Asphalt Paver Mast Control Point Offset for Surface Accuracy
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Solution Overview
Problem
Modern construction machines, despite advancements in sensors for real-time monitoring, still face challenges in achieving precise control and smooth surface laying during construction processes, particularly in asphalt paving, due to limitations in geospatial positioning and angle detection, leading to inaccuracies and surface ripples.
Innovation Solution
A construction machine control system that includes a position sensor and an angle sensor mounted on a mast to detect geospatial positions and angles, calculating a control point offset from a mast vector, and adjusting tow arms based on comparisons between the control point and a target point to minimize error and achieve desired mat thickness and smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If geospatial position and angle sensors are mounted on the mast to detect positions and angles for control point calculation, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensors (position sensor and angle sensor) into an integrated sensor system mounted on the mast. This merging approach allows simultaneous detection of both geospatial position and mast angles, improving overall measurement precision while reducing the number of separate sensor installations needed.
Solution Approach 2:
The sensor system mounted on the mast serves multiple functions: detecting geospatial position coordinates, measuring mast pitch angles, and measuring mast roll angles. This multi-functional approach improves measurement precision across multiple parameters while avoiding the complexity of separate sensor systems for each measurement type.
2Manufacturing precision
If the control point is spatially offset from the mast vector to improve surface laying accuracy, then manufacturing precision is improved, but calculation complexity increases
Solution Approach 1:
The control point is pre-calculated with a spatial offset from the mast vector based on the specific paving application requirements. This preliminary offset calculation accounts for the hydraulic system response characteristics and mat thickness requirements, allowing the control system to achieve better surface laying accuracy without requiring complex real-time adjustments during operation.
Solution Approach 2:
The offset control point acts as an intermediary between the mast position and the actual paving surface target. By introducing this intermediate reference point with a calculated offset, the system can compensate for hydraulic system lag and achieve more accurate surface laying, while the offset value itself simplifies the control calculations compared to direct mast-to-surface control.
3Productivity
If tow arms are adjusted based on error comparison between control point and target point, then productivity is improved, but control system complexity increases
Solution Approach 1:
The control system continuously compares the calculated control point position with the target point position, determines the error, and uses this feedback to automatically adjust the tow arm positions. This closed-loop feedback control improves paving productivity by maintaining accurate mat thickness and surface elevation, while the systematic feedback approach keeps control system complexity manageable through standardized control algorithms.
Solution Approach 2:
The tow arm adjustment system dynamically responds to real-time error signals by automatically modifying tow arm positions to eliminate deviations from the target surface profile. This dynamic control improves productivity by continuously optimizing the paving process, while the automated dynamic adjustment reduces the need for manual intervention and complex operator decision-making.
4Reliability
If sensors are mounted on the mast to enable real-time monitoring, then reliability is improved, but ease of operation decreases
Solution Approach 1:
Multiple sensor functions (position detection and angle measurement) are merged into a single integrated sensor package mounted on the mast. This consolidation improves reliability by ensuring all sensors are positioned optimally together, while also improving ease of operation by reducing the number of separate installation locations and maintenance access points required.
Data Source
AI summary
Systems and methods for controlling a construction machine, such as an asphalt paver, having a tractor, an implement coupled to the tractor via at least one tow arm, and a mast. A position sensor mounted to the mast may detect a geospatial position of the mast. An angle sensor may detect at least one angle associated with the mast. A control point may be calculated based on the geospatial position and the at least one angle. The control point may be spatially offset from a vector formed by a lengthwise extension of the mast. The at least one tow arm may be moved based on a comparison between the control point and a target point.