Two-Layer Road Milling with 3D Guidance
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Solution Overview
Problem
Existing road milling methods fail to optimize the milling process in two layers, leading to inefficient removal of unevenness, require costly and time-consuming 3D surface surveys, and do not effectively manage material separation for recycling, while also being limited by the length and accuracy of measurement devices.
Innovation Solution
A method and device that mills the road surface in two layers by continuously measuring the spatial position and cross slope of the milling drum during the first layer, creating a digital 3D model to guide the milling of the second layer, optimizing material separation and achieving optimal flatness and cross slopes without pre-surveying the original surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the road surface is milled in a single layer with constant depth, then the milling process is simple and quick, but it cannot fully remove unevenness longer than a few meters and cannot correct existing cross slopes
Solution Approach 1:
The milling process is divided into two distinct layers: a first layer milled with constant depth to remove bulk material quickly, and a second layer milled with variable depth based on digital 3D model guidance to achieve precise surface flatness and correct cross slopes. This segmentation allows each layer to optimize for its specific function.
Solution Approach 2:
A digital 3D model of the road surface is created before the second layer milling to pre-calculate the required variable milling depth. This preliminary action enables the second layer to be milled with precise control over flatness and cross slopes without requiring complex real-time measurements during operation.
2Manufacturing precision
If a 3D surface survey is conducted before milling to guide the process, then the milling precision is improved, but it requires costly and time-consuming pre-surveying equipment and procedures
Solution Approach 1:
The measurement function is extracted from separate pre-surveying equipment and integrated into the road milling machine itself. The milling machine is equipped with sensors that continuously measure the spatial position and cross slope during the first layer milling, eliminating the need for costly external 3D surveying equipment and procedures.
Solution Approach 2:
The measurement and milling operations are merged into a single integrated process. The road milling machine simultaneously performs the first layer milling and collects spatial position data, combining two previously separate operations into one unified process that reduces equipment complexity and costs.
3Manufacturing precision
If the entire road surface is milled in one layer to achieve optimal flatness, then the surface quality is improved, but the volume of material to be removed and recycled is increased
Solution Approach 1:
The road surface is milled in two layers with different purposes: the first layer removes the majority of material volume quickly with constant depth, while the second layer achieves the required surface flatness with minimal material removal. This segmentation significantly reduces the total volume of material that needs to be removed and recycled.
Solution Approach 2:
The second layer milling applies variable depth locally based on the digital 3D model, removing material only where necessary to achieve the target surface flatness. This local quality approach minimizes unnecessary material removal compared to uniform deep milling of the entire surface.
4Ease of operation
If manual control of milling depth is used, then the operation is simple, but it only copies existing unevenness and cannot correct deformations longer than the length of the road milling machine
Solution Approach 1:
The system uses feedback from continuous spatial position measurements during first layer milling to create a digital 3D model, which then guides the variable depth milling of the second layer. This feedback loop enables automatic correction of cross slopes and long-wavelength unevenness that manual control cannot achieve.
Solution Approach 2:
Manual operator control is replaced with an automated control system that uses digital 3D model data to automatically adjust the milling depth for the second layer. This substitution enables precise cross slope correction and eliminates the limitations of manual operation while maintaining ease of use through automated guidance.
Data Source
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AI summary
A method of milling the surface of the traffic area in at least two layers, in which the first layer is milled and at the same time the spatial position (X, Y, Z) of the road milling machine and the cross slope of the milling drum are measured continuously at each moment of milling the first layer, and the measured data is stored in the database of a 3D guidance computer. From the stored measured data representing the spatial positions (X, Y, Z) of the road milling machine and the cross slopes of the milling drum, a digital 3D model of the surface of the traffic area after milling the first layer is calculated in the 3D guidance computer. Subsequently, after milling the first layer using the digital 3D model of the surface of the traffic area after milling the first layer and the obtained digital 3D model of the desired target surface of the traffic area or obtained the digital differential model of the milling depths, at least the second layer is milled. The device for performing the method is also described.