Paver Screed Height Control for Real-Time Layer Thickness
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Solution Overview
Problem
Existing road construction methods fail to adjust the layer thickness of road surface materials like asphalt or concrete in real-time, leading to deviations from design specifications and excessive material usage.
Innovation Solution
A system and method for controlling a road construction process using a paver with a height-adjustable screed, which continuously receives position and thickness data to calculate and adjust the screed height in real-time, ensuring adherence to design specifications and optimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time layer thickness measurement and control is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system implements a closed-loop feedback control mechanism where ultrasonic sensors continuously measure the actual layer thickness of paved material, compare it against the nominal thickness from design data, and automatically adjust the screed height to correct deviations. This real-time feedback ensures manufacturing precision while automating the control process.
Solution Approach 2:
The patent replaces manual mechanical thickness measurement and adjustment methods with automated electronic sensing and control systems. Ultrasonic sensors substitute for physical thickness gauges, and automated control algorithms replace manual operator judgment, reducing the need for complex mechanical measurement devices while improving precision.
2Loss of substance
If real-time screed height adjustment is implemented, then loss of substance is reduced, but extent of automation increases
Solution Approach 1:
The system uses continuous feedback from ultrasonic thickness measurements to automatically adjust screed height, preventing both excessive material application and insufficient coverage. This automated feedback loop eliminates material waste by ensuring precise layer thickness control without requiring manual intervention.
Solution Approach 2:
The control system performs self-adjustment based on real-time thickness measurements, automatically correcting deviations from the nominal layer thickness without external intervention. The system serves itself by detecting thickness variations and autonomously modifying screed position to maintain optimal material application.
3Manufacturing precision
If continuous thickness monitoring is implemented, then manufacturing precision is improved, but use of energy increases
Solution Approach 1:
The system maintains continuous ultrasonic thickness monitoring and automated screed adjustment throughout the paving process, ensuring constant precision control. The continuous operation of sensors and control algorithms maintains manufacturing precision while optimizing material application efficiency.
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 real-time adjustment of the screed height to maintain accurate layer thickness, reducing deviations from design and minimizing material waste.
Implementation Method 1
EP 2 921 588 B1 and WO 2018/114669 A1 disclose examples for such sensor systems that are mounted on a paver and measure the thickness of a layer of road surface material during the construction process
Data Source
AI summary
A system and computer-implemented method for automatically controlling a construction process of a road section, the section comprising a plurality of subsections, the construction process comprising processing a road surface material layer using a paver with a height-adjustable screed, the paver travelling along a predetermined path, the method comprising receiving construction design data comprising information about the path and about a nominal surface and a nominal layer thickness of the paved road surface material layer for a multitude of positions along the path, receiving a set of rules comprising different priorities for each of the plurality of subsections, continuously receiving position data indicating a current position of the screed, continuously receiving thickness data indicating a current layer thickness of the paved road surface material layer, calculating a height-adjustment of the screed, generating, based on the calculation, control data to adjust a height of the screed.