Variable Vibratory Compactor Controller for Consistent Pavement Density
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Solution Overview
Problem
Current compaction methods rely heavily on operator judgment for adjusting vibratory mechanisms, leading to inconsistencies and potential human errors, resulting in increased construction time and costs due to pavement and rolling deficiencies in long road and highway projects.
Innovation Solution
A system and method that utilize a compactor with a variable vibratory mechanism, a location sensor, and a controller to determine a pass count and adjust the compaction effort based on location data, ensuring a target compaction effort is achieved, thereby minimizing human intervention and errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operator judgment and perception are used to adjust vibratory mechanism settings, then flexibility in compaction operation is maintained, but consistency and quality of compaction deteriorate due to human error and lack of standardization
Solution Approach 1:
The patent replaces the mechanical system of manual operator judgment and perception with an automated electronic control system. The controller receives input from sensors (accelerometers, GPS, etc.) and automatically adjusts vibratory mechanism settings, eliminating human error and inconsistency while maintaining operational flexibility through programmable parameters.
Solution Approach 2:
The system implements feedback by continuously monitoring compaction parameters through sensors (accelerometers measuring vibration response, GPS tracking location, counters tracking passes) and using this information to automatically adjust the vibratory mechanism. This closed-loop feedback ensures consistent compaction quality by responding to actual material conditions rather than relying on operator perception.
2Manufacturing precision
If multiple distinct compactors with different compaction efforts are used in series, then target compaction levels are achieved, but construction time and cost increase
Solution Approach 1:
The patent applies dynamics by making the compaction effort variable rather than static. A single compactor with a variable vibratory mechanism can dynamically adjust its compaction effort during operation based on real-time feedback from sensors and pass count, replacing the need for multiple static compactors with different fixed settings.
Solution Approach 2:
The system achieves universality by designing a single compactor that can perform multiple compaction functions. The variable vibratory mechanism can operate at different compaction efforts (light, medium, heavy) within a single machine, making it universally capable of handling various compaction requirements that previously required multiple specialized compactors.
3Reliability
If substantial operator training and preparation time are provided, then operator judgment capability is improved, but preparation time and operational complexity increase
Solution Approach 1:
The system implements self-service by enabling the compactor to automatically monitor and adjust its own operation without relying on operator judgment. The electronic control system with integrated sensors and controllers performs the functions that previously required trained operators, eliminating the need for extensive training while maintaining or improving reliability.
Solution Approach 2:
The patent replaces the human cognitive system (operator judgment and perception) with an electronic control system. This substitution eliminates the need for training operators to develop expertise, as the electronic system consistently applies compaction parameters based on sensor data and programmed logic from the outset.
Data Source
AI summary
A system for compacting a work area is described. The system includes a compactor having a variable vibratory mechanism for providing a compaction effort to the work area. The system further includes a location sensor to generate a location data for the compactor. The system further includes a controller in communication with the location sensor and the variable vibratory mechanism. The controller is configured to determine a pass count for the work area based on the location data. The controller is further configured to determine a target compaction effort for the work area based on the pass count. The controller is further configured to modify the compaction effort to the target compaction effort.