Concrete Texturing Machine with Crown Height Sensors
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Solution Overview
Problem
Existing concrete texturing machines lack precise control over texture application and edge detection, leading to inconsistent surface finishes and potential issues with skid resistance and noise reduction on newly formed concrete surfaces.
Innovation Solution
A texturing machine equipped with adjustable height columns, crown point actuators, and a sensor system for real-time height and edge detection, allowing for precise control of texture application and alignment with the concrete surface, including contactless sensor arrays for edge detection and a controller to adjust the machine's position and height accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional texturing machines are used without precise height control, then the device complexity is reduced, but the manufacturing precision of the concrete surface texture deteriorates
Solution Approach 1:
The texturing device employs dynamically adjustable height mechanisms that allow real-time modification of the texturing elements' position relative to the concrete surface. This dynamic adjustment capability enables the system to adapt to varying concrete surface profiles while maintaining consistent texture application, thereby improving manufacturing precision without requiring overly complex fixed structures
Solution Approach 2:
The system incorporates height sensors that continuously monitor the distance between the texturing device and the concrete surface, providing feedback signals to a control system. This feedback mechanism enables automatic adjustment of the texturing device height to maintain optimal contact pressure and consistent texture depth, significantly improving surface texture consistency while automating the control process
2Reliability
If contactless sensor arrays are used for edge detection, then the reliability of edge detection is improved, but the device complexity increases
Solution Approach 1:
The system replaces mechanical contact-based edge detection methods with contactless optical or electromagnetic sensors. These sensors detect the concrete layer edges without physical contact, eliminating wear and contamination issues associated with mechanical sensors, thereby improving detection reliability while using non-mechanical fields
3Manufacturing precision
If real-time height adjustment is implemented, then the manufacturing precision of the concrete surface is improved, but the productivity decreases due to additional adjustment time
Solution Approach 1:
The height adjustment mechanism operates continuously during the texturing process rather than requiring stop-and-adjust cycles. The sensor system continuously monitors surface height variations, and the actuation system continuously adjusts the texturing device position, maintaining uninterrupted texturing operation while ensuring consistent texture depth, thereby preserving productivity
Solution Approach 2:
The system incorporates automatic height control where the sensor feedback directly actuates the adjustment mechanism without requiring manual intervention. This self-regulating capability allows real-time precision adjustment while maintaining continuous operation, eliminating the productivity loss that would result from operator stops and manual adjustments
Data Source
AI summary
A texturing machine is provided for the subsequent treatment of a freshly produced concrete layer having a width between left and right edges and extending longitudinally in a working direction. Left and right height sensors are arranged to detect a height above the freshly produced concrete adjacent the left and right edges of the layer. At least one crown height sensor is arranged to detect a height above a crown of the freshly produced concrete layer. A controller is configured to receive input signals from the height sensors and to communicate height control sensors to the height adjustable columns and to communicate a crown control system to the crown actuator. A direction sensor may also detect at least one of the edges of the freshly produced concrete layer. The controller may receive a direction input signal from the direction sensor, and the controller may communicate a direction control signal to a steering actuator of one of the ground engaging units of the machine.