U.S. patent application number 10/382440 was filed with the patent office on 2003-12-04 for compaction roller.
Invention is credited to Stelbrink, Richard, Wachsmann, Steffen.
Application Number | 20030223817 10/382440 |
Document ID | / |
Family ID | 27740680 |
Filed Date | 2003-12-04 |
United States Patent
Application |
20030223817 |
Kind Code |
A1 |
Stelbrink, Richard ; et
al. |
December 4, 2003 |
Compaction roller
Abstract
The invention relates to a compaction roller having at least one
rolling body with a vibratory drive which comprises a drivable
exciter shaft with an unbalance. The shaft is mounted axially with
respect to the rolling body and in the body. The unbalance, which
comprises an unbalance cylinder arranged centrally with respect to
the axis of the rolling body, is held by the exciter shaft and has
an unbalance piston which can be adjusted hydraulically radially
with respect to the axis of the rolling body by means of an
adjusting device.
Inventors: |
Stelbrink, Richard;
(Salzkotten, DE) ; Wachsmann, Steffen; (Hess,
DE) |
Correspondence
Address: |
Alix, Yale & Ristas, LLP
750 Main Street
Hartford
CT
06103-2721
US
|
Family ID: |
27740680 |
Appl. No.: |
10/382440 |
Filed: |
March 6, 2003 |
Current U.S.
Class: |
404/122 |
Current CPC
Class: |
E01C 19/286
20130101 |
Class at
Publication: |
404/122 |
International
Class: |
E01C 019/26 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 7, 2002 |
DE |
102 10 049.7 |
Claims
What is claimed is:
1. A compaction roller having at least one rolling body with a
vibratory drive; the vibratory drive being turned on to produce a
vibration having an amplitude and a frequency and comprising a
drivable exciter shaft mounted axially within said rolling body, an
external adjusting device, a control valve and a hydraulic oil
source; the exciter shaft having an unbalance device comprising an
unbalance cylinder and an unbalance piston; the unbalance cylinder
being held by the exciter shaft, centrally with respect to the axis
of the rolling body; the unbalance piston being hydraulically
radially adjustable with respect to the axis of the rolling body;
the adjusting device being in fluid communication with the
unbalance cylinder through a bore in the exciter shaft, the
adjusting device supplying hydraulic fluid in a controlled manner
to infinitely variably adapt the amplitude of the vibration to
paving situations; the adjusting device having an actuating
cylinder and an actuating piston, the actuating cylinder defining a
chamber, the actuating piston being disposed within the chamber,
the chamber of the actuating cylinder being in fluid communication
with the unbalance cylinder; an oil passage extending from the
actuating cylinder to the hydraulic oil source, the control valve
being disposed in the oil passage; the valve being moveable between
open and shut positions, the valve shutting when the unbalance
piston is in a radially central position, whereby moving the
unbalance piston from the central position increases or decreases
the amplitude of the vibration.
2. The compaction roller of claim 1, wherein the control valve
shuts when the vibration has a minimum operating frequency.
3. The compaction roller of claim 1, wherein the control valve
opens to provide fluid communication between the unbalance cylinder
and the hydraulic oil source after the vibratory drive has been
turned off.
4. The compaction roller of claim 3, wherein the control valve
provides fluid communication between the actuating cylinder and the
hydraulic oil source after the vibratory drive has been turned
off.
5. The compaction roller of claim 3, wherein the actuating piston
is moveable between extended and retracted positions within the
actuating cylinder, the control valve being openable when the
actuating piston is in the retracted position.
6. The compaction roller of claim 4, wherein the actuating piston
is moveable between extended and retracted positions within the
actuating cylinder, the control valve being openable when the
actuating piston is in the retracted position.
7. The compaction roller of claim 5, wherein when the unbalance
cylinder is filled with hydraulic oil, the actuating piston can be
moved to the extended position.
8. The compaction roller of claim 6, wherein when the unbalance
cylinder is filled with hydraulic oil, the actuating piston can be
moved to the extended position.
9. The compaction roller of claim 1, the vibratory drive further
comprising a rotary bushing connecting the unbalance cylinder to
the adjusting device, the rotary bushing being supported on the
rolling body by a damping element.
10. The compaction roller of claim 9, the vibratory drive further
comprising a tube, a first piston disposed at a first end of the
tube, and a second piston disposed at a second end of the tube, the
first piston being axially moveably, rotationally fixedly connected
to the rotary bushing, the second piston being axially moveably,
rotationally fixedly connected to the exciter shaft.
11. The compaction roller of claim 1, wherein the actuating piston
is mechanically or hydraulically adjustable.
12. The compaction roller of claim 11, wherein the vibratory drive
further comprises sensory means for monitoring the position of the
actuating piston.
13. The compaction roller of claim 1, the vibratory device further
comprising means for measuring a compaction performance of the
rolling body and means for controlling the adjusting device as a
function of a measurement of the compaction performance of the
rolling body.
14. The compaction roller of claim 1, wherein the unbalance piston
is filled with a heavy metal.
Description
BACKGROUND OF THE INVENTION
[0001] The invention relates to a compaction roller as it is used
for the compaction of materials in earthwork and road
construction.
[0002] In earthworks or road construction, it is desirable to
compact unbound and hydraulic-bound or bituminous-bound materials
as rapidly as possible to the prescribed Proctor or Marshall
density, but at the same time to prevent over-compaction and, in
particular in the case of wearing courses, to minimize particle
fragmentation of the mineral constituents.
[0003] In the case of bituminous road surfaces, smoothing of the
surface during compaction should be avoided in order to ensure
either good bonding between courses or, in the case of wearing
courses, a high level of grip. The setting of optimum system
parameters for short compaction times is an absolute necessity in
the case of bituminous materials since cooling of the material
causes the compactability to diminish and, in the most unfavorable
case, the prescribed final density cannot be achieved. When
compacting drain asphalt (open-pore asphalt), the pores in the
region close to the surface must not be closed, so that the desired
water drainage can be obtained and the effect known as
"air-pumping" reduced when automobile tires roll in the contact
zone between tire and roadway.
[0004] Where vibration amplitudes of the rolling body are
excessively high or where vibration frequencies are close to the
natural frequency of, for example, bridge structures or other
structures, it is possible that these may become damaged, so that
in these cases, especially where rollers with conventional
eccentrically loaded rotating shafts are concerned, the vibration
has to be switched off to avoid damage. The result of this then is
that, in order to reach the prescribed final density, a greater
number of static roller passes is required if the final density can
be achieved at all by means of static rolling.
[0005] It is known that vibratory rollers for compacting unbound
soils and hydraulic or bituminous courses can be equipped with an
eccentrically loaded rotating shaft. In this case, at least one
fixed unbalance is provided. It is additionally possible, as is
usually the case, for an additional changeover weight to be
provided in order to generate two different nominal amplitudes.
However, there is no possibility of adjusting the amplitude between
the two nominal amplitudes.
[0006] It is also known that asphalt compaction can be performed by
means of what is known as oscillation using a rolling body without
circular or directional vibrations, European Patent EP 0 053 598 B.
However, compaction to depth does not take place, since here the
material is compacted solely by a static linear load and
alternating exposure to shear stress. The enforced slip between the
rolling body and ground makes traction problems unavoidable. The
oscillating moment is generated by two unbalanced shafts which are
mounted parallel to the axis of rotation of the roller and of which
their unbalances, offset by 180.degree., run synchronously in the
same direction. In the case of bituminous materials, the
oscillating effect can lead to undesirable ripples, to smoothing
effects and to pore closure.
[0007] In compaction rollers, it is also known for the angle
between an unbalance which can be rotated around the rolling body
axis, and a fixed unbalance to be adjusted so that the resulting
unbalance can be set in an infinitely variable manner.
[0008] German document DE 69425111 T2 discloses a compaction roller
whose unbalance, which is arranged so as to be rotatable
transversely with respect to the rolling body axis, can be adjusted
in an infinitely variable manner via a hydraulic cylinder and a
connecting rod. However, this is very expensive and complex.
[0009] In the compaction rollers which are described in German
Patent Application DE 4 129 182 A1 and European Patent Application
EP 0 954 187 A2, a directional vibrator comprises at least two
exciter shafts which run in opposite directions and whose resulting
force can be rotated without moment in an infinitely variable
manner from a horizontal direction into a vertical direction. The
nominal amplitude or unbalance is not changed in this system. It is
also the case here, in particular where horizontal vibrations are
concerned, that undesirable ripples, smoothing effects and pore
closures can occur.
[0010] German Patent Application DE 100 31 617 A1 also discloses a
vibration generator for a soil compaction machine in which an
exciter shaft is provided with an unbalance, a cylinder arranged
radially with respect to the exciter shaft and having a
spring-loaded piston being used for the purpose of bringing about
automatic adjustment of the unbalance by virtue of the centrifugal
force changing through a change in the speed of rotation. Apart
from the fact that the high degree of non-linearity of centrifugal
forces having variable eccentricity and speed of rotation cannot
completely compensate for the spring forces of metal or oil
springs, it is also the case here that each frequency is assigned
exactly one amplitude. In addition, from a standing start the
unbalance shaft can only be accelerated with a high degree of
unbalance.
SUMMARY OF THE INVENTION
[0011] It is an object of the invention to provide a compaction
roller which permits optimum adaptation of the vibration to the
particular road building materials or to the local circumstances,
such as the presence of bridges and vibration-sensitive structures
and installations.
[0012] Thus, the invention concerns a compaction roller having at
least one rolling body with a vibratory drive which comprises a
drivable exciter shaft with an unbalance, said shaft being mounted
axially with respect to the rolling body and in said body, the
unbalance comprising an unbalance cylinder which is arranged
centrally with respect to the axis of the rolling body, is held by
the exciter shaft and has an unbalance piston which can be adjusted
hydraulically radially with respect to the axis of the rolling body
and to which hydraulic fluid can be supplied in a controlled manner
from outside by means of an external adjusting device via a bore in
the exciter shaft, with infinitely variable adaptation of the
nominal amplitude to paving situations, the adjusting device having
an actuating cylinder with an actuating piston and a chamber of the
actuating cylinder communicating with the unbalance cylinder,
wherein the chamber of the actuating cylinder in communication with
the unbalance cylinder is connected via a controllable valve to a
hydraulic oil source for the purpose of leakage oil replacement,
which valve shuts in a central position of the unbalance piston,
from which the nominal amplitude can be increased or reduced.
[0013] In this context, an actuating cylinder is provided whose
chamber of the actuating cylinder in communication with the
unbalance cylinder is connected via a controllable valve to a
hydraulic source for the purpose of leakage oil replacement, which
valve shuts in a central or intermediate position between the two
end positions of the unbalance piston, from which the nominal
amplitude can be increased or reduced.
[0014] This makes it possible to carry out leakage oil replacement
and calibration, with the result that by so doing the compaction
result is not impaired. Furthermore, it is possible in a
structurally simple manner to adjust the nominal amplitude of the
vibration of the rolling body. This further allows the vibration
frequency and the traveling speed of the vibratory roller to be
automatically adapted to the nominal amplitude, once again in order
to obtain optimum compaction results. Thus, the compaction of great
layer thicknesses, for example anti-frost layers, thin layer
thicknesses, for example a surface layer for compact asphalt, and
sensitive layers such as open-pore asphalt, can be ensured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention may be better understood and its
numerous objects and advantages will become apparent to those
skilled in the art by reference to the accompanying drawings in
which:
[0016] FIG. 1 shows a schematic side view of a tandem compaction
roller.
[0017] FIG. 2 shows a rolling body of the tandem compaction roller
of FIG. 1, in section.
[0018] FIG. 3 shows a detail of FIG. 2.
[0019] FIGS. 4a and 4b show two embodiments of an adjusting device
for adjusting the nominal amplitude of the tandem compaction roller
of FIG. 1.
[0020] FIGS. 5a to 5c show three different operating settings for
an embodiment of the tandem compaction roller of FIG. 1.
[0021] FIGS. 6a to 6c show three different operating settings for a
further embodiment of the tandem compaction roller of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] The tandem compaction roller shown in FIG. 1 comprises a
superstructure 1 with driver's cab, a rolling body 2 and 3 being
mounted via steerable swivel couplings 4 at the front and rear
underneath said superstructure. Situated between the two rolling
bodies 2, 3 is an engine compartment 5 which houses a drive engine,
usually a Diesel engine.
[0023] As shown in FIG. 2, the front and/or rear rolling body 2, 3
comprises two tire halves 6a, 6b arranged side by side in the axial
direction and a respective radially extending tire endplate 7 with
a central through-opening. A respective bearing flange 8 is
fastened on the tire endplate 7. The two tire halves 6a, 6b are
connected to one another so as to be rotatable about the rolling
body axis via the two bearing flanges 8 and a spacer tube 9, by a
bearing 10, for instance a roller bearing, being arranged between a
bearing flange 8 and the spacer tube 9.
[0024] The swivel coupling 4 connected steerably to the
superstructure 1 is connected elastically on both sides to a
respective hollow hydraulic travel motor 12 via damping elements
11, for example rubber-metal elements, and a flange plate 39. On
the output side the travel motors 12 are connected via a flange 13
to the adjacent bearing flange 8 and thus drive the respective tire
halves 6a, 6b.
[0025] Situated in the center of the rolling body is an exciter
shaft 14 which is driven by a hydraulic vibration motor 15 and is
mounted opposite the bearing flanges 8 via bearings. An unbalance
cylinder 16 is mounted centrally in a bore in the exciter shaft 14.
For this purpose, the unbalance cylinder 16 has a corresponding
collar and, on the opposite side, a threaded section for clamping
by means of a clamping ring and a pair of nuts. The unbalance
cylinder 16 accommodates an unbalance piston 17 such that it can be
adjusted hydraulically radially with respect to the rolling body
axis.
[0026] When changing the eccentricity by displacing the unbalance
piston 17, the unbalance in the exciter shaft 14, which is
sufficient to achieve the smallest nominal amplitude of the rolling
body, can be added in an infinitely variable manner. The unbalance
piston 17 may be filled with lead in order that where there is
minimal construction space as large an adjustment range as possible
for the nominal amplitude can be achieved.
[0027] The unbalance piston 17 is equipped with guide bands and a
piston sealing ring. Deformations of the exciter shaft 14 (bending
caused by centrifugal forces) are not transmitted to the unbalance
cylinder 16, as a result of sufficient play. The required amount of
oil for displacing the unbalance piston 17 is made available
through a bore 18 in the exciter shaft 14. The oil pressure is
transmitted to the head of the piston via a taper of the unbalance
piston 17 and bores 19.
[0028] Situated in one of the bearing flanges 8 is an oil inlet and
outlet nipple 20 for the purpose of lubricating the space within
the spacer tube 9, and the adjacent bearings, etc.
[0029] As can be seen in FIG. 3, the pressurization of the
unbalance piston 17 by means of an exactly metered amount of oil
for displacing the unbalance piston 17 is performed via a rotary
bushing 21 which, by virtue of rubber springs 22 and an additional
vibrating mass 23, is suspended with low vibration on one of the
travel motors 12. The vibrating mass 23 accommodates an adapter 24
which bears a piston 25 such that it can be displaced, the piston
being connected via a tube 26 to a further piston 27 accommodated
by the exciter shaft 14. Radial and axial displacements between the
rotary bushing 21 and the exciter shaft 14 as a result of thermal
expansions are compensated for by seals 28 of the pistons 25, 27.
Pins 29 prevent rotational slip between the seals 28 and the
exciter shaft 14 or the adapter 24 of the rotary bushing 21.
[0030] According to the embodiment shown in FIG. 4a, the required
oil volume for changing the position of the unbalance piston 17 is
metered by displacing an adjusting piston 34 of an actuating
cylinder 40. Here, the piston rod 30 of the adjusting piston 34 is
connected to a trapezoidal or ball screw drive 31 whose spindle is
not displaceable (self-locking) under the action of tensile or
compressive stress. The screw drive 31 is driven by an electric or
hydraulic motor 32. An incremental travel measurement on the piston
rod or, if appropriate, angular measurement on the screw drive 31
(preferably integrated therein and therefore not shown) is used to
set the eccentricity of the unbalance piston 17 or the nominal
amplitude. For the purpose of calibration and for leakage oil
compensation, there is provided on the piston side an oil passage
whose 2/2-way valve 33 can automatically be switched to the flow
position as a function of the operating state.
[0031] According to the embodiment shown in FIG. 4b, the required
oil volume for changing the position of the unbalance piston 17
using the adjusting piston 34 and its piston rod 30 is modified on
the piston rod side by a variable oil volume. To this end,
electromagnets of a 3/3-way valve 35 are activated cyclically in
such a way that the adjusting piston 34 can be displaced by very
small distances. When the 3/3-way valve 35 is pressure-connected,
the adjusting piston 34 moves in the piston side direction and when
tank-connected, because of the centrifugal force of the unbalance
piston 17, in the piston rod side direction. The locking zero
position of the 3/3-way valve 35 here replaces the self-locking
action of the screw drive 31 of FIG. 4a. The sole function of the
adjusting piston 34 with piston rod 30 here is incremental travel
measurement for the purpose of setting the eccentricity of the
unbalance piston 17 or the nominal amplitude. The calibration and
leakage oil compensation correspond to those of FIG. 4a.
[0032] FIGS. 5a to 5c depict various positions of the unbalance
piston 17 in combination with an adjusting device according to FIG.
4a (the same applies to the adjusting device of FIG. 4b). The
unbalance piston 17 is in the position shown in FIG. 5a during the
following four operating states:
[0033] 1. With the vibrating device at a standstill and the diesel
engine running, the oil pressure at the unbalance piston 17
corresponds to the inlet pressure at the 2/2-way valve 33, which is
fundamentally connected to flow in this operating state. As a
result, the leakage oil quantity is replaced and at the same time
the unbalance piston 17 is forced in the direction of smallest
eccentricity against the "minimum unbalance" stop
(calibration).
[0034] 2. The vibratory drive should be accelerated as quickly as
possible with the lowest mass moment of inertia until the minimum
operating frequency has been reached. Consequently, resonance
ranges are rapidly passed through with the smallest nominal
amplitude so that adjoining assemblies such as rotary swivel
couplings 4 or superstructure 1 and their connections are only
slightly stressed. When the minimum operating frequency has been
reached, the 2/2-way valve 33 blocks the oil flow. Leakage oil
replacement and calibration are automatically ended at the same
time.
[0035] 3. The smallest nominal amplitude is set at the maximum
vibrator frequency. The 2/2-way valve 33 is opened, with the result
that leakage oil is replaced and calibration takes place.
[0036] 4. When the vibratory drive is switched off, the unbalance
piston 17 automatically moves in the direction of smallest nominal
amplitude in order to brake the vibratory drive with a small mass
moment of inertia. As soon as the position of the adjusting piston
34 corresponds to that of FIG. 5a, the inlet pressure at the
2/2-way valve 33 is connected to flow. From this point in time,
leakage oil can be replaced and the system calibrated.
[0037] The unbalance piston 17 is in the position shown in FIG. 5b
only with the nominal amplitude set manually or automatically to
maximum and with minimum operating frequency. The 2/2-way valve 33
is here connected to flow and the oil pressure corresponds to the
inlet pressure of the directional valve. In this operating state,
leakage oil can be replaced and the system calibrated. As soon as
the adjusting piston 34 has reached the position of FIG. 5b, the
2/2-way valve 33 is immediately automatically closed. The nominal
amplitude from this operating state can subsequently be reduced in
an infinitely variable manner. The operating frequency is subject
to follow-up control in the direction of smaller nominal amplitude,
for example by means of characteristic map control, to avoid
exceeding the permissible centrifugal force of the unbalance piston
17.
[0038] When the unbalance piston 17 is in the position shown in
FIG. 5c, the 2/2-way valve 33 is closed and leakage oil replacement
and calibration are not possible. The nominal amplitude can be
increased or reduced in an infinitely variable manner from this
operating state. The operating frequency is subjected to follow-up
control in the direction of smaller nominal amplitude, as is the
position of the unbalance piston 17 in the direction of larger
nominal amplitude.
[0039] When the vibratory drive is switched off, the unbalance
piston 17 is displaced from the positions shown in FIGS. 5b and 5c
immediately in the direction of smallest nominal amplitude,
independently of the decreasing operating frequency.
[0040] To achieve optimum soil or asphalt compaction, the vibration
frequency is matched to the nominal amplitude, as described above.
It is possible at the same time to automatically set the optimum
rolling speed as a function of the vibration frequency and for this
to be displayed to the roller driver. The position of the unbalance
piston 17 can either be adjusted manually or automatically
controlled as a function of the density (stiffness) of the ground.
In tandem vibratory rollers, it is possible for either only the
front or only the rear or for both rolling bodies 2, 3 to be fitted
with an unbalance which can be adjusted in the manner described
above.
[0041] In the embodiment shown in FIGS. 6a to 6c, a directional
valve 35 is provided instead of the hydraulic motor 32 of FIGS. 5a
to 5c, this valve being connected to the chamber of the actuating
cylinder 34 on the piston rod side while the directional valve 33,
in this case a three-way valve, is again connected to the chamber
of the actuating cylinder 40 upstream of the adjusting piston
34.
[0042] In the embodiment shown in FIG. 6a, where the vibration is
switched off after the adjusting piston 34 is completely retracted,
the unbalance cylinder 16 is filled up with oil from the hydraulic
source via a pump 37. For this purpose, at the same time as the
vibration is switched off, the directional valve 33 is connected as
shown in FIG. 6a. A pressure-limiting valve 36 is connected to the
line from the pump 37 to the directional valve 33. If said valve 36
responds, this means that the unbalance cylinder 16 is completely
filled with oil.
[0043] On reaching the state when the unbalance cylinder 16 is
completely filled with oil, FIG. 6b, the directional valve 33 is
switched over so that oil can flow back to the hydraulic source
from the actuating cylinder 40, specifically from the chamber
upstream of the adjusting piston 34, via a pressure-limiting valve
38, whereas the previously closed directional valve 35 is opened so
that hydraulic oil can adjust the adjusting piston 34.
Consequently, the quantity of oil in the adjusting cylinder 40 is
returned completely to the hydraulic source, as a result of which
the system is calibrated at the same time.
[0044] If this state is reached, the directional valves 33, 35 are
closed and the vibration can be switched on, FIG. 6c. If then a
certain frequency, for example 28 Hz, is reached, the amplitude is
adjusted from the position of smallest amplitude shown in FIG. 6c
by corresponding opening of the directional valve 35.
[0045] In this embodiment, apart from leakage oil replacement and
calibration, there also simultaneously takes place an additional
exchange of at least a large proportion of the total amount of
hydraulic oil in the system comprising the cylinders 16 and 40 on
each occasion that vibration compaction is stopped or interrupted.
This is advantageous as regards ageing of the hydraulic oil and
cooling thereof.
[0046] While preferred embodiments have been shown and described,
various modifications and substitutions may be made thereto without
departing from the spirit and scope of the invention. Accordingly,
it is to be understood that the present invention has been
described by way of illustration and not limitation.
* * * * *