Road Paver Screed Leveling With Dual-Sensor Offset Control
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Solution Overview
Problem
Manual leveling of bridge approaches in construction is inefficient and non-reproducible, leading to quality issues and increased personnel requirements due to varying subsoil conditions, which current systems like Big Sonic-Ski or Super-Ski systems struggle to address effectively.
Innovation Solution
A leveling system for pavers with a measuring system and control system, utilizing at least two sensors to determine elevation differences and calculate offsets, allowing automated adjustment of the screed for precise layer thickness control, including the use of regression lines and predictive models for enhanced accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual leveling adjustment is performed by switching between individual sensors, then the leveling can be adapted to varying subsoil conditions, but the process becomes non-reproducible and increases personnel requirements
Solution Approach 1:
The system enables autonomous leveling by automatically switching between sensors and adjusting the screed position based on measured elevation data, eliminating the need for manual intervention and making the system self-regulating
Solution Approach 2:
The control system continuously receives elevation measurements from multiple sensors, compares them against target values, and automatically adjusts the screed position accordingly, creating a closed-loop feedback system that adapts to varying subsoil conditions
2Adaptability or versatility
If manual leveling adjustment is performed by switching between individual sensors, then the leveling can be adapted to varying subsoil conditions, but the quality becomes affected due to non-reproducible procedures
Solution Approach 1:
The system autonomously performs sensor switching and screed adjustment based on pre-programmed logic and real-time measurements, ensuring reproducible procedures that consistently achieve the desired leveling quality
Solution Approach 2:
The control system is pre-configured with target elevation values and switching criteria, allowing it to automatically execute reproducible leveling procedures without manual intervention
3Extent of automation
If two sensors are used to scan the subgrade and determine displacement, then automated leveling control can be achieved, but the device complexity increases
Solution Approach 1:
The control system performs multiple functions including automatic sensor switching, elevation calculation, offset determination, and screed control using a single integrated unit, reducing overall system complexity despite the addition of sensors
Solution Approach 2:
The patent combines the functions of multiple sensors and the control system into an integrated measuring and control apparatus that operates as a unified system, managing complexity through functional integration
4Productivity
If automated sensor switching and screed control is implemented, then personnel requirements are reduced, but the system complexity increases
Solution Approach 1:
The control system autonomously manages sensor switching and screed adjustment without requiring manual operation, achieving high automation while managing complexity through integrated design
Solution Approach 2:
The patent replaces manual mechanical adjustment operations with an automated control system that uses electronic sensors and computer-controlled screed positioning, reducing personnel requirements while managing complexity through electronic automation
Data Source
Figure 1A~1C
Figure 2
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AI summary
Leveling system for a road paver (1) with a screed (10), comprising: a measuring system (30); and a control system; wherein the measuring system (30) has a first and a second sensor, the first sensor (34a) being arranged in the direction of travel in front of the second sensor (34b) and being configured to measure a first distance from the first sensor (34a) to another subsoil or surface with a height level offset by a factor (V) in order to obtain a first height value; and wherein the second sensor (34b) being arranged in the direction of travel in front of the screed (10) of the road paver (1) and being configured to measure a second distance from the second sensor (34b) to a subsoil of the construction machine or a reference of the construction machine in order to obtain a second height value;wherein the control system is configured to determine the offset (V) by calculating the difference between the first and second height values, wherein the control system is further configured to determine a setpoint for adjustment based on the offset (V); wherein the control system is configured to control the plank (10) depending on the setpoint.