Asphalt Compactor Stop/Start Assist Control

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Solution Overview

Problem

Asphalt compactors face issues with directional changes during compaction, leading to defects like bumps or divots in the asphalt mat, especially when stopping and reversing, which can result in a washboard road surface if not performed correctly.

Innovation Solution

A control system for asphalt compactors that includes a controller to steer the machine at a desired turning angle, turn off the vibratory system, slow down and stop after a predetermined distance, and then move in the opposite direction, restarting the vibratory system as needed, to perform directional changes autonomously and avoid perpendicular stops.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the asphalt compactor performs directional changes during compaction, then the compactor can navigate the work area and complete the compaction route, but defects (bumps or divots) are left in the asphalt mat

Engineering Contradiction:

Improvedirectional change capabilityVSAvoidasphalt mat surface quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system performs preliminary actions by slowing down the compactor before the directional change and turning off the vibratory system in advance. This preparatory sequence ensures that the compactor is in the correct state (reduced speed, no vibration) before executing the turn, preventing surface defects while maintaining the ability to navigate the work area

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts operating parameters during directional changes by automatically slowing down the compactor and controlling the vibratory system. This dynamic control allows the compactor to adapt its speed and vibration state during turns, enabling smooth directional changes without leaving bumps or divots in the asphalt mat

Inventive Principle:

Principle #15Dynamics

2Productivity

If the asphalt compactor stops and reverses during compaction, then the compactor can follow the predetermined route plan with many directional changes, but a divot is left in the mat

Engineering Contradiction:

Improveroute plan executionVSAvoidasphalt mat surface quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary actions by slowing down the compactor before stopping and turning off the vibratory system before reversal. This preparatory sequence ensures that the compactor is in the correct state (reduced speed, no vibration) before executing the stop and reverse maneuver, preventing divots while maintaining route plan execution

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback from the control system to monitor and adjust the compactor's speed and vibratory system state during stop and reverse operations. This automated feedback control ensures that the compactor slows down appropriately and turns off vibration at the right moment, preventing surface defects while completing the predetermined route

Inventive Principle:

Principle #23Feedback

3Ease of operation

If the operator performs directional changes manually, then the compactor can change direction, but incorrect operation results in bumps or divots in the asphalt

Engineering Contradiction:

Improvedirectional change operationVSAvoidasphalt mat surface quality

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system performs self-service by automatically controlling the speed and vibratory system during directional changes. The control system autonomously slows down the compactor and turns off the vibratory system without requiring manual operator intervention, eliminating human error and ensuring consistent, defect-free directional changes

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces manual mechanical operation with an automated control system that electronically manages the compactor's speed and vibratory system. This substitution of manual control with automated electronic control eliminates operator error and ensures precise, repeatable directional changes that prevent surface defects

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach ensures smooth directional changes, preventing divots and maintaining a flat road surface by controlling the compactor's steering, vibration, and propulsion during turns, thereby improving compaction quality and reducing defects.

Implementation Method 1

utilizing the weight of a roller drum to provide the compressive forces that compact the material

Methodology Applied

Scientific EffectWeight: Gravitation

Implementation Method 2

some compactors are configured to also induce a vibratory force to the surface

Methodology Applied

Scientific EffectVibration: Vibration

Data Source

PatentUS20240318388A1Asphalt compactor stop/start assist

Publication Date: 2024.09.26 CATERPILLAR PAVING PROD INC

AI summary

A system for assisting an asphalt compactor in performing a directional change can include a controller configured to perform a turn-out for the asphalt compactor by steering the asphalt compactor at a desired turning angle on an asphalt mat; the controller configured to turn off a vibratory system for the asphalt compactor during the turn-out; the controller configured to slow down and stop the asphalt compactor after a desired distance into the turn-out; and the controller configured to move the asphalt compactor in an opposite direction and restart the vibratory system.