U.S. patent application number 14/487505 was filed with the patent office on 2016-03-17 for device and process for controlling compaction based on previously mapped data.
This patent application is currently assigned to Caterpillar Paving Products Inc.. The applicant listed for this patent is Caterpillar Paving Products Inc.. Invention is credited to Paul T. Corcoran, Allen DeClerk, Nicholas Oetken.
Application Number | 20160076205 14/487505 |
Document ID | / |
Family ID | 55454211 |
Filed Date | 2016-03-17 |
United States Patent
Application |
20160076205 |
Kind Code |
A1 |
Corcoran; Paul T. ; et
al. |
March 17, 2016 |
Device and Process for Controlling Compaction Based on Previously
Mapped Data
Abstract
This disclosure provides a system and method for compacting
materials, and more specifically, a system and method for
proactively varying compaction effort over a mat of materials
located at a worksite area responsive to previously mapped data
relating to the compaction makeup of that specific worksite
area.
Inventors: |
Corcoran; Paul T.;
(Washington, IL) ; Oetken; Nicholas; (Brooklyn
Park, MN) ; DeClerk; Allen; (Princeton, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Caterpillar Paving Products Inc. |
Brooklyn Park |
MN |
US |
|
|
Assignee: |
Caterpillar Paving Products
Inc.
Brooklyn Park
MN
|
Family ID: |
55454211 |
Appl. No.: |
14/487505 |
Filed: |
September 16, 2014 |
Current U.S.
Class: |
73/784 |
Current CPC
Class: |
E02D 3/026 20130101;
E01C 19/288 20130101 |
International
Class: |
E01C 19/28 20060101
E01C019/28; E02D 3/026 20060101 E02D003/026 |
Claims
1. A system for compacting a mat of material comprising; collecting
compaction data from at least two different areas of a mat of
materials, the compaction data comprising the current level of
compaction for that area of the mat; comparing the compaction data
collected for each area of the mat with a desired final compaction
for that area of the mat; calculating an additional compaction
required for any areas of the mat requiring additional compaction;
dividing the mat into subsegments requiring additional compaction
based upon the collected compaction data thereby creating a
compaction map; calculating an additional amount of compaction
required for any subsegments requiring additional compaction;
controlling a compactor based upon the calculation of additional
compaction required for any subsegments requiring additional
compaction by varying compaction effort of the compactor over such
subsegments as the compactor travels over the subsegments to
provide a final desired total compaction for each such
subsegment.
2. The system of claim 1 wherein the varying of compaction effort
comprises varying of vibratory frequency or vibratory amplitude of
a vibratory apparatus operatively connected to a mat-engaging
implement of the compactor.
3. The system of claim 2 wherein the mat-engaging implement is a
roller.
4. The system of claim 1 wherein the controlling of the compactor
is accomplished automatically by an electronic control unit.
5. The system of claim 1 wherein the controlling of the compactor
is accomplished manually by an operator.
6. The system of claim 1 wherein the compaction data is collected
from specifically designed and implemented worksite surveys,
testing, or probing.
7. The system of claim 1 wherein the varying of compaction effort
of the compactor over such subsegments is continuous.
8. The system of claim 1 further comprising controlling the
compactor to avoid subsegments that have been calculated to be
compacted as desired.
9. The system of claim 1 wherein the compactor is a smooth double
drum compactor.
10. The system of claim 1 wherein the compactor is a tow-behind
compactor.
11. The system of claim 1 wherein the varying of compaction effort
comprises turning on or turning off a vibratory apparatus
operatively connected to a mat-engaging implement of the
compactor.
12. A system for managing worksite machine traffic over a worksite
comprising; collecting compaction data from at least two different
areas of a mat of materials, the compaction data comprising the
current level of compaction for that area of the mat; comparing the
compaction data collected for each area of the mat with a desired
final compaction for that area of the mat; dividing the mat into
subsegments requiring no additional compaction based upon the
collected compaction data thereby creating a compaction map;
controlling a worksite machine based upon the compaction map to
avoid subsegments requiring no additional compaction.
13. The system of claim 12 wherein the controlling of the worksite
machine is accomplished automatically by an electronic control
unit.
14. The system of claim 12 wherein the controlling of the worksite
machine is accomplished manually by an operator.
15. The system of claim 12 wherein the worksite machine is a
hauling unit, on-road truck, off-road truck, paving machine, cold
planer or reclaimer.
16. The system of claim 12 wherein the controlling of the worksite
machine includes controlling the worksite machine in real-time as
the worksite machine arrives at a designated subsegment of the
worksite.
17. A system for compacting a mat of material comprising;
collecting compaction data from at least two different areas of a
mat of materials, the compaction data comprising the current level
of compaction for that area of the mat; comparing the compaction
data collected for each area of the mat with a desired final
compaction for that area of the mat; calculating an additional
compaction required for any areas of the mat requiring additional
compaction; dividing the mat into subsegments requiring additional
compaction based upon the collected compaction data thereby
creating a compaction map; calculating an additional amount of
compaction required for any subsegments requiring additional
compaction; controlling at least two compactors based upon the
calculation of additional compaction required for any subsegments
requiring additional compaction by varying compaction effort of the
compactors over such subsegments as the compactors travel over the
subsegments to provide a final desired total compaction for each
such subsegment.
18. The system of claim 17 wherein the controlling of the
compactors is accomplished automatically by an electronic control
unit.
19. The system of claim 17 wherein the controlling of the
compactors is accomplished manually by an operator.
20. The system of claim 17 wherein the controlling of the
compactors includes controlling the compactors such that the
compactor closest in proximity to a subsegment requiring compaction
is controlled to provide the desired final compaction to that
subsegment.
Description
TECHNICAL FIELD
[0001] The disclosure relates generally to machines and control
strategies used in compacting materials, and relates more
particularly to proactively varying compaction effort over a mat of
material located at a worksite area responsive to previously mapped
data relating to the compaction makeup of that specific worksite
area.
BACKGROUND
[0002] In the construction industry, the quality and durability of
the final surface being laid (whether asphalt, or concrete, or
other) is highly dependent on the substrate or mat materials
located thereunder. Accordingly, in site preparation compaction of
the substrate materials must be carefully considered and monitored
in order to provide the desired final surface. Given various site
condition variability, substrate compaction/makeup can vary
significantly over varying locations at the site. Additionally,
there are instances when multiple compaction efforts may be made by
multiple machines over the same site prior to the laying of the
final surface thereover.
[0003] In general desired site preparation by compaction is
achieved by driving, pushing or towing a machine having rotating
drums across the substrate of interest to increase its density and
uniformity. Compactors are often equipped with vibratory
apparatuses to increase and control energy transfer between the
compactor and the substrate. As noted above, different substrates,
and similar substrates having different qualities such as moisture
level, thickness and other qualities, will tend to respond
differently to compactor interaction with the substrate. The
response of a material to compactor interaction can affect the
smoothness that is ultimately achievable in the final surface.
[0004] Various machines are known in the art, for preparing a
subgrade prior to preparing the mat upon which the final surface
will be laid. These machines include, but are not limited to, cold
planers, recyclers and other reclaiming machines. In general, these
machines travel across a region of a work area upon which a mat of
material is to be paved, and process the existing material, either
by grinding up, mixing and re-depositing the material, or by
cutting away a layer of material for disposal elsewhere.
[0005] As noted above, different materials may have widely varying
"compaction responses" or changes in properties resulting from
coverage with a compactor machine. For instance, sandy or granular
soils tend to exhibit a different change in relative stiffness than
do soils high in clay content each time a compactor is passed over
a given region. Local variations in material composition or
moisture content within a work area, as well as changes in moisture
content over time can also result in non-uniformity in stiffness
even where compactor coverage has been uniform. Like many
heavy-duty construction machines, compactors can be quite expensive
to operate, and thus unnecessary work or remedial actions create
undesired expense. It is additionally noted that excess compaction
may be problematic not just due to unnecessary wasted time and
expense, but also due to the fact that excess compaction can lead
to de-compaction or crushing of aggregate material due to high
amplitude from a vibratory compaction system or over-compaction
from excessive compaction effort.
[0006] In this regard, substantial effort has been made to test
substrate quality, compaction, etc. prior to and during final
compaction before the final surface is laid thereover. For example,
some known methods include detecting the quality of the compaction
by taking a boring sample and analyzing the sample in a laboratory.
At least some of the drawbacks of this procedure include that it is
time consuming, the measurement is performed only by way of spot
checks and only after termination of at least the first compacting
process thus making it difficult, if not impossible to adjust
compaction effort during compaction. Other known methods of
compaction testing include the use of electronic probes which are
manually applied to the site and are capable of detecting a degree
of compaction existing at a given spot. Such electronic probes
offer the advantage of delivering individual results already while
the compacting is still in progress. Also in this measuring method,
however, the spot-wise character of the measurements makes it
impossible to obtain results on the whole treated surface.
[0007] Further intelligent compaction technology is growing in
acceptance and use. For example, U.S. Pat. No. 8,057,124 B2,
assigned to Wacker Neuson Produktion GmbH & Co., discloses a
method and device for measuring soil parameters. That patent
discloses a system and method for approximating the actual gradient
of the contact force and a contact surface parameter that takes
into account the geometry and shape of the contact surface to
calculate a dynamic modulus of deformation. Additionally, U.S. Pat.
No. 7,873,492 assigned to Hamm AG discloses a method for predicting
compaction over an entire subsurface utilizing data taken from
subsegments thereof. While the systems and methods disclosed in
these patents may have some utility, none provide a proactive
control of a compaction device before the compaction device reaches
the previously mapped worksite area.
SUMMARY
[0008] In one aspect, a system for proactively varying compaction
effort over a mat of material located at a worksite area responsive
to previously mapped data relating to the compaction makeup thereof
is provided. More specifically, in some aspects of the disclosure,
systems and methods for proactively varying compaction effort over
a mat of materials comprising a worksite using historical
compaction data (or compaction data from other sources) with
precise location and machine measurement data as to that worksite
area is disclosed. In aspects of the disclosure, the additional
amount of compaction needed to provide the exact desired amount of
compaction may be calculated. In accordance therewith, a compaction
machine having variable compaction effort, such as variable
vibratory frequency and/or amplitude, may be automatically and
proactively adjusted based upon the aforementioned historical data
or other compaction data in a proactive manner to precisely provide
the amount of compaction necessary to provide the total final
desired compaction.
[0009] In accordance with aspects of the disclosure, proactive
changes in vibratory frequency, amplitude, etc., may be made in
real-time as the compaction machine approaches and works on a
previously mapped worksite area requiring a change in compaction
effort to provide the desired total compaction. The disclosure thus
avoids reactive changes to compaction effort occurring after the
compaction machine has arrived at or even passed the specific
worksite area or failing to provide the total amount of compaction
necessary in a single pass. Additionally, the disclosed system may
advantageously prevent operation of the compaction machine at the
wrong worksite location, or in circumstances where more than one
machine is being used on a worksite, prevent use of the wrong
machine in the wrong location. Further in accordance with the
disclosure, the disclosed system may be used to control multiple
compactors to provide desired compaction for subsegments of the
worksite.
[0010] In one aspect of the disclosure, the worksite information
may be supplied from multiple sources, including, but not limited
to, a prior pass by the compaction machine, other worksite
machines, or specifically designed and implemented worksite
surveys, testing, etc. Additional embodiments of the present
disclosure include a system for controlling construction machine
traffic on a worksite area including all machines causing ground
compaction, not just purpose-built compaction machines
Additionally, the present disclosure may provide automated control
of all compaction machines on a worksite to insure the right
machine is used at the right location to proactively provide
desired compaction.
BRIEF DESCRIPTION OF THE DRAWING(S)
[0011] FIG. 1 is a side diagrammatic view of an exemplary compactor
for use in accordance with aspects of the disclosure; and
[0012] FIG. 2 is a pictorial view of a display illustrating a
mapped paving worksite according to aspects of the disclosure.
DETAILED DESCRIPTION
[0013] The disclosure relates generally to a system and method for
proactively varying compaction effort over a mat of materials
located at a worksite area responsive to previously mapped data
relating to the compaction makeup of that specific worksite area.
Specifically, the disclosure relates to proactive changes in
vibratory frequency, amplitude, etc., that may be made in real-time
to compaction machines as the compaction machines approach and work
on worksite locations that have previously been mapped with
specific compaction information related to subsegments of the
worksite.
[0014] In accordance with the foregoing, FIG. 1 illustrates a side
view of a compactor 10 working on a mat of materials Z located
generally at a worksite area. In particular, FIG. 1 illustrates an
exemplary compactor 10 of the self-propelled type that can travel
over a surface S under its own power that may implement aspects of
the disclosure. In particular, FIG. 1 depicts a smooth double drum
compactor 10 of the type commonly used on asphalt and also on fine
grained base materials such as fill sand. It is to be understood,
however, that the present disclosure also applies to work machines,
including compactors, with various styles of tips or "teeth" that
are commonly used on earth material bases and sub bases for
earthworks construction, particularly on cohesive fill materials.
Additionally, work machines such as self-propelled two-wheel and
four-wheel compactors, tow-behind systems, single drum "padfoot"
vibratory machines, four wheel "tamping" foot machines, the
traditional "sheep's foot" towed rollers, etc. are also known and
maybe used in accordance with the disclosure. Additionally, aspects
of the present disclosure may involve other types of worksite
machines that may compact a worksite area (whether designed to or
not), including, but not limited to: hauling units, such as
scrapers; articulated trucks and on-road trucks, such as side
dumps, or rear dumps; paving machines; cold planers; reclaimers;
etc.
[0015] In accordance with aspects of the disclosure, the compactor
10 may include a body or frame 12 that inter-operatively connects
and associates the various physical and structural features that
enable the compactor 10 to function. These features may include an
operator cab 20 that is mounted on top of the frame 12 from which
an operator may control and direct operation of the compactor 10.
Additionally, a steering system 21 and similar controls may be
located within the operator cab 20. To propel the compactor 10 over
the surface S, a power system (not shown), such as an internal
combustion engine, can also be mounted to the frame 12 and can
generate power that is converted to physically move the compactor
10. As shown in FIG. 2, one or more other implements may be
connected to the compactor 10, including, but not limited to a
blade 36. Such devices may include, but are not limited to devices
for loading, lifting, and brushing, and may include, for example,
buckets, forked lifting devices, brushes, grapples, cutters,
shears, breakers/hammers, augers, and others.
[0016] To enable physical motion of the compactor 10, the compactor
10 includes a first roller drum 24 and a second roller drum 22 that
are in rolling contact with the surface S. For reference purposes,
the compactor 10 can have a typical direction of travel such that
the first roller drum 24 may be considered the forward roller drum
and the second roller drum 22 considered the rearward roller drum.
The first (forward) and second (rearward) roller drums 24, 22 can
be cylindrical structures that are rotatably coupled to and can
rotate with respect to the frame 12. Because of their forward and
rearward positions and their dimensions, the first (forward) and
second (rearward) roller drums 24, 22 support the frame 12 of the
compactor 10 above the surface S and allow it to travel over the
surface S. Each drum 24, 22 may be provided with a vibratory
apparatus, each of which may have an adjustable vibration
amplitude, adjustable vibration frequency and/or adjustable
vibration direction. Varying energy transfer could also include
turning one or both of vibratory apparatuses on or off.
[0017] To facilitate control and coordination of the compactor 10,
a controller 39 such as an electronic control unit 40 may be
utilized. The main interface (not shown) of the controller 39 may
be located in the operator cab 20 for access by the operator and
may communicate with the steering system 21, the power system, and
with various other sensors and controls on the compactor 10. While
the controller 39 illustrated in FIG. 1 is represented as a single
unit, in other embodiments of the disclosure, the controller 39 may
be distributed as a plurality of distinct but interoperating units,
incorporated into another component, or located at a different
location on or off the compactor 10.
[0018] The controller 39 may include sensors 32 configured to sense
a parameter indicative of the acceleration, velocity, and/or force
of a component of the compactor 10. The components may include the
first (forward) and/or second (rearward) roller drums 24, 22, the
compactor frame 12, or the like. Additionally, there may be more
than one type of sensor located on the compactor 10. For example,
there may be sensors sensing the vertical acceleration of the
roller drums 22, 24. Such sensors may be accelerometers and may
include, but are not limited to, laser accelerometers, low
frequency accelerometers, bulk micromachined capacitive
accelerometers, strain gauge accelerometers, and bulk micromachined
piezoelectric accelerometers among others.
[0019] In one aspect of the disclosure, the sensors 32 may sense
force. In accordance with such an embodiment, the sensors 32 may
be, but are not limited to, load cells, strain gauges, or the like.
In another aspect, the sensors 32 may be located at or close to a
center point of axle 30, at or close to a longitudinal centerline
of frame 12. The transmitted signals may include sonic signals, RF
signals, or laser signals, for example, transmitted via a
transmitter 34 mounted with sensors 32 in a housing 38. Sensors 32
may include a non-contact sensor such as the examples noted
above.
[0020] Controller 39 may further include a phase sensor 33. Phase
sensor 33 may be used to measure the phase angle of a vibratory
force imparted by the first (forward) and/or second (rearward)
roller drums 24, 22 to the ground. The phase angle may be measured
in real time and transmitted to an electronic controller (not
shown) for later use in accordance with aspects of the disclosure.
Controller 39 may further include a location sensor 46 resident on
compactor 10 which receives global or local positioning data used
in establishing and tracking geographic position of compactor 10
within a worksite area. In one aspect, further described herein,
data received via the location sensor 46 may be linked with data
received from sensors 32, 33 to map compaction data relative to the
position data of the compactor 10 for use in accordance with the
disclosure. Controller 39 may be used to calculate the exact amount
of additional compaction needed to provide the total desired amount
of compaction to a particular worksite area. Controller 39 may also
be used to control aspects of the vibratory apparatuses provided on
each drum 24, 22 in order to control the vibration amplitude,
vibration frequency and/or vibration direction to provide the
desired compaction as is known to those of ordinary skill in the
art. Controller 39 may continuously control the vibratory
apparatuses in real-time, varying the vibration amplitude,
vibration frequency, and/or vibration direction to provide the
total desired amount of compaction as calculated by the controller
39.
[0021] Controller 39 may further include an electronic control unit
40 which includes at least one data processor 42 and a computer
readable memory 44. Electronic control unit 40 may be coupled with
sensors 32, 33 and also with location sensor 46, and may be
configured to output a signal responsive to inputs received with
respect to previously mapped worksite compaction data. As shown in
FIG. 1, a display 48 also may be coupled with electronic control
unit 40 and may be positioned in the operator cab 20 to display
various data to an operator relating to machine position,
previously mapped compaction data, or still other parameters. In
the illustrated aspect, the controller 39 is resident on the
compactor 10.
[0022] It should be appreciated that in other aspects, controller
39 or parts thereof might be located remotely from the compactor
10, such as at an on-site or offsite management office. In such an
aspect, data gathered relating to position of compactor 10 and
compaction data might be transmitted to a remote computer,
processed, and control commands sent to the compactor 10 to direct
an operator to take or forego certain actions, or to direct
compactor 10 to autonomously take or forego certain actions. Taking
actions in response to the previously mapped compaction data when
combined with current position data might include commencing travel
of compactor 10 within a work area, stopping travel of compactor 10
within a work area, or redirecting or otherwise changing a planned
compactor 10 travel path or coverage pattern. Computer readable
memory 44 may store computer executable code including a control
algorithm for determining exact variation of vibratory amplitude,
frequency, and/or speed of the compactor over a worksite area in
order to achieve final desired compaction of the substrate Z.
[0023] In accordance with the disclosure, FIG. 2 is a pictorial
view of a display illustrating a mapped compaction state of a
worksite. The worksite has been fragmented into smaller work areas,
or subsegments, of length L and width W. The subsegments represent
specific information collected relating to each subsegment relevant
to the degree of compaction thereof. In accordance with aspects of
the disclosure, the controller 39, may then calculate the
additional amount of compaction needed, if any, to provide the
total desired amount of compaction for each subsegment. Thus having
been provided with a map of the degree of compaction of the
subsegments of the worksite, and utilizing the location sensor 46,
compaction effort of the compactor 10 may be adjusted in real-time
by continuously varying compactor 10 speed, and/or vibratory
amplitude or frequency of the drums 24, 22 proactively to provide
the exact total desired compaction for each subsegment needing
additional compaction. In one embodiment, the control may be made
by an operator manually. In other embodiments, the compaction
effort may be adjusted automatically by the controller 39 through
an algorithm in the electronic control unit 40.
[0024] In accordance with aspects of the disclosure, the
information as to compaction status of the subsegments may be
derived from multiple available sources including, but not limited
to, worksite machines (including other compactors), or specifically
designed and implemented worksite surveys, testing, probing, etc.
Further, the movement of worksite machines other than compactors
may be controlled over the various subsegments to provide
compaction (where additional marginal compaction is desired) or to
prevent compaction, by diverting worksite machines away from
subsegments that are properly compacted. Such control may be in the
form of messages transmitted to the operators of the worksite
machines or by automatic control thereof.
[0025] More specifically, in aspects of the disclosure, the map of
subsegments of the work area may designate certain areas as
compacted as desired and thus "off limits" to further worksite
machine traffic over such subsegments. In accordance therewith,
either a message indicating that a worksite machine is approaching
a fully compacted subsegment is sent to the operator of the machine
in real-time warning of the approaching fully compacted subsegment
or the worksite machine is automatically controlled to avoid the
subsegment.
INDUSTRIAL APPLICABILITY
[0026] The present disclosure is useful in a multitude of
construction applications. By utilizing aspects of the present
disclosure to proactively vary compaction effort over a mat of
material located at a worksite area responsive to previously mapped
data, unnecessary and undesired compaction effort may be prevented.
Utilizing automatic control thereof may prevent operator error and
allow more efficient worksite control.
[0027] In accordance with aspects of the disclosure, based upon
previously developed compaction data as to worksite subsegments, a
map may be created of the existing compaction status of the
subsegments. Utilizing the existing map, all worksite traffic,
including, but not limited to, compaction machine traffic, may be
monitored and controlled. Further in accordance with aspects of the
disclosure, compaction equipment may continue to take compaction
readings to confirm that desired compaction has been achieved on a
subsegment by subsegment basis and mapping may be updated in
accordance therewith. In specific embodiments of the disclosure,
compaction effort is controlled through varying compactor roller
vibratory frequency and/or amplitude, and/or compactor speed over
worksite subsegments.
[0028] In accordance with other embodiments of the disclosure,
compactor 10 travel speed, compactor travel direction, and/or
compactor effort may be controlled via electronic control unit 40
may be through access to a computer network via transmitter (not
shown). The communication channels that may be used in connection
therewith may be any type of wired or wireless electronic
communications network, such as, e.g., a wired/wireless local area
network (LAN), a wired/wireless personal area network (PAN), a
wired/wireless home area network (HAN), a wired/wireless wide area
network (WAN), a campus network, a metropolitan network, an
enterprise private network, a virtual private network (VPN), an
internetwork, a backbone network (BBN), a global area network
(GAN), the Internet, an intranet, an extranet, an overlay network,
a cellular telephone network, a Personal Communications Service
(PCS), using known protocols such as the Global System for Mobile
Communications (GSM), CDMA (Code-Division Multiple Access), W-CDMA
(Wideband Code-Division Multiple Access), Wireless Fidelity
(Wi-Fi), Bluetooth, Long Term Evolution (LTE), EVolution-Data
Optimized (EVDO) and/or the like, and/or a combination of two or
more thereof.
[0029] Further control in accordance with the disclosure may be
implemented in any type of computing devices, such as, e.g., a
desktop computer, personal computer, a laptop/mobile computer, a
personal data assistant (PDA), a mobile phone, a tablet computer,
cloud computing device, and the like, with wired/wireless
communications capabilities via the communication channels.
[0030] The many features and advantages of the disclosure are
apparent from the detailed specification, and, thus, it is intended
by the appended claims to cover all such features and advantages of
the disclosure which fall within the true spirit and scope of the
disclosure. Further, since numerous modifications and variations
will readily occur to those skilled in the art, it is not desired
to limit the disclosure to the exact construction and operation
illustrated and described, and, accordingly, all suitable
modifications and equivalents may be resorted to that fall within
the scope of the disclosure.
* * * * *