Correction unit

Abstract

A correction unit (13) for correcting the position of a side plate (2,2) of a screed (4) of a road paving machine (1) for constructing a road pavement relative to a line (12) on an underlying surface on which the road paving machine (1) is adapted to move, the correction unit (13) comprising a sensor device, where the sensor device is adapted to sense at least part of said underlying surface comprising the line (12) and identify a displacement of the side plate (2,2) of the screed (4) of the road paving machine (1) relative to the line (12) on the underlying surface and provide a sensing signal for controlling the position of the side plate (2,2).

Claims

1. A screed of a road paving machine for moving along an underlying surface while adding a strip of pavement material to said underlying surface, wherein a position of a side plate of the screed determines a position of an edge of the strip of road pavement material added, the screed comprising: a correction unit for correcting the position of said side plate, said correction unit comprising a sensor device; wherein the sensor device is adapted to capture an at least two-dimensional image of at least part of said underlying surface comprising an edge of an existing road pavement, said image identifying a line or edge along which a new strip of road pavement is to be constructed, and said image containing at least two-dimensional information about the position of the line or edge in a moving direction of said road paving machine, and therefrom identify a displacement of the side plate of the screed of the road paving machine relative to the line or edge of said existing road pavement and provide a sensing signal for controlling the position of the side plate; wherein the line or edge is defined by an upper part of a slope or contour between the existing road pavement and the underlying surface; and wherein a control unit receives the sensing signal from the sensor device and utilizes the sensing signal to control the position of the side plate.

2. A road paving machine for moving along an underlying surface while adding a strip of pavement material to said underlying surface, wherein a position of a side plate of a screed of the road paving machine determines a position of an edge of the strip of road pavement material added, the road paving machine comprising: a towing machine adapted to move on the underlying surface, a screed comprising at least one side plate, and a correction unit for correcting the position of said side plate, said correction unit comprising a sensor device, wherein the sensor device is adapted to capture an at least two-dimensional image of at least part of said underlying surface comprising an edge of an existing road pavement, said image identifying a line or edge along which a new strip of road pavement is to be constructed, and said image containing at least two-dimensional information about the position of the line or edge in a moving direction of said road paving machine, and therefrom identify a displacement of the side plate of the screed of the road paving machine relative to the line or edge of said existing road pavement, and provide a sensing signal for controlling the position of the side plate, and wherein the line or edge is defined by an upper part of a slope or contour between the existing road pavement and the underlying surface; and wherein a control unit receives the sensing signal from the sensor device and utilizes the sensing signal to control the position of the side plate.

3. A correction unit for correcting a position of a side plate of a screed of a road paving machine for moving along an underlying surface while adding a strip of pavement material to said underlying surface, wherein the position of the side plate determines a position of an edge of the strip of road pavement material added, said correction unit comprising: a sensor device adapted to capture an at least two-dimensional image of at least part of said underlying surface comprising an edge of an existing road pavement, said image identifying a line or edge along which a new strip of road pavement is to be constructed, said image containing at least two-dimensional information about an extension of the line or edge in a moving direction of said road paving machine along said underlying surface, wherein, based on said captured image containing at least two-dimensional information about the extension of the line or edge along said underlying surface, the correction unit is configured to identify a displacement of the side plate of the screed of the road paving machine relative to the line or edge of said existing road pavement and provide a sensing signal for controlling the position of the side plate, wherein the line or edge is defined by an upper part of a slope or contour between the existing road pavement and the underlying surface, and wherein a control unit receives the sensing signal from the sensor device and utilizes the sensing signal to control the position of the side plate.

4. The correction unit of claim 3, wherein the correction unit comprises the control unit that receives the sensing signal from the sensor device and the control unit is adapted to adjust the position of said side plate relative to the edge based on the sensing signal for controlling the position of the side plate.

5. The correction unit of claim 3, wherein: a light source directs light at the line or edge at an angle relative to a vertical axis of the line or edge; a shadow is cast by the line or edge based on the light; and the line or edge is identified, at least in part, by identifying the shadow.

6. The correction unit of claim 5, wherein a width of the shadow is utilized to obtain information indicating a height of the existing road pavement.

7. The correction unit of claim 3, wherein the sensor device comprises a detecting unit.

8. The correction unit of claim 7, wherein the sensor device comprises an emitting unit.

9. The correction unit of claim 7, wherein the detecting unit comprises at least one optical part.

10. The correction unit of claim 8, wherein the emitting unit and the detecting unit are arranged at an angle relative to each other.

11. The correction unit of claim 8, wherein the emitting unit comprises a light source.

12. The correction unit of claim 11, wherein the detecting unit comprises a camera.

13. The correction unit of claim 12, wherein the light source is positioned at an angle relative to the underlying surface, and the camera is positioned substantially orthogonal to the underlying surface and configured to detect light from the light source being reflected from the underlying surface.

14. The correction unit of claim 13, wherein the correction unit is further configured to detect a change in the position of the camera relative to the side plate of the screed.

15. The correction unit of claim 3, wherein the correction unit is further configured to adjust the position of at least part of the correction unit relative to the position of the side plate of the screed.

16. The correction unit of claim 3, wherein the sensor device is further adapted to sense at least part of said underlying surface comprising the edge of the existing road pavement and therefrom identify a thickness of the existing road pavement and provide a sensing signal for controlling an amount of pavement material to be added.

Description

(1) The structure and function of the correction unit and the method of using it will be described in more detail below with references to exemplary embodiments shown in the drawings wherein,

(2) FIGS. 1a and 1 b show an embodiment of the correction unit in combination with a screed of a road paving machine, seen from above and in front of the screed, respectively.

(3) FIG. 2 shows an embodiment of an image, made by the camera of the correction unit, of the underlying surface of the road paving machine.

(4) FIGS. 3a, 3b and 3c show three embodiments of the emitting unit connected to the detecting unit.

(5) FIGS. 4a and 4b show two embodiments of the correction unit connected to the screed of a road paving machine, seen from in front of and above the screed, respectively.

(6) In the figures the correction unit is inter alia shown having a six-sided shape with a four-sided cross section and the connection part comprising two straight elements arranged with an angle to each other. However, it should be understood that other cross-sections, such as circular, triangular, many-sided . . . are also intended within the scope of the present invention.

(7) In the figures, embodiments, which show the connection to one type of screed, are illustrated. The person skilled in the art will understand that the illustrated combinations of correction unit and screeds and road paving machines are not to be understood as exhaustive and that the correction unit may be mounted on various kinds of screeds and road paving machines.

(8) FIGS. 1a and 1 b show an embodiment of the correction unit in combination with a screed of a road paving machine, seen from above and in front, respectively, of the screed relative to the direction of movement of the road paving machine.

(9) In FIG. 1a, the road paving machine 1 is seen from above. Only the side plates 2, 2 and part of the basis part 3 of the screed 4 of the road paving machine 1 are shown for clarity.

(10) The side plate 2 of the screed 4 may be moved substantially orthogonal to the driving direction 5 of the road paving machine 1. The movement of the side plate 2 of the screed 4 is indicated by the arrows 6a and 6b. However, it is foreseen within the present invention that the side plate 2 may also move with an angle relative to the driving direction 5 of the road paving machine 1.

(11) In front of the basis part 3 of the screed, the road pavement material 7, such as asphalt, is being placed. The road pavement material 7 is being distributed by the screed 4, i.e. by the basis part 3 and the side plates 2,2 of the screed 4, across the area 8 defined by said basis part 3 and the side plates 2,2 of the screed 4 as the road pavement material 7 comes into contact with the basis part 3 of the screed 4.

(12) The road paving machine 1 may be moving along an already existing strip of road pavement 9 and at the same time construct a new strip of road pavement 10. The new strip of road pavement 10 may be constructed with an overlap 11 to the existing strip of road pavement 9, such that the density and quality of the new strip of road pavement 10 may be maximised at the overlap 11.

(13) The edge 12 of an existing strip of road pavement 9 may be of various types. Thus, the edge 12 may be of butt joint (paver construction), butt joint (milled or cutback) or notched wedge joint, where butt joint may comprise a vertical or sharp angle or be undefined, and the notched wedge joint may comprise a sharp angle relative to the underlying surface.

(14) The size of the overlap 11 may vary inter alia depending on the type of the edge 12 and on the way in which the existing 9 and new strip of road pavement 10 are constructed. For example, the existing 9 and new strip of road pavement 10 may be constructed simultaneously or with a time interval in between so that the existing strip of road pavement 9 may have cooled for both butt joint or notched wedge joint types of edges, in which case the size of the overlap 11 may be 3-4 mm, 1-1.5 inches, or 0.5-1 inches, respectively. However, within the present invention it is understood, that there may also be an overlap of 0 mm. Thus, the side plates 2, 2 may be adapted to be adjusted to at least these distances.

(15) The correction unit 13 may comprise a sensor device (not shown) comprising an emitting unit 14, comprising an optical part such as a light source 14 as illustrated in FIG. 1a, and a detecting unit 15, such as a camera as illustrated in FIG. 1a. Both light source 14 and camera 15 may be positioned in front of the side plate 2 of the screed 4 so that said side plate 2 does not affect the view of the camera 15. The light source 14 may emit light at the underlying surface of the road paving machine 1 which may comprise the existing strip of road pavement 9 and the surface 16 on which the new strip of road pavement 10 is to be constructed. The light source 14 may comprise one or more LEDs. The dimension of the light source 14 may be 45 mm50 mm200 mm. However, other dimensions depending inter alia on the number of lights are foreseen within the present invention.

(16) In FIG. 1a, the cones of light of the light source 14 may be directed at the edge 12 of the existing road pavement 10 and at the existing strip of road pavement 9 and surface 16 on which the new strip of road pavement 10 is to be constructed adjacent to the edge 12. The camera 15 may be positioned just in front of the side plate 2 of the screed 4 and thus be positioned in the plane of the side plate 2. The camera 15 may be arranged vertically with a precision of +1-5 degrees in relation to the underlying surface and viewing the underlying surface.

(17) The camera 14 may comprise a resolution of 12801024 pixel, with an angle of view of 17 degrees. The dimensions of the camera may be 100 mm100 mm60 mm. However, other dimensions are foreseen within the present invention. The precision of the correction unit 13 may be +/6 mm, or may be +/1-3 mm, or may even be +/1 mm.

(18) Within the present invention, it is foreseen that both side plates 2,2 may comprise a correction unit 13.

(19) In FIG. 1b, the road paving machine 1 is seen from the front relative to the driving direction of the road paving machine 1. For similar feature as shown in FIG. 1a, similar reference numbers have been applied.

(20) In the embodiment of FIG. 1b, it is shown that the light source 14 may be positioned near the outer side of the side plate 2 of the screed 4 and in the embodiment of FIG. 1b, the light source 14 is positioned over the existing strip of road pavement 9 and thus may be overlapping the existing strip of road pavement 9 with a larger distance than the side plate 2 of the screed 4 and the camera 15. Furthermore, it is shown that the light source 14 may be positioned with an angle to the underlying surface and emit light towards the edge 12 of the existing strip of road pavement 9.

(21) The camera 15 may be positioned in front of the side plate 2 of the screed 4 and insect the plane of the side plate 2 of the screed 4. The camera 15 may be positioned vertically. Thus, the camera 15 may be positioned so that it may make an image of the cone of light made by the light source 14 and of the edge 12 of the existing strip of road pavement 9. The camera may be positioned so that the middle of the camera view and thus of the image made by the camera 14 is aligned with the plane of the inner surface 17 of the side plate 2 of the screed 4. However, the camera 14 may be shifted relative to the plane of the inner surface 17 of the side plate 2 of the screed 4 depending on the wanted size of the overlap 11.

(22) The light source 14 may be positioned with a height x, and the camera 15 may be positioned with a height y above the surface of the existing strip of road pavement 9. The height x may be 0.2 m and the height y may be 0.5 m. The light source 14 may be arranged with an angle a relative to the camera 15. The angle a may be 45 degrees.

(23) The correction unit 13 may comprise a device for indicating the view of the camera 15 on the underlying surface, such as a laser pointer.

(24) The correction unit 13 may furthermore comprise a device for logging e.g. the images made by the camera 15, or the size of the overlap 11.

(25) FIG. 2 shows an embodiment of an image 18, made by the camera 15 of the correction unit 13, of the underlying surface of the road paving machine 1. For similar features as in the previous Figs., similar reference numbers have been used.

(26) In the embodiment of FIG. 2, the existing strip of road pavement 9 and the surface 16 on which the new strip of road pavement 10 is to be constructed is illustrated. The light source 14 is shown as emitting light in the direction indicated by the arrow 19. The light source 14 is shown as comprising three lights, where the cone of lights 20 of each of the three lights is directed at the edge 12 of the existing strip of road pavement 9. As the existing strip of road pavement 9 may be positioned vertically above the surface 16 on which the new strip of road pavement 10 is to be constructed and as the light source 14 may emit light at an angle, a shadow 21 is cast going from the edge 12 of the existing strip of road pavement 9 towards the surface 16 on which the new strip of road pavement 10 is to be constructed. The width of the shadow 21 may depend on the difference in heights of said existing strip 9 and said surface 16 and on the angle between the light source 14 and the existing strip of road pavement 9. The width of the shadow 21 may be analysed for determining the thickness of the existing strip of road pavement 9.

(27) On the basis of the position of the edge 12 of the existing strip of road pavement 9 relative to a reference, such as the middle of the image 18 or a reference point or line on the image 18 or a previously produced image 18 of the underlying surface, the displacement of the side plate 2 of the screed 4 of the road paving machine 1 relative to the line 12 on the underlying surface may be identified, and the sensor device may provide a sensing signal for controlling the position of the side plate 2.

(28) The sensor device may be connected to a control unit (not shown) adapted to receive the sensing signal from the sensor device and to adjust the position of the side plate 2 of the screed 4 of the road paving machine 1 relative to the edge 12 of the existing strip of road pavement 9 based on the sensing signal for controlling the position of the side plate 2 according to the predetermined overlap 11.

(29) The correction unit 13 may be adapted to control the quality of the image made by the camera 15 so as to control that the image 18 is sufficiently good for identifying the edge 12 of the existing strip of road pavement 9.

(30) The quality control may be adapted to identify whether the cone of light(s) 20 in the centre of the image 18 is/are brighter than at the borders 22 of the image 18. If this is not the case, the edge 12, or line 12 identified on the image 18, may have been cast by another light source.

(31) The quality control may be adapted to identify if sufficient contrast exists between light and shadow 21 on the image 18. If no sharp contrast exists, the sensor device may not identify the edge 12 of the existing strip of road pavement 9, or the correction unit 13 may be positioned too close to the underlying surface, or no edge 12 of the existing strip of the road pavement 9 may be present.

(32) The quality control may be adapted to divide the image 18 into two or more smaller areas and may be adapted to analyse each area separately. The edge 12 of the existing strip of the road pavement 9 may be identified in each area and the position of said edge 12 may be compared. In case said edge 12 is not identified approximately at the same position in the separate areas, and thus being approximately coherent, said edge 12 may not have been identified.

(33) The correction unit 13 may comprise a means for ensuring that the camera 14 is directed at the cone(s) of light at the underlying surface. The means may be a means for measuring the distance to the underlying surface, such as a laser, or a means for identifying where the cone(s) of light is/are positioned, such as a device for measuring light or an IR indicator.

(34) FIGS. 3a, 3b and 3c show three embodiments of the emitting unit 14 connected to the detecting unit 15. For similar features as shown in the previous Figs., similar reference numbers have been applied.

(35) In the embodiment of FIGS. 3a, 3b and 3c, the emitting unit 14 may be a light source 14, and the detecting unit 15 may be a camera 15. The camera 15 and the light source 14 may be positioned at a distance from each other and may as such be arranged in the same house or may be arranged in separate houses. The light source 14 is illustrated as emitting a light 23 at an underlying surface 24, and the camera 15 is illustrated as detecting light 23 emitted from the underlying surface 24.

(36) In the embodiment of FIG. 3a, the light source 14 and the camera 15 may be arranged in the same house 25. The house 25 may comprise a first end 26 comprising the camera 15 and a second end 27 comprising the light source 14. The first 26 and second end 27 may be connected by two straight parts 28, 28 being substantially orthogonal to each other.

(37) In the embodiment of FIG. 3b, the light source 14 and the camera 15 may be arranged in the same house 29. The house 29 may comprise a first end 30 comprising the camera 15 and a second end 31 comprising the light source 14. The first 30 and second end 31 may be connected by two straight parts 32, 32 being arranged with an angle to each other. Said angle may be larger than 90 degrees and smaller than 180 degrees.

(38) In the embodiment of FIG. 3c, the light source 14 and the camera 15 may be arranged in separate houses 33, 33. A first house 33 may comprise the camera 15, and a second house 33 may comprise the light source 14. The first 33 and second house 33 may be connected by two straight parts 34, 34 being substantially orthogonal to each other.

(39) FIGS. 4a and 4b show two embodiments of the correction unit 13 connected to the side plate 2 of the screed 4 of a road paving machine 1, seen from in front of and above the screed 4, respectively. For similar features, similar reference numbers have been used as in the previous Figs.

(40) In FIG. 4a, the correction unit 13 comprising the sensor device is shown as comprising a camera 15 positioned so that its centre is aligned with the inner surface 17 of the side plate 2 of the screed 4 and oriented towards the underlying surface 24 of the road paving machine 1. The light source 14 is shown as being positioned beside the side plate 2 of the screed 4, being oriented towards the underlying surface 24 with an angle relative to said underlying surface 24.

(41) The camera 15 and the light source 14 may be arranged in the same house 29 comprising a first end 30 comprising the camera 15 and a second end 31 comprising the light source 14. The first 30 and second end 31 may be connected by to straight parts 32,32 being arranged with an angle to each other.

(42) The correction unit 13 may be mounted on the side plate 2 of the screed 4 by means of a mounting part 35. The mounting part 35 may be fixed to said side plate 2 and to at least one of the straight parts 32,32 of the house 29. The mounting part 35 may ensure that the correction unit 13 is positioned in a correct manner relative to the side plate 2 of the screed 4.

(43) The mounting part 35 may be adapted to adjust the height of the correction unit 13 relative to the side plate 2 as not all side plates 2,2 have the same height.

(44) The mounting part 35 may be adapted to adjust the distance at which the correction unit 13 is positioned in front of the side plate 2 (relative to the direction of movement of the road paving machine 1) as the size of the side plate 2 at the vertically lower end may vary which may affect the image 18 detected by the camera 15.

(45) The mounting part 35 may be adapted to adjust how much a new strip of road pavement 10 is to overlap an existing strip of road pavement 9 along which the new strip of road pavement 10 is to be constructed. The correction unit 13 and/or the mounting part 35 may comprise a scale adapted to adjust the size of the overlap 11. The reference of the scale may be in line with the inner side surface 17 of the side plate 2 of the screed 4. The scale may be plus or minus 2 inches relative to the reference, but may also be larger if necessary. The overlap 11 and thus the position of the correction unit 13 may thus be adjusted with a high degree of precision and be locked in the wanted position. The scale may be adjusted manually or automatically.

(46) In FIG. 4b, the correction unit 13 connected to the side plate 2 of the screed 4 of a road paving machine 1 is seen from above.

(47) The correction unit 13 comprising the camera 15, the light source 14 and the house 29 is shown as being positioned by the mounting part 35 in front of the side plate 2 of the screed 4. The centre of the camera 15 is shown as being aligned with the plane P of the inner surface 17 of the side plate 2 of the screed 4.

(48) The line 12 may be based on a foundation or a curb, or the line 12 may be a wire.

(49) In case said line 12 is based on a foundation and the new strip of road pavement 10 is to be placed on and inside the edge of the foundation, the correction unit 13 may follow the edge of the foundation. In such case, the correction unit 13 may be turned around so that the light source 14 (or emitting unit) is positioned in front of, but between the side plates 2,2 of the screed 4, with an angle to the underlying surface 24. Thus, the light source 14 emits light from a higher lying foundation to the lower lying surrounding surface.

(50) In case said line 12 is based on a curb, the new strip of road pavement 10 is to be placed along the curb without an overlap. Thus, the correction unit 13 may identify the position of the edge of the curb and therefrom identify a displacement of the side plate 2 of the screed 4 of the road paving machine 1 relative to the edge of the curb, and provide a sensing signal for controlling the position of the side plate 2 to be substantially aligned with said edge of the curb.

(51) The line 12 may be wire, in case a new strip of road pavement 10 is to be constructed on e.g. a foundation as the first strip of road pavement on the foundation, which ensures a straight and precisely constructed strip of road pavement. To ensure focus of the camera on the wire, the height of the camera 14 relative to the side plate 2 of the screed 4 or the focus to the camera 14 may be adjusted.

(52) Thus, the line 12 may be a wire along which a new strip of road pavement 10 is to be constructed, e.g. a wire positioned on a planar surface without following e.g. an edge, or the line 12 may be a wire identifying an edge along which the new strip of road pavement 10 is to be constructed, where the wire may be arranged directly above or next to said edge.

(53) Modifications and combinations of the above principles and designs are foreseen within the scope of the present invention.