Machine, System and Method for Road Construction

This application is a continuation of U.S. patent application Ser. No. 18/182,295 that was filed on Mar. 10, 2024, which claims the benefit of priority from U.S. Provisional Application No. 63/323,803 that was filed on Mar. 25, 2022, the contents of all of which are expressly incorporated herein by reference.

The present disclosure relates generally to road construction and, more particularly, to a machine, system and method for constructing a road.

For the purposes of this disclosure, a road can be considered a durable surface (e.g., a route, way, path, drive, street, lane, lot, or similar thoroughfare or park) that has been prepared on land or over water to support any one or more of various types of traffic (e.g., vehicular traffic, pedestrian traffic, railway traffic, aircraft ground traffic, bicycle traffic, etc.). While roads can be constructed in a variety of different ways, most of these ways involve the application of a specialized material to an existing or newly prepared surface.

Asphalt is one example of a material specially prepared for use in building roads. Asphalt, also known as bitumen, is a binder used to adhere filler or reinforcement (e.g., sand, aggregate, etc.) together and to the underlying surface. An asphalt road is durable and flexible, allowing expansion and contraction without damage. The asphalt can be asphalt cement (AC), polymer modified asphalt (PMA), cutback, and emulsions. Other materials (e.g., primers, hardeners, additives, etc.) may be used together with asphalt when building roads.

Many different methods exist for applying asphalt (and/or other building materials) to an underlying surface during the making of a road. One method is known as Chip Sealing. During the Chip Sealing process, an asphalt mixture is prepared and loaded into a spray truck (e.g., the Blacktopper Centennial Distributor by E. D. Etnyre & Co. or the Asphalt Distributor BC-502 by Bearcat Manufacturing). The spray truck is equipped with a vessel that holds the emulsion, and a spray bar at a trailing end of the vessel that extends transversely across a width of the road. Any number of nozzles are mounted to the spray bar. An engine-driven pump presses the asphalt mixture from the vessel through the spray bar and nozzles and onto the underlying surface behind the spray truck, while the spray truck travels along a length of the surface. In some applications, another machine follows behind the spray truck and applies aggregate over the layer of asphalt, while yet another machine compacts the aggregate into the asphalt.

During the building of a road, it is possible to apply an incorrect amount of asphalt. When too much asphalt is applied, the asphalt can flush up through the aggregate and form a smooth upper surface that is slippery. An excessive amount of asphalt is also wasteful and expensive. When too little asphalt is applied, the aggregate may not stick to the road and can cause damage to vehicles traveling the road as the aggregate unravels from the underlying surface.

Typically, the asphalt is applied by the nozzles of the spray truck at a predetermined rate (e.g., a set volumetric amount per area of roadway) based on a plan generated in advance for a particular road. The road plan is manually prepared by an engineer based on average measurements previously captured over a broad stretch of the road (e.g., over an entire length of the road being constructed). The measurements can include an average texture of the underlying surface.

The rate of asphalt application required by the plan is electronically transferred into a distribution controller mounted on the spray truck. The controller monitors a travel speed of the truck along the road, and responsively adjusts operation of the pump such that an actual rate of discharge from the nozzles provides the planned rate along the length of the road.

While the conventional machine, control system and method discussed above may be adequate for some applications, it can also be less than optimal. For example, relying on only an average measurement of texture to determine the application rate for the entire road may result in over application in some areas and under application in other areas. In addition, the average texture measurements typically used to generate the plan may not consider all factors affecting performance of the road. Further, the conventional process for manually taking the texture measurements (e.g., using sand circles) and thereafter developing and implementing the plan may be slow, labor-intensive and expensive.

The disclosed machine, system and processes are directed to overcoming one or more of the problems set forth above and/or other problems of the prior art.

In one aspect, the present disclosure is directed to a method of building a road using a binder and a reinforcement. The method may include moving a machine over a surface on which the road is to be built, and generating a signal indicative of a texture of the surface during movement of the machine over the surface. The method may also include detecting a location of the texture on the surface, and determining, using a specially programmed processor, a positive amount of the binder to be applied to the location of the texture on the surface that varies based on the signal and on an embedment specification of the reinforcement. The method may further include automatically applying the positive amount of the binder to the location of the texture on the surface to build the road.

In another aspect, the present disclosure is directed to a method of building a new road over the top of an old road. This method may include moving a distributor over a surface of the old road and generating a signal indicative of a texture at the surface during movement of the distributor over the surface. The method may also include detecting a location of the texture on the surface, and determining, using a specially programmed processor, a positive amount of asphalt to be applied to the location of the texture on the surface that varies based on the signal and based on an embedment specification of an aggregate. The method may further include automatically spraying the positive amount of asphalt to the location of the texture on the surface, and applying the aggregate over the asphalt to build the new road.

In yet another aspect, the present disclosure is directed to a road building machine. The road building machine may include a vehicle, and a distribution arrangement mounted to the vehicle and configured to distribute a binder on to a surface as the vehicle moves over the surface. The road building machine may also include at least one sensor mounted to the vehicle and configured to generate a signal indicative of a distance between existing reinforcement at the surface to an upper surface of existing binder during movement of the vehicle over the surface. The road building machine may further include a locating device configured to detect a location of the texture, and a controller in communication with the distribution arrangement, the at least one sensor, and the locating device. The controller may be specially programmed to determine a positive amount of the material to be applied to the location of the distance based on the signal and an embedment specification for reinforcement to be newly applied, to automatically cause the distribution arrangement to distribute the positive amount of the binder on to the surface at the location of the distance as the vehicle moves over the surface; and to embed the reinforcement into the binder.

The terms “about” and/or “generally” as used herein serve to reasonably encompass or describe minor variations in numerical values measured by instrumental analysis or as a result of sample handling. Such minor variations may be considered to be “within engineering tolerances” and in the order of plus or minus 0% to 10%, plus or minus 0% to 5%, or plus or minus 0% to 1%, of the numerical values.

The term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

illustrates a work environment, in which one or more machinesare performing a road-building operation. It should be noted that, while building of a new roadwill be discussed in detail below, the concepts disclosed in this specification may be equally applicable to maintenance, rehabilitation and/or preservation of an existing road. As will also be explained in more detail below, a location, orientation, speed and/or trajectory of machine(s)may be tracked (e.g., by a network of satellites) during the road-building operations.

Machine(s)may be configured to apply one or more materials to an existing or newly prepared surfaceto form, build up, treat and/or repair at least a portion of road. The material may include, for example, an asphalt material, an asphalt mixture (e.g., including an asphalt emulsion, liquid, or slurry and a diluent, additives, fillers, binders, polymers, catalysts, etc.), concrete, a concrete mixture, a priming material, a cure-enhancing material, a strengthening material, a dust-controlling and/or stabilizing material, aggregate, and/or another road material known in the art. It should be noted that, while machine(s)will be described in detail as land-based machines, any one or more of the disclosed machine(s)could embody a non-land based machine (e.g., an aerial drone) configured to perform the same or similar operations, if desired. It is also contemplated that the configurations of and/or operations disclosed as being performed by a single machinecould alternatively be distributed among multiple different machines. Likewise, it is contemplated that the configurations of and/or operations disclosed as being performed by multiple different machinescould alternatively be integrated into a lesser number of machines (e.g., one machine).

illustrates multiple machinescooperating as a convoy to build up existing surfaceand form new road. Various convoy arrangements are envisioned that together may form new road. In one specific example, the convoy consists of one or more distributors (“distributor”—left-most machineillustrated in), followed by one or more aggregate spreaders (“spreader”) that are supplied with aggregate by any number of different haul trucks, followed by one or more compactors (right-most machineillustrated in). It is contemplated that the convoy could additionally include any number of surface-conditioning machines (e.g., milling machines, reclaiming machines, shaping machines, patching machines, etc.—not shown) that lead the distributor and condition surfaceprior to the application of new material.

It should be noted that, while the remainder of this disclosure will focus on the distributor introduced above, many (e.g., some or all) of the disclosed concepts may be applicable to one or more other machine(s)of the road-building convoy depicted in.

The distributor may include components that cooperate to apply one or more materials to surface. These components may include, among other things, a vehicle, one or more vessel(s)supported by vehicleand configured to hold the material(s), and a distribution arrangement (“arrangement”)configured to receive the material(s) from vesseland distribute (e.g., spray) the material(s) onto surfaceand/or road.

Vehiclemay, itself, be an assembly of components that supports and/or powers the other components/systems of machine. In the disclosed embodiment, these components may include a chassis, a power source mounted to the chassis, a drivetrain that is operatively connected to and driven by the power source, and one or more propulsion devices powered by the drivetrain. The power source may include any source known in the art for powering a vehicle. Example sources include an engine (e.g., a gasoline engine, a diesel engine, a gaseous fuel-powered engine, etc.), a battery, or a hybrid engine/battery configuration. Example drivetrains include a transmission, a driveline, a final drive, one or more electric motors, and/or a hybrid transmission/final drive or electric motor configuration. Example propulsion devices include wheels, tracks, feet, fans, jets, blades, and/or propellers.

The chassis of vehiclemay be configured to support vessel(s)and distribution arrangement. In the disclosed embodiment, only a single vesselis shown as being supported by the chassis. However, in some applications, multiple different materials may need to be separately discharged, simultaneously discharged and/or discharged together onto surfaceand/or road. In these embodiments, more than one vesselmay be mounted to the chassis. For example, as shown in, a first vesselmay be configured to hold a first material (e.g., a priming emulsion), and a second vesselmay be configured to hold a second material (e.g., an asphalt mixture). In some embodiments, a catalyst (e.g., a hardener that reacts with the asphalt mixture) may be held within an additional third vessel (not shown). Each of these vessel(s)may include an inlet to receive the material, an outlet to discharge the material, and any number of conditioning devices (e.g., mixers, agitators, heaters, coolers, recirculation circuits, sensors, valves, conduits, additive injectors, etc.)that serve to condition the material inside of vessel(s).

In the example of, arrangementmay include components mounted to the chassis of vehiclethat cooperate to selectively discharge the material from vessel(s)onto surfaceand/or road. The components may include, among other things, one or more pumps, one or more spray bars, and any number of nozzles.

Each pumpmay be controlled to draw material from a corresponding vessel or vesselsand direct the material under pressure to a corresponding one or more spray bars. In multi-pump embodiments, pumpsmay be arranged in parallel and independently controlled to provide a different flow rate and/or pressure of material to corresponding spray bars. Each pumpmay be mechanically, hydraulically, pneumatically, and/or electrically driven by the power source of vehicle(or another source, for example a chassis-mounted auxiliary power unit—not shown). In some embodiments, one or more of pumpscan be regulated somewhat or completely independent of the vehicle power source (e.g., an electrically powered pump may operate independent of speed and/or torque outputs of the power source) to provide a variable (e.g., infinitely variable) flowrate and/or pressure. In these embodiments, pumpsmay be rate- and/or pressure-regulated via a command directed to the corresponding pumps and/or associated motors (not shown) driving the pumps.

Spray bar(s)may be arranged lengthwise across a partial or full width of vehicle(e.g., at a leading end, at a trailing end, and/or at a point between the leading and trailing ends, relative to a normal or forward travel direction represented by an arrowillustrated in). Spray barsmay be fluidly connected to receive the pressurized material from pump(s). If multiple spray barsare included, they may be arranged in series or in parallel and configured to conduct the same or different materials to their associated nozzle(s).

In the disclosed embodiment shown in, a first spray baris fluidly connected to vesseland located at the leading end or a midpoint of vehicle(e.g., in front of front tires or between front and rear tires). Spray barmay be configured to conduct the priming emulsion from vesselto the nozzlesassociated with spray bar

In the same example of, at least one spray bar(e.g., a second spray barand a third spray bar) may be fluidly connected to vesseland located at the trailing end of vehicle(e.g., behind the rear tires). Spray barsare shown as being both configured to conduct an asphalt mixture from vesselto the nozzlesassociated with spray barsA distance between spray barand spray barsmay be selected to allow the priming material sprayed by nozzlesof spray barto penetrate surfaceand/or to attain another prerequisite (e.g., to partially or fully dry) before the asphalt mixture is sprayed onto the priming material by nozzlesof spray bars

In the example of, multiple spray barsare utilized at the trailing end of vehiclefor several reasons. First, a greater volume of material may be discharged via utilization of multiple spray bars. Second, a greater flexibility in control over the spraying of the material may be available. For example, each of spray barscould be supplied with material via a single pumpand have a similar flowrate and/or pressure or be supplied with material via separate pumpsthat have different flowrates and/or pressures. In either embodiment, spray barcould be utilized alone, spray barcould be used alone, or spray barsandcould be activated together to provide an even greater range of flow rates and/or pressures.

It should be noted that spray barscould alternatively be associated with different vesselsand be configured to conduct different materials to their corresponding nozzles, if desired. For example, spray barmay conduct the asphalt mixture from vesselwhile spray barmay trail spray barand conduct a different material (e.g., a chemical catalyst, heated air, etc.) that affects the way (e.g., a speed) that the asphalt mixture cures and/or hardens (“bricks”). The cure-enhancing material may be sprayed onto surfaceat the same time as or after the asphalt material is sprayed. For example, the material from spray barmay pass through the material spraying from spray barsuch that the two materials mix in the air prior to coating surfaceand/or mix just as they coat surface.

In some embodiments, when multiple spray barsare included, each spray barmay discharge material to a separate segment across the width of vehicleor to overlapping or common segments. For example, spray barsmay be arranged end-to-end or in adjacent (e.g., overlapping) rows. In one particular embodiment, a first spray barextends across the entire width, while an additional one or more spray barsoverlap the first spray barand extends only across a partial width (e.g., only across wheel path or seam areas).

Each spray barmay function as a manifold for the corresponding nozzlesfluidly receiving material therefrom. In one particular embodiment, forty-eight nozzlesare distributed along the length of each spray barand across the width of vehicle. In this embodiment, a length of each spray baris sixteen feet, such that vehiclehas a nozzle density of three nozzles per foot. It is contemplated, however, that the number of nozzlesand/or the length of each spray barcould be different.

Any type, size, and/or configuration of nozzlemay be utilized in conjunction with arrangement. In some embodiments, multiple types/sizes, and/or configurations of nozzlesmay be utilized at the same time. It is also contemplated that nozzlesmay be selectively swapped out for nozzlesof different types, sizes and/or configurations to provide a different rate and/or profile of material application.

Nozzlesmay be independently regulated, regulated all together, or regulated in groups, as desired. For example, one or more valvesmay be associated with each spray bar, each nozzle, or different groupings of nozzles. Valvemay be any type of valve known in the art for regulating a flow of pressurized material. In the example of, valveis a poppet-style valve associated separately with each nozzle, and the flow/pressure of material supplied to each nozzleis regulated via operation of the corresponding pump and/or another valve (e.g., a butterfly valve) associated with spray bar. Each nozzlemay be controlled to spray a desired amount of material within a given period of time based on the pressure of the material within spray bar, how often the poppit valve is opened, how far the poppit valve is opened, and/or how long the poppit valve remains open. When nozzlesare regulated in groups, an actuator(e.g., a pneumatic cylinder, an electric solenoid, a hydraulic pilot, etc.) may be associated with multiple valvesto synchronize their openings/closings.

In some embodiments, nozzlesmay be dynamically adjustable. For example, nozzlesmay be rotated and/or shifted (e.g., side-to-side) to adjust a spray angle, spray area, spray orientation, and/or spray overlap. In these embodiments, an additional rotary and/or linear actuator (not shown) may be associated with each nozzleor grouping of nozzles.

It is contemplated that spray bars, together with their associated nozzles, may also or alternatively be dynamically adjustable. For example, spray barsmay be extended, folded, tilted, and/or separately deployed to adjust a width, depth, and/or overlap of spray areas. Any number/type of actuators and any configuration of motions platforms (e.g., hinges, sliding carriages, linkages, etc.) may be used to facilitate these motions.

In some applications (e.g., the application shown in), vehiclemay also include an operator station housing informational devices(shown in) and/or control devicesusable by a human operator to regulate vehicleand/or distribution arrangement. Example informational devicesmay include, among other things, a display screen, a speaker, a visual indicator (e.g., a light indicator, a dial indicator, a level indicator, etc.), a tactile device (e.g., a seat rumbler or stick vibrator), etc. Example control devicesmay include, among other things, a joystick, a steering wheel, a pedal, a switch, a button (e.g., a virtual button on a display screen or a physical button), a lever, a keyboard, a mouse, a key, etc. Information about machinemay be relayed to the operator via informational devices, and control instructions or commands for machinemay be received from the operator via control devices.

It is contemplated that the operator station of machinemay be omitted, in some applications. For example, machinecould be at least partially controlled in a remote and/or autonomous manner. In these applications, the operator station may be minimized, located remotely (e.g., offboard vehicle), and/or completely omitted. In other applications, machinecould embody a trailer towed behind another vehicle. In this latter example, the operator station may be mounted on the other vehicle and used to monitor and control operations occurring on and/or performed by the trailer.

As also shown in, a control system (“system”)may be associated with machineand configured to regulate one or more operations of machinein an automated or semi-automated manner. For example, systemmay be configured to generate a plan for building road, and also regulate distribution of the road material(s) contained in vessel(s)onto surfaceaccording to the plan for road(e.g., while machinetravels along surface). As will be explained in more detail below, the plan may include segmentation of surfaceinto multiple separate areas that require different application rates (e.g., material layer thicknesses) and/or types of road material(s). System(e.g., a controllerof system) may interact with any number of acquisition devices to acquire information about surface, the material(s) to be applied and/or being applied to surface, environment, and specifications for road. System(e.g., controller) may receive, generate and/or modify the plan for roadbased on the acquired information. System(e.g., controller) may then regulate any number of control devices to ensure that machinedistributes the material(s) according to the plan.

Controllermay include, among other things, one or more processors, any number of input/output (“I/O”) devices, and one or more memories for storing programs and data. The programs may include, for example, any number of planning and/or paving apps and an operating system.

Each of the processor(s) may be a single or multi-core processor configured with virtual processing technologies, and specially programmed with logic to simultaneously execute and control any number of operations. The processor(s) may be configured to implement virtual machine technologies, machine learning technologies, artificial intelligence, neural networks, machine logic, and/or other known technologies to execute, control, run, manipulate, analyze and/or store any number of software modules, applications, programs, etc. In addition, in some embodiments, the processor(s) may include one or more specialized hardware, software, and/or firmware modules (not shown) specially configured with particular circuitry, instructions, algorithms, and/or data to perform functions of the disclosed methods. It is appreciated that other types of processor arrangements could be implemented that provide for the capabilities disclosed herein.

The memory can be a volatile or non-volatile, magnetic, semiconductor, tape, optical, removable, non-removable, or other type of storage device or tangible and/or non-transitory computer-readable medium that stores one or more executable programs, such as analysis, planning and/or paving apps and the operating system. Common forms of non-transitory media include, for example, a flash drive, a flexible disk, a hard disk, a solid state drive, magnetic tape or other magnetic data storage medium, a CD-ROM or other optical data storage medium, any physical medium with patterns of holes, a RAM, a PROM, an EPROM, a FLASH-EPROM or other flash memory, NVRAM, a cache, a register or other memory chip or cartridge, and networked versions of the same.

The memory may store instructions that enable the processor(s) to execute one or more applications, such as the analysis, planning and/or paving apps, the operating system, and any other type of application or software known to be available on computer systems. Alternatively or additionally, the instructions, application programs, etc. can be stored in an internal and/or external database (e.g., a cloud storage system—not shown) that is in direct communication with controller, such as one or more databasesor memories accessible via one or more networks (not shown). The memory can include one or more memory devices that store data and instructions used to perform one or more features of the disclosed embodiments. The memory can also include any combination of one or more databases controlled by memory controller devices (e.g., servers, etc.) or software, such as document management systems, Microsoft SQL databases, SharePoint databases, Oracle™ databases, Sybase™ databases, or other relational databases.

In some embodiments, controlleris communicatively connected to one or more remote memory devices (e.g., remote databases—not shown) through a network (not shown). The remote memory devices can be configured to store information that controllercan access and/or manage. By way of example, the remote memory devices could be document management systems, government databases (e.g., a geographic information system—GIS, a spectral signature library such as the USGS library, digital elevation models, land cover/use maps, etc.), and private libraries and databases (e.g., Microsoft SQL database, SharePoint databases, Oracle databases, Sybase databases, Cassandra, HBase, or other relational or non-relational databases or regular files). Systems and methods consistent with disclosed embodiments, however, are not limited to separate databases or even to the use of a database.

The programs may include one or more software or firmware modules causing the processor(s) to perform one or more functions of the disclosed embodiments. Moreover, the processor(s) can execute one or more programs located remotely from controller. For example, controllercan access one or more remote programs that, when executed, perform functions related to disclosed embodiments. In some embodiments, the programs stored in the memory and executed by the processor(s) can include one or more of the analysis, planning, and/or paving apps and the operating system. The apps may cause the processor(s) to perform one or more functions of the disclosed methods.

The operating system may perform known operating system functions when executed by one or more processors of controller. By way of example, the operating system may include Microsoft Windows, Unix, Linux, OSX, IOS, Raspberry Pi OS (e.g., Rapbian), Android, or another type of the operating system. Accordingly, disclosed embodiments can operate and function with computer systems running any type of the operating system.

The I/O devices may include one or more interfaces (e.g., informational and/or control devices,) for receiving signals or input from a user (e.g., an operator of machine, an observing technician, a remote engineer, etc.), and for providing signals or output to the user and/or machinethat allow roadto be built.

The analysis, planning and/or paving apps may cause controllerto perform methods related to generating, receiving, processing, analyzing, storing, and/or transmitting data in association with operation of machineand corresponding analysis/planning/paving of road. For example, the apps may be able to configure controllerto perform operations including: receiving instructions from an engineer of roadregarding specifications, materials to be used, desired characteristics, and/or desired performance of road; capturing sensory data associated with machine, surface, the environment, and/or the materials; receiving control instructions from the operator and/or the user of machineduring operation; processing the instructions, specifications, characteristics, performance criteria, sensory data and control instructions; generating one or more possible plans for building road; analyzing and/or optimizing the plans; providing recommendations of one or more plans; controlling machineto build roadvia a recommended and/or selected plan; analyzing the building of roadin real or near-real time; and/or providing feedback and adjustments to machinefor improving current and/or future building operations.

The input and output devices useable by controllerduring planning and/or building of roadmay be standalone devices or devices that are embedded within, mounted on, and/or otherwise associated with machine. As shown in, the input devices may include, among other things, one or more location input devices, one or more environment input devices, one or more (e.g., a plurality of) surface input devices, one or more machine input devices, and one or more distribution input devices.

Location input device(s)may include any number of mechanisms configured to generate location data indicative of a geographical position, orientation, heading, speed, and/or acceleration of machinerelative to a local reference point, a coordinate system associated with environment, a coordinate system associated with Earth, or any other type of 2-D or 3-D coordinate system.

In one application, an example location input deviceembodies an electronic receiver configured to communicate with satellite(s)(referring to) or a local radio or laser transmitting system (not shown) and used to determine a relative geographical location of itself. This location input devicemay receive and analyze high-frequency, low-power radio or laser signals from multiple locations to triangulate a relative 3-D geographical position and orientation. In some embodiments, location input devicemay also be configured to determine a location and/or orientation of a particular part of machine(e.g., of distribution arrangement, each spray bar, each nozzle, each area being sprayed with material, each device, each area being scanned by each device, etc.). Based on signals generated by location input device(s)(i.e., based on the location data) and based on known kinematics of machine, controllermay be able to determine in real or near-real time the position, heading, travel speed, acceleration, and/or orientation of machineand/or any system component mounted to machine, relative to one or more areas of surface.