CONCRETE SCREEDING MACHINE AND SCREEDING PROCESS

Abstract

A screeding machine for screeding uncured concrete includes a base unit positionable at a support surface, and a screed head assembly movably mounted at the base unit. The screed head assembly includes (i) a grade establishing member and (ii) a vibrating member. Elevation actuators are operable to adjust elevation of the screed head assembly responsive at least in part to elevation sensors that sense elevation of respective ends of the screed head assembly. A control system, responsive to signals from the elevation sensors, controls the elevation actuators to set the grade of the uncured concrete. The screed head assembly is positionable at a screeding location and is movable over the uncured concrete in a screeding direction to screed the concrete. A sensor senses the surface of the screeded concrete and generates an output. The output of the sensor is processed to determine a quality level of the screeded concrete surface.

Description

FIELD OF THE INVENTION

The present invention relates generally to an apparatus and method for screeding freshly poured concrete that has been placed over a support surface.

BACKGROUND OF THE INVENTION

Screeding devices or machines are used to level and smooth uncured concrete to a desired grade. Known screeding machines typically include a screed head, which includes a vibrating member and a grade setting device, such as a plow and/or an auger device. Such screeding machines are used to smooth and screed concrete placed over a horizontal support surface, such as a floor of a building or structure.

SUMMARY OF THE INVENTION

A screeding machine for screeding uncured concrete includes a base unit positionable at a support surface and a screed head assembly movably mounted at the base unit via an extendable and retractable mechanism. The screed head assembly includes (i) a grade establishing member and (ii) a vibrating member. Elevation actuators are operable to adjust elevation of the screed head assembly responsive at least in part to elevation sensors that sense elevation of respective ends of the screed head assembly. A control system, responsive to signals from the elevation sensors, controls the elevation actuators to set the grade of the uncured concrete. The screed head assembly is positionable at a screeding location via extension of the extendable and retractable mechanism and is movable over the uncured concrete in the screeding direction from the screeding location via retraction of the extendable and retractable mechanism to screed the concrete. The screeding machine includes a sensor that senses the surface of the screeded concrete and generates an output. The output of the sensor is processed to determine a quality level of the screeded concrete surface. The sensor may comprise, for example, a three dimensional laser scanner, a radar sensor, a laser sensor, or a lidar sensor.

These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a concrete screeding machine;

FIG. 1A is an enlarged perspective view of the region A in FIG. 1;

FIG. 2 is a side elevation view of the concrete screeding machine of FIG. 1;

FIG. 2A is an enlarged view of the region A in FIG. 2;

FIG. 3 is a perspective view of another concrete screeding machine;

FIG. 4 is a side elevation view of the concrete screeding machine of FIG. 3;

FIG. 4A is an enlarged view of the region A in FIG. 4;

FIG. 5 is a perspective view of another concrete screeding machine;

FIG. 5A is an enlarged perspective view of the region A in FIG. 5;

FIG. 6 is a side elevation view of the concrete screeding machine of FIG. 5;

FIG. 6A is an enlarged view of the region A in FIG. 6;

FIG. 7 is a side elevation view of another concrete screeding machine;

FIG. 7A is an enlarged perspective view of the region A in FIG. 7;

FIG. 8 is another side elevation view of the concrete screeding machine of FIG. 7;

FIG. 8A is an enlarged view of the region A in FIG. 8;

FIG. 9 is a side elevation of the screed head with an automated grade checking device;

FIG. 10 is a perspective view of a displayed image with graphic overlays indicating screed head locations when the boom is extended; and

FIG. 11 is another perspective view of the displayed image with graphic overlays, showing the boom in the extended position.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depicted therein, a concrete leveling and screeding machine 10 includes a base unit 12 with an extendable and retractable support or mechanism, such as a boom 14 extending from the base unit and supporting a screeding head or assembly 16 at an outer end thereof (FIG. 1). The base unit 12 is movable or drivable to a targeted area at a support surface with uncured concrete placed thereat, and the base unit may include an upper portion 12a that rotates or pivots about a base portion 12b to swing the boom and screeding head to a targeted location. The base portion 12b includes a plurality of wheels (e.g., four wheels) that are rotatably drivable and steerable to maneuver the base unit 12 to an appropriate screeding position relative to the concrete to be screeded.

When the machine is positioned at the screeding position, the boom 14 is extendable to move the screeding head 16 over the placed, uncured concrete to a starting position. The boom is then retracted to pull the screeding head toward the base unit, while the screeding head 16 operates to establish a desired grade of the concrete surface and smooth or finish or screed the concrete. In the illustrated embodiment, the screeding head includes a grade setting device 18 (such as a roller plow or vibrating plow and/or auger) and a vibrating member 20. The screeding machine may include a plurality of stabilizers 22, which may be extendable and retractable relative to the base portion 12, to support and stabilize the machine on the support surface during the screeding operation. The controller of the screeding machine individually controls the elevation cylinders 26 of the screed head to raise and lower the screed head responsive to signals generated by sensors of the machine, such as, for example, responsive to signals generated by laser receivers 24, which sense a laser reference plane generated at the work site, or such as, for example, 3D target/sonic tracers or any suitable sensor or sensing system that operates to generate an output indicative of the grade or angle or location of the screed head at the concrete.

The screeding machine comprises a pressurized hydraulic fluid system powered by an engine (or electrically operable motor, such as a battery-powered motor) at the base unit that drives the hydraulic system to generate pressurized fluid for controlling the elevation actuators or cylinders 26 and stabilizers 22 and for rotating the upper base portion 12a relative to the lower base portion 12b and for controlling the extension and retraction mechanism (such as the telescoping boom or articulating arm or any other suitable mechanism that operates to extend and retract while supporting the screed head) and for driving and steering of the wheels of the base unit. The screeding machine 10 and the screeding head or assembly 16 may utilize aspects of the screeding machines and screeding heads described in U.S. Pat. Nos. 4,655,633; 4,930,935; 6,227,761; 6,976,805; 7,044,681; 7,121,762; 7,175,363; 7,195,423; 7,396,186; 7,850,396; 8,038,366; 9,835,610; 10,060,900; 10,190,268 and/or 10,895,045, and/or U.S. Publication Nos. US-2010-0196096 and/or US-2007-0116520, which are all hereby incorporated herein by reference in their entireties.

During or after the machine has screeded the concrete surface, the operator or the screeding machine or the screeding system may determine the quality of the screeded concrete surface. For example, the machine may include one or more sensors at or near the screed head that capture sensor data representative of the screeded concrete surface, whereby the captured sensor data may be processed to determine flatness or levelness or smoothness or consistency of the surface of the screeded concrete, as discussed below.

The machine or system may monitor operation of the machine, such as by monitoring and adjusting the machine settings based on pass performance vs grade requirement (e.g., boom and valve speeds, machine attitude, etc.), and providing feedback on pass performance vs. grade requirement (touchdowns, laser alerts, column block, head rotate, machine rotate, etc.). The machine or system may also or otherwise monitor the floor quality, such as by measuring the screeded concrete vs grade requirement, such as via scanning/measuring results in real-time and recording/sharing the results with the operator so the operator can react and adjust the machine operation.

The equipment monitoring may include monitoring engine/hydraulic gauges, monitoring head settings, maintenance, tracking location, troubleshooting issues (faster customer support resolution), changing software settings, providing feedback on machine performance, and/or providing updates to machine software.

The machine may be monitored to determine machine attitude improvements, whereby proper machine attitude (pitch) improves screed accuracy. The machine or system may set elevation control speeds based on boom retract speeds, so as to correlate the boom retract speed for best performance. For example, when the boom is retracted at a faster speed, the elevation cylinder travel speeds are increased in order to maintain the screed head on grade, and when the boom retraction speed is reduced, the elevation cylinder travel speeds are also reduced so the screed head does not overshoot its grade control as the boom and screed head are retracted. The machine or system may incorporate aspects of the floor levelness systems into the base screed, including monitoring for column block and monitoring screed head touch-down quality and auto-setting machine attitude (pitch), such as by utilizing aspects of the machines and systems described in U.S. Pat. Nos. 10,895,045; 10,060,900; 9,835,610 and/or 7,044,681, which are hereby incorporated herein by reference in their entireties.

The machine or system may utilize one or more scanners or sensors, such as a radar sensor, a lidar sensor, a forward-looking infrared (FLIR) sensor, a three dimensional laser scanner (e.g., a FARO/Trimble scanner), and/or the like. Optionally, the information gathered via the sensors capturing sensor data and a processor processing the captured sensor data, may be displayed for viewing by the operator. For example, the information may be displayed at a display screen or head-up display at the machine or a virtual display at the machine or at goggles worn by the operator. The display may be used for displaying set up checklists, startup checklists, troubleshooting checklists, and/or the like. For rock tamping, 3D profiling and broom and cure applications, operators could view break lines. Optionally, such a head up display and goggles may be used for training operators.

In the illustrated embodiment of FIGS. 1-2A, the screeding machine has a plurality of radar sensors 28 (or may include a plurality of lidar sensors or other suitable ranging sensor) disposed along the screed head (such as at or near the elevation sensor masts or such as inboard of the elevation sensors to avoid scanning or sensing areas that the plow or auger does not cut) and sensing downward toward the concrete surface that has been screeded by the screed head (see FIG. 2A). The sensor measures the grade and the system alerts the operator when it exceeds a threshold. The radar device is disposed at the head and senses the concrete surface for determining trends as the screed head moves along and screeds the concrete surface. The system may generate warning lights when the sensor senses that the surface is above or below selected settings.

The sensor may be positioned at the screed head to screed the region in front of the plow to determine the amount of concrete in front of the plow. The screed typically works better with concrete on the plow so the operator knows the placement is not low. At the end of a screeding pass if there is no concrete in front of the plow, the vibrator can cause the concrete to sluff off (i.e., to slide towards the screed, which brings the screeded elevation below required grade). In such a situation, the screed head elevation can be perfect, but the concrete surface elevation may be low. The distance sensor (e.g., radar sensor or lidar sensor) may be mounted at the vibrator side of the screed head or at the lower head.

For example, the distance sensor may be at the vibrator side of the screed head. If the placement is low, the screed head can run over it and leave a surface that looks good, but will be low. Concerns may also arise where if the concrete is wet (high slump) the auger is not as effective at cutting and holding grade so there may be more blow by which raises the final grade left behind the vibrator. By determining the distance to the concrete behind the vibrator, an operator can be alerted to such deviations and can adjust the screeding accordingly.

Optionally, for example, the distance sensor may be mounted on the lower head and reads or senses the distance to the top of the concrete in front of the plow. When the sensor senses a larger distance (low concrete), the system will alert the operator of a low concrete situation.

The distance sensor may also determine when there are slump changes. For example, if the initial grade is set on a 6 inch slump, and a load of 3 inch slump is delivered, the screeded elevation will be lower. The distance sensor on the head can read or sense or determine this change and alert the operator.

In the illustrated embodiment, the radar device is mounted on the lower head and takes readings as the machine is screeding. The system can capture these readings and save them, and may generate an alert or warning when the reading is beyond some preset tolerance. The system may keep an average tolerance above and below grade to create a score for every screeding pass. An additional feature would be to determine and store the location of every screeding pass.

During operation of the screeding machine, the measured data may be stored in the screed data. When a screeding pass is re-screeded, the first pass is eliminated and replaced with the second pass. The accuracy of each pass can be tracked and saved to be able to review later. For example, the system may monitor the screeding process and floor and may display screed pass profiles, and may save the profile tracks of multiple passes for review while the machine is operating or at a later time or date.

In the illustrated embodiment of FIGS. 3-4A, the screeding machine has a lidar sensor or lidar meter 30 (or may include one or more laser sensors or radar sensors or other suitable ranging sensor) disposed at the laser receiver mast or inboard of the laser receivers and sensing downward toward the concrete surface that has been screeded by the screed head (see FIG. 4A). The sensor reads or senses the accuracy of the concrete surface and the system (responsive to the sensor output) adjusts the grade sensor the amount required to bring the head to grade. The operator and screeding machine may then make another screeding pass and read the accuracy of the surface and adjust the grade sensor as necessary. The feedback or readings may be provided at the end of a screed pass or in real time while the operator is performing the screed pass. This feature may be turned on and off as necessary or desired. The sensor is a very accurate measuring device (e.g., a lidar sensor or radar sensor). After the screeding pass is complete, the operator can move (e.g., extend the boom) the machine back out over the previously screeded pass with the head above the concrete (e.g., one inch above grade). When the head is stable and located at a desired location to take a grade reading, the system may record the height of the concrete surface. From that measurement the system can automatically adjust the grade setting in the control system. Typically, the grade can be checked at both sides of the head. The machine can then make the next pass and the grade can be rechecked to see if is accurate before proceeding until another grade check is necessary.

Optionally, the machine may include an automated grade checking device or system, whereby the grade of the screeded concrete surface may be checked (e.g., may be episodically or periodically checked during a screed pass, such as via laser sensors) to determine if the concrete surface is screeded to the right grade. For example, and such as shown in FIG. 9, an automated grade rod 36 may be attached at the screed head or elevation cylinders and may be episodically or periodically lowered to engage the concrete surface to determine the actual grade of the concrete surface relative to the laser reference plane. In the illustrated embodiment, the grade rod 36 is pivotally mounted at the machine (e.g., via a gimbal or other suitable pivoting linkage or mechanism) and may be lowered so that a foot or base or pad of the grade rod engages the screeded concrete surface (behind the screed head). The rod or pole may be telescoping and graduated for height setting, with a laser receiving device or laser receiver attached at or near an upper end of the rod. The laser receiver receives or senses the laser beam or laser reference plane and outputs the distance the sensed beam is from the center of the laser receiver.

Thus, the laser receiver of the grade rod senses the laser plane and the system can determine if the actual grade of the concrete surface is higher or lower than the desired or set grade. The laser receiver of the grade rod generates an output that is communicated (e.g., wirelessly communicated) to a receiver of the machine, whereby the screeding machine may adjust the elevation actuators to accommodate any determined offset of the actual grade compared to the set grade. In other words, the laser receiving device may communicate to the screeding machine's control system so that the distance error can be transmitted to the machine and the elevation setpoint can be changed based on the error amount. For example, if the actual grade is determined to be lower than the target, the machine or system may adjust the elevation actuators to raise upward that amount so that the screeded concrete surface is at the set grade. The grade rod may be episodically lowered down automatically (e.g., every 10 feet or other suitable distance, or every 10 seconds or other suitable time period), or may be lowered responsive to an operator input, to determine the actual grade at multiple locations along the screed pass.

In the illustrated embodiment of FIGS. 5-6A, the screeding machine has a three dimensional (3D) laser scanner 32 (e.g., a Trimble scanner or a FARO scanner, such as a FARO scanner commercially available from FARO Technologies of Lake Mary, FL) disposed at the boom (near the screed head) and sensing downward toward the concrete surface behind the screed head that has been screeded by the screed head (see FIG. 4A). The sensor scans the concrete surface during and/or after the screeding pass is complete and shares the accuracy and/or heat map on a display to the screed operator (optionally while the operator is operating the machine or at a later time after the screeding pass is completed). Optionally, warning lights or other alerts (audible, haptic, visual) may be generated when the scan determines the concrete surface is above or below selected parameters. The scanner is mounted high enough so that it can scan over the screed head to scan the screeded concrete surface. The operator can simply run the machine (pull levers) and the system and machine (responsive to the scanner) auto-adapts.

In order for the system to operate properly, the sensors and system need to be setup and calibrated. The machine may learn from the actual screeding to adjust the settings to optimize itself for future screeding passes. For example, the system may include a machine attitude sensor. Responsive to the sensor, and rather than have the user null the sensor in for/aft and right/left orientation (i.e., during set up of the machine, the user nulls or zeros out the sensors over a known elevation benchmark), the machine can recognize issues following a few screeding passes to correct itself and adjust parameters to get it right on the next screeding pass.

For example, if the grade is being checked with the scanner and the average grade shows ⅛ high, then the system adjusts the grade on the receiver. If the machine attitude is too far forward, the head will pull up too quickly. This will show in the laser strike data (it will look like the valve speed is too slow). However, if there is a machine attitude sensor that says the attitude is ideal (e.g., a one percent forward slope), and the valve currents are within a normal range, it would suggest there is a problem. The system may also need to receive inputs pertaining to boom retract speed, but if that is correct, and strike data still shows the head pulling up too far out of the laser receiver dead band, it would be a strong indicator that the machine attitude sensor is not actually correct. The machine could then automatically adjust the null point of the sensor to compensate for this to see if the laser strike data improves.

Optionally, the sensor senses (and the system measures or determines) the grade of the screeded concrete surface and alerts the operator when it exceeds some threshold.

As shown in FIGS. 5-6A, the scanner may be mounted at the upper frame of the machine. Optionally, the scanner may be gimbal-mounted to reduce the movement/vibration from the machine. The scanner may scan faster and the processor may process scanner data faster by taking less scan points or processing less scan points, such that the scanner may provide close to real-time alerts and adjustments during the screeding pass. The system may also generate a pass quality by creating an average above and below grade to create a score for every screeding pass. An additional feature may include determining and storing the location of every screeding pass. When a pass is re-screeded, the first pass is eliminated and replaced with the second pass. The accuracy of each pass is tracked and saved to be able to review later.

The sensor and processor may detect small imperfections at the surface, such as may be caused when the screed head drags rocks across the surface and the cream does not fill in the grooves and seal up the surface. This may occur more frequently when the mud is stiffer or at a lower slump. The system may detect the appearance of the surface with the scanner(s) or camera(s) or sensor(s), and based on processing of sensor data captured by the scanner(s) or camera(s) or sensor(s), the system may determine a quality level of the floor and generate an alert when the quality level is below a threshold level (i.e., indicative of a poor quality surface).

The outputs of the devices may be used to generate displays for viewing by the operator before, during and/or after the screeding pass(es). The display device may comprise a display device at the screeding machine, or a tablet or smart or artificial intelligence (AI) glasses or goggles (that display a virtual display of information for viewing by the person wearing the goggles). A score may be created for each screeding pass, and the scores may be stored to get an average score (such as for training or for improving the floor quality). The operator or a supervisor or trainer may review the displayed results at a display screen remote from the machine, such as at an office or remote location, either in real-time (while the machine is operating) or at a later time or date.

For example, when training an operator, each screeding pass may be scored or rated, and the operator can see when improvements to the score are made during subsequent screeding passes. The system may have an “AUTO” switch that is turned on to create these automated features to work. The machine can operate in either mode. When training an operator, the system may score the pass quality with it in manual mode and then the operator may flip a switch to be able to run in “AUTO” mode and score that pass. The improved score would show the benefit of the “AUTO” mode.

Optionally, the screeding machine may include a camera that views forward of the machine and of the screed head, and a video display screen may display video images from the camera of the scene in front of the machine and screed head. For example, the camera may be disposed at the screed head and view away from the base unit, or the camera may be disposed at the base unit and view toward the screed head. Optionally, and such as shown in FIGS. 10 and 11, graphic overlays may be generated on the displayed video images to show where the boom and the screed head will reach when the boom is fully extended. For example, a line or set of lines 38 (which may be displayed in a selected color or pattern) may indicate to the operator where the vibrator trailing edge and the vibrator left/right edges may be when the boom is extended (FIG. 11 shows the boom extended), while another line or set of lines 40 (which may be displayed in another selected color or pattern) may indicate to the operator where the plow reach is and where the plow left/right edges may be when the boom is extended. Such a display and graphic overlays will assist in showing the operator where the screed head will be to see if the screed head will be close to wall or will reach the last pass area and to make sure the screed head does not extend into or contact a wall or column or other object present at the support surface. For new operators, who may have trouble judging distance that the boom can extend the head to, this helps avoid booming out and discovering that the boom cannot reach the previously screeded concrete, and then having to retract the boom, drive closer, and then extend the boom again. To save time, the display screen can overlay head reach (i.e. lines) over the forward facing video feed and the operator can line up the machine using the overlay to ensure they can extend the boom to the necessary or target distance.

Another camera may capture images ahead of the screed head during the screeding pass (i.e., the camera may be mounted at the screed head and view toward the base unit, or the same camera discussed above may be disposed at the base unit and view toward the screed head). Video images captured by that camera may be displayed during the screeding pass, and graphic overlays may also be generated at the video display during the screed pass to show the projected path of travel of the screed head during the screed pass to indicate to the operator if the screed head is moving toward or is about to collide with an object or column.

The graphic overlays may be electronically generated and shown at the video display screen as colored lines, which may change from green (if there is no object or obstruction present in the extension or retraction path of the screed head) to red (if there is an object or obstruction detected in the extension or retraction path of the screed head). Optionally, the graphic overlays may vary in intensity or color or may be intermittently flashed on and off to alert the operator if an object or obstruction is detected in the path of travel of the screed head. The object or obstruction may be detected via image processing of image data captured by the camera or via one or more other sensors of the screeding machine.

As shown in FIGS. 7-8A, the screeding machine may include an angle sensor 34 at the base portion of the machine to detect the attitude or orientation or levelness of the base portion (e.g., after the stabilizers have been lowered and the machine is in position to extend the boom to perform a screeding pass). The angle sensor is a multi-axis sensor that senses the angle or attitude or orientation of the base portion of the machine relative to a horizontal plane. The system may, responsive to an output of the angle sensor, extend/retract one or more of the stabilizers to level or set the base portion at the desired or appropriate orientation. For example (such as responsive to a user actuating an input or button or switch), the stabilizers may be actuated to extend so that the stabilizers support the machine at the support surface, and the rear stabilizers may be extended an additional amount to set the machine attitude at a set amount leaning forward to consistently set the attitude or tilt or angle of the boom as the boom is retracted during a screeding pass. The system may monitor outputs from the angle sensor and may adjust one or more stabilizers as the boom is extended and retracted, in order to counter any shifts in attitude or orientation or pitch of the base portion with the boom extended. Operators can attempt to do this manually but are inconsistent which affects the quality of the floor. Optionally, the front boom rollers (that rollingly support the boom as it extends and retracts) at the lower frame or base unit and/or the boom may be adjustable to adjust the attitude of the boom relative to the base unit and support surface as the boom extends and retracts.

Thus, the machine or system monitors operation of the machine and monitors the floor quality of the screeded concrete surface. The machine may include machine attitude for the control system, where pressure transducers may be disposed at the stabilizers so that the stabilizers stop when they hit the ground and adjust to set the orientation of the machine. The machine or system may include an adjustment mechanism for boom orientation. The machine or system may lock out stabilizer movement when the boom is extended (such as responsive to a boom position sensor).

The machine may also or otherwise control elevation speeds, where the speeds during screeding passes are stored and graphed or evaluated at different locations and at different boom retract speeds. The control system or algorithms may be programmed to control the elevation speeds and to adjust to the boom retract speeds.

The machine may also track and monitor and evaluate screed landings, and may limit (or alert the operator) rotating when in the column block mode.

As discussed above, the machine or system may include a sensing device (e.g., radar sensor, laser, lidar sensor, etc.) that is mounted at the screed head and used to measure or sense the screeded concrete surface to find aberrations or trends (e.g., trends of plow loads, sluff off, blow by, tearing, chatter, etc.). The machine or system may include a scanner (e.g., a three dimensional laser scanner) that accurately measures the concrete surface and that may generate a heat map of the surface. The scanners may be used intermittently or episodically to increase response times and processing of data, in order to provide faster results to the operator. The system may alert the operator of issues (e.g., when the system determines that the surface is beyond a tolerance value) sensed via a visual or audible or haptic alert at the machine or may display information to the operator on a tablet or smart goggles.

The screeding machine 10 may comprise a remotely controlled machine (i.e., no operator station on the base of the machine), such that an operator can control the extension and retraction of the boom and the rotation of the screed head and the elevation of the screed head and actuation of the roller plow and vibrator, etc., via a remote control device separate and remote from the machine. The remote control device may wirelessly communicate with a controller or control system of the machine via any suitable means, such as radio communication or other wireless communications. The remote control may also include remote control of the base unit to drive and steer the wheels (such as four wheel steering, two wheel steering and/or crab steering or the like) of the base unit to position the machine at a screeding location. For example, the control system of the machine may be (i) autonomous, (ii) controllable via remote diagnostics (dial up to the machine controller), and/or (iii) operable responsive to a remote controller usable by an operator remote from the screeding machine.

Therefore, the system or machine or method for screeding uncured concrete a screed head assembly, a pair of elevation sensors disposed at opposite ends of the screed head assembly, and a control. The screed head assembly is moved over the concrete surface via the screeding machine to screed the concrete surface. The elevation sensors or laser receivers sense an elevation of the respective end region of the screed head assembly relative to a laser-generated reference plane established above the concrete surface, and the elevation cylinders operate to adjust the height of the screed head responsive to the laser signal received by the laser receivers to screed the concrete at the appropriate grade. Although shown and described as having the elevation actuators or cylinders disposed at and attached at the ends of the screed head, the screeding machine may include other types of elevation actuators, such as actuators or cylinders disposed at the extendable and retractable mechanism or boom or disposed at the base unit or the like.

The machine or system includes one or more sensors for sensing floor parameters, such as height, flatness, and trends in the floor, and/or the machine or system may include one or more sensors for monitoring the machine during screeding. The outputs of the sensors are processed to determine trends or issues with the floor and/or to determine machine operation, whereby an alert may be generated to the operator when floor quality issues are detected. The system may control or adjust operation of the machine responsive to determined floor quality issues. For example, the machine or system may adjust the elevation cylinder control speeds, boom retract speed and/or machine attitude based on the floor elevation accuracy reading and trend data. The system or machine thus receives feedback from the actual floor quality, and thus can determine and accommodate for sluff-off at the end of the pass, a low spot in the placed concrete at the plow, blow-by or any of the other aberrations in the actual screeded concrete surface or floor. The machine may monitor the screeding process and floor and advise (such as via display of information) on surface quality, such as from a consolidation/sealing aspect.

Changes and modifications to the specifically described embodiments can be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law.

Claims

1. A screeding machine for screeding uncured concrete, the screeding machine comprising: a base unit positionable at a support surface;a screed head assembly movably mounted at the base unit, wherein the screed head assembly comprises (i) a grade establishing member and (ii) a vibrating member;elevation actuators operable to adjust elevation of the screed head assembly responsive at least in part to elevation sensors that sense elevation of respective end regions of the screed head assembly;a control system, wherein the control system, responsive to signals from the elevation sensors, controls the elevation actuators to set the grade of the uncured concrete;wherein the screed head assembly is positionable at a screeding location and is movable over the uncured concrete in a screeding direction from the screeding location to screed the concrete;a sensor that senses the surface of the screeded concrete and generates an output; andwherein the output of the sensor is processed to determine a quality level of the screeded concrete surface.

2. The screeding machine of claim 1, wherein the sensor comprises a three dimensional laser scanner.

3. The screeding machine of claim 2, wherein the three dimensional laser scanner scans the screeded concrete surface and provides one selected from the group consisting of (i) an accuracy map on a display for viewing by an operator of the screeding machine and (ii) a heat map on the display for viewing by the operator of the screeding machine.

4. The screeding machine of claim 2, wherein the three dimensional laser scanner scans the screeded concrete surface and generates an alert to an operator of the screeding machine when the three dimensional laser scanner determines that the screeded concrete surface is above or below selected parameters.

5. The screeding machine of claim 2, wherein the three dimensional laser scanner is gimbal-mounted at the screeding machine.

6. The screeding machine of claim 1, wherein the sensor comprises a ranging sensor and the output is indicative of height of the ranging sensor above the screeded concrete surface.

7. The screeding machine of claim 6, wherein the screeding machine generates an alert responsive to determination that the height is more than a threshold distance from a target height.

8. The screeding machine of claim 6, wherein the ranging sensor comprises a plurality of ranging sensors disposed along the screed head assembly.

9. The screeding machine of claim 6, wherein the ranging sensor comprises one selected from the group consisting of (i) a radar sensor, (ii) a laser sensor, and (iii) a lidar sensor.

10. The screeding machine of claim 6, wherein the ranging sensor is disposed at or near the elevation sensors.

11. The screeding machine of claim 6, wherein the ranging sensor senses the accuracy of the screeded concrete surface, and wherein the screeding machine, responsive to the sensor output, adjusts the elevation sensors to bring the screed head assembly to the desired grade.

12. The screeding machine of claim 1, wherein the outputs of the sensor are used to generate displays at a display device for viewing by an operator by the screeding machine before a screeding pass, during the screeding pass or after the screeding pass.

13. The screeding machine of claim 12, wherein the display device comprises at least one selected from the group consisting of (i) a display device at the screeding machine, (ii) a hand-held tablet, and (iii) smart glasses.

14. The screeding machine of claim 12, wherein the display displays a rating score to the operator that is indicative of quality of one or more aspects of the screeding pass.

15. The screeding machine of claim 14, wherein, if the displayed score is below a threshold score, the screeding machine alerts the operator.

16. The screeding machine of claim 14, wherein, if the displayed score is below a threshold score, the screeding machine alerts the operator and requires the operator to acknowledge the out of tolerance score in order to continue screeding.

17. The screeding machine of claim 1, further comprising a video display screen operable to display video images derived from image data captured by a camera of the screeding machine, wherein the displayed video images are viewable by the operator while operating the screeding machine.

18. The screeding machine of claim 17, wherein graphic overlays are generated at the video display screen to assist the operator in extending and retracting the screed head relative to the base unit.

19. The screeding machine of claim 18, wherein the graphic overlays include a graphic overlay that is indicative of an extended position of the screed head.

20. The screeding machine of claim 1, wherein, based at least in part on the output of the sensor, a score is created for each screeding pass, and scores are stored over multiple screeding passes to get an average score.

21. The screeding machine of claim 20, wherein the screeding machine stores the location of each pass and corresponding score.

22. The screeding machine of claim 1, wherein the screeding machine comprises a wheeled unit that is moved through the concrete during a screeding pass.

23. The screeding machine of claim 1, wherein the elevation sensors comprise laser receivers disposed at respective elevation actuators for sensing an elevation of the respective end region of the screed head assembly relative to a laser generated reference plane.

24. The screeding machine of claim 23, wherein the screeding machine, based at least in part on the sensed elevation, adjusts the elevation in the actuators when selected.

25. The screeding machine of claim 1, wherein the control system is one selected from the group consisting of (i) autonomous, (ii) controllable via remote diagnostics, and (iii) operable responsive to a remote controller usable by an operator remote from the screeding machine.

26. The screeding machine of claim 1, wherein the grade establishing member comprises one selected from the group consisting of (i) a roller plow, (ii) a vibrating plow, (iii) an auger, and (iv) a non-vibrating plow.

27. The screeding machine of claim 1, wherein the determined quality level of the screeded concrete surface comprises an elevation accuracy of the screeded concrete surface.

28. The screeding machine of claim 1, wherein the screed head assembly is movably mounted at the base unit via an extendable and retractable mechanism, and wherein the screed head assembly is positionable at the screeding location via extension of the extendable and retractable mechanism and is movable over the uncured concrete in the screeding direction from the screeding location via retraction of the extendable and retractable mechanism to screed the concrete.

29. The screeding machine of claim 1, wherein the elevation actuators are disposed at the screed head.

30. The screeding machine of claim 1, wherein the elevation actuators are disposed at the base unit.

31. The screeding machine of claim 1, further comprising an angle sensor disposed at the base unit and operable to sense tilt or pitch of the base unit relative to a horizontal plane.

32. The screeding machine of claim 31, wherein the screeding machine is operable to adjust the tilt or pitch of the base unit responsive to an output of the angle sensor.

33. The screeding machine of claim 32, wherein the base unit comprises a plurality of stabilizers that are extendable and retractable responsive to the output of the angle sensor to adjust the tilt or pitch of the base unit.

34. The screeding machine of claim 1, wherein the screeding machine is operable to adjust the elevation actuator control speeds responsive to the output of the sensor.

35. The screeding machine of claim 1, wherein the screeding machine is operable to adjust moving speed of the screed head during a screed pass responsive to the output of the sensor.

36. The screeding machine of claim 35, wherein the screed head assembly is movably mounted at the base unit via an extendable and retractable mechanism, and wherein the screed head assembly is positionable at the screeding location via extension of the extendable and retractable mechanism and is movable over the uncured concrete in the screeding direction from the screeding location via retraction of the extendable and retractable mechanism to screed the concrete, and wherein the screeding machine is operable to adjust a retraction speed of the extendable and retractable mechanism to adjust the moving speed of the screed head during the screed pass.

37. The screeding machine of claim 1, wherein the screeding machine is operable to adjust the elevation actuator control speeds based at least in part on the moving speed of the screed head during the screed pass.

38. The screeding machine of claim 1, wherein the screeding machine is operable to adjust machine attitude responsive to the output of the sensor.

39. The screeding machine of claim 1, wherein the sensor is disposed at a grade checking rod that is episodically engaged with the screeded concrete surface to determine actual grade of the screeded concrete surface relative to a target grade set by the elevation actuators and elevation sensors.

40. The screeding machine of claim 1, further comprising a laser sensor that episodically determines actual grade of the screeded concrete surface.

41. A method for screeding uncured concrete, the method comprising: providing a screeding machine having a base unit and a screed head assembly movably mounted at the base unit, wherein the screed head assembly comprises (i) a grade establishing member and (ii) a vibrating member;adjusting elevation of the screed head assembly responsive at least in part to elevation sensors that sense elevation of respective end regions of the screed head assembly to set the grade of the uncured concrete;positioning the screed head assembly at a screeding location and moving the screed head assembly over the uncured concrete in a screeding direction from the screeding location to screed the concrete;sensing the surface of the screeded concrete via a sensor of the screeding machine; anddetermining a quality level of the screeded concrete surface via processing outputs of the sensor.

42. The method of claim 41, wherein the sensor comprises a three dimensional laser scanner.

43. The method of claim 42, wherein the three dimensional laser scanner scans the screeded concrete surface and provides an accuracy and/or heat map on a display for viewing by an operator of the screeding machine.

44. The method of claim 42, wherein the three dimensional laser scanner scans the screeded concrete surface, and wherein the method further comprises generating an alert to an operator of the screeding machine when the three dimensional laser scanner determines that the screeded concrete surface is above or below selected parameters.

45. The method of claim 41, wherein the sensor comprises a ranging sensor and the output of the sensor is indicative of height of the ranging sensor above the screeded concrete surface.

46. The method of claim 45, wherein the screeding machine generates an alert responsive to determination that the height is more than a threshold distance from a target height.

47. The method of claim 45, wherein the ranging sensor comprises one selected from the group consisting of (i) a radar sensor, (ii) a laser sensor, and (iii) a lidar sensor.

48. The method of claim 45, wherein the ranging sensor senses the accuracy of the screeded concrete surface, and wherein the screeding machine, responsive to the sensor output, adjusts the elevation sensors to bring the screed head assembly to the desired grade.

49. The method of claim 41, wherein the outputs of the sensor are used to generate displays at a display device for viewing by an operator by the screeding machine before a screeding pass, during the screeding pass or after the screeding pass.

50. The method of claim 49, wherein the display displays a rating score to the operator that is indicative of quality of one or more aspects of the screeding pass, and wherein the operator is alerted when if the displayed score is below a threshold score.

51. The method of claim 41, further comprising a video display screen operable to display video images derived from image data captured by a camera of the screeding machine, wherein the method comprises displaying video images that are viewable by the operator while operating the screeding machine.

52. The method of claim 51, further comprising displaying graphic overlays at the displayed video images at the video display screen to assist the operator in extending and retracting the screed head relative to the base unit, wherein the graphic overlays include a graphic overlay that is indicative of an extended position of the screed head.

53. The method of claim 41, wherein the determined quality level of the screeded concrete surface comprises an elevation accuracy of the screeded concrete surface.

54. The method of claim 41, wherein the screed head assembly is movably mounted at the base unit via an extendable and retractable mechanism, and wherein the screed head assembly is positioned at the screeding location via extending the extendable and retractable mechanism and wherein the screed head assembly is moved over the uncured concrete in the screeding direction from the screeding location via retraction of the extendable and retractable mechanism to screed the concrete.

55. The method of claim 41, further comprising an angle sensor disposed at the base unit and operable to sense tilt or pitch of the base unit relative to a horizontal plane, and wherein the screeding machine is operable to adjust the tilt or pitch of the base unit responsive to an output of the angle sensor.

56. The method of claim 41, further comprising adjusting the elevation actuator control speeds responsive to the output of the sensor.

57. The method of claim 41, further comprising adjusting moving speed of the screed head during a screed pass responsive to the output of the sensor.

58. The method of claim 57, wherein the screed head assembly is movably mounted at the base unit via an extendable and retractable mechanism, and wherein the screed head assembly is positioned at the screeding location via extending the extendable and retractable mechanism, and wherein the screed head assembly is moved over the uncured concrete in the screeding direction from the screeding location via retracting the extendable and retractable mechanism to screed the concrete, and wherein the method comprises adjusting a retraction speed of the extendable and retractable mechanism to adjust the moving speed of the screed head during the screed pass.

59. The method of claim 41, further comprising adjusting the elevation actuator control speeds based at least in part on the moving speed of the screed head during the screed pass.

60. The method of claim 41, further comprising adjusting machine attitude responsive to the output of the sensor.

61. The method of claim 41, wherein the sensor is disposed at a grade checking rod that is episodically engaged with the screeded concrete surface to determine actual grade of the screeded concrete surface relative to a target grade set by the elevation sensors.

62. The method of claim 41, further comprising a laser sensor that episodically determines actual grade of the screeded concrete surface.