Vehicle-Based Joint Sealing System with Dynamic Flow Control
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Solution Overview
Problem
Existing methods for sealing concrete pavement joints are slow and inconsistent, limited by the rate at which operators can walk and dispense sealant, leading to inefficiencies in large applications.
Innovation Solution
A semi-automated system comprising a vehicle with a control system that adjusts the flow of sealant and vehicle speed to ensure precise and efficient sealing, using sensors and pumps to maintain an appropriate ratio of sealant flow to joint dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sealant dispensing is used by a worker with a nozzle and reservoir, then the system is simple to operate, but the sealing speed and productivity are limited by the operator's walking rate and dispensing consistency
Solution Approach 1:
The patent replaces the manual mechanical dispensing system with an automated pump-controlled system. The pump is controlled by a controller that receives signals from a speed sensor, automatically adjusting sealant flow rate based on vehicle speed to maintain consistent sealing without manual intervention.
Solution Approach 2:
The system uses feedback from speed sensors to automatically adjust the pump flow rate, enabling the system to self-regulate sealant dispensing based on its own operating conditions without requiring external manual control.
2Manufacturing precision
If a worker manually dispenses sealant with a long-handle nozzle, then the equipment is simple, but the consistency and accuracy of sealant application are limited by operator skill and fatigue
Solution Approach 1:
The system incorporates speed sensors that continuously monitor vehicle speed and feed this information back to the controller, which automatically adjusts the pump flow rate to maintain consistent sealant application regardless of speed variations or joint dimension changes.
Solution Approach 2:
The manual dispensing mechanism is replaced with an electronically controlled pump system that uses sensors and controllers to automatically regulate sealant flow, eliminating variability introduced by manual operation.
3Speed
If the vehicle travels faster to increase productivity, then the sealing speed improves, but the sealant flow rate must be increased proportionally to maintain appropriate coverage
Solution Approach 1:
The system dynamically adjusts the pump flow rate in real-time based on the vehicle's speed. As speed increases, the controller automatically increases sealant flow proportionally, and vice versa, maintaining optimal sealant-to-speed ratio throughout operation.
Solution Approach 2:
Speed sensors provide continuous feedback to the controller, which automatically modulates the pump flow rate to match vehicle speed, ensuring consistent sealant application density regardless of travel speed variations.
Data Source
AI summary
A pavement joint sealing system that meters out an appropriate amount of sealant over potentially varying speeds and especially with potentially varying joint dimensions. Given the joint dimensions, the system is able to determine and enforce an effective ratio between the applicator speed and the sealant flow rate.