Road Paver Screed Leveling for Ground Offset Transitions
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Solution Overview
Problem
Manual leveling processes in bridge constructions are non-reproducible, affecting quality and increasing personnel requirements, especially at ground transitions where height offsets occur.
Innovation Solution
A leveling system for road pavers with a screed, equipped with two sensors to measure distances to different ground levels, a controller to determine offsets, and automate the adjustment process using a set value for screed control, enabling reproducible and efficient layer thickness adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual leveling processes are used at ground transitions, then personnel can adjust the necks to eliminate steps, but the process becomes non-reproducible affecting quality and increasing personnel requirements
Solution Approach 1:
The patent replaces manual mechanical adjustment operations with an automated optical measurement and control system. The measuring system uses optical sensors to detect ground heights and calculate offsets, while the control system automatically adjusts the neck position based on measured data, eliminating the need for manual intervention and ensuring reproducible results
Solution Approach 2:
The system enables the leveling process to be self-regulating through automatic feedback control. The measuring system continuously monitors ground transitions, the control system processes the data to determine required adjustments, and the actuation system automatically implements corrections without external human input, making the process self-sufficient and reproducible
2Productivity
If manual switching to different individual sensors is used, then the measuring system can scan the ground, but the personnel efficiency decreases due to increased personnel requirements
Solution Approach 1:
The patent merges multiple sensor functions into a single integrated measuring system. Instead of manually switching between individual sensors, the system combines multiple optical sensors that simultaneously measure ground heights at different positions, with a control system that automatically processes all sensor data to determine the required neck adjustment, thereby increasing personnel efficiency while managing device complexity through integration
3Manufacturing precision
If a cable is used as a reference scanned by the measuring system, then a clean neck can be obtained, but the measurement process becomes more complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by measuring and calculating the ground offset before the actual paving operation begins. The measuring system scans the ground transition in advance, the control system calculates the required neck adjustment based on measured heights, and the system pre-positions the neck at the correct height, ensuring a clean transition is achieved from the start without requiring time-consuming adjustments during operation
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
Automated leveling improves quality and reduces personnel efficiency by ensuring consistent transitions over varying ground levels, particularly at bridge structures.
Implementation Method 1
the first sensor is arranged in front of the second sensor in the direction of travel and is configured to measure a first distance from the first sensor to a further ground or surface with a height level offset by an offset in order to obtain a first height value
Implementation Method 2
the second sensor is arranged in front of the screed of the road paver in the direction of travel and is configured to measure a second distance from the second sensor to a ground of the construction machine or a reference of the construction machine in order to obtain a second height value
Data Source
AI summary
A leveling system for a road paver with a screed, having: a measuring system; and a controller; the measuring system having first and second sensors, the first sensor being arranged in front of the second sensor in the direction of travel and configured to measure a first distance from the first sensor to a further ground with an offset height level to obtain a first height value, and the second sensor being arranged in front of the screed and configured to measure a second distance from the second sensor to a ground or reference of the construction machine to obtain a second height value; the controller being configured to determine the offset based on the first and second height values by forming a difference, to determine a set value for an adjustment based on the offset, and to control the screed depending on the set value.