Integration of Configurable Material Movement System with Conventional Bridge Paving Equipment

This application claims the benefit of U.S. provisional application Ser. No. 63/633,427, filed Apr. 12, 2024, the disclosure of which is hereby incorporated in its entirety by reference herein.

The present disclosure relates to bridge construction and material moving equipment and gantry crane systems.

Bridge construction involves multiple stages of equipment and labor-intensive processes to assemble and pave bridge decks.

A bridge construction system includes a frame structure, support legs, and a plurality of spaced-apart carriages. The frame structure has first and second ends. The support legs extend downward from the frame structure proximate to the first and second ends. The support legs are configured to elevate the frame structure. The plurality of spaced-apart carriages is disposed on the frame structure. The plurality of spaced-apart carriages is movable along the frame structure between the first and second ends.

A bridge construction system includes a frame structure, support legs, a carriage, and a support beam. The frame structure has first and second ends. The support legs extend downward from the frame structure proximate to the first and second ends. The support legs are configured to elevate the frame structure. The carriage is disposed on the frame structure. The carriage is movable between the first and second ends of the fame. The support beam is rotatably secured to the lower end of the carriage. The support beam is configured to pivot relative to the carriage and the frame structure.

A bridge construction equipment kit includes plurality of interconnectable trusses, support legs, and interchangeable carriages. Each of the interconnectable trusses are attachable to each other. The plurality of interconnectable trusses is configured to form frame structures having varying lengths and varying loads. The support legs are attachable to the frame structures. The support legs are configured to elevate the frame structures. The interchangeable carriages are configured to engage the frame structures such that the carriages are movable along the lengths of the support structures. At least one of the interchangeable carriages includes paving equipment. At least one of the interchangeable carriages includes material transportation and lifting equipment.

The interchangeable carriages can include carriages specific to the type of material being transported, optimized to carry varying loads, or varying sizes, and shapes. Some carriages provide elevation for additional headroom (lifting space). Some carriages can rotate or spin to assist in load placement.

Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

Referring, a perspective view of a bridge construction systemincluding paving equipment is illustrated. The bridge construction systemincludes a frame structurethat extends between a first endand a second end. The frame structureis comprised of a plurality of interconnectable trusses. The plurality of interconnectable trussesmay be connected to each other via pins or a pinned connectionalong the bottoms of the interconnectable trusses. A crown adjustment, which may include threaded rods, may connect the tops of the plurality of interconnectable trussesto each other. The crown adjustment, or more specifically, the threaded rods, may be utilized to pull the tops of the plurality of interconnectable trussestoward each other or to push the tops of the plurality of interconnectable trussesaway each other, which results in the adjacent interconnectable trussespivoting about the pinned connectionwhich increases or decreases a slope or gradient of the interconnectable trussesin directions extending outward from the corresponding pinned connectionstoward the first endand second end.

Support legsextending downward from the frame structureproximate to the first endand second end. The support legsare configured to elevate and lower the frame structurerelative to a supporting surface (e.g., the ground or a bridge deck that is being paved). Actuators, such as but not limited to hydraulic cylinders, hydraulic motors, pneumatic cylinders, electrical solenoids, electric motors, hand cranks, etc., may be utilized to raise and lower the support legs. The support legsinclude wheels. A position of the bridge construction systemis adjustable along the wheelsin a direction. Directionis orthogonal or transverse to a directionextending between the first endand second endof the frame structure. Some of the wheelsmay be drive wheelsthat receive power from a source (e.g., an internal combustion engine, electric motor, hydraulic pump, electric motor, etc.) to propel the bridge construction systemalong direction. For example, the bridge construction systemmay include a power unitthat includes an internal combustion engine or electric motor that powers a hydraulic pump. Such a hydraulic pump in turn may be connected to hydraulic motors that are connected to the drive wheelsto propel the bridge construction system. Some the wheelsmay not receive power and may be referred to as idle wheels.

One or more carriages or trolliesmay be disposed on the frame structure. The one or more trolliesmay be movable between the first endand second endalong the frame structurein direction. The power unitmay be configured to deliver power to the one or more trolliesto propel the one or more trolliesalong direction. For example, the one or more trolliesmay be connected to hydraulic motors to propel the one or more trolliesalong direction, where such hydraulic motors are powered by the internal combustion engine or electric motor and hydraulic pump of the power unit.

In, paving equipmentis secured to a single trolleythat is disposed on the frame structure. In this configuration, the paving equipment is configured to pave material (e.g., finish wet cement) that has been place onto a bridge deck. The paving equipmentmakes one or more passes over each section of such a bridge deck via moving the trolleybetween the first endand second endto pave each section of the bridge deck. Once a section of the bridge deck has been paved, the bridge construction systemis indexed to another section of the bridge deck via the drive wheels. The paving equipmentmay include a drag pan, paving rollers, a vibrator(e.g., a rota-vibe), and augers(e.g., left and right augers).

The bridge construction systemmay include a control console or control unitthat is configured to control the various components of the bridge construction system. For example, the control unitmay include a human machine interface that includes various buttons, knobs, levers, dials, touch screens, or any other user interface known in the art. The control unitmay further include a controller. The human machine interface is connected to the controller. The controller operates the various functions of the bridge construction systemin response to a user input from the human machine interface. For example, in response to receiving inputs from the human machine interface, the controller may open and close electrically operated solenoids to operate hydraulic motors or send signal to electric motors to operate the drive wheelsto propel the bridge construction system, propel the one or more trolliesalong direction, control equipment secured to the one or more trollies, etc.

Such a controller may be part of a larger control system and may be controlled by various other controllers throughout the bridge construction system. It should therefore be understood that the controller and one or more other controllers can collectively be referred to as a “controller” that controls various actuators in response to signals from various sensors or inputs from an interface to control functions the bridge construction system. The controller may include a microprocessor or central processing unit (CPU) in communication with various types of computer readable storage devices or media (e.g., a non-transitory computer readable medium having instructions stored thereon). Computer readable storage devices or media may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the CPU is powered down. Computer-readable storage devices or media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMS (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the controller in controlling the bridge construction system.

Control logic or functions performed by the controller may be represented by flow charts or similar diagrams in one or more figures. These figures provide representative control strategies and/or logic that may be implemented using one or more processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Although not always explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending upon the particular processing strategy being used. Similarly, the order of processing is not necessarily required to achieve the features and advantages described herein, but is provided for ease of illustration and description. The control logic may be implemented primarily in software executed by a microprocessor-based controller. Of course, the control logic may be implemented in software, hardware, or a combination of software and hardware in one or more controllers depending upon the particular application. When implemented in software, the control logic may be provided in one or more computer-readable storage devices or media having stored data representing code or instructions executed by a computer to control the bridge construction systemor its subsystems. The computer-readable storage devices or media may include one or more of a number of known physical devices which utilize electric, magnetic, and/or optical storage to keep executable instructions and associated calibration information, operating variables, and the like.

Alternatively, engaging the human machine interface may include directly opening and closing hydraulic valves and/or directly opening and closing electrical switches to control the function of the bridge construction system(e.g., moving the trolley, advancing the bridge construction systemvia the wheels on the support legs, operating the equipment secured to the trolley, etc.). Limiting device or switches may be utilized to limit the travel distance of the trolleyalong the first endand second endof the frame structure, limit movement of the support legs, or limit operating the equipment secured to the trolley. Such limiting devices or switches may reduce hydraulic pressure operating various components (e.g., by opening a relief valve) or alternatively eliminate electrical power being deliver to the various components of the bridge construction system.

Referring to, the bridge construction systemis illustrated to include material transportation and lifting equipment arranged in a first configuration as opposed to the paving equipment. More specifically, the bridge construction systemis arranged to include a plurality of carriages or trollies. It should be understood, however, that the bridge construction systemmay be arranged to include one or more trollies. The trolliesare disposed on the frame structureand are spaced-apart from each other. More specifically, one trolleyis disposed on each the interconnectable trussesforming the frame structure. Each trolleyis movable between the first endand second endalong the frame structurein direction. A lifting mechanism or liftmaybe secured to the trollies. The liftsare configured to raise and lower loads, such as construction materialsfor installation onto a bridge deck. For example, the liftsmay be configured to lift and lower premade concrete slabsinto desired positions onto the bridge deck. Alternatively, if straps, hooks, clips, or loops are used in lieu of the lift, the construction materialsmay be raised or lowered via raising or lowering the support legs. The construction materialsmay also be raised or lowered via a combination of raising or lowering the liftsand raising or lowering the support legs.

The liftsmay indirectly engage the construction materialsvia intermediate rigging equipment, such as spreader bars, in the event the construction materialinclude predetermined or preset contact points. The liftsmay comprise hoists, winches, or any other device or actuator know in the art (e.g., hydraulic cylinder, pneumatic cylinders, electrical solenoids, electrical motors, etc.). The liftsmay include latches, clips, or hooksthat provide a connection between the liftsand the construction materials. In conjunction or in lieu of, the latches, clips, or hooksmay provide a connection between the liftsand any intermediate rigging equipment, such as the spreader bars.

With the inclusion of such liftson the tollies, the bridge construction systemmay also be a gantry crane system. Furthermore, the number trolliesand liftsmay be adjusted or configured based on the necessity of the construction or material handling project. Therefore, the bridge construction systemmay more specifically be a configurable gantry crane system.

Referring to, the trolliesand a corresponding drive system for the trollies is illustrated. Each trolleyincludes a subframe. The liftsmay be removably secured to the subframeso that other equipment (e.g., the paving equipment) may be secured to the subframein lieu of the lifts. For example, the liftsand other equipment (e.g., the paving equipment) may be secured to the subframevia clipand eyeletconnection. The frame structure(or more specifically the interconnectable trusses) may include carriage rails or guide rails. The trolliesmay include guide wheelsand hold-down wheelsthat engage the guide railsto facilitate movement of the trolliesalong the railsin direction. The guide wheelsand hold-down wheelsmay also secure the trolliesto the guide railsby preventing vertical movement of the trollies. The trolleydepicted inmay have a different structure from the trolleydepicted inor may have the same structure with different equipment (e.g., material transportation equipment as opposed to the paving equipment) secured thereto.

The drive system for the trolliesis configured to provide the driving force to adjust the positions of the trolliesbetween the first endand second endalong the frame structurein direction. More specifically, the drive system includes at least one actuatorconfigured to adjust the positions of the trolliesalong the frame structurebetween the first endand second end. The at least one actuatormay be a hydraulic motor as illustrated, where such a hydraulic motor is connected to the hydraulic pump of the power unit. Alternatively, the at least one actuatormay be an electric motor or other device (hydraulic cylinder, pneumatic cylinder, electrical solenoid, etc.) operable to move the trollies along direction.

In the illustrated configuration, the at least one actuatorincludes one actuator that is connected to each of the trolliesby chains. The actuatorand chainconnection to each of the trolliesfacilitates simultaneously movement of the trolliesin directionand operates to maintain constant relative distances between trollies. The trolliesmay be connected to the chains via teeth(e.g., gear teeth). The actuatoris secured to a controller end framethat may be secured to the frame structurealong one of the ends,. The chainsextend between the controller end frameand an idler end frame. The idler end framemay be secured to the frame structurealong the other of the ends,opposite to the controller end frame. The chainsmay be connected to sprockets or gears. The gearsmay be attached to drive shafts. The drive shaftsmay be rotatably connected to the controller end frameand idler end framevia bearings. The actuatormay be directly connected to one of the drive shaftsor may be indirectly connected by additional gearsand chains, or via any other mechanical connection that facilitates movement.

Additional chains, actuators, gears, drive shafts, bearings, etc. may be added to the system, so that each trolleyhas a separate drive system and is capable of moving along the frame structurebetween the first endand second endin directionindependently of the other trollies. Alternatively, the actuatorcould be connected to each of the trolliesvia clutches, where the clutches are configured to open and closed to disconnect and connect the trollies from the actuator, which would operate to facilitate independent movement of each trolleybased on which clutches are opened or closed. In another alternative, one actuatormay be disposed on each trolleyand may be configured to drive the wheels (e.g., the guide wheelsand/or the hold-down wheels) of the trolleyto independently move the trolliesalong the frame structurebetween the first endand second endin direction.

Referring to, the bridge construction systemis illustrated to include material transportation equipment arranged in a second configuration as opposed to the paving equipment, and as opposed to the material transportation equipment arranged according to the first configuration. More specifically, the bridge construction systemis arranged to include a rotational trolleyand a corresponding support beamthat is rotatably secured to a lower end of the rotational trolley. The support beamis configured to pivot relative to the rotational trolleyand the frame structure. Although only one rotational trolleyis illustrated, the bridge construction systemmay include multiple rotational trolliesand corresponding support beams. The rotational trolleymay be disposed on the frame structure.

The rotational trolleymay be movable between the first endand second endalong the frame structurein direction. The power unitmay be configured to deliver power to the rotational trolleyto propel the rotational trolleyalong direction. The rotational trolleymay include guide wheelsand hold-down wheelsthat engage the guide railsto facilitate movement of the rotational trolleyin a manner similar to trollies. The rotational trolleymay include any of the drive systems described with respect to trolliesto facilitate synchronized or independent movement of one or more of the rotational trolliesalong the frame structure in direction.

An actuatormay be secured to the rotational trolley. The actuatoris configured to pivot the support beamrelative to the rotational trolley. The actuatormay be an electric motor or other device (hydraulic cylinder, pneumatic cylinder, electrical solenoid, hydraulic motor, etc.) operable to rotate the beamrelative to the rotational trolley. The support beamis positioned in a first orientation in, and in a second orientation in. The first and second orientations may be transverse or orthogonal to each other. Such rotation allows for placement of construction materials at various orientations, including orthogonal orientations. This may be particularly desirable when placing rebar or reinforcing steel onto a bridge deck at orthogonal orientations prior to pouring concrete over the rebar or reinforcing steel.

At least one strap, hook, clip, or loopmay be secured to the support beam. The at least one hook or loop is configured to engage and support construction materials (e.g., rebar or reinforcing steel over which concrete may be poured during the construction of a bridge). Alternatively, at least one liftmay be secured to the support beam. The least one lift is configured to raise and lower such construction materials (e.g., rebar or reinforcing steel). The straps, hooks, clips, or loopsare illustrated inwhile the liftsare illustrated as an alternative in. The liftsmay comprise hoists, winches, or any other device or actuator know in the art (e.g., hydraulic cylinder, pneumatic cylinders, electrical solenoids, electrical motors, etc.). The liftsmay include latches, clips, or hooksthat provide a connection between the liftsand the construction materials (e.g., rebar or reinforcing steel). If the straps, hooks, clips, or loopsare used in lieu of the lift, the construction materialsmay be raised or lowered via raising or lowering the support legs. The construction materialsmay also be raised or lowered via a combination of raising or lowering the liftsand raising or lowering the support legs.

The bridge construction systemmay comprise a configurable kit where the end user may interchange the various components describe above with respect toto meet the needs of the end user. For example, the interconnectable trussesmay be attachable to each other and may be configured to form frame structuresof varying lengths and heights. This is advantageous since all bridges are not uniform and vary in size. For example, one or more of the interconnectable trussesmay be added for constructing wider bridges or subtracted for constructing narrower bridges. The support legsmay be repositioned to desired locations in response to adding or subtracting one or more of the interconnectable trusses.

The number trollies (trolliesand rotational trollies) may be added or subtracted depending on the size of the bridge being constructed or based on whether or not the trolley is being used for paving or for movement of the construction materials. For example, if the bridge construction systemis being utilized to pave the bridge deck, the paving equipment(e.g., drag pan, paving rollers, vibrator, and augers) may be attached to the trolley (e.g., see).

On the other hand, if the bridge construction systemis being utilized for movement of the construction materials, the trollieshaving liftssecured thereto (e.g.,) may be attached to the frame structurefor movement of the construction materials. If transportation and rotation of the construction materialsis required, one or more of the rotational trolleysand one or more corresponding support beamsmay be attached to the frame structurefor movement of the construction materials. If rotation but not raising/lowering of the construction materialsis required, the at least one strap, hook, clip, or loopmay be secured to the support beam. If rotation and raising/lowering of the construction materialsis required, one or more of the liftsand corresponding latches, clips, or hooksmay be secured to the support beam.

The three trollies (e.g., trolliesand rotational trolley) depicted in,, andmay be different components that are attachable to the frame structurebased the current need (e.g., bridge deck paving, material movement, etc.). Also, equipment other than the equipment depicted herein (e.g., paving equipment, material movement equipment, etc.) may be attached to the trollies.

Referring to, a trolleyand a corresponding drive system is illustrated. The trolleymay be an alternative configuration of the trolliesdepicted in. The trolleyand may be utilized in the same manner as the trolliesas described herein. Furthermore, the trolleymay be utilized in lieu of any of the trolliesdescribed herein and as depicted in. Therefore, the trolleymay be representative of multiple trollies.

The trolleyincludes a subframe. One of the of liftsmay be removably secured to the subframeso that other equipment (e.g., the paving equipment) may be secured to the subframein lieu of the lift. For example, the liftand other equipment (e.g., the paving equipment) may be secured to the subframevia a clipand eyeletconnection. The frame structure(or more specifically the interconnectable trusses) may include carriage rails or guide rails. The trolleymay include guide wheelsand hold-down wheelsthat engage the guide railsto facilitate movement of the trolleyalong the railsin direction. The guide wheelsand hold-down wheelsmay also secure the trolleyto the guide railsby preventing vertical movement of the trolley.

The drive system for the trolleyis configured to provide the driving force to adjust the position of the trolleybetween the first endand second endalong the frame structurein direction. More specifically, the drive system may correspond to the drive system depicted in. The trolleymay be connected to the drive system and moved by the drive system in the same manner as trollies.

In an alternative configuration, an actuatormay be disposed on the trolleyand may be configured to drive the wheels (e.g., the guide wheelsand/or the hold-down wheels) of the trolleyto independently move the trolleyalong the frame structurebetween the first endand second endin direction. The actuatormay be a hydraulic motor, where such a hydraulic motor is connected to the hydraulic pump of a power unit or generator. Alternatively, the actuatormay be an electric motor or other device (hydraulic cylinder, pneumatic cylinder, electrical solenoid, etc.). If the actuatoris electric (e.g., an electric motor), the actuatormay receive electrical power from the power unit or generator. The power unit or generatormay also be connected to the liftto provide power (e.g., electric, hydraulic, etc.) to the lift. Again, the liftsmay comprise hoists, winches, or any other device or actuator know in the art (e.g., hydraulic cylinder, pneumatic cylinders, electrical solenoids, electrical motors, etc.).

The trolleymay include a main bodysupportable on the frame structure. The trolleymay also include a rack, shelf, or platformthat is offset from the main body. The platformis also supportable on the frame structure. More specifically, each of the main bodyand platformmay include a portion of the guide wheelsand a portion of the hold-down wheels, which moveably secure the main bodyand platformto the frame structure. The power unit or generatormay be disposed, secured, and/or supported on the platform. The power unit or generatoris operable to power the construction material transportation equipment (e.g., the lift).

It should be understood that the designations of first, second, third, fourth, etc. for any component, state, or condition described herein may be rearranged in the claims so that they are in chronological order with respect to the claims. Furthermore, it should be understood that any component, state, or condition described herein that does not have a numerical designation may be given a designation of first, second, third, fourth, etc. in the claims if one or more of the specific component, state, or condition are claimed.

The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form further embodiments that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.