ASPHALT DELIVERY AND COMPACTION METHOD

TECHNICAL FIELD

Aspects of the disclosure relate generally to systems and methods for pavement paving, and more specifically to computer controlled aggregate material paving systems.

BACKGROUND

Aggregate materials, such as asphalt and concrete, are commonly used to build and repair roads, parking lots, and other areas where a smooth durable surface is desired. Asphalt concrete (often abbreviated as “asphalt”) may include an aggregate, additives, and a binding material, usually having a bituminous binder.

Smooth road surfaces improve ride quality and reduce surface water collection areas. Compacted asphalt is more durable and has a higher load carrying capacity than initially deposited and spread asphalt because the process of compacting the asphalt removes air spaces contained within the aggregate and binder mix. In general, as air is removed, asphalt density increases and increasing the compacted asphalt density (typically described as a percentage maximum theoretical density) improves the longevity and load carrying capacity of a road. As an example, many road projects have a target density ranging between 93% and 96%.

However, asphalt does not behave as a free-flowing fluid because the aggregate will extrude into nearby contours but will not free-flow more than a few centimeters without direct agitation. Moreover, when working on asphalt, the compression and extrusion forces produced under a screed and/or compactor are not enough to homogenize the density of the asphalt across an entire width of the screed or compactor. As an example, compaction analysis typically shows that particles are mostly restrained in a horizontal plane such that the compaction may be approximated as only having a vertical movement. As a result, this generally simplifies the required lift height and compaction estimates at the job site because mass is conserved, where the relationship for mass is described by mass=(density)(volume), which results in the following ratio (density₁)(volume₁)=(density₂)(volume₂) because mass is conserved. By utilizing this relationship, when the vertical dimension, or height, of the asphalt is the only changing dimension, the ratio may be rewritten as (density₁)(height₁)=(density₂) (height₂).

As an example, delivered asphalt poured from a dump truck can have a relative density as low as 60%; and utilizing this type of asphalt when paving and compacting over an uneven sub-base, or a sub-base having localized irregularities, can result in bridging, where the asphalt that is compacted over these types of raised sub-base irregularities can quickly reach a high density and hold the weight of the screed and compactor as if the asphalt were a solid material. As a result, this generally prevents consistent asphalt compaction over lower surface irregularities. For example, an evenly spread top surface of asphalt spread over an uneven sub-base with approximately 0.5-inch peaks and approximately 0.5-inch pits, a nominal starting lift height of approximately 2.0 inches, and with the asphalt material delivered at approximately 65% relative density may start with a minimum lift of approximately 1.5 inches, a nominal lift of approximately 2 inches, and a maximum lift of approximately 2.5 inches. Compaction will likely stop when the minimum areas reach a high relative density, for example 97%. In this example, the new minimum height may be determined as

$65 % \times \frac{1.5 inches}{97 %} ≅ 1 inch$

or an 0.5-inch overall height reduction. The relative density of the asphalt material over the nominal height areas may be determined as

$65 % \times \frac{2. inches}{1.5 inches} ≅ 87 % .$

The relative density in material over the localized pits may be

$65 % \times \frac{2.5 inches}{2. inches} ≅ 81 % .$

In this bridging example, the highly compacted asphalt material over peaks supports the compacting surface, resulting in areas with relative compaction as low as 81%. Generally, the uncompacted surface, or starting height, can be directly viewed exiting some trench paver designs, but is usually a flow stagnation plane which intersects the invisible material head stagnation line as it contacts the front edge of the screed. Material below this stagnation plane will generally compact and pass under the screed, while material above will usually slowly circulate above the stagnation plane.

As a result, grading, milling, and otherwise preparing sub-base surfaces requires significant effort and equipment investment. As an example, when repairing a road, it is common practice to mill a trench at least 8 feet wide (a typical minimum paving width) even if only repairing a 2 foot wide defect because this additional effort is generally required to maintain consistent compaction from the initially deposited material through the entire paving process to the target density while also trying to make the fully compacted repaired surface flush with the existing road surface at the edge of the repaired section. Therefore, there is a need for a system and method to address these issues.

SUMMARY

Techniques are discussed for dynamically paving a surface of a sub-based with aggregate material. The techniques include a method for controlling a plurality of gates for dynamically paving a surface of a sub-base with aggregate material, the method comprising: receiving a digital model of a portion of the sub-base that is to be paved with the aggregate material, wherein the digital model includes a plurality of cells that correspond to the portion of the sub-base; comparing each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion of the sub-base; and adjusting a position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model, wherein each gate is configured to independently change the position of the gate relative to the surface of the sub-base and distribute aggregate material on the surface of the sub-base based on the position of the gate.

Also discussed are techniques that include a method for receiving the digital model of a portion of the sub-base that is to be paved with the aggregate material, where the digital model includes the plurality of cells that correspond to the portion of the sub-base; comparing each cell of the digital model to the corresponding desired cell of a plurality of desired cells of the desired digital model of the portion of the sub-base; and adjusting the position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model, where each gate is configured to independently change the position of the gate relative to the surface of the sub-base and distribute aggregate material on the surface of the sub-base based on the position of the gate.

Other devices, apparatuses, systems, methods, features, and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional devices, apparatuses, systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the disclosure and their advantages can be better understood with reference to the following drawings/figures and the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements/parts illustrated throughout the different views in one or more of the figures, wherein showings therein are for purposes of illustrating embodiments of the present disclosure and not for purposes of limiting the same. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure.

FIG. 1 is a system block diagram of an example of an implementation a dynamic asphalt paver (DAP) in accordance with the present disclosure

FIG. 2 is a system block diagram of an example of another implementation of a DAP is shown in accordance with the present disclosure.

FIG. 3 is a side-view of an example of an implementation of an asphalt paver incorporating the DAP shown in FIGS. 1 and 2 in the accordance with the disclosure.

FIG. 4 is a zoomed in side-view of the asphalt paver shown in FIG. 3.

FIG. 5A is a perspective view of an example of an implementation of a first total volume of asphalt in accordance to the present disclosure.

FIG. 5B is a perspective view of an example of an implementation of a second total volume of asphalt in accordance to the present disclosure.

FIG. 6 is a top-view of an example of an implementation of an DAP that includes a hopper, a conveyor, a lateral distribution device, and a material leveling device in accordance with the present disclosure.

FIG. 7 is an iso view of another example of the DAP in accordance with the present disclosure.

FIG. 8 is a top-perspective view of an example of surface irregularities and bridging on pavement.

FIG. 9 is functional block diagram of an example of paving over surface irregularities with bridging on pavement.

FIG. 10 is a functional block diagram of an example of dynamically paving over surface irregularities without bridging in accordance with the present disclosure.

FIG. 11 is a functional block diagram of an example of dynamic surface deposited over the surface irregularities to avoid bridging in accordance with the present disclosure.

FIG. 12 illustrates an example of an implementation of a paving method in accordance with the present disclosure.

FIG. 13 illustrates several examples of digital surface formats in accordance with the present disclosure.

FIG. 14 illustrates multiple gates for dynamic paving operating over an uneven sub-base in accordance with the present disclosure.

FIG. 15 illustrates a DAP with a hopper, conveyor, operator station, and augers in accordance with the present disclosure.

FIG. 16 is a system block diagram of the plurality of gates and row of calculation cells of the DAP shown in FIG. 15 in accordance with the present disclosure.

FIG. 17 illustrates an asphalt paver with a hopper, conveyor, operator station, and augers at two moments in time in accordance with the present disclosure.

FIG. 18 illustrates an asphalt paver with a hopper, conveyor, operator station, and augers in accordance with the present disclosure.

FIG. 19 illustrates various alignments of calculation cells within the row of calculation cells or within the calculation cell grid in accordance with the present disclosure.

FIG. 20 is a flowchart of an example of an implementation of a method of operation of the DAP in accordance with the present disclosure.

FIG. 21 is a flowchart of an example of an implementation of another method for controlling multiple gates for dynamic paving in accordance with the present disclosure.

FIG. 22 is a front view of an example of an implementation of an input/output (I/O) device illustrating a current paving cross-section of the DAP in an example of operation in accordance with the present disclosure.

FIG. 23 is a front view of an example of an implementation of the I/O device of

FIG. 22 illustrating a projected path of the DAP in an example of operation in accordance with the present disclosure.

FIG. 24 is a cross-section view of an example of an implementation of a trench paver.

FIG. 25 is an isometric view of the trench paver shown in FIG. 24.

FIG. 26 is a front view of the trench paver with gates aligned with non-vertical roll angle in accordance with the present disclosure.

FIG. 27 is a side view of the trench paver with gates being pushed with a tractor to pave a surface of a sub-base in accordance with the present disclosure.

DETAILED DESCRIPTION

Techniques are discussed for an apparatus and method for aggregate material delivery and compaction method. In accordance with various embodiments/implementations of the present disclosure, systems and methods for dynamically paving structures with aggregate materials, such as asphalt, concrete, or both, are disclosed.

Structures such as, for example, roadways, parking lots, and other areas where a smooth durable surface is desired are commonly paved with aggregate materials, such as asphalt, concrete, or both (generally referred to as “asphalt concrete”), can develop ruts and potholes. Asphalt concrete (herein abbreviated and referred to simply as “asphalt”) may include an aggregate, additives, and a binding material, usually having a bituminous binder. The features of these types of structures sometimes require that an asphalt surface be removed and replaced. It is desirable to have a system and method which adapts the uncompacted surface height of the asphalt according to the sub-base contour below that surface. This will reduce or eliminate bridging and allow a consistent compacted density regardless of the sub-base irregularities. The term sub-base typically refers to a layer of aggregate material such, for example, gravel, crushed stone, or sand that is placed on the ground soil (generally referred to as sub-grade) before the asphalt base in installed on the sub-base. In this disclosure, the sub-base also refers to an existing road surface to be paved over, the surface remaining after a partial or complete removal of an existing road surface, the typical sub-base surface previously mentioned, any other surface over which a layer of asphalt is to be paved, or a combination thereof.

Existing asphalt paying systems adjust paved lift height for variations in the sub-base (i.e., a layer of gravel that is placed on top of subgrade—i.e., the ground) height that span the entire width of the paving pass. Most of these known systems adjust the tow point height or screed angle of attack to create a momentary increase in paved depth. While this may work for the full width variations, it is not generally effective over localized irregularities.

The environmental impact of these known roadway resurfacing techniques is significant because the old used asphalt must be reprocessed or disposed of and new asphalt is petroleum based and energy intensive to produce. Both of these actions are a significant source of CO₂and it has been estimated that 90 million tons of asphalt has been milled and reprocessed in the United States (U.S.) each year, and that 0.5 metric tons CO₂are released per ton of fresh asphalt paved.

The techniques discussed herein for dynamically paving roads with asphalt address these issues by discussing a dynamic paving material paver (herein referred to as a “dynamic paving device,” “dynamic asphalt paver” and abbreviated as “DAP”) with multiple gates for dynamic paving a surface of a sub-base of a structure.

As an example, the DAP may be configured to deposit different amounts of aggregate material, e.g. asphalt, responsive to variations in a roadway surface. For example, the DAP may be configured to deposit more asphalt over the location of a pothole or a rut in a roadway that may then be compacted by traditional means. These techniques are then utilized to significantly reduce the amount of topcoat of the roadway that should be removed prior to deposition of a new topcoat. For example, traditional means for repairing a crack or tire rut in a roadway would typically involve milling 8-foot-wide sections of the roadway resulting in the removal of large sections of undamaged material in addition to the specific damaged material immediately surrounding the crack or tire rut. The techniques discussed herein reduce both the amount of used asphalt that should be disposed of and the amount of new asphalt that should be used in resurfacing the damaged roadways.

In this disclosure, where possible, the same reference numbers will be used throughout the drawings to refer to the same or similar parts. In this disclosure, techniques are discussed for and in relation to a DAP for paving a surface of a sub-base with aggregate material.

In general, utilizing these techniques a DAP may comprise a plurality of gates for distributing the aggregate material on the surface of the sub-base, at least one memory, and at least one processor communicatively coupled to the at least one memory and the plurality of gates. In this example, each gate of the plurality of gates is configured to independently change the position of the gate relative to the surface of the sub-base and distribute the aggregate material on the surface of the sub-base based on the position of the gate. Further, the at least one processor is configured to: receive a digital model of a portion of the sub-base that is to be paved with the aggregate material, wherein the digital model includes a plurality of cells that correspond to the portion of the sub-base; compare each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion of the sub-base; and adjust a position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model.

In these examples, it is noted that in this disclosure, aggregate materials, such as asphalt, concrete, and other similar materials, are commonly used to build and repair roads, parking lots, and other areas where a smooth durable surface is desired. Asphalt concrete, often abbreviated as simply as “asphalt,” may comprise of aggregate, additives, and a binding material, usually comprising a bituminous binder. As such, the aggregate material may be selected from a group consisting of asphalt, concrete, asphalt-concrete, bituminous pitch with sand, and bituminous pitch with gravel. For case of description the aggregate material will be simply described as by the term “asphalt,” even though it is appreciated that the term of “asphalt” in this disclosure may also include aggregate material that includes asphalt, concrete, asphalt-concrete, bituminous pitch with sand, bituminous pitch with gravel, or other similar type of material.

The description herein may refer to sequences of actions to be performed, for example, by elements of a computing device. Various actions described herein can be performed by specific circuits (e.g., an application specific integrated circuit (ASIC)), by program instructions being executed by one or more processors, or by a combination of both. Sequences of actions described herein may be embodied within a non-transitory computer-readable medium having stored thereon a corresponding set of computer instructions that upon execution would cause an associated processor to perform the functionality described herein. Thus, the various examples described herein may be embodied in a number of different forms, all of which are within the scope of the disclosure, including claimed subject matter.

Referring to FIG. 1, a system block diagram of an example of an implementation of a DAP 100 is shown in accordance with the present disclosure. In this example, the DAP 100 may include a plurality of gates 102 for distributing the asphalt 104 (i.e., the aggregate material) on the surface 106 of the sub-base 108, at least one memory 110, and the at least one processor 112 communicatively coupled to the at least one memory 110 and the plurality of gates 102. The DAP 100 may also optionally include an input/output (I/O) device 114 that allows an operator 116 of the DAP 100 to input or receive information from the DAP 100. The DAP 100 may also be in signal communication with one or more sensors 120 that optionally provide information about the surface 106 of the sub-base 108 and the properties of the asphalt 104. Examples of the I/O device 114 may include a keyboard, touch screen, display screen, or other similar devices. Also, the I/O device 114 may include at least one transceiver that is capable of being in signal communication with one or more mobile devices that may include, for example, a smartphone, tablet, or other mobile device that allows the operator 116 to communicate and optionally control the DAP 100.

In this example, the at least one processor 112 may be, for example, a central processing unit, microprocessor, digital signal processor, application specific integrated circuit (ASIC), or other type of processing device. The at least one memory 110 may be, for example, a random access memory (RAM), read only memory (ROM), or other types of storage device such as, for example, a flash memory, hard drive, etc. In this example, the combination of the at least one processor 112 and at least one memory 110 may be referred to generally as a controller 115 which may, optionally, also include the I/O device 114 and other processor, memory, interfaces (not shown), or software.

In this example, each gate of the plurality of gates 102 is configured to independently change the position of the gate relative to the surface 106 of the sub-base 108 and distribute the asphalt 104 on the surface 106 of the sub-base 108 based on the position of the gate. The at least one processor 112 is also configured to: receive a digital model of a portion 118 of the sub-base 108 that is to be paved with the asphalt 104, where the digital model includes a plurality of cells that correspond to the portion 118 of the sub-base 108; compare each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion 118 of the sub-base 108; and adjust a position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model.

In this example, the portion 118 of the sub-base 108 may be detected and/or scanned by one or more sensors 120. In this example, the one or more sensors 120 may include, for example, an imaging device (e.g., an image scanner, a radar, a light detection and ranging (LiDAR) device, or other measuring device). The one or more sensors 120 may be in signal communication with the at least one processor 112.

In FIG. 2, a system block diagram is shown of an example of another implementation of a DAP 200 in accordance with the present disclosure. In this example, the DAP 200 includes the same elements described in relation to DAP 100 shown in FIG. 1 plus some optional additional elements.

In this example, the DAP 200 may again include the plurality of gates 102 for distributing the asphalt 104 on the surface 106 of the sub-base 108, the at least one memory 110, and the at least one processor 112 communicatively coupled to the at least one memory 110 and the plurality of gates 102. However, in this example, the DAP 200 also may include the I/O device 114, a material distribution device 202, a plurality of actuators 204 mechanically coupled to the plurality of gates 102, and a compacting device 206. The at least one processor 112 may be in signal communication with the one or more sensors 120 and the compacting device 206 may be configured to operate in combination with a material leveling device 208 (that may be external to the DAP 200) such, as for example, a screed. The material distribution device 202 may be, for example, a conveyer system/belt for moving the asphalt 104 from the DAP 200 to the plurality of gates 102.

The circuits, components, modules, and/or devices of, or associated with the DAP 100 and/or DAP 200 and other devices are described as being in signal communication, communicatively coupled, and/or electrically coupled (or simply “coupled”) with each other, where signal communication refers to any type of communication and/or connection between the circuits, components, modules, and/or devices that allows a circuit, component, module, and/or device to pass and/or receive signals and/or information from another circuit, component, module, and/or device. The communication and/or connection may be along any signal path between the circuits, components, modules, and/or devices that allow signals and/or information to pass from one circuit, component, module, and/or device to another and includes wireless or wired signal paths. The signal paths may be physical, such as, for example, conductive wires, electromagnetic wave guides, cables, attached and/or electromagnetic or mechanically coupled terminals, semi-conductive or dielectric materials or devices, or other similar physical connections or couplings. Additionally, signal paths may be non-physical such as free-space (in the case of electromagnetic propagation) or information paths through digital components where communication information may be passed from one circuit, component, module, and/or device to another in varying digital formats without passing through a direct electromagnetic connection.

In FIG. 3, a side-view of an example of an implementation of a DAP 300 is shown in the accordance with the disclosure. In this example, the DAP 300 is configured to receive the asphalt 104 from a truck 302 in front/ahead of the DAP 300. The DAP 300 may incorporate the elements described in DAP 100, DAP 200, or both, shown in FIGS. 1 and 2.

In this example, the DAP 300 includes: a hopper 304 for reviewing and storing the asphalt 104; a pavement sensor 306 for scanning the surface 106 of the sub-base 108 ahead of the DAP 300; the plurality of gates 102;; a conveyor 308 (i.e., the material distribution device 202) to move the asphalt 104 from the hopper 304 to the plurality of gates 102; an auger 310 for distributing the asphalt 104 from the conveyor 308 to the plurality of gates 102; the plurality of actuators 204; the compacting device 206 to compact the asphalt 104 on to the surface 106 of the sub-base 108; a drive system 312 that may include wheels or a track system; and a control station 314 for the operator 116 to operate the controls of the DAP 300. In this example, the control station 314 may be, include, or be in signal communication with the DAP 100, DAP 200, or both. In this example, a zoomed in view 316 will be shown and described in relation to FIG. 4.

FIG. 4 is a zoomed in view 316 of the DAP 300 shown in FIG. 3. As seen in both FIGS. 3 and 4, the material leveling device 208 may be a separate mechanical device that is towed behind the DAP 300. As an example, the material leveling device 208 may be implemented, for example, as a screed that levels the asphalt 104 that has been passed by the plurality of gates 102 and compacted by the compacting device 206 located almost adjacent and behind to the plurality of gates 102 relative to a forward direction of travel along the surface 106 of the sub-base 108. In this example, the material leveling device 208 may be attached to the DAP 300 via, for example, a pair of tow arms 318 that are attached to a rear portion of the DAP 300. Further, a second compactor 320 (e.g., a heavy roller) may also be optionally attached to the rear portion of the DAP 300 for further compacting the asphalt 104 that has been laid on the surface 106 of the sub-base 108. Moreover, in this example, the plurality of actuators 204 may be each mechanically coupled to a corresponding gate of the plurality of gates 102, where a plurality of actuator position sensors 322 may be mechanically to corresponding gates of the plurality of gates 102 to measure the position of each gate of the plurality of gates 102 relative to the surface 106 of the sub-base 108. Further still, the DAP 300 may include various additional sensors to measure the asphalt density and/or height of the combined asphalt 104 and surface 106 of the sub-base 108. As an example, the DAP 300 may include one or more sensors that may include an asphalt density sensor 324, a post-gate sensor 326, a post-screed sensor 328, and a post-compactor sensor 330 (if the second compactor 320 is present). In these examples, the final height of the combination of the asphalt 104 and the surface 106 of the sub-base 108 may be either a first combined asphalt 104 and sub-base 108 after the material leveling device 208 (if the second compactor 320 is not present) or the second combined asphalt 104 and sub-base 108 after the second compactor 320 if present. The final height of the combination of the asphalt 104 and sub-base 108 is a desired finished surface height for the surface 106 of the sub-base 108 that is predetermined and may be provided by a third-party such, for example, a customer that is contracting for the sub-base 108 to be paved by the DAP 300.

In this disclosure, this desired finished surface height may be provided to the DAP 300 via a digital model of the desired surface parameters of the surface 106 of the sub-base 108. In this disclosure, the predetermined digital model of the desired surface parameters of the surface 106 of the sub-base 108 is generally referred to as a “desired digital model” that may include a plurality of desired cells that correspond to a plurality of surface cells of the digital model of the desired surface parameters of the surface 106 of the sub-base 108. The DAP 300 may utilize these desired cells as references to compare against the received measured cells from, for example, the pavement sensor 306.

In this example, the received measured cells may be utilized to produce a digital model of the received measured cells that are located either in front of, or beneath, (relative to the forward movement of the DAP 300) the plurality of gates 102 of the DAP 300, where each measured cell corresponds to a sub-portion of the portion 118 of the sub-base 108. By comparing the each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion 118 of the sub-base 108 with the DAP 300 the DAP 300 is configured to adjust a position of each gate (of the plurality of gates 102) in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model. In this example, each gate is configured to independently change the position of the gate relative to the surface 106 of the sub-base 108 and distribute the asphalt 104 on the surface 106 of the sub-base 108 based on the position of the gate.

In general, the pavement sensor 306 may also be configured to detect a flatness of the portion 118 of the surface 106 of the sub-base 108 and the variations in flatness of the surface 106 of the sub-base 108 prior to addition of the asphalt 104 to the surface 106 of the sub-base 108. The post-gate sensor 326 may also be configured to detect the variations in flatness of the asphalt 104 after the addition of the asphalt 104 to the surface 106 of the sub-base 108 and compaction of the combination of the asphalt 104 and the sub-base 108 with the compacting device 206; and the post-screed sensor 328 may also be configured to detect the variations in flatness of the asphalt 104 after the material leveling device 208 has passed over the combination of the asphalt 104 and the sub-base 108, prior to being further compacted by the second compactor 320. The post-compactor sensor 330 may be configured to detect the variations in flatness of the asphalt 104 after the compaction of the combination of the asphalt 104 and the sub-base 108 with the second compactor 320.

In this example, if the asphalt density sensor 324 is present, the DAP is configured to measure the density of the asphalt 104 in the hopper 304 of the DAP 300. If the post-gate sensor 326 is present, the post-gate sensor 326 may also be an asphalt density type of sensor that is configured to measure the density of the asphalt 104 that has been laid on the surface 106 of the sub-base 108 by the plurality of gates 102 and compacted with the compacting device 206. Alternatively, the post-gate sensor 326 may be a sensor (such as, for example, an image sensor, radar, LiDAR, or other type of measurement sensor) that is configured to measure the height of the combined asphalt 104 and surface 106 of the sub-base 108 that has been laid on the surface 106 of the sub-base 108 by the plurality of gates 102 and compacted with the compacting device 206. Similarly, the post-screed sensor 328, if present, may also be an asphalt density type of sensor that is configured to measure the density of the asphalt 104 that has been laid on the surface 106 of the sub-base 108 by the plurality of gates 102, compacted with the compacting device 206, and leveled by the material leveling device 208. Alternatively, the post-screed sensor 328 may be a sensor (such as, for example, an image sensor, radar, LiDAR, or other type of measurement sensor) that is configured to measure the height of the combined asphalt 104 and surface 106 of the sub-base 108 that has been laid on the surface 106 of the sub-base 108 by the plurality of gates 102, compacted with the compacting device 206, and leveled by the material leveling device 208. Moreover, the post-compactor sensor 330, if present, may also be an asphalt density type of sensor that is configured to measure the density of the asphalt 104 that has been laid on the surface 106 of the sub-base 108 by the plurality of gates 102, compacted with the compacting device 206, leveled by the material leveling device 208, and further compacted by the second compactor 320. Alternatively, the post-compactor sensor 330 may be a sensor (such as, for example, an image sensor, radar, LiDAR, or other type of measurement sensor) that is configured to measure the height of the combined asphalt 104 and surface 106 of the sub-base 108 that has been laid on the surface 106 of the sub-base 108 by the plurality of gates 102, compacted with the compacting device 206, leveled by the material leveling device 208, and further compacted by the second compactor 320. In this example, the second compactor 320 may be, for example, a heavy roller type machine.

In this example, the DAP 300 may include the compacting device 206 located proximate to, and behind, the plurality of gates 102, where the compacting device 206 is configured to compact the asphalt 104 from the flow of the asphalt 104 that is not partially obstructed by the plurality of gates 102. As discussed previously, the DAP 300 may include the material leveling device 208 that may include, for example, a screed having a screed surface, where the plurality of actuators 204 is configured to control a height of the compacting device 206 relative to the screed surface to produce a flat surface of paving material on the surface 106 of the sub-base 108. In this example, the compacting device 206 may include at least one compressor disposed between the plurality of gates 102 and the surface 106, the at least one compressor being configured to compress the asphalt 104. The compacting device 206 may include a plurality of compressors and each of the compressors of the plurality of compressor is configured to compress the asphalt 104 on the surface 106 of the sub-base 108 to a different height. Moreover, the compacting device 206 may be divided into a plurality of compressor segments, where each of the compressor segments may be configured to apply a different force on the asphalt 104 or compress the asphalt 104 to a different height.

In these examples, each gate of the plurality of gates 102 may be separately height adjustable, independently adjustable in both height and angle, disposed at a different angle relative to each other gate of the plurality of gates 102, or any combination of thereof.

Turning to FIGS. 5A and 5B, perspective views are shown for examples of units of volume of asphalt in accordance to the present disclosure. These examples illustrate the difference between a relative density of a lower density of the asphalt 104 in FIG. 5A and a maximum theoretical density of the asphalt 104 in FIG. 5B. Specifically, in FIG. 5A, a perspective view of an example of an implementation of a first combination of the asphalt 104 and sub-base 108 (herein referred to as first asphalt 500) is shown in accordance to the present disclosure, while in FIG. 5B, a perspective view of an example of an implementation of a second combination of the asphalt 104 and sub-base 108 (herein referred to as second asphalt 502) is shown in accordance to the present disclosure.

In these examples, a unit volume of asphalt (either first asphalt 500 or second asphalt 502) can be considered to be a mixture of three parts, aggregate displaced volume, binder displaced volume, and air volume. For example, the first asphalt 500 may include a mixture of aggregate displaced volume 504, binder displaced volume 506, and air volume 508, while the second asphalt 502 may include mixture of aggregate displaced volume 510 and binder displaced volume 512, with no air volume. In this example, the first asphalt 500 may have a first height 514 and the second asphalt 502 may have a second height 516 that is less than the first height 514. In these examples, the maximum theoretical density occurs when all air (i.e., air volume 508) has been removed from the unit volume of asphalt (i.e., first asphalt 500). During compaction, particles of asphalt aggregate typically cannot move laterally. They are either constrained by neighboring asphalt or construction surfaces, such as curbs. The aggregate particles at the edge of unrestrained lifts may partially extrude, however, this movement is negligible within a few centimeters of the unrestrained edge. The mass within the volume of asphalt is the sum of aggregate and binder mass and the mass of air is insignificant. The relative density is defined as partially compacted density divided by maximum theoretical density. The mass in this ratio of two densities is equal; therefore, the ratio can be simplified to

$\frac{{Volume}_{Max}}{{Volume}_{\partial Compaction}} .$

Because the height is the only meaningful change in a compacted unit volume, this can be further simplified to S/H, where S (i.e., the second height 516) is the height of the maximum theoretical density volume and H (i.e., the first height 514) is the height of the corresponding partially compacted volume.

Turning to FIG. 6, a top-view of an example of an implementation of an DAP 600 that may include a hopper 602, a conveyor 604, a lateral distribution device 606 such as, for example, an at least one auger 608, and a material leveling device 610 such as, for example, a screed. In this example, the hopper 602 may include an open top to receive fresh asphalt 104, temporarily hold the asphalt 104, and dispense the asphalt 104, via the conveyor 604, through an opening in the back wall 612 of the hopper 602. The asphalt 104 is moved by the conveyor 604 from the hopper 602 to a lateral distribution device 606 (i.e., a material distribution device). In this example, the hopper 602 may be disposed towards the front of the DAP 600, and an operator 116 may control the DAP 600 from a control station 314 behind the hopper 602. Moreover, in this example, the material leveling device 610 may combine the functions a material leveling device, a surface leveling device (e.g., a screed), a surface smoothing device, and a compacting device.

In an example of operation, the lateral distribution device 606 may move the asphalt 104 laterally across the area of a surface to be paved where the asphalt 104 is placed in front of material leveling device 610. The asphalt 104 collects in front of material leveling device 610 and may be further distributed across the width of the material leveling device 610 as collected piles of the asphalt 104 in front of the material leveling device 610 fall to the sides and also recirculate forward. The asphalt 104 passing under the material leveling device 610 may be partially compacted and the top surface of the asphalt 104 exiting the material leveling device 610 may be smoothed. In this example, a left screed extension 616 and right screed extension 518 may be configured to allow the material leveling device 610, left screed extension 616, and right screed extension 618 to vary a paved width along the surface to be paved. The DAP 600 may be configured to travel in a direction 620 and the lateral distribution device 606 may be configured to move the asphalt 104 along a direction approximately normal to the direction 620 of travel of the DAP 600 as indicated by directional arrows 622 and 624.

In this disclosure, the material leveling device 610 may be configured as a free-floating screed that is a leveling device that is configured to spread and smooth out (i.e., “screed”) a paving material (i.e., the asphalt 104) below it. In general, the material leveling device 610 is configured to be physically connected to a tractor portion of a paving machine (e.g., the DAP 600) via at least one towing arm (i.e., the pair of tow arms 318).

In typical operation, the asphalt is transferred from the hopper 602 at the front of the tractor to the material leveling device 610 via the conveyor 604 and lateral distribution device 606, and the at least one auger 608 spread it across the width of the material leveling device 610. The asphalt then flows out across the width of the material leveling device 610. Adjusting the settings of the material leveling device 610 will change the placement depth and width of the asphalt, as well as the amount of asphalt being placed on the paving surface.

In this example as a free-floating screed, the material leveling device 610 may be physically connected to the tractor portion of the DAP 600 via at least one tow arm (i.e., the pair of tow arms 318). As such, the material leveling device 610 can “float” vertically relative to the DAP 600, which allows the DAP 600 to traverse an uneven ground while the material leveling device 610 floats over the asphalt 104 placed in front of the material leveling device 610.

FIG. 7 is an iso view of another example of the DAP 600. The DAP 600 is shown to have a first tow arm 700 an a second tow arm 702. In this view the left screed extension 616 is partially retracted while right screed extension 618 is fully extended.

Turning to FIG. 8, a top-perspective view of an example of surface irregularities and bridging on pavement is shown. FIG. 9 is functional block diagram of an example of paving over surface irregularities with bridging on pavement. FIG. 10 is a functional block diagram of an example of dynamically paving over surface irregularities without bridging in accordance with the present disclosure. FIG. 11 is a functional block diagram of an example of dynamic surface deposited over the surface irregularities to avoid bridging in accordance with the present disclosure.

In general, FIGS. 8-11 illustrate road and paving defects which the present disclosure corrects. The surface defects, including localized surface irregularities (i.e., first surface irregularity 800 and second surface irregularity 802), pavement cracks 804, and pavement joint separation 806 along a pavement 808 that can be detected using a sensor 810 (e.g., the pavement sensor 306 of FIG. 3). The surface defects along the surface 812 of the pavement 808 may also be present after paving preparation operations are complete, usually as localized depressions in the sub-base 108. The present invention discloses several multiple gate dynamic paving embodiments which place additional asphalt 814 over surface irregularities 800 which extend below the surface 812 of the sub-base 108, and which reduce the quantity of asphalt 814 over raised surface irregularities (i.e., second surface irregularity 802). In this example, the surface 812 of the asphalt 104 is located over both compressed asphalt 814 and uncompacted asphalt 815. In these figures, a screed (i.e., the material leveling device 208) and a compacting device (i.e., the compacting device 206) are moving in the direction of travel 816 for paving. The matching asphalt 814 deposition with surface irregularities prevents differential compaction, or regions of reduced density bridged asphalt. In general, bridging is difficult to detect without advanced density measurement devices.

FIG. 9 illustrates known paving practices in areas with surface irregularities or different height trench overlays. The screed 900 may deposit a smooth upper surface of homogeneous partially compacted asphalt 902 over the irregularities (i.e., first surface irregularity 904 and second surface irregularity 906), of the sub-base 108. The compactor 908 may also create a smooth top surface 910, which results in bridged asphalt which is not compacted to the same density as the supporting asphalt 902 surrounding the bridged area.

FIGS. 10 and 11 illustrate paving practices enabled by the present disclosure. The plurality of gates 1000 create a dynamic surface over the irregularities of the surface 1002 with asphalt 1004, including areas around, for example, a crack removal by localized milling and/or joint separation removed by localized milling. When combined with the compacting device 1006, the density of asphalt 1100 exiting the screed 1008 is much closer to maximum theoretical density and is approximately homogeneous across the paved width.

Turning back to FIG. 9, FIG. 9 illustrates a paving method in areas with localized surface irregularities (i.e., first surface irregularity 904 and second surface irregularity 906) or trench cuts 912. The screed 900 moving in direction of travel 816 will create a smooth upper surface (i.e. top surface 910) of homogeneous, partially compacted asphalt over the irregularities (i.e., first surface irregularity 904 and second surface irregularity 906) and the trench cuts 912. The compactor 908 also creates the smooth top surface 910, which results in partially compacted asphalt 902, sometimes called bridged asphalt 914, which is not compacted to the same density as the supporting asphalt (i.e., asphalt 902) surrounding the bridged area of the bridged asphalt 914.

FIG. 12 illustrates an example of an implementation of a paving method a surface 1200 of pavement in accordance with the present disclosure. In some cases, surface defects, such as pavement cracks 1202 and joint separations 1204, are removed by a milling machine prior to paving. As an example, surface 1200 defects which are shown in this illustration are for descriptive purposes because they are usually removed prior to paving. FIG. 12 shows examples where surface 1200 defects have been removed resulting in a localized surface irregularity (i.e., first surface irregularity 1206 and second surface irregularity 1208). In this example, the plurality of gates 1210 create a dynamic surface over the surface irregularities. When combined with the compactor 1212, the density of asphalt 1214 exiting the screed 1216 is much closer to the maximum theoretical density and is homogeneous across the paved width.

In this example, the surface 1200 to be paved can be scanned using the sensor 1218 (e.g., a scanner), which may be attached to DAP or to an independent vehicle.

FIG. 13 illustrates several examples of digital surface formats (for example, a first digital surface format 1300, a second digital surface format 1302, a third digital surface format 1304, and a fourth digital surface format 1306) according to the present disclosure. Each format converts measurements of a measured surface 1308 into a digital processing system usable format. In this example, measurements of measured surface 1308 may be collected by sensor 1218, by inertial sensors on the DAP, by physical contact sensors, or by any other devices with an analog or digital electric output.

For example, the first digital surface format 1300 collects a series of point measurements into a large number of points, called a point cloud 1310. As the number of points in a given area increase, the collection of points more accurately represents measured surface 1308. The second digital surface format 1302 may utilize a grid of pixels 1312. When viewed from the top, the grid of pixels 1312 are continuous and non-overlapping. Each pixel of the pixels 1312 may be assigned a height value, usually representing the average height of the measured surface 1308 covered by that pixel. In general, smaller pixels have a higher surface density and more accurately represent measured surface 1308. The third digital surface format 1304 may combine a series of height measurements 1314 recorded along one or more trace lines 1316. The height measurements 1314 may be evenly spaced or unevenly spaced. Trace lines 1316 may be evenly spaced or unevenly spaced. The height measurements 1314 may be a list of values or may be the result of a formula approximating values along trace lines 1316.

The fourth digital surface format 1306 may combine mesh nodes 1318 into a surface approximating mesh 1320. The mesh nodes 1318 may be evenly spaced or unevenly spaced; and the mesh nodes 1318 heights may be usually calculated to make the average of the mesh 1320 height approximate to the average measured surface 1308 height.

It is appreciated that these example digital surface formats are not exclusive and are included for illustration purposes. The asphalt delivery and compaction method described in FIG. 21 may use these and other digital surface formats.

FIG. 14 illustrates plurality of gates 1400 for dynamic paving operating over an uneven sub-base 1402. In this example a screed follows behind the plurality of gates 1400, both of which are moving in direction of travel 1404. A cross section perpendicular to the gates may be also included in the illustration which shows sub-base 1402 at the cross section location, the desired finished surface 1406, the target gate height 1408, the actual gate height 1410, the target gate height tolerance 1412, and the collision tolerance 1414.

FIG. 15 illustrates a DAP 1500 with a hopper 1502, conveyor 1504, control station 1506, and augers 1508. In this example, the DAP 1500 and screed 1510 move in direction of travel 1512. A row of calculation cells 1514 is virtually created in a digital processing unit (i.e., the at least one processor 112) and stored (i.e., at least one memory 110). The row of calculated cells 1514 contains multiple calculation cells and is aligned with the plurality of gates 1516 (i.e., the plurality of gate 102). In this example, the rear edge of the row of calculation cells 1514 may be located a distance ahead of or behind the front face of the plurality of gates 1516 by cell to gate offset 1518.

In this example, within each cell 1520, a digital surface (e.g., the first digital surface format 1300, the second digital surface format 1302, the third digital surface format 1304, and the fourth digital surface format 1306) may be evaluated and an average sub-base is determined. In some cases, the maximum sub-base height within each cell 920 may also be determined. Furthermore, within each cell 920, an average finished surface height may also be determined. In this example, the row of cells 1514 may be positioned relative to the plurality of gates 1516. In this example, calculated values may be updated with each iteration identified in FIG. 21.

FIG. 16 is a system block diagram of the plurality of gates 1516 and row of calculation cells 1514 of the DAP 1500 shown in FIG. 15 in accordance with the present disclosure. This figure expands on the details described in relation to DAP 1500. Specifically, the plurality of gates 1516 are shown as having N gates that include, for example, first gate 1600, second gate 1602, third gate 1604, and N^thgate 1606, where N may be any integer number. Similarly, the row of calculation cells 1514 may also include a plurality of cells having N cells that include, for example, a first cell 1607 (e.g., cell 1520 of FIG. 15), second cell 1608, third cell 1610, and N^thcell 1612.

In this example, the plurality of gates 1516 are located at a first position 1614 and the row of calculation cells 1514 is located at a second position 1616. In this example, the second position 1616 may be ahead of the first position 1614 along the direction of travel 1512. Both the plurality of gates 1516 and the row of calculation cells 1514 may be located behind a lateral distribution device 1618 that is located at a third position 1620 along the direction of travel 1512.

In this example, the gate offset 1518 is equal to the distance between the first position 1614 and second position 1616 and the lateral distribution device 1618 may be the augers 1508 shown in FIG. 15. Similar to FIG. 6, the lateral distribution device 1618 may include two sides (a first side 1622 and a second side 1624) that may be located at opposite sides of the lateral distribution device 1618 where a center line 1626 divides the lateral distribution device 1618 into the first side 1622 and the second side 1624. In an example of operation, the lateral distribution device 1618 may receive the asphalt 104 and distribute it in a first direction 1628 to a first set of gates (e.g., the gates located below the center line 1626 that may include the first gate 1600, the second gate 1602, and the third gate 1604) over a first set of calculation cells (e.g., the cells located below the center line 1626 that may include the first cell 1607, the second cell 1608, and the third cell 1610) and in a second direction 1630 to a second set of gates (e.g., the gates located above the center line 1626 until the N^thgate 1606) over the second set of calculation cells (e.g., the calculation cells located above the center line 1626 until the N^thcalculation cell 1612).

FIG. 17 illustrates a DAP 1700 with a hopper 1502, conveyor 1504, control station 1506, and augers 1508. In this example, the DAP 1700, augers 1508, screed 1510, plurality of gates 1516 are shown at two moments in time (first time 1702 and a second time 1704). As described previously, the screed 1510 and the plurality of gates 1516 move in direction of travel 1512. In this example, a row of calculation cells 1706 may be virtually created in the digital processing unit (i.e., the at least one processor 112). The row of calculation cells 1706 includes multiple calculation cells and is aligned with the plurality of gates 1516. In this example, the left side of the illustration shows the first moment in time (at first time 1702) when the plurality of gates 1516 have not yet passed over calculation cells 1706.

The right side of the illustration shows a later moment in time (at second time 1704) when plurality of gates 1516 are passing over the row of calculation cells 1706. In this example, the calculation cells 1706 are positioned relative to the sub-base 1708. In this example, the calculated values for the average sub-base 1708, average finished surface, and target gate height 1408 do not need to be updated every iteration.

FIG. 18 illustrates a DAP 1800 with a hopper 1502, conveyor 1504, control station 1506, and augers 1508. The DAP 1800 and screed 1510 move in direction of travel 1512. In this example, multiple rows of calculation cells 1802 may be virtually created in the digital processing unit (i.e., the at least one processor 112). These multiple rows form a calculation cell grid 1804. As an example, the cell grid 1804 may move with the plurality of gate 1516 as the plurality of gate 1516 move over sub-base 1806. As another example, the cell grid 1804 may move with the screed 1510, left extension (i.e., left extension 616) and the right extension (i.e., right extension 618). In yet another example, the cell grid 1804 may not move relative to sub-base 1806. In this example, the cell grid 1804 may have a gate offset 1808 from the plurality of gates 1516.

FIG. 19 illustrates various alignments of calculation cells within the row of calculation cells 1900 or within the calculation cell grid (e.g. a first calculation cell grid 1904, second calculation cell grid 1906, or third calculation cell grid 1908). These examples may use one or more cell alignments discussed herein. The screed 1510, plurality of gates 1516, and direction of travel 1512 are included for reference.

In these examples, the row of calculation cells 1900 may maintain a cell width that is equal to a gate width of the plurality of gates 1516. In another example, the first cell grid 1904 may include cells widths that exceed the gate width. Also, in yet another example, the first cell grid 1904 may include cells widths that are narrower than a signal gate width as will discussed later in relation to FIG. 21. In this example, the minimum cell width of the cells may be, for example, no less than one-half of a resolution of the sensor (i.e., the pavement sensor 306) or no less than three times the aggregate size, whichever is larger.

This example may further include cells that have overlapping boundaries. In this example, defining cell boundaries with overlapping edges reduces the opening height difference of neighboring gates within the plurality of gates 1516 and smooths the target gate height surface. In this example, the cell width may be fixed or may be adjusted as a secondary calculation between gate height iterations discussed in the method described in relation to FIG. 21.

As another example, in the second grid 1906, the cell may have edges that are not aligned which may be useful when extending screed 1510 extensions or paving around corners. In yet another example, the third grid 1908 illustrates calculation cells that are separated by a cell edge gap 1910 and an optional second cell edge gap 1911. In this example, adding the cell edge gap 1910 (and/or optional edge path 1911) between cells may increase the opening height difference of neighboring gates of the plurality of gates 1516 and increases target gate height surface variability. In this example, adding an edge gap (i.e., the edge gap 1910 and optional second edge gap 1911) reduces blending between cells, which could lead to larger step changes between iterations. When paving with larger aggregate sizes, larger movement steps may improve material (i.e., asphalt 118) flow through the gates. When combined with a larger gate position tolerance (which helps prevent gates from constantly making micro-corrections which have not impact on the paved surface), gaps between cells may also reduce or eliminate gate dither (i.e., constant micro-adjustments).

Turning back to FIGS. 3 and 4, the DAP 300 is configured to receive asphalt 104 from the truck 302. The DAP 300 rides on a drive system 312 such as wheels or tracks driven by a motor or engine.

The material leveling device 208 (e.g., a screed) may be connected to DAP 300 by means of the pair of tow arms 318 where each tow arm may be connected to DAP 300 via an axially rotatable tow point 400 and to screed 210 at an axially rotatable hinge point. The plurality of gates 102 may be located between auger 310 and material leveling device 208. As an example, the plurality of gates 102 may be attached to the DAP 300 using a gate support structure 402.

In an example of operation, the asphalt 104 distributed by auger 310 contacts the gate material contacting face 406. When one or more gates of the plurality of gates 102 are open, the asphalt 104 through the open area under the open gate. The asphalt 104 may be initially compacted by the compacting device 206 located between plurality of gates 102 and material leveling device 208.

In an example of operation, the gate height is controlled by the method discussed in relation to FIGS. 20 and 21. The gate height may be increased over depression surface irregularities (e.g., first surface irregularity 800, first surface irregularity 904, or first surface irregularity 1206), decreased over raised surface irregularities (e.g., second surface irregularity 802, second surface irregularity 906, or second surface irregularity 1208), and offsets sub-base 108 waviness. The surface sensor (e.g., sensor(s) 120, sensor 306, sensor 810, or sensor 1218) or multiple surface sensors collect information which is then processed to create digital surface such as, for example, the first digital surface format 1300, the second digital surface format 1302, the third digital surface format 1304, or fourth digital surface format 1306. In this example, the gate heights (of the plurality of gates 102) may be measured using actuator position sensors 322. In other examples, actuator position sensors 322 may be replaced with another sensor which measures the gate height through physical, electromagnetic, or other means.

In this example, asphalt density sensor 324 may include one or more sensors that measure asphalt 104 density as it passes through the DAP 300. In this disclosure, the distributed asphalt 104 density is discussed in relation to FIG. 21. In general, the distributed asphalt 104 density is most accurately measured after the auger 310 but more easily measured in the conveyor 308. In this disclosure, it is useful to know density between the major compacting steps with compacting device 206, material leveling device 208, and second compactor 320. As such, the post-gate sensor 326, post-screed sensor 328, and post-compactor sensor 330 may all be optionally density sensors to measure the density of the asphalt 104 after the different compacting steps performed by the compacting device 206, material leveling device 208, and second compactor 320.

FIG. 20 is a flowchart of an example of an implementation of a method 2000 of operation of the DAP in accordance with the present disclosure. The method 2000 may comprise: receiving, at stage 2002, a digital model of a portion of the sub-base that is to be paved with the aggregate material, wherein the digital model includes a plurality of cells that correspond to the portion of the sub-base; comparing, at stage 2004, each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion of the sub-base; and adjusting, at stage 2006, a position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model, wherein each gate is configured to independently change the position of the gate relative to the surface of the sub-base and distribute aggregate material on the surface of the sub-base based on the position of the gate.

FIG. 21 is a flowchart of an example of an implementation of another method 2100 for controlling multiple gates for a DAP in accordance with the present disclosure. In this example the method 2100 is for controlling the plurality of gates 102 for a DAP, such as the plurality of gates 102 described previously in relation to FIGS. 1-4, 10-12, and 14-18. For case of description, the method 2100 is described with reference to elements shown and described in FIGS. 1-18; however, the method 2000 can be used with other machines and other dynamic paving devices, and likewise, the plurality of gates 102 can be used with other methods.

In this example, the method 2100 starts at stage 2102, with determination iterations that contain one or more determination loops. This may occur manually when the operator 116 sends a signal to the machine, automatically when the machine reaches predefined conditions such as location, speed, or asphalt distribution, or automatically after the completion of a prior loop. A single determination loop may evaluate one grid cell (e.g., cell grid 1804) as will be discussed later at stage 2104, several loops may evaluate multiple grid cells (e.g., first calculation cell 1607 through N^thcalculation cell 1612), and an iteration combines the results of all the loops performed for one moment in time, typically before updating positions. If the iteration follows a prior loop, data loaded in the previous loop or loops may remain in the processor (i.e., the at least one processor 112) memory (i.e., at least one memory 110) and may not need to be entered again.

At stage 2104, a calculation cell boundary may be defined. For example, in the examples described previously, the calculation cell boundaries may be defined relative to the gate (of the plurality of gates 102) position. In many cases, a screed 1510 movement may be sufficiently slow in comparison to the calculation speed that, for a single determination loop repeated to determine values in each individual cell, the location at the start of the determination loop may be considered a screed 1510 and gate position throughout the entire series of determination loops within one iteration. In another example, a predicted screed 1510 and gate location at a point other than the start of the iteration may be used to define the cell boundary. This may use a single screed 1510 location with corresponding gate locations aligned with neighboring gate locations, or may use more than one screed 1510 locations within the iteration time with gate locations which may not be aligned with neighboring gates in the same iteration.

In the two previous examples, the cell boundary remains unchanged through an iteration. In another example, not shown, the cell boundary and average digital surface values are continuously updated and made available for cell calculations. In the continuous update example, two parallel loops may occur after stage 2102. One loop may define cell boundaries, determine gate position, determine average sub-base surface within each cell, and determine average finished surface within each cell. The results of these determinations may be continuously updated and passed to the other parallel calculation loop. The second parallel calculation loop may follows the same iteration path as the described method 2100, but replaces digital surface data entry and cell average height determination/calculations with values provided by the first loop.

At stage 2106, the at least one processor 112 may receive a digital model of a portion 118 of the sub-base 108 that is to be paved with the asphalt 104, where the digital model includes a plurality of cells that correspond to the portion 118 of the sub-base 108. In this example, the digital model may include the measured surface 1308 and at least one digital surface (e.g., the first digital surface format 1300, the second digital surface format 1302, the third digital surface format 1304, or the fourth digital surface format 1306) of the sub-base 108 as discussed in relation to FIG. 13. At this stage, the digital surface for the sub-base 108 may be loaded into the at least one processor 112. In this example, the at least one processor 112 may replace any previously loaded digital surface information with a new version for each iteration. In another example, the at least one processor 112 may upload a digital surface for the sub-base 108 once as a one-time initialization prior to starting cell iterations.

In a similar example digital surface information (e.g., reviewed from the pavement sensor 306) may be divided into smaller sections that may be aligned or partially overlapping. The at least one processor 112 may compare a digital surface (see previous description in relation to FIG. 13) for sub-base 108 with the predicted gate location (i.e., the first position 1614) for the current iteration or for one or more future iterations. If a first section of the digital surface does not cover the predicted calculation area (e.g., the portion 118 of the sub-base 108), a second section of the digital surface data files may be loaded into the at least one memory 110. When all the gates (of the plurality of gates 102) have passed over a digital surface data file, that data file may be removed from the controller 115 memory (i.e., at least one memory 110).

At stage 2108, the average sub-base height within a cell 920 may be determined/calculated using the digital surface loaded in the at least one memory 110 and the cell boundary determined at stage 2104.

At stage 2110, the digital surface for the desired finished surface may be loaded into the controller 115 (i.e., the combination of the at least one processor 112 and at least one memory 110). In this example, the at least one processor 112 may replace any previously loaded digital surface information with a new version each iteration. In another example, the at least one processor 112 may upload a digital surface for the desired finished surface (e.g., desired finished surface 1406 shown in FIG. 14) as a one-time initialization prior to starting the cell iterations.

In these examples, the digital surface information may be divided into smaller sections which may be aligned or partially overlapping. The at least one processor 112 may then compare digital surface for the desired finished surface (e.g., desired finished surface 1406 shown in FIG. 14) with the predicted gate location (e.g., first position 1614) for the current iteration or for one or more future iterations. If the first section of digital surface does not cover the predicted calculation area, a second section of digital surface data files may be loaded to the combination of the at least one processor 112 and at least one memory 110. When all the gates (of the plurality of gates 102) have passed over a digital surface section, that section may be removed from the at least one memory 110.

At stage 2112, an average finished surface target height within a cell may be determined/calculated using the digital surface loaded at stage 2110 and the cell boundary(s) determined at stage 2104.

At stage 2114, the average finished surface target height is compared with the average sub-base height within the boundaries of cell. At decision stage 2116, if the average finished surface target height is greater than the average sub-base height, at stage 2118, the average sub-base height is subtracted from the average finished surface target height to determine the average height difference. If, instead, the average finished surface target height is not greater than the average sub-base height, the method would then determine a minimum gate height at stage 2128 where the target gate height may be determined/calculated.

In this example, a warning signal may be sent to the operator 116, at stage 2120, when the average sub-base height exceeds the average finished surface height within the cell boundaries. Another similar example may include sending a warning signal when the average sub-base height exceeds the average finished surface height by a predetermined alarm tolerance.

At stage 2122, density of the asphalt 104 is determined and loaded into the at least one memory 110. The density of the asphalt 104 may be determined either by utilizing a default uncompacted asphalt value (that is predetermined and provided by a supplier of the asphalt 104) or measured by utilizing the asphalt density sensor 324 described and shown in FIGS. 3 and 4.

In this example, for default value of uncompacted asphalt 104 relative density, the asphalt 104 which has been laterally distributed by an auger, the relative density is typically between 50% and 65%. As such, an operator adjustable default value within this range may be loaded and utilized. In some examples, operators 116 may have equipment which can quickly measure delivered asphalt 104 density in hopper 278, conveyor 275, or immediately after exiting auger 274 via a sensor (e.g., asphalt density sensor 324). In this case, the operator may adjust the default uncompacted asphalt 104 density with a new value.

Instead of using default values, the DAP may collect information from one or more density sensors (as described previously), evaluate the signal from those sensors to confirm proper sensor operation, and update the at least one memory 110 with a new measured relative density value. As an example, the measured values may replace the prior iteration values. In another example, signal processing, such as rolling averages or Kalman filtering, may be applied to reduce sensor noise prior to updating the iteration value.

The at least one processor 112 may identify which relative density value should be used for the current calculation loop. In one example, the default uncompacted relative density may be used unless a measured value exists. In another example, the default uncompacted relative density of may be used unless a value has been measured with sensors within a specified time frame, for example within the past 60 seconds. In yet another example, the measured uncompacted asphalt density may be compared with the typical uncompacted relative density range. If the measured density is outside the range, it may be replaced by the default relative density and a warning signal may be sent to the at least one processor 112. The determination of uncompacted asphalt relative density may use parts or all of the methods identified in these embodiments.

At stage 2124, the desired compacted asphalt 104 relative density may be loaded into at least one memory 110. The desired compacted asphalt 104 relative density may be specified in the bid documents for large projects such as highways or runways, or may be identified by operators for small projects, such as driveways and golf cart paths. Generally, the desired compacted asphalt relative density usually ranges between 90% and 97%. In some cases, a maximum relative density may be set at 100%. In one example, one value for the target relative density may be loaded into at least one memory 110 for each iteration. In another example, the target relative density may be loaded as part of a program initialization and may not be reloaded into at least one memory 110 as part of the gate location calculation loop.

In a further example (not shown), additional density sensors may measure the compacted asphalt 104 density. This data may be automatically entered into the at least one processor 112 and used to update the desired compacted asphalt relative density. If the sensor measured relative density is within specified values, it may be used to automatically replace the manually entered target value. If the sensor measured relative density is outside specified values, a warning signal may be sent to the the at least one processor 112.

At stage 2126, a density ratio between the desired compacted material density (i.e., the final density) and the distributed material density (whether estimated or measured) may be calculated. The density ratio is the desired compacted asphalt relative density divided by the uncompacted asphalt relative density. As an example, the distributed material density, desired compacted material density, or both, may have relative density values updated before the start of a subsequent gate location calculation loop. In this example, the updated values of the distributed material density, desired compacted material density, or both may be loaded in the at least one memory 110 as a step in the calculation loop. In another example, the default values or static values may be used for both the distributed material density and the desired compacted material density. In this case, a default density ratio may be entered directly into the at least one processor 112. The default density ratio may be loaded as part of an initialization routine prior to starting any gate location calculation loops.

At stage 2128, a target gate height may be determined/calculated. In this example, the cell left and right boundaries are aligned with gate left and right edges, and the cell is located relative to the gate. The target gate height equals the average desired finished surface height in the cell, determined at stage 2124, plus the average sub-base to finished surface height difference, determined at stage 2112, times the result of the density ratio output (determined at stage 2126) minus 1. In another example, the gate width overlaps only a partial cell width. In this case, the target gate height calculated at stage 2128 applies to the gate. In yet another example, the gate width overlaps two or more cell widths. In this case, the target gate height is the weighted average of the cell target gate heights calculated in at stage 2128. For example, if the gate overlaps all of a first cell and half of second cell, and the cells were of the same width, the target gate height would be ⅔ of first cell plus ⅓ of second cell.

At stage 2130, the actual gate height (e.g., of a first gate) may be entered into controller 115 from a sensor. At stage 2132, a gate height tolerance (i.e., target gate height tolerance 1412) may be entered into controller 115. In this example, the gate height tolerance may be a changeable value previously loaded into a program initialization file and may remain unchanged throughout the various iterations. In another example, the cell calculation loops may be paused while a new gate height tolerance is entered. In yet another example, the gate height tolerance may be manually updated in parallel with ongoing calculation loops, with the initial value used until the new value is entered.

At stage 2134, the actual gate height is compared with the target gate height. At decision stage 2136, if the height values are within half the tolerance entered at stage 2132, no gate movement signal is sent to controller 115. If, instead, the height values differ by more than half tolerance entered at stage 2132, at stage 2138, they system sends a gate move signal to controller 115 indicating the direction and distance gate must move to change from the actual gate height of at stage 2130 to the target gate height of stage 2128. At stage 2140, the calculation loop for a cell ends, a cell index is reset, and the loop is repeated with the new cell index.

In this method 2100, the number of loops and cell index may be controlled. In examples with a single row of cells, the cells index sequentially across the front of gates. Once the cell values have been indexed through all cells in row of cells, the index is reset to the first cell and the calculation loops are repeated. In embodiments with cells arranged in calculation grid, cell loops may be indexed through a row first then reset for the column, or may be indexed through a column first then reset for the next row. In other embodiments, specific cells within row or grid may have more than one loop performed. For example, cells aligned with a laterally moving, or extending, screed extension may have additional calculation loops performed while extensions are moving laterally.

In some examples, the at least one processor 112 speed may significantly exceed gate forward travel and extensions lateral travel. A defined pause between each iteration may be added. This pause may be entered as a time delay ranging between 0.001 and 0.1 seconds, or may be entered as an at least one processor 112 cycle count.

FIG. 22 is a front view of an example of an implementation of an I/O device 2200 (e.g., I/O device 114) displaying a current paving cross-section of the DAP in an example of operation in accordance with the present disclosure. In this example, the I/O device 2200 may be part of an operator interface that is in signal communication with the controller 115. For example, the I/O device 2200 may be configured to illustrate the current gate positions of the plurality of gates 102 on as a current gate location display 2202. In this example, the dynamic paving cross section 2204 (i.e., the target gate height 1408 shown in FIG. 14) parallel with a plurality of individual gates 2210 (i.e., the individual gates of the plurality of gates 102) in shown with a sub-base 2218 (i.e., the uneven sub-base 1402 shown in FIG. 14) at the cross section location, the desired finished surface 2220 (i.e., the desired finished surface 1406 from FIG. 14), the target gate height 2222 (i.e., the target gate height 1408), the actual gate height 2224, the target gate height tolerance 2226 (i.e., the target gate height tolerance 1412), and the collision tolerance 2228 (i.e., the collision tolerance 1414 shown in FIG. 14). For purposes of illustration, the individual gate 2210 image shows a total of twelve (12) gates for the plurality of gates 102).

In this example, the current gate location display 2202 may indicate any gates 2210 which are out of height tolerance with, for example, a highlight 2206, a symbol in the gate location table 2208, a symbol on the individual gate 2210 image, a change in the individual gate 2210 image color or boundary, or a combination of indicators. As a further example, the gates that are out of location tolerance may be moved from their current location to the target location according to method 2100 for controlling the plurality of gates 102 for a DAP previously described in relation to FIG. 21.

In this example, the current gate location display 2202 may also include a collision alarm 2212 that indicates any gate 2210 that are projected to impact any localized irregularities (e.g., the first surface irregularity 904 or second surface irregularity 906) or the sub-base 2218 (i.e., the sub-base 108). The collision alarm 2212 may include, for example, a highlight around gate information in the gate location table 2208, a symbol or text in gate location table 2208, a symbol on individual gate 2210 image, a change in individual gate 2210 image color or boundary, a symbol on individual gate 2210 image, an audible alarm, or a combination of indicators. Further, in this example, the gates that are projected to impact localized irregularities or sub-base 2218 may be moved from their current location to a location outside the collision tolerance zone (i.e., the collision tolerance 1414) according to the method 2100 for controlling the plurality of gates 102 for a DAP previously described in relation to FIG. 21.

In this example, the gate location tolerance 2214 and the collision tolerance 2216 may be displayed and may be edited by, for example, the operator 116, service personnel, or equipment manufacturers. It is appreciated that other examples of the gate location display 2202 may include content arranged in other locations, content displayed on separate screen pages accessed through, for example, menu buttons or other display change buttons, additional content, and elements of the described content as content in other screen pages.

FIG. 23 is a front view of an example of an implementation of an I/O device 2200 displaying a projected path (i.e., a target gate path 2300) of the DAP in an example of operation in accordance with the present disclosure. In this example, an operator interface may be displayed and configured on the projected paving path display 2302. The projected path of multiple gates (i.e., the plurality of gates 102) for dynamic paving may be configured to show a current gate location 2304, individual gate 2210 images, and the target gate path 2306. In this example, the surfaces displayed may be changed using a surface selection interface 2308 to the different selected surfaces 2310 that may be, for example, the sub-base (i.e., sub-base 2218 or sub-base 108), to the desired finished surface (i.e., desired finished surface 1406), to target gate height (i.e., target gate height 1408), to the actual gate path. Additionally, the actual gate height and individual gate 2210 images may be included or removed from the projected paving path display 2302.

In these examples, it is appreciated by those of ordinary skill that additional examples may show the projected paving path in a side view, top view, or other orthogonal view. Visualization of the digital surface may use smaller pixels, point clouds, meshed surfaces, 3D volume meshed surfaces, or other screen renderings of digital surface data. These example displays may show one or more surfaces at the same time with one or more surfaces having partially translucent color.

Turning to FIG. 24, a cross-section view of an example of an implementation of a trench paver 2400 is shown. In this example, the trench paver 2400 may be part of the DAP 100 described previously, where the plurality of gates 102 are located within the trench paver 2400. In this example, the trench paver 2400 may be pushed forward by a paver tractor.

In this example, the asphalt 104 (not shown) may be placed on the sub-base 2402 in front of trench paver 2400, which collects the asphalt 104 between the trench paver 2400 side walls 2404. In this example, a rear wall 2406 collects the asphalt 104 and distributes it across the width of trench paver 2400. A strike-off plate 2408, attached to the rear wall 2406, creates an opening 2410 between sub-base 2402, side walls 2404, and the strike-off plate 2408. The asphalt 104 passing through this opening 2410 is typically compacted by a separate machine. In some cases, a trench paver screed 2412 may be attached to the trench paver 2400. The trench paver screed 2412 may partially compact the asphalt 104 and smooth the top surface of asphalt 104 on the sub-base 2402.

In this example, if the trench paver screed 2412 is included as part of the trench paver 2400, trench paver screed 2412 may be attached with height adjusting screws. In some cases, the trench paver screed 2412 may be attached to the trench paver 2400 with the pair of tow-arms 330. The trench paver 2400 in this example may not have a traction system and may utilize a coupling plate 2414 that attaches the trench paver 2400 to, for example, a powered machine, such as a tractor, skid-steer loader, or wheeled loader. The powered machine may push trench paver 2400, which slides on the lower edges of side walls 2404 with, for example, skids 2416. In an example of operation, the trench paver 2400 may be pushed in the direction of travel 2418.

FIG. 25 is an isometric view of the trench paver 2400. In this view, the strike-off plate 2408 may be set at a desired paved lift above the sub-base 2402. As an example, the strike-off plate 2408 height may be fixed before a paving run. Some embodiments may allow dynamic adjustments to the entire strike-off plate 2408 height, but may not allow differential height adjustments across the width of the rear wall.

As an additional example based on the plurality of gates 102 for dynamic paving with an updated trench paver may be utilized to replace the previous trench paver 2400 strike-off plate 2408. For simplicity and ease of illustration, the multiple gates may be perpendicular to a direction of travel 2418 of the trench paver. In these examples, the multiple gates (i.e., the plurality of gate 102) may have orientation angles that may be fixed or rotatably adjustable.

Turning to FIG. 26, a front view of the trench paver 2500 with multiple gates 2502 aligned with a non-vertical roll angle 2504 is shown in accordance with the present disclosure. In this example, the roll angle 2504 (noted as angle “λ”) may vary, for example, between approximately 30 and approximately 160 degrees. In this example, the multiple gates 2502 may be tilted to the left, with a roll angle, for example, between approximately 30 and approximately 85 degrees, allowing the rightmost gates to contact asphalt 104 with a minimum of overhead structure. Likewise, the multiple gates 2502 may be optionally configured approximately normal to the ground (i.e., approximately perpendicular to the pavement) or tilted to the right, with a roll angle, for example, between approximately 95 and approximately 160 degrees, allows the leftmost gates to contact asphalt 104 with a minimum of overhead structure. In these examples, the multiple gates 2502 may move parallel to the gate front face along a gate movement 2506.

In FIG. 27, a side view of the trench paver 2500 with multiple gates 2502 is shown paving a surface 2700 of a sub-base 2702 with asphalt 2704 in accordance with the present disclosure. In this example, the trench paver 2500 is mechanically coupled to a tractor 2706 with a connection mechanism 2708. In an example of operation, the tractor 2706 pushes the trench paver 2500 in a forward direction 2710 along the surface 2700 that has the asphalt 2704 deposited in front of the trench paver 2500. As the trench paver 2500 moves in the forward direction 2710, parts of the asphalt 2704 are collected within the side walls 2404 of the trench paver 2500 and are deposited on the surface 2700 via the multiple gates 2502 (based on the methods previously discussed) and compressed with a compacting device (i.e., compacting device 206), material leveling device 208 (i.e., a screed—not shown), or combination of both, located behind the multiple gates 2502 to produce a finished desired surface 2712.

Implementation examples

Implementation examples are provided in the following numbered clauses.

Clause 1. A method for controlling a plurality of gates for dynamically paving a surface of a sub-base with aggregate material, the method comprising: receiving a digital model of a portion of the sub-base that is to be paved with the aggregate material, wherein the digital model includes a plurality of cells that correspond to the portion of the sub-base; comparing each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion of the sub-base; and adjusting a position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model, wherein each gate is configured to independently change the position of the gate relative to the surface of the sub-base and distribute aggregate material on the surface of the sub-base based on the position of the gate.

Clause 2. The method of clause 1, wherein the aggregate material is selected from a group consisting of asphalt, concrete, asphalt-concrete, bituminous pitch with sand, and bituminous pitch with gravel.

Clause 3. The method of clause 1, wherein the position is selected from a group consisting of a height position relative to the surface of the sub-base, an angled position relative to the surface of the sub-base, a pitched position relative to the surface of the sub-base, and a yaw position relative to the surface of the sub-base.

Clause 4. The method of clause 1, further comprising distributing the aggregate material on to the surface of the sub-base to produce a pre-compacted surface that includes a combination of the surface of the sub-base and the distributed aggregate material, wherein the desired digital model includes a desired final surface of a final combination of the surface of the sub-base and a final amount of the aggregate material.

Clause 5. The method of clause 4, further including compacting the pre-compacted surface to produce an actual final surface.

Clause 6. The method of clause 5, further including comparing the pre-compacted surface to the desired final surface, adjusting the position of each gate in response to comparing the pre-compacted surface to the desired final surface.

Clause 7. The method of clause 6, further including receiving sensor data from a sensor that is configured to measure the pre-compacted surface.

Clause 8. The method of clause 5, further including comparing the actual final surface to the desired final surface, adjusting the position in response to comparing the actual final surface to the desired final surface.

Clause 9. The method of clause 8, further including receiving sensor data from a sensor that is configured to measure the actual final surface.

Clause 10. The method of clause 1, wherein the portion of the sub-base of the digital model is located ahead of the plurality of gates along a forward direction of travel of the plurality of gates, and receiving the digital model of the portion of the sub-base includes receiving sensing data of the portion of the sub-base from a sensor located ahead of the plurality of gates along the forward direction of travel of the plurality of gates, and creating the digital model of the portion of the sub-base from the sensing data.

Clause 11. The method of clause 10, wherein creating the digital model of the portion of the sub-base includes determining a first cell boundary of the at least a first cell relative to a position of the at least a first gate to produce a first gate offset between the at least first cell and the at least first gate.

Clause 12. The method of clause 11, wherein creating the digital model of the portion of the sub-base further includes determining a second cell boundary of a second cell relative to a position of a second gate of the plurality of gates that corresponds and aligns to second cell, and determining whether the second cell boundary overlaps at least part of the first cell boundary.

Clause 13. The method of clause 1, further including determining an average sub-base height in the at least a first cell, wherein comparing each cell of the plurality of cells to the desired cell of the plurality of desired cells includes determining a cell height difference that is equal to a difference between a finished cell height of the at least first cell and the average sub-base height, and determining whether the cell height difference is less than a threshold value, and the finished cell height is a desired cell height of the first desired cell of the plurality of desired cells of the desired digital model.

Clause 14. The method of clause 13, wherein adjusting a position of each gate includes adjusting the first height based on the cell height difference.

Clause 15. A dynamic asphalt paver (DAP) for paving a surface of a sub-base with aggregate material, the DAP comprising: a plurality of gates for distributing the aggregate material on the surface of the sub-base, wherein each gate of the plurality of gates is configured to independently move in a vertical direction that is normal to the surface of the sub-base; at least one memory; and at least one processor communicatively coupled to the at least one memory and the plurality of gates, wherein the at least one processor is configured to: receiving a digital model of a portion of the sub-base that is to be paved with the aggregate material, wherein the digital model includes a plurality of cells that correspond to the portion of the sub-base; comparing each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion of the sub-base; and adjusting a position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model, wherein each gate is configured to independently change the position of the gate relative to the surface of the sub-base and distribute aggregate material on the surface of the sub-base based on the position of the gate.

Clause 16. The DAP of clause 15, wherein the aggregate material is selected from a group consisting of asphalt, concrete, asphalt-concrete, bituminous pitch with sand, and bituminous pitch with gravel.

Clause 17. The DAP of clause 15, wherein the position is selected from a group consisting of a height position relative to the surface of the sub-base, an angled position relative to the surface of the sub-base, a pitched position relative to the surface of the sub-base, and a yaw position relative to the surface of the sub-base.

Clause 18. The DAP of clause 15, wherein the at least one processor is further configured to distribute the aggregate material on to the surface of the sub-base to produce a pre-compacted surface that includes a combination of the surface of the sub-base and the distributed aggregate material, wherein the desired digital model includes a desired final surface of a final combination of the surface of the sub-base and a final amount of the aggregate material.

Clause 19. The DAP of clause 18, wherein the at least one processor is further configured to compact the pre-compacted surface to produce an actual final surface.

Clause 20. The DAP of clause 19, wherein the at least one processor is further configured to compare the pre-compacted surface to the desired final surface, adjust the position of each gate in response to comparing the pre-compacted surface to the desired final surface.

Clause 21. The DAP of clause 20, wherein the at least one processor is further configured to receive sensor data from a sensor that is configured to measure the pre-compacted surface.

Clause 22. The DAP of clause 19, wherein the at least one processor is further configured to compare the actual final surface to the desired final surface, adjust the position in response to comparing the actual final surface to the desired final surface.

Clause 23. The DAP of clause 22, wherein the at least one processor is further configured to receive sensor data from a sensor that is configured to measure the actual final surface.

Clause 24. The DAP of clause 15, wherein the portion of the sub-base of the digital model is located ahead of the plurality of gates along a forward direction of travel of the plurality of gates, and receiving the digital model of the portion of the sub-base includes receiving sensing data of the portion of the sub-base from a sensor located ahead of the plurality of gates along the forward direction of travel of the plurality of gates, and creating the digital model of the portion of the sub-base from the sensing data.

Clause 25. The DAP of clause 24, wherein creating the digital model of the portion of the sub-base includes determining a first cell boundary of the at least a first cell relative to a position of the at least a first gate to produce a first gate offset between the at least first cell and the at least first gate.

Clause 26. The DAP of clause 25, wherein creating the digital model of the portion of the sub-base further includes determining a second cell boundary of a second cell relative to a position of a second gate of the plurality of gates that corresponds and aligns to second cell, and determining whether the second cell boundary overlaps at least part of the first cell boundary.

Clause 27. The DAP of clause 15, wherein the at least one processor is further configured to determine an average sub-base height in the at least a first cell, wherein comparing each cell of the plurality of cells to the desired cell of the plurality of desired cells includes determining a cell height difference that is equal to a difference between a finished cell height of the at least first cell and the average sub-base height, and determining whether the cell height difference is less than a threshold value, and the finished cell height is a desired cell height of the first desired cell of the plurality of desired cells of the desired digital model.

Clause 28. The DAP of clause 27, wherein adjusting a position of each gate includes adjusting the first height based on the cell height difference.

Clause 29. A dynamic asphalt paver (DAP) for paving a surface of a sub-base with aggregate material, the DAP comprising: means for receiving a digital model of a portion of the sub-base that is to be paved with the aggregate material, wherein the digital model includes a plurality of cells that correspond to the portion of the sub-base; means for comparing each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion of the sub-base; and means for adjusting a position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model, wherein each gate is configured to independently change the position of the gate relative to the surface of the sub-base and distribute aggregate material on the surface of the sub-base based on the position of the gate.

Clause 30. The DAP of clause 29, wherein the aggregate material is selected from a group consisting of asphalt, concrete, asphalt-concrete, bituminous pitch with sand, and bituminous pitch with gravel.

Clause 31. The DAP of clause 29, wherein the position is selected from a group consisting of a height position relative to the surface of the sub-base, an angled position relative to the surface of the sub-base, a pitched position relative to the surface of the sub-base, and a yaw position relative to the surface of the sub-base.

Clause 32. The DAP of clause 29, further comprising means for distributing the aggregate material on to the surface of the sub-base to produce a pre-compacted surface that includes a combination of the surface of the sub-base and the distributed aggregate material, wherein the desired digital model includes a desired final surface of a final combination of the surface of the sub-base and a final amount of the aggregate material.

Clause 33. The DAP of clause 32, further including compacting the pre-compacted surface to produce an actual final surface.

Clause 34. The DAP of clause 33, further including means for comparing the pre-compacted surface to the desired final surface, means for adjusting the position of each gate in response to means for comparing the pre-compacted surface to the desired final surface.

Clause 35. The DAP of clause 34, further including means for receiving sensor data from a sensor that is configured to measure the pre-compacted surface.

Clause 36. The DAP of clause 33, further including means for comparing the actual final surface to the desired final surface, means for adjusting the position in response to means for comparing the actual final surface to the desired final surface.

Clause 37. The DAP of clause 36, further including means for receiving sensor data from a sensor that is configured to measure the actual final surface.

Clause 38. The DAP of clause 29, wherein the portion of the sub-base of the digital model is located ahead of the plurality of gates along a forward direction of travel of the plurality of gates, and means for receiving the digital model of the portion of the sub-base includes means for receiving sensing data of the portion of the sub-base from a sensor located ahead of the plurality of gates along the forward direction of travel of the plurality of gates, and means for creating the digital model of the portion of the sub-base from the sensing data.

Clause 39. The DAP of clause 38, wherein means for creating the digital model of the portion of the sub-base includes means for determining a first cell boundary of the at least a first cell relative to a position of the at least a first gate to produce a first gate offset between the at least first cell and the at least first gate.

Clause 40. The DAP of clause 39, wherein means for creating the digital model of the portion of the sub-base further includes means for determining a second cell boundary of a second cell relative to a position of a second gate of the plurality of gates that corresponds and aligns to second cell, and means for determining whether the second cell boundary overlaps at least part of the first cell boundary.

Clause 41. The DAP of clause 29, further including means for determining an average sub-base height in the at least a first cell, wherein means for comparing each cell of the plurality of cells to the desired cell of the plurality of desired cells includes means for determining a cell height difference that is equal to a difference between a finished cell height of the at least first cell and the average sub-base height, and means for determining whether the cell height difference is less than a threshold value, and the finished cell height is a desired cell height of the first desired cell of the plurality of desired cells of the desired digital model.

Clause 42. The DAP of clause 41, wherein means for adjusting a position of each gate includes means for adjusting the first height based on the cell height difference.

Clause 13. A non-transitory processor-readable storage medium comprising processor-readable instructions configured to cause one or more processors of a dynamic asphalt paver (DAP) to perform controlling a plurality of gates for dynamically paving a surface of a sub-base with aggregate material, the non-transitory processor-readable storage medium comprising: code for receiving a digital model of a portion of the sub-base that is to be paved with the aggregate material, wherein the digital model includes a plurality of cells that correspond to the portion of the sub-base; code for comparing each cell of the digital model to a corresponding desired cell of a plurality of desired cells of a desired digital model of the portion of the sub-base; and code for adjusting a position of each gate in response to comparing each cell of the digital model to a corresponding desired cell of the desired digital model, wherein each gate is configured to independently change the position of the gate relative to the surface of the sub-base and distribute aggregate material on the surface of the sub-base based on the position of the gate.

Other examples and implementations are within the scope of the disclosure and appended claims. For example, due to the nature of software and computers, functions described above can be implemented using software executed by a processor, hardware, firmware, hardwiring, or a combination of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.

As used herein, the singular forms “a,” “an,” and “the” include the plural forms as well, unless the context clearly indicates otherwise. Thus, reference to a device in the singular (e.g., “a device,” “the device”), including in the claims, includes at least one, i.e., one or more, of such devices (e.g., “a processor” includes at least one processor (e.g., one processor, two processors, etc.), “the processor” includes at least one processor, “a memory” includes at least one memory, “the memory” includes at least one memory, etc.). The phrases “at least one” and “one or more” are used interchangeably and such that “at least one” referred-to object and “one or more” referred-to objects include implementations that have one referred-to object and implementations that have multiple referred-to objects. For example, “at least one processor” and “one or more processors” each includes implementations that have one processor and implementations that have multiple processors.

The terms “comprises,” “comprising,” “includes,” and/or “including,” as used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Also, as used herein, “or” as used in a list of items (possibly prefaced by “at least one of” or prefaced by “one or more of”) indicates a disjunctive list such that, for example, a list of “at least one of A, B, or C,” or a list of “one or more of A, B, or C” or a list of “A or B or C” means A, or B, or C, or AB (A and B), or AC (A and C), or BC (B and C), or ABC (i.e., A and B and C), or combinations with more than one feature (e.g., AA, AAB, ABBC, etc.). Thus, a recitation that an item, e.g., a processor, is configured to perform a function regarding at least one of A or B, or a recitation that an item is configured to perform a function A or a function B, means that the item may be configured to perform the function regarding A, or may be configured to perform the function regarding B, or may be configured to perform the function regarding A and B. For example, a phrase of “a processor configured to measure at least one of A or B” or “a processor configured to measure A or measure B” means that the processor may be configured to measure A (and may or may not be configured to measure B), or may be configured to measure B (and may or may not be configured to measure A), or may be configured to measure A and measure B (and may be configured to select which, or both, of A and B to measure). Similarly, a recitation of a means for measuring at least one of A or B includes means for measuring A (which may or may not be able to measure B), or means for measuring B (and may or may not be configured to measure A), or means for measuring A and B (which may be able to select which, or both, of A and B to measure). As another example, a recitation that an item, e.g., a processor, is configured to at least one of perform function X or perform function Y means that the item may be configured to perform the function X, or may be configured to perform the function Y, or may be configured to perform the function X and to perform the function Y. For example, a phrase of “a processor configured to at least one of measure X or measure Y” means that the processor may be configured to measure X (and may or may not be configured to measure Y), or may be configured to measure Y (and may or may not be configured to measure X), or may be configured to measure X and to measure Y (and may be configured to select which, or both, of X and Y to measure).

As used herein, unless otherwise stated, a statement that a function or operation is “based on” an item or condition means that the function or operation is based on the stated item or condition and may be based on one or more items and/or conditions in addition to the stated item or condition.

Substantial variations may be made in accordance with specific requirements. For example, customized hardware might also be used, and/or particular elements might be implemented in hardware, software (including portable software, such as applets, etc.) executed by a processor, or both. Further, connection to other computing devices such as network input/output devices may be employed. Components, functional or otherwise, shown in the figures and/or discussed herein as being connected or communicating with each other are communicatively coupled unless otherwise noted. That is, they may be directly or indirectly connected to enable communication between them.

The systems and devices discussed above are examples. Various configurations may omit, substitute, or add various procedures or components as appropriate. For instance, features described with respect to certain configurations may be combined in various other configurations. Different aspects and elements of the configurations may be combined in a similar manner. Also, technology evolves and, thus, many of the elements are examples and do not limit the scope of the disclosure or claims.

A wireless communication system is one in which communications are conveyed wirelessly, i.e., by electromagnetic and/or acoustic waves propagating through atmospheric space rather than through a wire or other physical connection, between wireless communication devices. A wireless communication system (also called a wireless communications system, a wireless communication network, or a wireless communications network) may not have all communications transmitted wirelessly, but is configured to have at least some communications transmitted wirelessly. Further, the term “wireless communication device,” or similar term, does not require that the functionality of the device is exclusively, or even primarily, for communication, or that communication using the wireless communication device is exclusively, or even primarily, wireless, or that the device be a mobile device, but indicates that the device includes wireless communication capability (one-way or two-way), e.g., includes at least one radio (each radio being part of a transmitter, receiver, or transceiver) for wireless communication.

Specific details are given in the description herein to provide a thorough understanding of example configurations (including implementations). However, configurations may be practiced without these specific details. For example, well-known circuits, processes, algorithms, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the configurations. The description herein provides example configurations, and does not limit the scope, applicability, or configurations of the claims. Rather, the preceding description of the configurations provides a description for implementing described techniques. Various changes may be made in the function and arrangement of elements.

The terms “processor-readable medium,” “machine-readable medium,” and “computer-readable medium,” as used herein, refer to any medium that participates in providing data that causes a machine to operate in a specific fashion. Using a computing platform, various processor-readable media might be involved in providing instructions/code to processor(s) for execution and/or might be used to store and/or carry such instructions/code (e.g., as signals). In many implementations, a processor-readable medium is a physical and/or tangible storage medium. Such a medium may take many forms, including but not limited to, non-volatile media and volatile media. Non-volatile media include, for example, optical and/or magnetic disks. Volatile media include, without limitation, dynamic memory.

Having described several example configurations, various modifications, alternative constructions, and equivalents may be used. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of the disclosure. Also, a number of operations may be undertaken before, during, or after the above elements are considered. Accordingly, the above description does not bound the scope of the claims.

Unless otherwise indicated, “about” and/or “approximately” as used herein when referring to a measurable value such as an amount, a temporal duration, and the like, encompasses variations of ±20% or ±10%, ±5%, or ±0.1% from the specified value, as appropriate in the context of the systems, devices, circuits, methods, and other implementations described herein. Unless otherwise indicated, “substantially” as used herein when referring to a measurable value such as an amount, a temporal duration, a physical attribute (such as frequency), and the like, also encompasses variations of ±20% or ±10%, ±5%, or ±0.1% from the specified value, as appropriate in the context of the systems, devices, circuits, methods, and other implementations described herein.

A statement that a value exceeds (or is more than or above) a first threshold value is equivalent to a statement that the value meets or exceeds a second threshold value that is slightly greater than the first threshold value, e.g., the second threshold value being one value higher than the first threshold value in the resolution of a computing system. A statement that a value is less than (or is within or below) a first threshold value is equivalent to a statement that the value is less than or equal to a second threshold value that is slightly lower than the first threshold value, e.g., the second threshold value being one value lower than the first threshold value in the resolution of a computing system.

Number	Date	Country
63592091	Oct 2023	US
63592080	Oct 2023	US
63454542	Mar 2023	US
63310314	Feb 2022	US
63310572	Feb 2022	US

	Number	Date	Country
Parent	18919117	Oct 2024	US
Child	18922129		US

	Number	Date	Country
Parent	18616126	Mar 2024	US
Child	18922129		US
Parent	18109848	Feb 2023	US
Child	18616126		US

ASPHALT DELIVERY AND COMPACTION METHOD

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CROSS-REFERENCE TO RELATED APPLICATIONS

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