Abstract
A device and method for using microwave heating to repair defects in bitumen surfaces. The device identifies a defect in a bitumen layer and divides a region around the defect into a primary heating zone and a secondary heating zone. Microwaves transmitted through waveguides arranged over the primary and secondary heating zones heat the bitumen layer in each zone such that the temperature of the primary heating zone is always 20? C. higher than the temperature of the secondary heating zone. After heating the bitumen layer around the defect, the defect is filled with a pre-heated bitumen mixture compacted until a top surface of the pre-heated bitumen mixture is level with an original surface of the bitumen layer.
Claims
1-6. (canceled)
7. A device for repairing bitumen surfaces comprising: an application unit comprising a microwave generator and a plurality of waveguides coupled to the microwave generator; and a control unit configured to: define a primary heating zone and a secondary heating zone of an area including a defect in a bitumen layer, and cause the microwave generator to transmit microwaves: through a first portion of the plurality of waveguides located above the primary heating zone of the bitumen layer to heat the bitumen layer within the primary heating zone to a first temperature, and through a second portion of the plurality of waveguides located above the secondary heating zone of the bitumen layer to heat the bitumen layer within the secondary heating zone to a second temperature.
8. The device of claim 7, wherein each of the plurality of waveguides terminate in one of a plurality of output chambers, and wherein a bottom side of each output chamber includes a sensor for measuring a temperature of the bitumen layer.
9. The device of claim 7, the application unit further comprising a casing, a frame, and a plurality of drive segments located between the casing and the frame, wherein the plurality of drive segments is connected to the control unit for controlling a position of the application unit over the bitumen layer.
10. The device of claim 9, wherein a bottom side of the casing includes at least one sensing camera.
11. The device of claim 7, further comprising a microwave oven for heating a bitumen filling mixture, wherein the microwave oven is separate from the application unit and includes: an internal combustion engine, a generator, a driven axel, and a steering axle.
12. A method for repairing a bitumen surface comprising: locating a defect in a bitumen layer; dividing an area containing the defect into a primary heating zone and a secondary heating zone, wherein the primary heating zone extends at least 10 mm on both sides of a defect edge, and wherein the secondary heating zone is adjacent to the primary heating zone having a width of at least 10 mm; applying microwave radiation to heat the primary heating zone and the secondary heating zone, wherein the primary heating zone is heated to a first temperature and the secondary heating zone is heated to a second temperature, and wherein the first temperature at least 20? C. higher than the second temperature; filling the defect with a pre-heated bitumen mixture when the primary heating zone is heated to the first temperature and the secondary heating zone is heated to the second temperature; and compacting the pre-heated bitumen mixture until a top surface of the pre-heated bitumen mixture is level with an original surface of the bitumen layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The invention will be explained in more detail by means of the drawings, wherein:
[0037] FIG. 1 is a schematic section of the application unit,
[0038] FIG. 2 shows a view of the underside of the application unit,
[0039] FIG. 3 shows a schematic section of the entire device including its drive and service unit,
[0040] FIG. 4 shows the marking of the zones on the underside of the application unit,
[0041] FIG. 5 represents a road surface with a fissure-shaped defect showing the top view of the heating zone, and
[0042] FIG. 6 represents a road surface with a fissure-shaped defect showing the cross-section of the heating zone,
[0043] FIG. 7 represents a road surface with a major pothole failure showing the top view of the heating zone, and
[0044] FIG. 8 represents a road surface with a major pothole failure showing the cross-section of the heating zone.
DESCRIPTION OF THE INVENTION
[0045] The device for repairing bitumen surfaces consists of a drive unit comprising a generator 11. an internal combustion engine 12. a main control system 13. a microwave oven 14 for heating the bitumen mixture, a cooling system 15, a driven axle 16, a steering axle 17, a handle 18 for controlling the steering axle, and a control display 19 with controls, which are connected via a lifting mechanism 10 to a part with the application unit 22. wherein there are further arranged the control unit 1, the power source 2 of the microwave generator 3, the microwave generator 3, the waveguide 4, the output chamber 5, the frame 6 of the application unit 22, the drive segment 7, the casing 8 of the application unit 22. the temperature measurement sensor 9, the sensing camera 20.
[0046] The electric generator 11 generating 3-phase voltage 230 V/50 Hz is connected to the diesel engine 12. The voltage is fed through the switchboard and fuse box to the power source 2 of the microwave generator 3, which consists of a high voltage transformer producing a voltage of 4000 V/5 kHz. This voltage supplies the microwave generators 3 with the power of 1 kW. Start-up of power sources 2 and regulation of their power is controlled by the control unit 1 according to the data from the temperature measurement sensors 9 and from the information entered by the operator on the control display 19. where the operator defines the primary heating zone 25 on the image from the sensing cameras 20. Based on the definition of the primary heating zone 25, the control unit 1 automatically defines the secondary heating zone 26.
[0047] The microwave generators 3 are mounted to aluminum waveguides 4. The waveguides 4 form a rectangular matrix (FIG. 2), with a stainless-steel lattice at the bottom, each segment of which forming one output chamber 5. A stainless-steel tube ensuring microwave attenuation is inserted into the output chamber 5 and a pyrometertemperature measuring sensor 9 is placed at its upper end. The signal from the temperature measuring sensor 9 is fed to the control unit 1.
[0048] The waveguide 4 matrix is circumferentially clamped by frame 6 of application unit 22. Between the frame 6 and the casing 8, drive segments 7 consisting of rubber air bags are placed.
[0049] The rubber bags are connected to a pressure air distribution system fitted with electronically controlled air valves. These air valves are controlled from the control unit 1 so as to move the entire matrix of waveguides 4 in the transverse and longitudinal direction at the time of heating, thereby homogenizing the heating of the bitumen layer. Pressurized air is produced by a reciprocating compressor and stored in an air tankboth located at the combustion engine 12.
[0050] The sensing camera 20 is placed on the casing 8. The sensing camera 20 transmits the image of the road surface to the control unit 1, which displays it on the control display 19 and allows the operator to guide the machine to the defect and subsequently define the primary heating zone 25.
[0051] Boxes with power sources 2 which are cooled by air blown into the boxes by a fan are placed above the waveguides 4.
[0052] The casing 8 is attached to a steel lifting mechanism 10, which is lifted by an electrically driven screw lifting mechanism.
[0053] The microwave oven 14 for heating the bitumen mixture consists of a stainless-steel chamber into which the waveguides 4 are inserted. The microwave generators 3 are placed at their upper end. As with the application unit 22, the microwave generators 3 are powered from the power source 2, which consists of a high voltage transformer producing a voltage of 4000 V/5 kHz, to which the voltage of 230 V/50 Hz from the electrical generator 11 is fed via a switchboard and fuse box. The microwave oven 14 for heating the bitumen mixture is equipped with a stainless-steel door with integrated microwave shielding.
[0054] The chassis of the device is provided with two separate electrically driven wheels forming a driven axle 16, and one steering wheel forming a steering axle 17 which is not driven is provided at the front of the chassis. This steering axle 17 is attached firmly to the control handle 18. The control handle 18 contains manual controls that control the driven axle 16. The device direction of travel is controlled mechanically by turning the control handle 18. At the front of the machine, above the control handle 18, there is a control unit 1 with a control display 19 with controls. The operator uses the control display 19 and the control unit 1 to transmit instructions to the device and to obtain information about the status of the device.
[0055] The device operated in such a way, that the edge of the bitumen layer defect and its immediate vicinity forms the primary zone 25 that is heated by microwave radiation to a temperature of 70? C. to 195? C. and the secondary heating zone 26, which is adjacent to the primary heating zone 25. is heated to a temperature of 30? C. to 110? C., where the temperature of the primary heating zone 25 is always at least 20? C. higher than the temperature of the secondary heating zone 26, and where, after the primary zone 25 and secondary zone 26 have been heated to the desired temperature, the damaged area is then filled with a hot bitumen mixture of the same type as that used to construct the damaged bitumen layer and compacted to a level with the original surface. Microwave radiation is applied by means of separate heating segments, the power and time of operation of which is controlled for each heating segment independently and separately by means of the control unit 1.
[0056] The division of the damaged bitumen layer surface with the defect into a primary heating zone 25 and a secondary heating zone 26 and their controlled heating to different temperatures eliminates the necessity of using microwave radiation susceptors, while reducing the energy consumption for heating by applying microwave energy only to the areas that must be heated for technological reasons and leaving the rest of the surface unaffected by the microwave radiation.
Example 1Pothole
[0057] The method of repairing a pothole by means of the device, according to FIGS. 7 and 8, in a bitumen surface is carried out by the device operator starting the combustion engine 12 driving the generator 11, which supplies electrical energy to the steering axle 16, the microwave oven 14, the application unit 22 and the device control unit 1. The operator lifts the application unit 22 into the transport position and drives the device off the transport vehicle (van or tow) onto the road. Next, he drives the device to the defect 24 and uses the control display 19, to which the image from the sensing cameras 20 is transmitted, to guide the device over the defect 24 to be repaired. He lowers the application unit 22 to the working position, i.e. places it on the road surface so that it covers the part of the defect to be repaired. The operator places the solidified bitumen mixture of defined quality in a paper bag in the microwave oven 14 located on the device. Based on the weight information and the input temperature of the mixture, the control unit 1 evaluates the length and method of heating the oven 14 so that the mixture in the bag is heated homogeneously to a temperature of 135? C. in the shortest possible time. The control unit 1 activates the power sources 2, which trigger the production of microwaves from the microwave generators 3 in the oven 14. The operator uses the control display 19 to mark the primary heating zone 25. The control unit 1 defines the secondary heating zone 26 around the marked primary zone 25. If the primary zone 25 and secondary zone 26 form a closed curve, a space may be formed within the secondary zone 26 that is not actively heated. The operator instructs the control unit 1 to start heating the primary 25 and secondary 26 heating zones, the control unit 1 activates the power supplies 2 to supply power to the microwave generators 3, which start producing microwaves. The microwaves pass through the waveguides 4 and the output chamber 5 into the bitumen layer below the output chamber 5, which is heated by their action. Thus, microwave heating is realized in the heating segments 21 located above the heating zones 25 and 26. Based on the bitumen layer temperature information from the temperature sensors 9, the control unit 1 regulates the microwave heating power of each heating segment 21 and at the same time regulates the microwave power of the microwave oven 14 based on the information about the weight and the inlet temperature of the mixture. The primary zone 25 reaches a temperature of 70? C., the secondary zone 26 reaches a temperature of 50? C. and the mixture in the microwave oven reaches a temperature of 135? C. in the shortest possible time. During the heating of the bitumen layer, the device control unit 1 moves the entire application unit 22 by the drive segments 7 in the longitudinal and transverse directions so as to achieve homogeneous heating of the bitumen layer throughout the entire volume to the desired temperatures. The device control unit 1 evaluates all temperatures during the heating process, i.e. the temperature of the mixture in the oven, the temperature of the primary zone 25 and the secondary zone 26, and stops the heating when the target temperatures are reached. Upon completion of heating, the operator raises the application unit 22 to the transport position and moves the equipment away from the defect 24 so that there is sufficient space to pour and then compact the added bitumen mixture at the location of the defect 24. The operator uses a spray gun to apply a bonding spray to the primary zone 25 and the bottom of the defect 24 The operator removes the paper bag containing the heated bitumen mixture from the microwave oven 14 and fills the volume of defect 24 with it. He compacts the added bitumen mixture. During compaction, the original bitumen mixture in the primary zone 25 is blended with the newly added mixture, so that no transitions or seams can be observed. The road surface at the repair site will thus retain the characteristics of the original road surface.
Example 2Pothole
[0058] The method of repairing a pothole by means of the device, according to FIGS. 7 and 8, in a bitumen surface is carried out by the device operator starting the combustion engine 12 driving the generator 11, which supplies electrical energy to the driven axle 16, the microwave oven 14, the microwave application unit 22 and the device control unit 1. The operator lifts the application unit 22 into the transport position and drives the device off the transport vehicle (van or tow) onto the road. Next, he drives the device to the defect 24 and guides the device over the defect 24 to be repaired by means of the display 19 to which the image from the sensing cameras 20 is transmitted. He lowers the application unit 22 to the working position, i.e. places it on the road surface so that it covers the part of the defect to be repaired. The operator places the solidified bitumen mixture of defined quality in a paper bag in the microwave oven 14 located on the device. Based on the weight information and the input temperature of the mixture, the control unit 1 evaluates the length and method of heating the oven so that the mixture in the bag is heated homogeneously to a temperature of 135? C. in the shortest possible time. The control unit 1 activates the magnetrons in the oven 14. The operator uses the control display 19 to mark the primary heating zone 25. The device control unit 1 defines the secondary heating zone 26 around the marked primary zone 25. If the primary zone 25 and secondary zone 26 form a closed curve, a space may be formed within the secondary zone 26 that is not actively heated. The operator instructs the control unit 1 to start heating the primary 25 and secondary 26 heating zones, the control unit 1 activates the power supplies 2 to supply power to the microwave generators 3, which start producing microwaves. The microwaves pass through the waveguides 4 and the output chamber 5 into the bitumen layer below the output chamber 5, which is heated by their action. Thus, microwave heating is realized in the heating segments 21 located above the heating zones 25 and 26. Based on the bitumen layer temperature information from the temperature sensors 9, the control unit 1 regulates the microwave heating power of each heating segment 21 and also regulates the microwave oven 14 power based on the weight and inlet temperature information of the mixture so that the primary zone reaches a temperature of 145? C., the secondary zone reaches a temperature of 80? C. and the mixture in the microwave oven reaches a temperature of 135? C. in the shortest possible time. During the heating of the bitumen layer, the device control unit 1 moves the entire application unit 22 by the drive segments 7 in the longitudinal and transverse directions so as to achieve homogeneous heating of the bitumen layer throughout the entire volume to the desired temperatures. The device control unit 1 evaluates all temperatures during the heating process, i.e. the temperature of the mixture in the oven, the temperature of the primary zone 25 and the secondary zone 26, and stops the heating when the target temperatures are reached. Upon completion of heating, the operator raises the application unit 22 to the transport position and moves the equipment away from the defect 24 so that there is sufficient space to pour and then compact the added bitumen mixture at the location of the defect 24. The operator uses a spray gun to apply a bonding spray to the primary zone 25 and the bottom of the defect 24. The operator removes the paper bag containing the heated bitumen mixture from the microwave oven and fills the volume of defect 24 with it. He compacts the added bitumen mixture. During compaction, the original bitumen mixture in the primary zone 25 is blended with the newly added mixture, so that no transitions or seams can be observed. The road surface at the repair site will thus retain the characteristics of the original road surface.
Example 3Fissure
[0059] The method of repairing a fissure by means of the device, according to FIGS. 5 and 6, in a bitumen surface is carried out by the operator of the device starting the combustion engine 12 driving the generator 11, which supplies electrical energy to the driven axle 16, the microwave oven 14, the microwave application unit 22 and the device control unit 1. The operator lifts the application unit 22 into the transport position and drives the device off the transport vehicle (van or tow) onto the road. Next, he drives the device to the defect 24 and guides the device over the defect 24 to be repaired by means of the display 19 to which the image from the sensing cameras 20 is transmitted. He lowers the application unit 22 to the working position, i.e. places it on the road surface so that it covers the part of the defect to be repaired. The operator places the solidified bitumen mixture of defined quality in a paper bag in the microwave oven 14 located on the device. Based on the weight information and the input temperature of the mixture, the control unit 1 evaluates the length and method of heating the oven so that the mixture in the bag is heated homogeneously to a temperature of 170? C. in the shortest possible time. The control unit 1 activates the magnetrons in the oven 14. The operator uses the control display 19 to mark the primary heating zone 25. The device control unit 1 defines the secondary heating zone 26 around the marked primary zone 25. If the primary zone 25 forms a straight line, the secondary zone 26 is formed only outside this line. The operator instructs the control unit 1 to start heating the primary 25 and secondary 26 heating zones, the control unit 1 activates the power supplies 2 to supply power to the microwave generators 3, which start producing microwaves. The microwaves pass through the waveguides 4 and the output chamber 5 into the bitumen layer below the output chamber 5, which is heated by their action. Thus, microwave heating is realized in the heating segments 21 located above the heating zones 25 and 26. Based on the bitumen layer temperature information from the temperature sensors 9, the control unit 1 regulates the microwave heating power of each heating segment 21 and also regulates the microwave oven 14 power based on the weight and inlet temperature information of the mixture so that the primary zone 25 reaches a temperature of 195? C., the secondary zone 26 reaches a temperature of 110? C. and the mixture in the microwave oven reaches a temperature of 170? C. in the shortest possible time. During the heating of the bitumen layer, the device control unit 1 moves the entire application unit 22 by the drive segments 7 in the longitudinal and transverse directions so as to achieve homogeneous heating of the bitumen layer throughout the entire volume to the desired temperatures. The device control unit 1 evaluates all temperatures during the heating process, i.e. the temperature of the mixture in the oven, the temperature of the primary zone 25 and the secondary zone 26, and stops the heating when the target temperatures are reached. Upon completion of heating, the operator raises the application unit 22 to the transport position and moves the equipment away from the defect 24 so that there is sufficient space to pour and then compact the added bitumen mixture at the location of the defect 24. The operator uses a spray gun to apply a bonding spray to the primary zone 25 and the bottom of the defect 24 The operator removes the paper bag containing the heated bitumen mixture from the microwave oven 14 and fills the volume of defect 24 with it. He compacts the added bitumen mixture. During compaction, the original bitumen mixture in the primary zone 25 is blended with the newly added mixture, so that no transitions or seams can be observed. The road surface at the repair site will thus retain the characteristics of the original road surface.
Example 4Fissure
[0060] The method of repairing a fissure by means of the device, according to FIGS. 5 and 6, in a bitumen surface is carried out by the operator of the device starting the combustion engine 12 driving the generator 11, which supplies electrical energy to the driven axle 16, the microwave oven 14. the microwave application unit 22 and the device control unit 1. The operator lifts the application unit 22 into the transport position and drives the device off the transport vehicle (van or tow) onto the road. Next, he drives the device to the defect 24 and guides the device over the defect 24 to be repaired by means of the display 19 to which the image from the sensing cameras 20 is transmitted. He lowers the application unit 22 to the working position, i.e. places it on the road surface so that it covers the part of the defect to be repaired. The operator places the solidified bitumen mixture of defined quality in a paper bag in the microwave oven 14 located on the device. Based on the weight information and the input temperature of the mixture, the control unit 1 evaluates the length and method of heating the oven so that the mixture in the bag is heated homogeneously to a temperature of 145? C. in the shortest possible time. The control unit 1 activates the magnetrons in the oven 14. The operator uses the control display 19 to mark the primary heating zone 25. The device control unit 1 defines the secondary heating zone 26 around the marked primary zone 25. If the primary zone 25 forms a straight line, the secondary zone 26 is formed only outside this line. The operator instructs the control unit 1 to start heating the primary 25 and secondary 26 heating zones, the control unit 1 activates the power supplies 2 to supply power to the microwave generators 3, which start producing microwaves. The microwaves pass through the waveguides 4 and the output chamber 5 into the bitumen layer below the output chamber 5, which is heated by their action. Thus, microwave heating is realized in the heating segments 21 located above the heating zones 25 and 26. Based on the bitumen layer temperature information from the temperature sensors 9, the control unit 1 regulates the microwave heating power of each heating segment 21 and also regulates the microwave oven 14 power based on the weight and inlet temperature information of the mixture so that the primary zone 25 reaches a temperature of 80? C., the secondary zone 26 reaches a temperature of 30? C. and the mixture in the microwave oven reaches a temperature of 145? C. in the shortest possible time. During the heating of the bitumen layer, the device control unit 1 moves the entire application unit 22 by the drive segments 7 in the longitudinal and transverse directions so as to achieve homogeneous heating of the bitumen layer throughout the entire volume to the desired temperatures. The device control unit 1 evaluates all temperatures during the heating process, i.e. the temperature of the mixture in the oven, the temperature of the primary zone 25 and the secondary zone 26, and stops the heating when the target temperatures are reached. Upon completion of heating, the operator raises the application unit 22 to the transport position and moves the equipment away from the defect 24 so that there is sufficient space to pour and then compact the added bitumen mixture at the location of the defect 24. The operator uses a spray gun to apply a bonding spray to the primary zone 25 and the bottom of the defect 24. The operator removes the paper bag containing the heated bitumen mixture from the microwave oven and fills the volume of defect 24 with it. He compacts the added bitumen mixture. During compaction, the original bitumen mixture in the primary zone 25 is blended with the newly added mixture, so that no transitions or seams can be observed. The road surface at the repair site will thus retain the characteristics of the original road surface.
INDUSTRIAL APPLICABILITY
[0061] The repair method, as well as the device according to the present invention, can be used for periodic repairs of bitumen surfaces, in particular for the operative repair of small potholes and fissures across seasons. This means that it can be used especially in the transport infrastructure in the context of road repair, but also in other sectors where bitumen surfaces that are subject to stress are used.
REFERENCE SIGNS LIST
[0062] 1control unit [0063] 2microwave generator power source [0064] 3microwave generator [0065] 4waveguide [0066] 5output chamber [0067] 6application unit frame [0068] 7drive segment [0069] 8application unit casing [0070] 9temperature measurement sensor [0071] 10lifting mechanism [0072] 11generator [0073] 12combustion engine [0074] 13main control system [0075] 14microwave oven for heating the bitumen mixture [0076] 15cooling system [0077] 16driven axle [0078] 17steering axle [0079] 18steering axle control handle [0080] 19control display and controls [0081] 20sensing camera [0082] 21heating segments [0083] 22application unit [0084] 23edge of the repaired defect [0085] 24defect [0086] 25primary heating zone [0087] 26secondary heating zone
