Road Surface Texture Sensing for Precise Asphalt Application
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Solution Overview
Problem
Conventional road construction methods rely on average texture measurements, leading to inconsistent asphalt application, which can result in over-application in some areas and under-application in others, causing slipperiness or damage, and are labor-intensive and expensive.
Innovation Solution
A road building machine equipped with sensors to detect surface texture, a locating device to identify texture locations, and a controller to determine and automatically apply the appropriate amount of material based on these signals, optimizing asphalt distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If average texture measurements are used to determine asphalt application rate, then the process is simple and fast, but the application precision deteriorates leading to over-application in some areas and under-application in others
Solution Approach 1:
The road surface is divided into multiple segments along its length, with each segment having its own texture measurement and corresponding asphalt application rate. The spray bar is divided into multiple nozzle groups that can be independently controlled to apply different amounts of asphalt to different segments, resolving the contradiction between simple control and precise application.
Solution Approach 2:
Different segments of the road receive different asphalt application rates based on their specific texture characteristics. The system measures texture locally for each segment and adjusts the asphalt application rate accordingly, ensuring each area receives the precise amount needed for its specific conditions rather than applying a uniform rate across the entire road.
2Productivity
If manual texture measurement methods are used, then the equipment is simple, but the productivity deteriorates due to labor-intensive processes
Solution Approach 1:
Manual sand circle texture measurement methods are replaced with automated optical or laser-based texture measurement systems mounted on the spray truck. These systems automatically capture texture data as the truck moves along the road, eliminating manual measurement operations and significantly increasing productivity while reducing labor requirements.
Solution Approach 2:
The system automatically performs texture measurement, data processing, and asphalt application rate determination without requiring manual intervention. The controller autonomously coordinates between texture measurement devices, calculates appropriate application rates for each segment, and controls the spray nozzles based on real-time measurements, enabling the system to service itself during operation.
3Reliability
If uniform asphalt application rate is applied across the entire road, then the control process is simple, but the reliability deteriorates causing slipperiness or aggregate damage
Solution Approach 1:
The asphalt application rate is dynamically adjusted for each road segment based on real-time texture measurements. As the spray truck moves along the road, the system continuously measures texture, calculates the appropriate application rate for the current segment, and adjusts the nozzle output accordingly, creating a dynamic control system that adapts to varying road conditions rather than maintaining a static uniform rate.
Solution Approach 2:
The system incorporates feedback loops where texture measurement data from each segment is fed back to the controller, which then adjusts the asphalt application rate for that segment. This closed-loop control ensures that the actual texture conditions are continuously monitored and used to optimize the application rate, improving reliability by preventing both over-application and under-application.
Data Source
AI summary
A method of building a road is disclosed. The method may include moving a machine over a surface on which the road is to be built, and generating a signal indicative of a texture of the surface during movement of the machine over the surface. The method may also include detecting a location of the texture on the surface, and determining, using a specially programmed processor, an amount of a material to be applied to the location of the texture on the surface based on the signal. The method may further include automatically applying the amount of material to the location of the texture on the surface to build the road.