Dynamic Paver Gates for Consistent Compaction
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Solution Overview
Problem
Existing asphalt paving systems face challenges in achieving consistent compaction density over uneven sub-bases due to bridging issues, where high-density asphalt forms over peaks and leaves low-density areas uncompacted, requiring excessive material removal and replacement, and resulting in environmental impacts from reprocessing and energy-intensive production.
Innovation Solution
A dynamic paving material paver with multiple gates and actuators that partially obstruct the flow of asphalt, allowing for adaptive distribution and compaction across sub-base irregularities, reducing the need for extensive material removal and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional asphalt paving is used over uneven sub-base, then material can be applied continuously, but compaction density becomes inconsistent due to bridging over peaks
Solution Approach 1:
The material distribution system is segmented into multiple independently controllable gates across the paving width, allowing differential material flow control to different zones (peaks vs. pits) while maintaining continuous paving operation
Solution Approach 2:
The system applies local quality control by adjusting material distribution and compaction parameters specifically for different sub-base zones (peaks requiring less material, pits requiring more material), achieving consistent compaction density across uneven surfaces
2Manufacturing precision
If compaction is applied over uneven sub-base, then peaks reach high density quickly, but this creates bridging that prevents consistent compaction over pits
Solution Approach 1:
The system dynamically adjusts material distribution and compaction forces in real-time based on detected sub-base irregularities, adapting compaction parameters to local conditions (peak vs. pit zones) rather than applying uniform compaction
Solution Approach 2:
The system uses sensors to detect sub-base irregularities and provides feedback to control material distribution and compaction, creating a closed-loop system that adapts to varying ground conditions across the paving width
3Manufacturing precision
If extensive material removal and replacement is performed to achieve consistent compaction, then compaction quality improves, but energy consumption and environmental impact increase
Solution Approach 1:
The system performs preliminary action by detecting sub-base irregularities before paving and pre-adjusting material distribution and compaction parameters, preventing compaction inconsistencies rather than requiring corrective material removal and replacement later
Data Source
AI summary
Disclosed is a dynamic paving material paver. The dynamic paving material paver may comprise: a material distribution device; a material leveling device; at least one actuator; and a plurality of gates configured to distribute a paving material on a sub-base via the material leveling device, wherein the plurality of gates are mechanically coupled to the at least one actuator, configured to partially obstruct a flow of the paving material received from the material distribution device, and located proximate to, and ahead of, the material leveling device in a direction of the flow of paving material from the material distribution device.