Road Paver Screed Temperature Control via Predictive Heating
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Solution Overview
Problem
Current methods for controlling road finishers are not energy-efficient, particularly during periods of increased energy demand such as the start of a paving process or driving uphill, leading to unnecessary fuel consumption and peak loads on the primary drive unit.
Innovation Solution
A predictive control method that anticipates future energy demands by overheating the screed and overcooling the cooling medium before an increased energy state occurs, allowing for the temporary deactivation of energy-consuming components to manage peak loads and optimize the primary drive unit's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the screed heating system operates continuously to maintain operating temperature, then the screed temperature is stable and material does not solidify, but fuel consumption increases during periods of low energy demand
Solution Approach 1:
The control system pre-heats the screed to a temperature above the normal operating temperature range before an anticipated period of increased energy demand. This preliminary action ensures that when the heating system must be deactivated due to peak load conditions, the screed retains sufficient temperature to prevent material solidification, thereby maintaining reliability while reducing energy consumption during critical periods.
2Power
If the primary drive unit operates at high power to meet peak energy demands, then all energy-consuming components can be powered, but the drive unit operates outside its optimal range and fuel efficiency decreases
Solution Approach 1:
The control system anticipates periods of increased energy demand and pre-heats the screed before these periods occur. This allows the primary drive unit to operate within its optimal power range during normal conditions, and when peak demand is anticipated, the pre-heated screed can tolerate temporary deactivation of the heating system, thus avoiding the need to operate the drive unit at inefficient high-power levels.
Solution Approach 2:
The system dynamically adjusts the screed temperature parameter by heating it to a higher temperature than the normal operating range before anticipated peak demand periods. This parameter change creates a thermal buffer that allows the heating system to be deactivated during peak load conditions without compromising material quality, thereby enabling the primary drive unit to operate more efficiently.
3Use of energy by moving object
If the screed heating system is deactivated during peak energy demand, then fuel consumption is reduced, but the screed temperature may drop and cause material to solidify
Solution Approach 1:
The control system performs preliminary heating of the screed to a temperature above the normal operating range before an anticipated period of increased energy demand. This creates a thermal reserve that allows the heating system to be safely deactivated during peak load conditions without the screed temperature dropping below the threshold that would cause material solidification, thus maintaining material flow continuity.
Solution Approach 2:
The system prepares a thermal cushion by overheating the screed before anticipated peak demand periods. This beforehand cushioning with excess heat ensures that when the heating system is deactivated due to energy constraints, the screed temperature remains sufficient to prevent material solidification, thereby cushioning against the potential reliability problem.
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
This approach reduces fuel consumption by allowing the primary drive unit to operate within its optimal range longer, absorbing peak energy demands and maintaining sufficient screed temperature to prevent material solidification, thereby enhancing energy efficiency.
Implementation Method 1
the screed heater is an electric screed heater with electric resistance heating elements, which is supplied with energy by the primary drive unit via a generator
Implementation Method 2
a cooling system with a cooling medium and a fan for cooling the cooling medium below the predetermined cooling medium operating temperature value or range
Data Source
Figure 1~2
AI summary
According to one variant, a road paver (1) is controlled by a primary drive unit (M), a material hopper (3), and a screed (5) via a screed heater (7) powered by energy generated by the primary drive unit (M). During paving operations, the screed heater (7) heats the screed (5) by regulating its temperature to a predetermined operating temperature or within a predetermined operating temperature range. The road paver (1) proactively detects future operating conditions of increased energy demand. If such a future operating condition is detected, the screed heater (7) heats the screed (5) beyond the predetermined operating temperature or operating temperature range.When the operating condition of increased energy demand occurs, the plank heating (7) is deactivated, at least temporarily.