Paving Machine Material Deposition Monitoring System
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Solution Overview
Problem
Existing paving machines face challenges in accurately monitoring and adjusting the amount of asphalt deposited, leading to potential over or under application, which can result in increased costs or penalties due to variations in paving thickness and width, and the existing solutions are not optimal as they may not accurately account for different types of paving materials.
Innovation Solution
A monitoring system for paving machines that includes an input device for operator feedback on screed height, a controller to determine material deposition based on received signals, and a correction factor calculation to ensure accurate material application, utilizing sensors and actuators to adjust screed settings and conveyance systems for precise material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material height sensors are used to determine instantaneous yield, then yield monitoring is enabled, but measurement accuracy deteriorates because the sensors only reflect material on the conveyor rather than actual deposited material
Solution Approach 1:
The system uses feedback from the correction factor calculation to continuously improve measurement accuracy. By comparing delivered material amount with calculated deposited amount and applying the correction factor to subsequent measurements, the system progressively refines the accuracy of yield monitoring without requiring direct sensors on the deposited material.
Solution Approach 2:
The correction factor acts as an intermediary that bridges the gap between indirect measurements (conveyor material height) and actual deposited material. This intermediary element allows the system to translate conveyor sensor data into accurate deposition measurements by accounting for the relationship between delivered and deposited material.
2Measurement precision
If a calibration curve is used to determine material weight, then weight determination is enabled, but accuracy deteriorates when applied to various types of paving materials with different properties
Solution Approach 1:
The system changes the parameter being measured from material-specific properties (which vary by material type) to process parameters (delivered amount, screed height, speed) that are consistent across different material types. This allows the same monitoring system to accurately track material deposition regardless of the specific paving material being used.
Solution Approach 2:
The monitoring system is designed to be universal and applicable to different types of paving materials. By focusing on process parameters rather than material-specific calibration, the system can be used across multiple material types without requiring material-specific recalibration, enhancing its versatility and adaptability.
3Manufacturing precision
If real-time monitoring of asphalt deposition is implemented, then material application accuracy is improved, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The system uses existing components on the paver (conveyor, hopper, screed) and leverages process parameters that are already being tracked (delivered material amount, machine speed) to calculate deposition. This self-service approach minimizes the need for additional complex sensors and measurement devices while still achieving real-time monitoring capability.
Data Source
AI summary
A monitoring system for a paving machine having a screed may include an input device configured to receive a first input from an operator of the paving machine, the first input being indicative of a height of the screed above a work surface, and a controller electronically connected to the input device. The controller may be configured to determine an amount of a material deposited by the paving machine based on the first input, receive a signal indicative of an amount of a material delivered to the paving machine, and determine a correction factor based on the amount of the material deposited by the paving machine and the amount of the material delivered to the paving machine.