Paver Control System for Pavement Thickness and Pre-compaction
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Solution Overview
Problem
Existing road finisher technologies lack direct process control, burdening operators with the responsibility of selecting machine parameters, leading to suboptimal pavement thickness, evenness, and structure, with inefficient energy consumption and increased wear on working components.
Innovation Solution
A control system that accounts for the angle of attack as a control variable, regulating tamper stroke and frequency to achieve optimal pavement thickness, evenness, and structure, while minimizing energy consumption and wear, allowing for direct and automatic control of the paving process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the operator manually selects machine parameters (tamper frequency, tamper stroke, paving speed) based on experience, then the system remains simple to operate, but the paving quality (thickness, evenness, structure) deteriorates and energy consumption increases
Solution Approach 1:
The control system automatically adjusts machine parameters (tamper frequency, tamper stroke, paving speed) based on real-time monitoring of paving quality indicators, replacing manual operator selection with automated parameter optimization. This resolves the contradiction by achieving high paving quality through automatic parameter changes while reducing operator burden to simple monitoring and oversight functions.
Solution Approach 2:
The system implements closed-loop feedback by continuously monitoring paving quality (thickness, evenness, structure) and using this information to automatically adjust machine parameters. The feedback mechanism enables the system to self-optimize paving quality without requiring operator expertise, thus improving manufacturing precision while reducing operational complexity.
2Manufacturing precision
If the tamper frequency is increased to improve pre-compaction, then the compaction quality improves, but energy consumption and wear on working components increase
Solution Approach 1:
The system dynamically adjusts tamper frequency and stroke based on real-time paving conditions and quality requirements rather than operating at fixed high settings. This dynamic optimization achieves necessary compaction quality while minimizing energy consumption and component wear by using only the tamper intensity required for each specific condition.
Solution Approach 2:
The control system optimizes tamper parameters (frequency, stroke) as variable inputs based on monitored paving quality, replacing fixed high-intensity operation with adaptive parameter adjustment. This achieves optimal pre-compaction quality while reducing overall energy consumption and wear by matching tamper intensity to actual needs.
3Manufacturing precision
If the angle of attack of the screed is not controlled, then the machine operation is simple, but the pavement thickness and evenness deteriorate
Solution Approach 1:
The system uses feedback from thickness and evenness sensors to automatically adjust the angle of attack of the screed, maintaining optimal paving quality without requiring manual intervention. The feedback loop continuously monitors pavement characteristics and adjusts screed angle accordingly, resolving the contradiction between precision and complexity.
Solution Approach 2:
The control system performs self-adjustment of the screed angle based on monitored paving quality, eliminating the need for constant operator intervention. The system serves itself by automatically correcting angle deviations to maintain optimal pavement thickness and evenness, thus improving precision while the complexity is managed through automation rather than manual complexity.
4Use of energy by moving object
If multiple machine parameters are manually adjusted to optimize paving quality, then the energy consumption and wear can be reduced, but the operator responsibility and complexity increase
Solution Approach 1:
The control system automatically performs the optimization of multiple machine parameters (tamper frequency, stroke, paving speed, screed angle) without requiring operator expertise or manual adjustment. The system monitors paving quality and self-adjusts parameters to achieve optimal energy efficiency and reduced wear, transferring the complexity from operator responsibility to automated control.
Solution Approach 2:
The system uses feedback from quality sensors to automatically optimize multiple parameters simultaneously, achieving energy efficiency and reduced wear without requiring operator intervention. The closed-loop control continuously adjusts parameters based on actual paving outcomes, resolving the contradiction by making the system self-optimizing rather than operator-dependent.
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
Enables operators to achieve optimal pre-compaction, evenness, and structure with minimal energy consumption and reduced wear on working components, even for untrained operators, by automatically adjusting tamper stroke and frequency based on real-time process data.
Implementation Method 1
a tamper (14) which can be operated via an eccentric drive with selectable stroke H and selectable frequency F
Implementation Method 2
optionally a vibration device for the screed plate
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
In a method for controlling the process of installing a pavement (6) of a selectable thickness (S) using a paver (1) having a screed (3) towed by drawbars (8) and moving at a paving speed (V), wherein the screed (3) has a pre-compaction system (13) with at least one tamper (14) operable with selectable stroke and selectable frequency (HF), pivot points (9) of the drawbars (8) adjustable via leveling cylinders (10), and the drawbars (8) height-adjustable by means of lifting cylinders (28), the paving process (36) is automatically controlled by means of an automatic control system (25) in which a target value for the pavement thickness is entered, an actual angle of attack (α) of the screed (3), the actual pavement thickness (S) and the paving speed (V) are recorded and transmitted as information to the control system (25), which consists at least of the transmitted Information is generated and transmitted to actuators, including control signals.which are automatically implemented by this under rules of the actual pavement thickness to the target value and optimization of an operating point of the pre-compaction system (13). The road paver has a computerized, either fully automatic or operator-assisted control system (25) for directly controlling the paving process (36) under rules of the pavement thickness to a predetermined target value and for optimizing the operating point of the pre-compaction system, which is connected to sensors at least for detecting the angle of attack (α) of the screed (3), the pavement thickness (S) and the paving speed (V).