3D Bridge Deck Finisher with Real-Time Sensor Feedback
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Solution Overview
Problem
Conventional bridge paving methods are labor-intensive and prone to inaccuracies, especially when dealing with complex designs and transitions, due to the reliance on vertical profile rails and outdated surveying techniques.
Innovation Solution
A bridge paving machine and method that converts a desired 3D design into a surface model, using an on-board computer system to adjust in real-time based on data from external and paving machine sensors, predicting and correcting for beam deflections and environmental factors to ensure accurate paving without vertical profile rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional vertical profile rails and surveying techniques are used, then the paving process can be guided, but the labor intensity increases and measurement precision deteriorates
Solution Approach 1:
The patent replaces the mechanical surveying system with vertical profile rails and manual surveying techniques with an automated laser scanning system. The laser scanner captures 3D point cloud data of the bridge deck surface, and a computer system processes this data to generate precise elevation profiles, eliminating the need for manual surveying and reducing labor intensity while improving measurement precision.
Solution Approach 2:
The patent creates a digital 3D model of the bridge deck surface by scanning physical reference marks and measuring devices. The laser scanner captures the spatial coordinates of reference marks placed on the bridge deck, and the computer system reconstructs the surface geometry from these digital copies, enabling precise measurement without direct manual measurement.
2Reliability
If conventional surveying methods are used for complex pavement designs, then the paving can be completed, but the measurement precision and reliability deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where the laser scanner continuously measures the actual bridge deck surface profile during the paving process. The computer system compares the measured profile with the desired design profile and calculates deviations, providing real-time feedback to adjust the paving process and ensure reliable completion of complex pavement designs.
Solution Approach 2:
The patent transitions from traditional 2D surveying measurements to 3D spatial measurement. The laser scanner captures x, y, and z coordinates of the bridge deck surface, creating a comprehensive 3D point cloud that accurately represents surface deflections and complex geometries, thereby improving measurement precision and reliability for complex pavement designs.
3Productivity
If vertical profile rails are used to guide paving, then the paving process can be controlled, but the device complexity and loss of time increase
Solution Approach 1:
The patent extracts and removes the vertical profile rails from the paving system. Instead of using physical rails to guide the paving process, the system uses a laser scanner to capture spatial data and a computer system to process this data, generating digital elevation profiles that guide the paving operation without requiring complex physical guidance structures.
Solution Approach 2:
The patent replaces the mechanical vertical profile rail system with an optical-mechanical laser scanning system and computer processing system. The laser scanner optically measures the bridge deck surface, and the computer system processes the data to generate control profiles, eliminating the need for complex mechanical guidance rails and improving paving efficiency.
Data Source
AI summary
A bridge paving machine and method for paving a 3D design without vertical profile rails includes converting a desired design into a 3D surface model to account for certain factors known to cause deviations in the paving processes and paving the 3D surface model in the expectation that factors will cause the 3D surface model to deflect into the desired design. An on-board computer system adjusts the 3D surface model in real-time to correct for on-site variables. The on-board computer system receives data from various external sensors, including deflection sensors fixed to girders in the bride structure, and paving machine-based sensors, and uses various predictive models to predict surface deflection based on the sensor data. The 3D surface model is continuously updated based on the predictive models and actual measured deflections.