally, the system automatically switches to an emergency safety mode based on historical trajectory calculation.

5. A construction process applied to the 3D intelligent paving equipment as described in any one of claims 1 to 4, characterized in that, Includes the following steps: S1. Subgrade data mining and modeling: Use measuring equipment to collect three-dimensional data of the subgrade to generate a digital ground model (DTM), and compare the measured DTM with the design parameters to generate a 3D control benchmark model with thickness pre-compensation function. S2. Mast Dynamic Geometric Compensation: During the paving process, the control system monitors the values ​​of the tilt sensor in real time; when the paver vibrates or travels and causes the mast to deviate from the gravity line, the system corrects the spatial coordinates of the prism in real time according to the tilt angle to obtain the true reference elevation of the screed. S3. Dual-station redundant real-time monitoring: Two total stations are used to simultaneously track and lock the 360° prism, and the control system compares the coordinate difference fed back by the two instruments in real time; when the difference exceeds the set accuracy threshold, the system automatically triggers a construction warning and locks the attitude of the hydraulic controller. S4. Parameter correction based on measured feedback: The measured subgrade data collected in step S1 is spatially superimposed with the screed elevation trajectory recorded in real time by the paver, the current real-time loose paving thickness is dynamically calculated, and the loose paving coefficient compensation value of subsequent road sections is automatically fine-tuned according to the deviation trend. S5. Continuous station switching and smooth transition: The backup total station relay mode is adopted, and the data link is used at the line-of-sight limit to achieve seamless and smooth switching of the positioning reference from the current station to the target station, maintaining the continuity of hydraulic system adjustment commands.

6. The construction process according to claim 5, characterized in that: In step S2, the compensation calculation frequency of the tilt sensor is kept consistent with the sampling frequency of the total station to eliminate the interference of high-frequency mechanical vibration on elevation control.

7. The construction process according to claim 5, characterized in that: In step S3, the accuracy threshold is preset to ±3mm; this step achieves real-time proactive diagnosis of station stability and signal obstruction risk through redundant coverage of two hardware devices.

8. The construction process according to claim 5, characterized in that: In step S5, for dual-machine paving conditions, multiple pavers establish a data sharing link through vehicle-mounted radios. The system automatically corrects the modeling benchmark of subsequent pavers based on the measured loose paving data of the leading paver position to ensure the consistency of flatness at the joints.

9. A construction process according to claim 5, characterized in that: The process also includes a real-time construction data storage step, which uploads positioning coordinates, hydraulic commands and attitude feedback data to the cloud management platform in real time to generate traceable digital construction archives.

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