Road Paving Digital Twin Control for Precise Milling and Layer Thickness
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Solution Overview
Problem
Current digital systems for supporting road surface installation operations generate and utilize limited digital data, which hampers the improvement of installation quality and operational efficiency in road surface production and renewal processes.
Innovation Solution
A method involving spatial measurement of existing and new road surfaces using sensors, creation of digital target profiles, and at least partially automated control of milling machines and pavers to ensure precise milling and paving, utilizing data processing units and GNSS modules for accurate positioning and material calculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If digital systems are used to support road surface installation operations, then operational efficiency is improved, but the systems currently generate and utilize limited digital data which hampers further improvement of installation quality and operational efficiency
Solution Approach 1:
The patent implements comprehensive feedback loops where sensors continuously measure actual milling profiles and paving results, compare them against target profiles, and automatically adjust machine operations. This closed-loop feedback system transforms limited digital data into comprehensive real-time information, enabling continuous improvement of both installation quality and operational efficiency without the trade-off present in conventional systems
Solution Approach 2:
The patent introduces digital twins as intermediary virtual models that mirror the physical road surface construction process. These digital twins integrate data from multiple sources (milling machines, pavers, sensors) and serve as a mediator between physical operations and decision-making systems, transforming limited operational data into comprehensive digital representations that enhance both productivity and information utilization
2Manufacturing precision
If automated control systems are implemented for milling machines and pavers, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs universal control architecture where a single integrated control system manages multiple functions including milling machine control, paver control, sensor data acquisition, digital twin generation, and automatic adjustment. This multi-functional approach achieves high manufacturing precision while reducing overall system complexity by eliminating the need for separate specialized control systems for each operation
Solution Approach 2:
The automated control system incorporates self-adjustment capabilities where the system automatically monitors its own performance through sensors, compares actual results with target profiles, and makes real-time corrections without external intervention. This self-service mechanism maintains high installation quality while reducing the operational complexity that would otherwise require extensive manual monitoring and adjustment
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 enhances the precision and efficiency of road surface production by ensuring accurate spatial measurements, automated control of construction machinery, and optimal material usage, leading to improved quality and reduced operational costs.
Implementation Method 1
This can be done using laser measurement technology, ultrasound technology, infrared technology, optical technology in the visible wavelength range
Implementation Method 2
This can be done using laser measurement technology, ultrasound technology, infrared technology, optical technology in the visible wavelength range
Implementation Method 3
This can be done using laser measurement technology, ultrasound technology, infrared technology, optical technology in the visible wavelength range
Implementation Method 4
The location coordinate can be recorded by receiving a GNSS signal (Global Navigation Satellite System)
Data Source
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AI summary
A method for producing a road surface (23), in particular for renewing a road surface, comprising: spatial measurement of an existing roadway (9) using a sensor (13); creation of a digital target milling profile (39); creation of a digital target elevation profile (41) of a road surface (23) to be installed, and calculation of a layer thickness (Z1) based on the target milling profile (39) and the target elevation profile (41); at least semi-automated control of a milling machine (5) for milling an actual milling profile (19) according to the specification of the target milling profile (39); spatial measurement of the milled actual milling profile (19); at least semi-automated control of a road paver (3) for installing the road surface (23) according to the specification of the target elevation profile (41). In addition, there is also an asphalt paving system (1).