A vibrating compaction device for a large thickness water stable base

Abstract

The application discloses a kind of vibration pressure implementation devices of large thickness water stable base, belong to roadbed construction equipment technical field.The device includes main frame, walking wheel support structure, compaction column module, hydraulic station and power system.Main frame is presented cuboid structure, and walking wheel support structure is arranged below four corner points thereof, driving wheel and driving motor are arranged on each walking wheel support structure, for realizing the movement of device.The central lower area of main frame is provided with compaction column module, and the module contains multiple compaction columns vertically lifted by lifting drive assembly, and vibration unit is arranged in each compaction column.By lifting drive assembly, compaction column is inserted into water stable base, and vibration unit is started, and vibration energy is directly applied to base deep, to realize uniform compaction from inside to outside.The application can efficiently and high-quality compact large thickness water stable base in one time.

Description

Technical Field

[0001] This invention relates to the field of roadbed construction equipment technology, and in particular to a vibratory compaction construction device for a thick water-stabilized base course. Background Technology

[0002] In the construction of modern infrastructure such as highways, airport runways, and high-speed railways, the stability and bearing capacity of the roadbed are crucial to ensuring the overall project quality and service life. Water-stabilized base courses, also known as cement-stabilized crushed stone base courses, are widely used as a semi-rigid base course due to their high strength, good slab-like structure, and excellent stability. With the increasing traffic loads and continuously improving design standards, the design thickness of water-stabilized base courses has also increased, with single-layer thicknesses reaching 40 cm, 50 cm, or even 60 cm becoming common. However, traditional processes and equipment face severe challenges in the compaction construction of such thick water-stabilized base courses, posing difficulties for operators.

[0003] In the absence of the device described in this invention, construction site operators primarily rely on traditional vibratory rollers for compaction work. When faced with laying thick water-stabilized layers, operators encounter the following specific difficulties: First, if attempting... Figure 1 When laying and compacting the entire thickness of a water-stabilized layer in one go, operators will find that conventional vibratory rollers, even heavy rollers, transmit compaction energy from top to bottom. This energy decays rapidly during transmission, resulting in a significant gradient in compaction. Even with repeated rolling, operators can only achieve the required density for the surface and upper-middle layers, while the bottom of the base layer is often under-compacted, with severely insufficient density. This puts operators in a dilemma: either accept the risk of substandard bottom compaction or over-compact, which could lead to crushing of the surface material, the "spring" effect, and damage to the material gradation, also affecting project quality. Secondly, to avoid uneven compaction in one go, projects commonly use a "layered laying and layered compaction" process. For example, a 50 cm thick base layer might be divided into two 25 cm thick layers for construction. This means that operators need to complete two complete processes of laying, shaping, rolling, and curing the water-stabilized material. This not only multiplies the workload of operators and significantly extends the construction period, but also places higher demands on the management and coordination of the construction site. Operators need to precisely control the thickness and moisture content of each layer, as negligence in any step can affect the final quality.

[0004] To address this, we provide a vibration compaction device for thick water-stabilized base courses. Summary of the Invention

[0005] To address the aforementioned problems, this invention proposes a vibration compaction construction device for thick water-stabilized base courses, which more accurately solves the problems mentioned in the background art.

[0006] This invention is achieved through the following technical solution: This invention proposes a vibration compaction construction device for a thick water-stabilized base course, comprising a main frame in the form of a cuboid, having a top platform, side wall structures, and a bottom crossbeam; a wheel support structure disposed below the four corners of the main frame, with a drive wheel connected to the bottom of each wheel support structure, and each drive wheel rotatably connected to the wheel support structure via bearings; a drive motor disposed inside each wheel support structure, the output end of the drive motor being connected to the corresponding drive wheel via a transmission structure for driving the drive wheel to rotate; and a compaction column module disposed in the lower central area of ​​the main frame, the compaction column module comprising multiple compaction columns and connecting to each wheel support structure. The device includes a lifting drive assembly and a guide sleeve corresponding to the compaction column. The compaction column includes a vibration unit. The compaction column has a cylindrical or square cross-section, and the vibration unit is installed inside or at the bottom. The lifting drive assembly includes a hydraulic cylinder, which is fixed to the bottom crossbeam of the main frame. The piston rod end of the hydraulic cylinder is connected to the top of the compaction column to drive the compaction column to lift vertically. The guide sleeve is fixed to the bottom crossbeam of the main frame, and the compaction column passes vertically through the guide sleeve. The guide sleeve is used to limit the lateral displacement of the compaction column. A hydraulic station and an electrical system are installed on the top platform. The hydraulic station or electrical system is used to provide power to the device.

[0007] Preferably, a control system is also included, disposed on the top platform. The control system includes an operating console and a controller. The operating console is electrically connected to the controller, and the controller is electrically connected to the drive motor, the lifting drive assembly, and the vibration unit, for controlling the movement of the device, the lifting and lowering of the compaction column, and the operating mode of the vibration unit.

[0008] Preferably, the main frame is welded from high-strength steel, the top platform is a planar rectangle, and each of the walking wheel support structures is an inverted "L" shape or a rectangular bracket, and is firmly fixed to the bottom of the main frame.

[0009] Preferably, each of the drive wheels is covered with wear-resistant rubber, and each of the drive motors drives the drive wheel to rotate through a reducer and a transmission shaft.

[0010] Preferably, the compaction columns in the compaction column module are arranged at equal intervals, and the bottom of the compaction columns is sharp or flat.

[0011] Preferably, the vibration unit includes an eccentric block motor and an eccentric block body, wherein the eccentric block motor generates high-frequency vibration by rotating the eccentric block body inside it at high speed.

[0012] Preferably, when the lifting drive assembly is a hydraulic cylinder, the hydraulic station includes a hydraulic pump, an oil tank, a valve group, and pipelines, and the hydraulic station provides power to the hydraulic cylinder.

[0013] Preferably, when the power system is a generator set, the generator set includes an engine and a generator body, and the generator set provides the electrical energy required for the operation of the device.

[0014] Preferably, the control system further includes a sensor array electrically connected to the controller, the sensor array including a depth sensor, a pressure sensor, and a positioning sensor.

[0015] Preferably, the depth sensor is installed on the top of the compaction column and the lifting drive assembly to monitor the insertion depth of the compaction column; the pressure sensor is installed on the bottom of the compaction column and the lifting drive assembly to monitor the compaction resistance; and the positioning sensor is used for positioning the device.

[0016] Compared with the prior art, the present invention provides a vibration compaction construction device for a thick water-stabilized base course, which has the following advantages: 1. This invention, by setting a compaction column module that can be vertically raised and lowered and has a built-in vibration unit, realizes the direct application of vibration energy to the deep interior of the water-stabilized base course. Through the working mode of insertion vibration, the energy diffuses from the inside of the material to the outside, thereby achieving a one-time, uniform and dense compaction effect on a thick base course from the inside out. This effectively solves the technical problem of high surface compaction and insufficient bottom compaction caused by the energy attenuation from top to bottom in traditional road rollers, ensuring that the entire base course has uniform and design-compliant density throughout the entire depth range.

[0017] 2. This invention, through its overall frame structure and array-like layout of multiple compaction columns, achieves synchronous and efficient immersion vibration compaction across the entire construction width. This allows construction units to lay and compact a water-stabilized layer up to 40-60 cm thick or even thicker in one go, completely eliminating the inefficient and potentially defective layered construction process. As a result, it significantly improves construction efficiency, shortens the construction period, and fundamentally eliminates the hidden danger of weak interlayer bonding, thereby significantly enhancing the integrity and durability of the roadbed.

[0018] 3. This invention, by equipping each compaction column with an independent lifting drive component and an advanced control system including an operating table and controller, as well as optional arrays of sensors for depth, pressure, etc., enables precise and independent digital control of the insertion depth, compaction force, and vibration mode of each compaction column. This allows the device to adaptively adjust and perform closed-loop control according to different states of the base material and design requirements, thereby ensuring uniform and controllable compaction quality, reducing reliance on operator experience, and providing a hardware foundation for automated and intelligent construction, greatly improving the accuracy and reliability of the construction process. Attached Figure Description

[0019] Figure 1 A schematic diagram of the structure of a vibration compaction device for a thick water-stabilized base course. Figure 1 ; Figure 2 A schematic diagram of the structure of a vibration compaction device for a thick water-stabilized base course. Figure 2 ; Figure 3 This is a schematic diagram of the installation of the walking wheel support structure in a vibratory compaction device for a thick water-stabilized base course; Figure 4 A cross-sectional schematic diagram of the main frame in a vibratory compaction device for a thick water-stabilized base course; Figure 5 This is a schematic diagram of the installation of the guide sleeve in a vibratory compaction device for a thick water-stabilized base course. Figure 6 A cross-sectional schematic diagram of the guide sleeve in a vibratory compaction device for a thick water-stabilized base course; Figure 7 This is a schematic diagram of the installation of the drive motor in a vibratory compaction device for a thick water-stabilized base course. Figure 8 This is a cross-sectional schematic diagram of the compaction column in a vibratory compaction construction device for a thick water-stabilized base course.

[0020] Component numbering list in the diagram: 1. Main frame; 11. Top platform; 12. Side wall structure; 13. Bottom crossbeam; 2. Walking wheel support structure; 21. Drive wheel; 22. Drive motor; 3. Compactor column module; 31. Compactor column; 311. Vibration unit; 312. Eccentric block motor; 313. Eccentric block body; 32. Lifting drive assembly; 33. Guide sleeve; 41. Hydraulic station; 42. Power system; 5. Control system; 51. Operating panel; 52. Controller. Detailed Implementation

[0021] Specifically, the supporting foundation of the device is the main frame 1. For example... Figure 1 , Figure 2As shown, the main frame 1 is a robust rectangular spatial structure, serving as the load-bearing skeleton of the entire device, and its design and manufacturing are crucial. Specifically, its main load-bearing structures, such as the multiple bottom crossbeams 13 and the corner columns, are preferably made of high-strength low-alloy steel, such as Q345B or higher grade rectangular steel pipes or I-beams. These profiles are connected using advanced welding processes such as CO2 gas shielded welding or submerged arc welding to form an integral spatial truss structure with extremely high torsional and bending stiffness. All welds must undergo non-destructive testing to ensure the reliability of the connections and the integrity of the structure. To cope with the harsh construction environment, the surface of the main frame 1 requires strict pretreatment, such as sandblasting to Sa2.5 grade, followed by spraying multiple layers of anti-rust primer, intermediate paint, and weather-resistant topcoat to ensure its long-term corrosion resistance. The main frame 1 can be structurally divided into three parts: the top platform 11, the side wall structure 12, and the bottom crossbeams 13. The top platform 11 is a flat rectangular steel structure platform with an anti-slip steel plate on its upper surface, providing space for the installation of large components and personnel maintenance. The side wall structure 12 connects the top platform 11 and the bottom crossbeam 13. It can be a truss structure composed of steel pipes, which reduces the overall weight while ensuring strength and facilitating observation of the internal equipment. The bottom crossbeam 13 is crucial for installing working components and is composed of multiple transverse and longitudinal I-beams or rectangular beams, forming a sturdy, grid-like chassis.

[0022] Reference Figure 6 Each compaction column 31 has a sealed core vibration unit 311 installed inside its internal cavity. This vibration unit 311 is the source of high-frequency vibration, and its specific structure is a specially designed eccentric block motor 312. This motor is a high-speed, vibration-resistant special motor, and one or a group of eccentric block bodies 313 with large mass and eccentricity are firmly fixed to its output shaft. When the controller issues a command, the eccentric block motor 312 is energized and rotates at a high speed of several thousand revolutions per minute. The high-speed rotating eccentric block body 313 will generate a huge, periodically changing centrifugal force (i.e., excitation force) because its center of mass does not coincide with the center of rotation. This excitation force is directly transmitted to the entire compaction column 31 through the motor housing and fixed bracket, causing it to generate strong, high-frequency simple harmonic vibration.

[0023] The coordinated operation of the entire device is directed by an integrated control system 5. For example... Figure 1 , Figure 2As shown, the control system 5 is also installed on the top platform 11, including an operator console 51 for interaction and a controller 52 as the control core. The operator console 51 is located in a rainproof and dustproof cab, and integrates a touch screen display, control handles, emergency stop buttons, etc., with an intuitive interface and convenient operation. The operator console 51 is electrically connected to the controller 52 via an industrial bus (such as a CAN bus). The controller 52 is typically a high-performance programmable logic controller (PLC) or an embedded industrial computer, which has powerful computing capabilities and rich input / output interfaces. The controller 52 is electrically connected to the frequency converters of all drive motors 22, the electro-hydraulic proportional valves of all lifting drive components 32 (hydraulic cylinders), and the starters of all vibration units 311 (eccentric block motors) through hardwiring or distributed I / O modules.

[0024] During operation, the operator sets the working parameters, such as compaction depth, vibration frequency, and travel speed, on the control panel 51. By operating the control handle, the controller 52 controls the four drive motors 22 to operate synchronously, precisely moving the device above the compaction station. After positioning, the operator starts the compaction program. The controller 52 sends a command to the electro-hydraulic proportional valve group of the hydraulic station 41, and high-pressure oil enters the rod chambers of all hydraulic cylinders. The piston rods retract, driving all compaction columns 31 to descend synchronously and smoothly, inserting into the pre-laid thick layer of water-stabilized material. When the compaction column 31 descends to the preset depth (achieved through time control or limit switches), the controller 52 immediately sends a command to start the eccentric block motors 312 in all vibration units 311. High-frequency vibration is transmitted directly to the deep layer of the water-stabilized material through the column body of the compaction column 31, causing the aggregate particles to move relative to each other under intense vibration, overcoming the friction and adhesion between particles, moving to a more stable position, and filling the voids. This inside-out vibration compaction method ensures that the density of the entire thick layer of material increases uniformly from bottom to top and from the inside out. After a preset vibration period, the controller 52 controls the hydraulic cylinder to lift the compaction column 31 upwards at an extremely slow speed while maintaining vibration. This process, called "vibration-pulling," further enhances the compaction effect and eliminates voids left in the material during lifting. Once the compaction column 31 is completely pulled out of the water-stabilized layer, the controller 52 stops the vibration unit. At this point, the compaction work for one station is complete. Subsequently, the operator moves the device to the next adjacent station, with a slight overlap between the two stations to ensure the continuity of the compaction area. The "positioning-insertion-vibration-pulling" cycle is then repeated until the compaction work for the entire construction section is completed.

[0025] First, to achieve precise control of the compaction depth, a high-precision depth sensor is installed next to each lifting drive assembly 32 (hydraulic cylinder) or directly integrated inside the hydraulic cylinder. For example, a wire-type displacement sensor can be installed between the bottom crossbeam 13 of the main frame 1 and the top connecting seat of the compaction column 31, or a magnetostrictive displacement sensor can be used to directly measure the extension length of the piston rod. These depth sensors can monitor and feed back the vertical position of each compaction column 31 relative to the main frame 1 in real time with millimeter-level accuracy to the controller 52.

[0026] Secondly, to achieve real-time monitoring of compaction, a pressure sensor is integrated into the system. The pressure sensor can be installed in two ways: one is by directly installing a pressure transmitter in the rodless chamber oil circuit of each hydraulic cylinder, indirectly reflecting the resistance of the water-stabilized material to the compaction column by monitoring the back pressure changes in the hydraulic system during the insertion and vibration of the compaction column. This resistance value has a strong positive correlation with the material's density. The other, more direct method is to embed a piezoresistive or piezoelectric pressure sensor inside the bottom end of the compaction column 31 to directly measure the pressure at which the compaction column contacts the material.

[0027] Third, in order to achieve precise positioning and path planning of the device, a high-precision positioning sensor, such as a Global Navigation Satellite System (GNSS) receiver that supports real-time dynamic differential technology (RTK), is installed on the top platform 11 of the main frame 1, with a positioning accuracy of up to centimeters.

[0028] The massive amounts of real-time data collected by these sensors are aggregated to the controller 52 via a high-speed bus. The software system of the controller 52 has the construction design parameters of the project pre-input, including the design compaction thickness, the required final compaction degree (usually expressed as a compaction degree percentage, which can be converted into a target pressure threshold), and the digital geographic boundary of the construction area.

[0029] In automated operation mode, the device operates as follows: The operator loads digital construction drawings on the control panel 51 and initiates automatic mode. The controller 52, based on the real-time position provided by the positioning sensors, automatically controls the walking wheel support structure 2, driving the device precisely to the construction starting point. Upon reaching the working position, the controller 52, based on real-time feedback from the depth sensors, performs independent closed-loop control on each lifting drive component 32, ensuring that the bottom of all compaction columns 31 precisely descends to a small height above the designed base elevation, achieving precise insertion depth control. During vibration compaction, the controller 52 continuously reads the values ​​from each pressure sensor. It determines in real-time whether the pressure value has reached the preset density target threshold. Once the pressure sensor reading below a compaction column in a certain area reaches the target, the controller can selectively reduce the vibration amplitude of that compaction column or stop its vibration early and begin lifting, thus avoiding over-compaction in localized areas. This adaptive closed-loop control based on real-time feedback ensures that the final compaction quality is highly uniform and precisely meets the target across the entire construction surface. Meanwhile, the controller 52 records all construction process data, including the coordinates of each point, compaction depth, final pressure value, and vibration time, forming a complete digital construction log. This provides a reliable basis for project quality traceability and acceptance. Once a workstation is completed, the controller 52 automatically navigates to the next workstation based on a preset path planning algorithm, achieving continuous, efficient, and automated unmanned operation. This intelligent upgrade greatly improves the accuracy, uniformity, and efficiency of construction, minimizing the impact of human factors on project quality.

[0030] Finally, it should be noted that the basic concepts have been described above. Obviously, for those skilled in the art, the detailed disclosure above is merely illustrative and does not constitute a limitation of this specification. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and corrections to this specification. Such modifications, improvements, and corrections are suggested in this specification, and therefore remain within the spirit and scope of the exemplary embodiments of this specification. Furthermore, this specification uses specific terms to describe embodiments of this specification. For example, "an embodiment," "one embodiment," and / or "some embodiments" refer to a feature, structure, or characteristic associated with at least one embodiment of this specification. Therefore, it should be emphasized and noted that "an embodiment," "one embodiment," or "an alternative embodiment" mentioned twice or more in different locations in this specification do not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of this specification can be appropriately combined. Moreover, unless expressly stated in the claims, the order of processing elements and sequences, the use of numbers and letters, or other names described in this specification are not intended to limit the order of the processes and methods of this specification.

Claims

1. A vibration compaction device for a thick water-stabilized base course, characterized in that, include: The main frame (1) has a cuboid structure and includes a top platform (11), side wall structure (12), and bottom crossbeam (13). The walking wheel support structure (2) is set below the four corner points of the main frame (1). The bottom of each walking wheel support structure (2) is connected to a drive wheel (21). Each drive wheel (21) is rotatably connected to the walking wheel support structure (2) through a bearing. A drive motor (22) is installed inside each of the walking wheel support structures (2). The output end of the drive motor (22) is connected to the corresponding drive wheel (21) through a transmission structure to drive the drive wheel (21) to rotate. The compaction column module (3) is located in the central lower region of the main frame (1). The compaction column module (3) includes multiple compaction columns (31) and lifting drive components (32) and guide sleeves (33) corresponding to each compaction column (31). The compaction column (31) includes a vibration unit (311). The compaction column (31) has a cylindrical or square cross-section, and a vibration unit (311) is installed inside or at the bottom. The lifting drive assembly (32) includes a hydraulic cylinder. The lifting drive assembly (32) is fixed on the bottom crossbeam (13) of the main frame (1). The end of its piston rod is connected to the top of the compaction column (31) for driving the compaction column (31) to rise and fall vertically. The guide sleeve (33) is fixed on the bottom crossbeam (13) of the main frame (1), and the compaction column (31) passes vertically through the guide sleeve (33). The guide sleeve (33) is used to limit the lateral displacement of the compaction column (31). A hydraulic station (41) and an electrical system (42) are provided on the top platform (11), the hydraulic station (41) or the electrical system (42) being used to provide power to the device.

2. The vibration compaction device for thick water-stabilized base courses according to claim 1, characterized in that, Also includes: The control system (5) is set on the top platform (11). The control system (5) includes an operating table (51) and a controller (52). The operating table (51) is electrically connected to the controller (52). The controller (52) is electrically connected to the drive motor (22), the lifting drive assembly (32), and the vibration unit (311). It is used to control the movement of the device, the lifting of the compaction column (31), and the working mode of the vibration unit (311).

3. The vibration compaction device for thick water-stabilized base courses according to claim 1, characterized in that, The main frame (1) is welded from high-strength steel. The top platform (11) is a planar rectangle. Each of the walking wheel support structures (2) is an inverted "L" shape or a rectangular bracket and is firmly fixed to the bottom of the main frame (1).

4. The vibration compaction device for thick water-stabilized base courses according to claim 1, characterized in that, Each of the drive wheels (21) is covered with wear-resistant rubber, and each of the drive motors (22) drives the drive wheel (21) to rotate through a reducer and a transmission shaft.

5. The vibration compaction device for thick water-stabilized base courses according to claim 1, characterized in that, The compaction columns (31) in the compaction column module (3) are arranged at equal intervals, and the bottom of the compaction columns (31) is sharp or flat.

6. The vibration compaction device for a thick water-stabilized base course according to claim 1, characterized in that, The vibration unit (311) includes an eccentric block motor (312) and an eccentric block body (313). The eccentric block motor (312) generates high-frequency vibration by rotating its internal eccentric block body (313) at high speed.

7. The vibration compaction device for thick water-stabilized base courses according to claim 1, characterized in that, When the lifting drive assembly (32) is a hydraulic cylinder, the hydraulic station (41) includes a hydraulic pump, an oil tank, a valve group and pipelines, and the hydraulic station (41) provides power to the hydraulic cylinder.

8. The vibration compaction device for thick water-stabilized base courses according to claim 1, characterized in that, When the power system (42) is a generator set, the generator set includes an engine and a generator body, and the generator set provides the electrical energy required for the operation of the device.

9. The vibration compaction device for a thick water-stabilized base course according to claim 1, characterized in that, The control system (5) also includes a sensor array, which is electrically connected to the controller (52). The sensor array includes a depth sensor, a pressure sensor, and a positioning sensor.

10. The vibration compaction device for a thick water-stabilized base course according to claim 9, characterized in that, The depth sensor is installed on the top of the compaction column (31) and the lifting drive assembly (32) to monitor the insertion depth of the compaction column (31); the pressure sensor is installed on the bottom of the compaction column (31) and the lifting drive assembly (32) to monitor the compaction resistance; the positioning sensor is used for positioning the device.

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