Asphalt roadway paving methods and apparatus

Abstract

The present invention provides improved paving vehicles for following a supply truck for use in paving asphalt roadways. The paving vehicles of the present invention need not be transported on a trailer, and are capable of traveling at low or relatively high speeds on their own. This is accomplished through the use of novel chassis and propulsion systems having two rear axles, with each axle coupled directly to its own hydraulic motor, such that each of the two hydraulic motors provides power to one axle. Embodiments of the invention also include reciprocating conveyor apparatus and methods, such that the conveyor apparatus may be moved to a lowered position to receive the gravity discharge of materials from a hopper and supply truck during a paving operation, and moved to a raised position in order to provide a wide margin of ground clearance when driving the paving vehicle, or loading or unloading the paving vehicle from a trailer.

Claims

1. A chassis for a paving vehicle comprising: a. a raised front frame and a raised rear frame separated by a lower central frame, wherein the raised front frame supports a conveyor assembly, the central frame supports an engine, and the raised rear frame supports an asphalt mixing chamber of the paving vehicle; b. a front axle engaged with said raised front frame; c. a pair of rear drive axles engaged with said raised rear frame, each rear axle including a differential attached to a drive axle; d. a pair of hydraulic motors, one for each of said pair of rear axles; e. a first coupler provided between a first of said hydraulic motors and a first of said rear drive axles, said coupler comprising a motor output flange and a pinion input flange; and f. a second coupler provided between a second of said hydraulic motors and a second of said rear drive axles, said second coupler comprising a second motor output flange and a second pinion input flange.

2. The chassis paving of claim 1 further comprising a first spring suspension system for said front axle and a second spring suspension system for each of said rear axles.

3. The chassis paving of claim 1 further comprising a first air brake system for said front axle and a second air brake system for each of said rear axles.

4. The chassis paving of claim 1 further comprising an input hopper attached to said front frame for receiving asphalt materials from a supply truck.

5. The chassis of claim 1 wherein the conveyor assembly is located above said front frame and is angled in order to convey materials received from said hopper assembly to the mixing chamber of said paving vehicle.

6. The chassis of claim 5 wherein said conveyor assembly is capable of reciprocating between a first lower position and a second upper position.

7. The chassis of claim 1 further comprising an engine above said central frame.

8. The chassis of claim 1 further comprising a mixing apparatus above said rear frame.

9. The chassis of claim 1 further comprising an observation platform at a rear of said vehicle.

10. A conveyor for providing paving materials to a paving machine comprising: a. a hopper assembly provided at a front of said machine for receiving said paving materials from a supply truck, said hopper assembly having a lower opening therein; b. a movable angled conveyor assembly for transferring said paving materials received from said hopper assembly to an interior of said paving machine, the conveyor assembly further comprising: i. an elongated rectangular box having an interior and an exterior; ii. a movable continuous belt inside said box for transferring said paving materials through said box; iii. a first opening in a top of said box at a lower end thereof for receiving said paving materials from said hopper; iv. a second opening at an upper end of said box through which said paving materials exit said box; and v. at least one motion imparting device attached to said box for imparting reciprocating motion to said box to move said box between a first lower position and a second upper position.

11. The conveyor of claim 10 further comprising at least one smooth lower exterior surface on said box and at least one corresponding bearing surface on said vehicle for slidably supporting said at least one smooth surface as said box reciprocates between upper and lower positions.

12. The conveyor of claim 11 further comprising a plurality of lateral bearing surfaces outside of said box for guiding said box along a straight path as said box reciprocates between upper and lower positions.

13. The conveyor of claim 10 wherein said first opening is located below said lower hopper opening when said conveyor box is in said first lower position.

14. The conveyor of claim 10 wherein the distance between said first lower position and said second upper position is between about 8 inches and about 18 inches.

15. The conveyor of claim 10 wherein the distance between said first lower position and said second upper position is about 14 inches.

16. The conveyor of claim 10 further comprising a chassis having a front frame member supporting a first pair of rotatable front wheels on a first axle, and a rear frame member supporting a second pair of rotatable rear wheels on a second axle and a third pair of rotatable rear wheels on a third axle.

17. The conveyor of claim 16 further comprising a first adjustable hydraulic motor for imparting motion to said second axle, and a second adjustable hydraulic motor for imparting motion to said third axle.

18. The conveyor of claim 16 further comprising at least one air brake mounted adjacent to at least one of said rear wheels.

19. A method of transporting a paving machine to a location where pavement is to be installed on a roadway comprising the steps of: a. raising a movable angled conveyor apparatus on the paving machine to an upper position; b. driving the paving machine to a location where paving is to be performed; c. engaging a hopper assembly at a front of said paving machine with a supply truck to receive asphalt paving materials from said supply truck; d. lowering said angled conveyor apparatus to a lower position such that an upper opening in said conveyor apparatus corresponds to a lower opening in said hopper; and e. receiving asphalt paving materials into said hopper from said supply truck, and conveying said materials through said conveyor.

20. The method of claim 19 comprising the additional steps of: g. disengaging the hopper from the supply truck; h. raising said movable angled conveyor apparatus back to an upper position; and i. driving the paving machine away from said paving location.

21. In a paving machine having an engine, an asphalt conveyor apparatus and an asphalt mixing chamber, the combination with said machine of a chassis comprising: a. a raised front frame and a raised rear frame separated by a lower central frame, wherein the raised front frame supports said conveyor assembly, the central frame supports said engine, and the raised rear frame supports said asphalt mixing chamber of the paving machine; b. a front axle engaged with said raised front frame; c. a pair of rear drive axles engaged with said raised rear frame, each rear axle including a differential attached to a drive axle; d. a pair of hydraulic motors, one for each of said pair of rear axles; e. a first coupler provided between a first of said hydraulic motors and a first of said rear drive axles, said coupler comprising a motor output flange and a pinion input flange; and f. a second coupler provided between a second of said hydraulic motors and a second of said rear drive axles, said second coupler comprising a second motor output flange and a second pinion input flange.

22. The combination of claim 21 further comprising a first spring suspension system for said front axle and a second spring suspension system for each of said rear axles.

23. The combination of claim 21 further comprising a first air brake system for said front axle and a second air brake system for each of said rear axles.

24. The combination of claim 21 further comprising an input hopper attached to said front frame for receiving asphalt materials from a supply truck.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a side view of a supply truck and an embodiment of the paving machine vehicle of the present invention.

(2) FIG. 2 is a top view of an embodiment of the present invention.

(3) FIG. 3 is a bottom view of an embodiment of the present invention.

(4) FIG. 4 is a side view of an embodiment of the present invention.

(5) FIG. 5 is a rear perspective view of an embodiment of the present invention.

(6) FIG. 6 is a rear view of an embodiment of the present invention.

(7) FIG. 7A is a sectional view of an embodiment of the present invention along line A-A of FIG. 6.

(8) FIG. 7B is a sectional view of an embodiment of the present invention showing the conveyor apparatus in a raised position.

(9) FIG. 8 is a perspective view of a lower frame assembly of an embodiment of the present invention.

(10) FIG. 9A is a bottom side view of a lower frame assembly of an embodiment of the present invention.

(11) FIG. 9B is a different bottom side view of a lower frame assembly of an embodiment of the present invention.

(12) FIG. 10 is a sectional side view of a lower frame assembly of an embodiment of the present invention.

(13) FIG. 11A is an expanded sectional side view of a lower front frame assembly of an embodiment of the present invention.

(14) FIG. 11B is an expanded sectional side view of a lower rear frame assembly of an embodiment of the present invention.

(15) FIG. 12 is a perspective view of a rear wheel assembly of an embodiment of the present invention.

(16) FIG. 13 is a bottom view of the rear wheel assembly of FIG. 12.

(17) FIG. 14A is an exploded view of one of the rear wheel assemblies of an embodiment of the present invention.

(18) FIG. 14B is a close up bottom view of one of the rear wheel assemblies of an embodiment of the present invention.

(19) FIG. 14C is a detailed bottom view of area A of FIG. 14B.

(20) FIG. 14D is a detailed exploded view of one of the rear wheel assemblies of an embodiment of the present invention.

(21) FIG. 14E is an end view of a pinion input flange of an embodiment of the present invention.

(22) FIG. 14F is side view of a motor output flange of an embodiment of the present invention.

(23) FIG. 14G is a side view of a coupler housing of an embodiment of the present invention.

(24) FIG. 14H is an end view of the coupler housing of FIG. 14F.

(25) FIG. 15 is a close-up side sectional view of an upper portion of a conveying apparatus of an embodiment of the present invention.

(26) FIG. 16 is an isolated top perspective view of a conveying apparatus of an embodiment of the present invention.

(27) FIG. 16A is an isolated bottom perspective view of a conveying apparatus of an embodiment of the present invention.

(28) FIG. 17 is a detailed view of an upper portion of a conveyor apparatus of an embodiment of the present invention.

(29) FIG. 18 is a detailed side sectional view of a front hopper and loading assembly of an embodiment of the present invention.

DETAILED DESCRIPTION

(30) Reference will now be made in detail to certain embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in reference to these embodiments, it will be understood that they are not intended to limit the invention. To the contrary, the invention is intended to cover alternatives, modifications, and equivalents that are included within the spirit and scope of the invention, including different combinations of the features identified herein. In the following disclosure, specific details are given to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without all of the specific details provided.

(31) Referring to the drawings, wherein like reference characters designate like or corresponding parts throughout the several views, and referring first to FIG. 1, it is seen that the present invention includes a paving machine 1000 designed to follow a supply truck 999 for applying asphalt binder material and aggregate material over a new or existing roadway. Referring to FIGS. 4 and 8, it is seen that the paving machine is also a vehicle that that capable of traveling on its own, and is mounted on a frame/chassis 1002 which supports a central chamber 1001 for heating and mixing asphalt paving materials, an engine, a front hopper assembly 2015, a rear observation platform, a pair of front wheels 1030 on a front axle 1012, and two pairs of rear wheels 1031 mounted on real axles 1032, 1033.

(32) As seen in FIGS. 4-7, an adjustable hopper assembly 2015 is provided at the front of the vehicle 1000, and is attached to the front portion 1011 of frame 1002. The supply truck 999 may be engaged with the hopper assembly 2015 which receives the output from the supply truck 999. A movable angled conveyor assembly 2003 is provided at the front of the vehicle 1000, having a lower end 2005 and an upper end 2006 for delivering paving materials from said hopper 2015 to said mixing chamber 1001. Referring to FIGS. 18-19, it is seen that the illustrated embodiment of the conveyor assembly 2003 may be in the form of an elongated rectangular box or channel 2008 having an interior and an exterior. A continuous movable belt 2019 is provided on the interior of the box 2008, and is wrapped around cylinders or rollers 2018 at opposite ends of the box which may be operated by a motor 2021 such that rotation of one or more of the cylinders causes the belt to slide along the bottom of the box in order to convey paving materials from the lower end of the box 2005 to the upper end of the box 2006. A motor mount 2022 and adjusting screw 2023 may be provided in embodiments to maintain tension on the belt. A first opening 2001 is provided in the upper surface of conveyor box 2006 at the lower end 2005 for receiving paving materials from hopper 2015. Hopper 2015 has an opening 2016 at a bottom thereof through which paving materials may fall by gravity through a chute 2017 and into opening 2001. Materials that fall through opening 2001 are conveyed upward through the angled conveyor assembly on the belt until they are discharged through upper opening 2004 into mixing chamber 1001.

(33) In the illustrated embodiment, angled conveyor box 2003 is reciprocally mounted inside the vehicle 1000 such that it may be adjustably moved from a lowermost position as shown in FIGS. 4 and 7A, to an uppermost position shown in FIG. 7B, or to any position in between. Conveyor 2003 may be moved to a lower or lowermost position during a paving operation, so that opening 2001 is underneath chute 2017 of the hopper 2015 receiving materials from the supply truck 999. Conveyor 2003 may be moved to an upper or uppermost position when the paving machine is not in use, such as during transport or storage.

(34) Referring to FIG. 16A, it is seen that one or more motion imparting apparatus 2007 may be attached to the conveyor 2003 to move it from or between the lowermost and uppermost positions. In the illustrated embodiment, the motion imparting apparatus 2007 is in the form of a pair of hydraulic pistons, although other devices may be used including without limitation air pistons, motors, cams, linkages and the like. Referring to the detailed view of FIG. 19, it is seen that the bottom of conveyor 2003 includes one or more smooth exterior surfaces or panels 2011, 2011A. These surfaces are designed to make contact with corresponding bearing surfaces 2012, 2013 on the frame of the vehicle. In some embodiments, two smooth surface panels 2011, 2011A are provided, with the first panel 2011 making contact with a first pair of bearing surfaces 2012, 2012A on the frame, and the second panel 2011A making contact with bearing surfaces 2013, 2013A on the frame. Activation of piston 2007 causes conveyor 2003 to move upward or downward, causing panels 2011, 2011A to slide along bearing surfaces 2012, 2012A, 2013 and 2013A. A plurality of additional bearing surfaces 2014 may also be provided along both sides of the conveyor 2003 to guide the conveyor 2003 along a straight path as it reciprocates between upper and lower positions. In embodiments of the invention, all of the bearing surfaces 2012, 2012A, 2013, 2013A and 2014 as well as panels 2011 and 2011A may be removed and replaced if they become worn, damaged or fatigued.

(35) FIG. 8 illustrates an exemplary embodiment of a lower frame assembly 1002 configured to support the various assemblies of the asphalt paving machine, and may include a raised front frame 1010 and a raised rear frame 1020 that are configured to accommodate, respectively, front and rear wheel and axle assemblies. The front frame 1010 may support a front suspension system 1011 that may be operable to provide Ackerman steering geometry. A conveyor system 2003 may also be provided above the front frame 1010. The rear frame 1020 may support a rear axle assembly 1021 that is operable to provide power to the rear wheels for driving the machine 1000 to a work site, and for moving the machine during paving operations. A mixing chamber 1001 for paving materials may be located above the rear frame 1020. The lower central frame area may support an engine, which may be a diesel engine, for operating the hydraulics of the machine. FIGS. 9A and 9B provide comparison views of the steering angle of the front wheels 1030 illustrating clockwise and counter-clockwise positions. FIG. 10 provides a sectional side view of the lower frame assembly with the right side wheels removed to provide a clear illustration of the components secured to the frame 1002.

(36) As illustrated in FIGS. 11B and 12, the illustrated exemplary embodiment of the invention includes a rear axle assembly 1021 that is designed to provide both high and low travel speeds of operation, in addition to spring suspension and air braking. The illustrated embodiment includes a pair of independent drive differentials 1050 coupled to the rear frame 1020. The rear frame may have a flange bracket 1029 that is connected to a bolster spring 1024 that is operable to damp vibrations in from the road. Each of the differentials 1050 may have a strut 1028 that is connected to the rear frame 1020. In some embodiments, as shown in FIG. 12, each of the two differentials 1050 may be in communication with one of two hydraulic motor couplers 1051 (e.g., drive shaft companion flange) that are, in turn, connected to one of two variable displacement hydraulic drive motors 1052. The rear differentials 1050 may have an axle shaft 1053 that secures at least one wheel 1031 to each end of the axle. Each wheel assembly may also include an air brake 1042.

(37) In embodiments of the invention, each of the hydraulic drive motors 1052 may be in hydraulic communication with a main pump that routes a working fluid from a reservoir to a routing block 1054. In such embodiments, the variable displacement hydraulic motors 1052 may provide a regulation of speed and position. Motors 1052 may be operable to propel the paving machine 1000 at road speeds in excess of 25 m.p.h. (up to as high as 60 m.p.h) in both forward and reverse. Motors 1052 may also be used to operate the paving machine at lower speeds (e.g., in the range of 3-5 m.p.h.) during a paving operation. It is to be appreciated that additional torque is provided when motors 1052 are operated at lower speeds, such as during a paving operation; and less torque is provided when motors 1052 are operated at higher speeds, such as when the machine is driven from one project location to another.

(38) The exemplary illustrated dual independent drive differentials 1050 shown in FIGS. 14A-B, may be coupled to an independent controller to provide a user with variation and control of the power input to the wheels while maintaining fluid dynamic pressure within the routing system (e.g., hoses connecting the main motor to the routing block 1054). The hydraulic motors 1052 may be hydro static motors (e.g., variable displacement axial piston, reverse displacement axial piston, fixed displacement axial piston), a low-speed high-torque motors (e.g., orbital motor, dowmax axial piston motor), gear motors, or high-speed hydraulic motors (e.g., fixed, variable, high-speed gear type), or the like. In some embodiments, the hydraulic motor couplings 1051 may be in communication with a transmission (e.g., automatic, continuously variable, fully manual, automated manual, etc.). Each of the drive motors 1052 may be independently controlled by the same hydraulic pump that has a flow rate corresponding to the throttle position of the operator.

(39) In some embodiments, as illustrated in FIG. 12 the rear axle assembly may have two wheels 1031 positioned at each end of the axles 1053 (e.g., dually). In such embodiments, the dual wheel configuration provides the load-bearing capabilities to tow and carry a large payload to the work site and the conveyor system 1000 with ease. The differential may be a limited-slip differential, open differential or have a locking mechanism such that the right and left wheels 1030 rotate at the same rate.

(40) The detailed views of FIGS. 14A-14H illustrate an exemplary embodiment of a coupler 1051 of the present invention provided between a hydraulic motor 1052 and differential 1050 with axle drive 1055. In this exemplary illustrated embodiment, coupler 1051 encloses a rotatable drive shaft 1071 from said motor 1052 that is engaged with a pinion input flange 1062 and a motor output flange 1068. One end of coupler 1051 is attached to motor 1052 using motor mounting flange 1057, and the opposite end of coupler 1051 is attached to axle drive 1055 using flange 1059. FIG. 14E illustrates an end view of a pinion input flange 1062, showing interior teeth 1063 which mate with splines on drive shaft 1071. A plurality of ridges and troughs 1064 are provided in a pattern on flange 1062 which fit into to a plurality of corresponding troughs and ridges 1069 on output flange 1068. A hub 1067 is provided on flange 1068 which fits over drive shaft 1071, and may be securely engaged therewith using bolt 1066.

(41) Rotation may be imparted to shaft 1071 from hydraulic motor 1052 which causes rotation of hub 1067, flange 1068 and troughs and ridges 1069. The interengagement of troughs and ridges 1069 with ridges and troughs 1064 on pinion input flange 1062, together with mating of splines 1072 and teeth 1063, causes the same rotation from motor 1052 to be directly imparted to input flange 1062. This rotation is transmitted through axle drive 1055 to differential 1050 and ultimately to the wheels 1031.

(42) In some embodiments, each of the rear wheels 1031 may have an air brake mechanism 1042 that is concentrically positioned at the wheel hub 1035 and is operable to stop the rotation of the wheels, thereby the vehicle. Each of the air brakes 1042 may be coupled to a brake control assembly 1045 to a quick-release valve that is in communication with a supply reservoir and compressor to actuate the braking action. It is to be appreciated that the air brakes, the hydraulic motors and other components of the paving machine are all operated by a central controller which controls all paving operations, including accommodation for variations in speed. For example and without limitation, when increased speed is requested, the hydraulic pump will gradually provide increased pressure to the hydraulic motors to increase speed; on the other hand, when the air brakes are applied, the controller recognizes that power to the hydraulic motors should be diminished, and reduces pressure, in order to slow the speed of the vehicle. In some embodiments, each of the air brakes may be in communication with an ABS controller and relay assembly 1056 that is attached to the front end of the frame 1002.

(43) As best illustrated in FIGS. 9A, 9B and 11A, it is seen that the illustrated exemplary front suspension system 1011 includes a front axle 1012 having steering knuckles 1013 at opposite ends and is secured to the front frame 1010 with a leaf spring 1014 and a strut 1018 connected to the front frame 1010. The leaf springs 1014 may have a forward end 1014A that connects to the front frame 1010 via a flange 1019 equipped with a rotating bar pin end bushing to allow for rotation and safe driving. The leaf springs 1014 may have a rear end 1014B connecting to a flange 1019. In some embodiments, the leaf spring rear end 1014B may connect to an intermediary pivot link 1016 that provides damping of road vibration and allows for the compression of the front suspension 1011 when the machine 1000 is driven in dynamic or uneven road conditions. The steering knuckles 1013 of a right, and left wheel may be in communication with a tie rod assembly 1015 that is operable to maintain the steering angle of the front wheels 1030. In some embodiments, the tie rod assembly 1015 may include a tie rod end arm that is operable to adjust the toe of the front wheels 1030 with respect to the centerline of the vehicle frame 1002. The steering knuckles 1030 may axially secure and align a wheel hub 1035 with the front axle 1012, and connect to a hydraulic actuator 1034. The wheel hub 1035 may have a drum air disk brake assembly 1040 and may secure the wheels to the steering assembly 1011. The maximum turning positions shown in FIGS. 9A and 9B are determined by the position of the hydraulic actuator 1034 that is in communication with the steering wheel of an operators control cabin.

(44) It is to be understood that variations, modifications, and permutations of embodiments of the present invention, and uses thereof, may be made without departing from the scope of the invention. It is also to be understood that the present invention is not limited by the specific embodiments, descriptions, or illustrations or combinations of either components or steps disclosed herein, and that different combinations of the features of the illustrated embodiments may be used in other embodiments, all within the scope of the invention. The illustrated embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. Although reference has been made to the accompanying figures, it is to be appreciated that these figures are exemplary and are not meant to limit the scope of the invention. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.