Real-Time Pavement Layer Analysis for Precise Milling Depth Control
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Solution Overview
Problem
Existing milling operations face inefficiencies due to unknown initial pavement layer thickness, leading to risks of damaging underlying structures, increased planning time, and downtime, and lack of flexibility in adapting to different surface layers.
Innovation Solution
A milling depth control system using a layer measuring sensor, such as ground penetrating radar, to identify and analyze surface layers in real-time, allowing for precise control of milling depth based on target interfaces between layers, and generating a milling depth map without prior knowledge, with features for user input and collision avoidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If milling depth is increased to remove more material, then productivity is improved, but risk of damaging underlying structures increases
Solution Approach 1:
The system performs preliminary scanning of the surface using a sensor (e.g., ground penetrating radar) before milling to identify the thickness and composition of pavement layers. This advance information allows the control system to set the appropriate milling depth that removes the desired material while stopping before damaging underlying structures, thus resolving the contradiction between increasing productivity and preventing harm.
2Reliability
If planning phase is extended to ensure safety, then reliability is improved, but loss of time increases
Solution Approach 1:
The system replaces manual inspection and planning methods with automated sensor-based detection and computer-controlled depth regulation. The sensor automatically scans and identifies layer structures, and the control system automatically determines safe milling depths, eliminating the need for time-consuming manual planning while maintaining high safety standards through precise, real-time control.
3Measurement precision
If manual inspection and planning are performed, then measurement precision of surface layers is improved, but productivity decreases
Solution Approach 1:
The system enables the milling operation to be self-sufficient by automatically detecting surface layer characteristics and determining milling parameters without requiring external manual inspection or planning. The sensor system and control unit work together to autonomously identify layer thicknesses and set appropriate milling depths, eliminating downtime associated with manual preparation while maintaining high measurement precision through automated detection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances operational efficiency by reducing planning time, minimizing equipment damage, and ensuring safe, flexible milling operations by accurately controlling milling depth and avoiding underground objects.
Implementation Method 1
The layer measuring sensor (8) is based on ground penetrating radar technology
Data Source
AI summary
A milling depth control system for a milling machine for milling a stratified surface and a milling machine equipped with a milling depth control system, wherein milling depth control is based on real time layer analysis of surface layers of a stratified surface to be milled. The milling depth control system comprises a surface layer measurement sensor, e.g. based on ground penetrating radar technology, installed at the front of the milling machine, and a data processing unit. The measurement data of the layer measuring sensor are used by the data processing unit to analyze individual surface layers of the stratified surface, e.g. by identifying different surface layers and determining layer thicknesses of the identified surface layers, in order to provide a control signal to a control unit of the milling machine to set the milling depth in real time.