Asphalt Control System Real-Time Moisture Monitoring
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Solution Overview
Problem
Conventional asphalt control systems fail to accurately and continuously monitor the amount of liquid asphalt cement, recycled liquid asphalt cement, moisture in recycled asphalt pavement, and moisture in aggregate materials in real time, leading to material waste, excess costs, and suboptimal mixes.
Innovation Solution
A control system that includes sensors and a microprocessor to continuously and real-time monitor and control the amounts of liquid asphalt cement, recycled asphalt pavement, and aggregate materials, ensuring precise injection rates and reducing waste and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional control systems are used for asphalt production, then the system is simple and easy to operate, but the measurement precision and manufacturing precision of asphalt mix composition deteriorate
Solution Approach 1:
The patent replaces conventional mechanical control systems with a sophisticated electronic control system that incorporates multiple sensors (weighing sensors, moisture sensors, temperature sensors) and a microprocessor-based controller. This substitution enables precise real-time measurement and control of liquid asphalt cement injection rates, transforming the system from manual/mechanical operation to automated electronic control, thereby achieving high measurement precision without sacrificing operational simplicity.
Solution Approach 2:
The control system implements continuous feedback loops where sensors monitor the actual amounts of materials being mixed and the injection rates of liquid asphalt cement, and the controller adjusts the injection rates based on this feedback to maintain precise composition control. This feedback mechanism ensures that the system maintains high measurement and manufacturing precision by constantly comparing actual values with target values and making real-time corrections.
2Productivity
If conventional control systems are used for asphalt production, then the device complexity is low, but the productivity and material utilization deteriorate due to material waste
Solution Approach 1:
The control system continuously monitors the composition of the asphalt mix and the injection rates of liquid asphalt cement, providing real-time feedback to the controller. This enables precise adjustment of material flow rates to match actual production needs, preventing both material waste from over-injection and production delays from under-injection, thereby simultaneously improving productivity and reducing material loss.
Solution Approach 2:
The system incorporates automatic material flow rate adjustment capabilities where the controller autonomously regulates the injection rates of liquid asphalt cement based on sensor feedback without requiring manual intervention. This self-adjusting mechanism ensures optimal material utilization by automatically compensating for variations in material properties and production conditions, reducing material waste while maintaining high productivity.
3Manufacturing precision
If conventional control systems are used for asphalt production, then the ease of operation is high, but the manufacturing precision of asphalt mix composition deteriorates
Solution Approach 1:
The control system performs automatic regulation of liquid asphalt cement injection rates based on real-time sensor feedback without requiring continuous manual adjustment. The system self-monitors material composition, self-calculates required injection rates, and self-adjusts flow rates to maintain precise manufacturing specifications. This automation maintains ease of operation by eliminating complex manual control tasks while achieving high manufacturing precision through intelligent autonomous control.
Solution Approach 2:
The patent replaces manual mechanical control operations with an electronic control system that uses microprocessors to automatically calculate and regulate injection rates. This substitution transforms the operational mode from manual adjustment to automated electronic control, maintaining operational simplicity through user-friendly interfaces while achieving superior manufacturing precision through precise electronic regulation of material flow rates.
4Manufacturing precision
If continuous real-time monitoring is implemented, then the measurement precision and manufacturing precision improve, but the device complexity and cost increase
Solution Approach 1:
The control system is designed as a multi-functional integrated unit that simultaneously performs multiple functions: weighing materials, monitoring moisture content, measuring temperature, controlling injection rates, calculating composition ratios, and adjusting flow rates in real-time. By consolidating these functions into a single unified control system rather than separate independent devices, the patent achieves high manufacturing precision while managing device complexity through functional integration and multi-purpose operation.
Data Source
AI summary
A system for controlling the production of an asphalt mix. The preferred system comprises an asphaltic material source, an asphaltic material sensor, a liquid asphalt cement source, a liquid asphalt cement meter, and a controller. The asphaltic material sensor communicates the amount of asphaltic material liquid asphalt cement and the amount of asphaltic material moisture contained in the amount of asphaltic material to the controller, the liquid asphalt cement meter communicates the amount of liquid asphalt cement provided by the liquid asphalt cement source to the controller, and the controller controls the amount of asphaltic material provided by the asphaltic material source and the amount of the liquid asphalt cement provided by the liquid asphalt cement source. A method comprising controlling the amount of asphaltic material and the amount of liquid asphalt cement provided to the asphalt mix substantially continuously and substantially in real time.