Road Finisher Spraying System with Sequential Control
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Solution Overview
Problem
Existing road finishers produce sprayed carpets with stepped profiles due to offset spraying facilities, leading to waste of bonding agent, unnecessary pre-impregnation, and environmental contamination, as well as bonding faults when connecting new and old cover layers.
Innovation Solution
A method and road finisher design where spraying facilities are activated or deactivated sequentially based on predetermined distances from a reference line, ensuring straight and linear front and rear boundaries of the sprayed carpet, eliminating manual work and waste, and minimizing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If spraying facilities are offset laterally to produce multi-strip sprayed lanes, then the sprayed carpet can cover the entire working width, but the front and rear boundaries form a stepped profile that does not align with the linear boundaries of the laid down cover layer
Solution Approach 1:
The spraying system is divided into multiple independent spraying facilities (first, second, and third spraying facilities) that can be controlled separately. Each spraying facility operates independently to spray different zones, allowing the system to produce a composite sprayed carpet with straight boundaries despite the lateral offset of individual facilities. This segmentation enables each facility to contribute to the overall rectangular shape without being constrained by the offset arrangement.
2Device complexity
If all spraying facilities are activated and deactivated simultaneously, then the spraying process is simplified, but bonding agent is wasted and environmental contamination occurs due to the stepped profile
Solution Approach 1:
The control system is configured to activate and deactivate spraying facilities in a predetermined sequence rather than simultaneously. The first spraying facility is activated first, followed by the second and third facilities in sequence. When deactivating, they are turned off in reverse sequence. This preliminary planning of activation/deactivation timing ensures that bonding agent is only sprayed when needed, eliminating waste and preventing environmental contamination from unnecessary spraying.
Solution Approach 2:
The control system monitors the position and status of each spraying facility and adjusts their activation/deactivation timing accordingly. By providing feedback on the operational state of each facility, the system can coordinate their operation to maintain straight front and rear boundaries of the sprayed carpet, ensuring that bonding agent is applied only to the required areas and preventing over-spraying that would cause waste and contamination.
3Area of stationary object
If manual spraying splash lances are used to complete the stepped profile, then coverage can be achieved, but locally excessive bonding agent is applied creating separation layers and bonding faults
Solution Approach 1:
The manual mechanical operation of spraying splash lances is replaced with an automated control system that manages multiple spraying facilities. The control system electronically coordinates the activation and deactivation of each spraying facility based on their positions, eliminating the need for manual intervention. This substitution ensures uniform and precise application of bonding agent without the local excesses that occur with manual operation, thereby maintaining reliable bonding quality across the entire working width.
4Length of moving object
If extension beams are mounted on the road finisher to spray outside regions, then the working width can be extended, but mounting and manipulation problems occur and space problems arise
Solution Approach 1:
The spraying facilities for the outside regions are merged with the existing road finisher structure rather than being added as separate extension beams. The first, second, and third spraying facilities are integrated into the road finisher's chassis and support structures, utilizing available mounting points and space. This merging approach extends the working width capability while avoiding the mounting and manipulation problems associated with separate extension beams, as the facilities are permanently and securely integrated into the road finisher design.
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
The method allows for the production of ideal rectangular sprayed carpets with continuous, straight boundaries, reducing bonding agent waste and environmental contamination, while ensuring proper bonding between new and old cover layers without manual errors.
Implementation Method 1
spraying facilities which are lateral bars distributed over the longitudinal extension of the road finisher
Data Source
AI summary
A road finisher F for producing a continuous sprayed carpet T of a bonding agent on a planum has a spraying system S on a vehicle having at least two spraying facilities 11, 11′, 14, 14′ which are located offset to each other in the and laterally to the traveling motion direction R and a control device which operates the spraying facilities using a method such that during a traveling motion of the vehicle a sprayed carpet T is produced with front and rear boundaries V, H which are continuous over the width of the sprayed carpet and which are parallel to a respective reference line L which is placed on the planum in front of the spraying facility which is the frontmost in traveling motion direction. The sprayed carpet T is produced such that each spraying facility 11, 11′, 14, 14′ first is activated or deactivated depending on the traveling motion with a predetermined distance from the or when reaching the respective reference line L.