Asphalt Paver Material Height Sensor Feedback Control
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Solution Overview
Problem
Asphalt pavers face challenges in maintaining a consistent material pile height due to operator subjectivity and variability in conveyor and auger speed settings, leading to uneven road surfaces.
Innovation Solution
The implementation of sensors on the screed to measure material pile size and transmit information to an Electronic Control Module (ECM), which calculates and adjusts conveyor and auger speeds to maintain a target pile size, automating the material feed process and eliminating the need for manual adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual adjustment of conveyor and auger speeds is used, then operator flexibility is maintained, but material pile height consistency deteriorates due to operator subjectivity
Solution Approach 1:
The patent implements a feedback control system where sensors continuously monitor the material pile height in front of the screed and transmit this information to an electronic control module (ECM). The ECM automatically adjusts conveyor and auger speeds based on the detected pile height, creating a closed-loop feedback system that maintains consistent material distribution without manual intervention.
Solution Approach 2:
The patent replaces the manual mechanical adjustment system with an automated electronic control system. Instead of operators manually adjusting speeds based on visual estimation, the system uses sensors to detect material pile height and an ECM to automatically regulate conveyor and auger speeds, substituting human judgment with automated sensing and control.
2Manufacturing precision
If automated sensor-based control is implemented, then material pile height consistency is improved, but device complexity increases
Solution Approach 1:
The system enables the paver to self-regulate its material feed operation. The sensors continuously monitor the material pile height and the ECM automatically adjusts conveyor and auger speeds without requiring external operator intervention, allowing the system to maintain optimal paving conditions autonomously throughout the paving process.
Solution Approach 2:
The electronic control module serves multiple functions: it receives signals from sensors, processes the material pile height information, calculates the appropriate speed adjustments, and controls both the conveyor and auger systems. This multi-functional design consolidates control capabilities into a single device, reducing overall system complexity despite the addition of automation components.
3Measurement precision
If continuous sensor monitoring is used, then material distribution accuracy is improved, but loss of time for calibration and setup increases
Solution Approach 1:
The system performs preliminary calibration actions automatically during initial setup. The sensors are pre-positioned on the screed to detect material pile height, and the ECM is pre-programmed with the control algorithm. When the paver begins operation, the system automatically calibrates by monitoring the initial material pile and adjusting speeds accordingly, eliminating the need for lengthy manual calibration procedures.
Data Source
AI summary
A method and apparatus is disclosed for controlling material feed for asphalt pavers. The material feed system includes a screed, feeder conveyor and a spreader auger. A sensor measures a material volume and transmits this information to an electronic control module (ECM). This information may be used as the target material volume, which the ECM may use to calculate a corresponding conveyor speed and auger speed. The sensor monitors the material volume as paving commences, and the ECM maintains the initial calibrated target size by adjusting the auger and conveyor rotational speeds.