Construction Machine Binder Injection Control for Soil Stabilization

Solution Overview

Problem

Existing construction machines struggle to proportionally introduce binders during the initial stages of soil stabilization, leading to uneven binder distribution and reduced stability in treated areas, necessitating post-processing and potentially damaging traffic surfaces.

Innovation Solution

A method that determines the current amount of milled material in the mixing chamber based on the milling depth and penetration speed, allowing for precise control of binder injection to maintain the specified mixing ratio, ensuring homogeneous soil consolidation across the entire work area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If binder injection is started at the beginning of the preparation process, then the mixing ratio can be maintained from the start, but the amount of binder introduced is too high leading to excessive binder in the material

Engineering Contradiction:

Improvemixing ratio controlVSAvoidbinder amount

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The binder injection system dynamically adjusts the binder flow rate based on the real-time quantity of milled material in the mixing chamber. During the preparation phase, as the milling drum penetrates the layer, the system continuously adapts the binder dosage to match the increasing material volume, transitioning from zero injection to full dosage as the chamber fills, thereby maintaining precise mixing ratios throughout the preparation process

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control system continuously monitors the quantity of milled material in the mixing chamber (based on milling depth and penetration speed) and uses this feedback to regulate the binder injection rate. This closed-loop control ensures that binder is injected in precise proportions to the actual material present, preventing both excessive and insufficient binder application during the preparation phase

Inventive Principle:

Principle #23Feedback

2Quantity of substance

If binder injection is delayed until the milling drum has completely penetrated the layer, then excessive binder is avoided, but the material already outside the mixing chamber can no longer be mixed with binder

Engineering Contradiction:

Improvebinder amountVSAvoidmixing ratio control

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The system initiates binder injection in advance, during the preparation phase when the milling drum is penetrating the layer and material is entering the mixing chamber. By starting injection before the drum reaches full penetration depth, the system ensures that material is mixed with binder while still within the mixing chamber, preventing the need for post-processing

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The binder injection system dynamically adjusts the binder flow rate based on the real-time quantity of milled material in the mixing chamber. During the preparation phase, as the milling drum penetrates the layer, the system continuously adapts the binder dosage to match the increasing material volume, transitioning from zero injection to full dosage as the chamber fills, thereby maintaining precise mixing ratios throughout the preparation process

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If manual control of binder introduction is used during the preparation process, then pump regulation limitations are avoided, but the material is not dosed according to specifications resulting in non-uniform stability

Engineering Contradiction:

Improvepump control flexibilityVSAvoiddosage accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The control system continuously monitors the quantity of milled material in the mixing chamber (based on milling depth and penetration speed) and uses this feedback to regulate the binder injection rate. This closed-loop control ensures that binder is injected in precise proportions to the actual material present, preventing both excessive and insufficient binder application during the preparation phase

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces manual mechanical pump control with an automated control system that uses sensors and control algorithms to regulate binder injection. This substitution of mechanical manual operation with automated control based on measured parameters (milling depth, penetration speed) enables precise dosage according to specifications while eliminating the limitations of manual pump regulation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2735650B2Method for treating layers, a construction machine and an auxiliary construction machine

Publication Date: 2018.09.26 WIRTGEN GMBH

Figure 1~2
Figure 3a~4a
Figure 4b~5

AI summary

The method involves milling the layers in a predetermined cutting depth by a construction machine with milling-or mixing roller. The milling-or mixing roller is surrounded by a roller housing (7) which limits the mixing chamber of the milling-or mixing roller. The quantity of binder supplied per unit time is automatically mixed in proportion to the milled material quantity milled per unit time in continuous operation. The determination of the current supplied binder quantity to reach the predetermined cutting depth takes place depending on the current milled milling material quantity present in mixing chamber during the adding process. An independent claim is included for a construction machine, particularly stabilizer or recycler with a chassis.