Compactor Effective Roller Radius Sensor for Real-Time Compaction
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Solution Overview
Problem
Current methods for determining compaction state in earthworks construction and road paving are delayed and inaccurate, relying on post-process measurements that fail to detect issues in real-time and often require costly rework.
Innovation Solution
A compactor with an electronic system that includes sensors to measure the effective roller radius, allowing for real-time determination of compaction state by comparing the actual and effective roller radii, and using this data to generate a compaction state map for efficient compaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If post process measurement methods such as nuclear density gages are used to measure compaction, then compaction state can be measured, but job delays occur and problems are not detected in real-time
Solution Approach 1:
The patent replaces traditional mechanical/post-process measurement methods (nuclear density gages) with an optical sensing system that uses light reflection to measure compaction state in real-time. The sensor system captures reflected light signals from the asphalt surface, processes them through algorithms, and provides immediate compaction feedback without requiring post-compaction measurement operations.
Solution Approach 2:
The compaction measurement system is integrated directly onto the compactor itself, allowing the compactor to perform its own real-time monitoring and assessment during operation. This eliminates the need for separate post-process measurement operations and enables immediate detection of compaction issues while they occur.
2Measurement precision
If post process measurements are used to determine compaction state, then compaction can be assessed, but the entire surface area cannot be tested as only a small fraction is measured
Solution Approach 1:
The patent divides the large surface area into multiple measurement zones by using multiple sensors positioned at different locations on the compactor. Each sensor independently measures the compaction state of its specific zone, and the results are combined to provide comprehensive coverage of the entire paved surface area, transforming a single-point measurement limitation into multi-point distributed measurement capability.
3Loss of time
If sensors are exposed to the work environment to measure asphalt surface properties, then real-time measurement is possible, but the sensors are exposed to hostile and dirty conditions
Solution Approach 1:
The patent introduces an intermediary optical system consisting of light sources and optical paths that allow the sensor to measure asphalt surface properties without direct physical contact. The sensor measures reflected light characteristics from a distance, using light as an intermediary carrier to transmit surface information back to the measurement device, thereby isolating the sensor from harsh environmental conditions while maintaining measurement capability.
Data Source
AI summary
Accurately determining the compaction state of a base material during the compaction process is a recognized problem in the construction industry. The present invention recognizes that the compaction state of the base material can be determined by ascertaining the effective roller radius of the compactor. In other words, in the case of powered compactors, the effective roller radius will asymptotically approach the actual roller radius as the base material changes from a soft un-compacted condition to a hard compacted state. Monitoring compaction state via indicative of an effective roller radius can be used alone as a means of determining compaction state in real time, or can be leveraged and combined with other independent means of monitoring the compaction state to a symbiotic affect in more accurately determining compaction state.