Variable vibratory mechanism

Abstract

A vibratory mechanism having a first eccentric weight coaxially rotatable with a second eccentric weight and a clutch operatively connecting the first and second eccentric weights. The clutch allows for co-rotation of the first and second eccentric weights and the ability to index the first eccentric weight relative to second eccentric weight to vary the vibrational amplitude.

Description

TECHNICAL FIELD

[0001] This invention relates generally to a vibratory compactor machines and, more particularly, to an infinitely variable amplitude and frequency vibratory mechanism.

BACKGROUND

[0002] Vibratory compactor machines are commonly employed for compacting freshly laid asphalt, soil, and other compactable materials. For example these compactor machines may include plate type compactors or rotating drum compactors with one or more drums. The drum type compactor functions to compact the material over which the machine is driven. In order to compact the material the drum assembly includes a vibratory mechanism including inner and outer eccentric weights arranged on a rotatable shaft within the interior cavity of the drum, for inducing vibrations on the drum.

[0003] The amplitude and frequency of the vibratory forces determine the degree of compaction of the material, and the speed and efficiency of the compaction process. The amplitude of the vibration forces is changed by altering the position of a pair of weights with respect to each other. The frequency of the vibration forces is managed by controlling the speed of a drive motor in the compactor drum.

[0004] The required amplitude of the vibration force may vary depending on the characteristics of the material being compacted. For instance, high amplitude works best on thick lifts or harsh mixes, while low amplitude works best on thin lifts and soft materials. Amplitude variation is important because different materials require different levels of compaction. Moreover, a single compacting process may require different amplitude levels because higher amplitude may be required at the beginning of the process, and the amplitude may be gradually lowered as the process is completed.

[0005] Conventional vibratory compactor machines are problematic in that the amplitude and frequency of the vibration force can only be set to certain predetermined levels, or the mechanisms for adjusting the vibration amplitude are complex. One such vibratory mechanism is disclosed in U.S. Pat. No. 4,350,460 issued to Lynn A. Schmelzer et al. on Sep. 21, 1982 and assigned to the Hyster Company.

[0006] The present invention is directed to overcome one or more of the problems as set forth above.

SUMMARY OF THE INVENTION

[0007] In one aspect of the invention, a vibratory mechanism is provided that includes an inner eccentric weight rotatably supported within a housing. An outer eccentric weight is rotatably supported and positioned about the inner eccentric weight. A clutch operatively connects the inner and outer eccentric weights.

[0008] According to another aspect of the invention, a method for controlling a vibration amplitude of a vibratory compactor includes abruptly changing a speed of one of an inner and outer eccentric weights to cause a clutch to slip, thereby causing inner and outer eccentric weights to move farther apart or closer together to change the vibration amplitude.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a side elevational view of a work machine embodying the present invention;

[0010] FIG. 2 shows an axial cross section view taken along line 2-2 through a compacting drum of the work machine of FIG. 1 embodying the present invention;

[0011] FIG. 3 is an enlarged sectional view of the vibrator pod shown in FIG. 2; and

[0012] FIG. 4 is a system diagram.

DETAILED DESCRIPTION

[0013] A work machine 10, for increasing the density of a compactable material 12 or mat such as soil, gravel, or bituminous mixtures, an example of which is shown in FIG. 1. The work machine 10 is for example, a double drum vibratory compactor, having a first compacting drum 14 and a second compacting drum 16 rotatably mounted on a main frame 18. The main frame 18 also supports an engine 20 that has a first and a second power source 22,24 conventionally connected thereto. Variable displacement fluid pumps or electrical generators can be used as interchangeable alternatives for the first and second power sources 22,24 without departing from the present invention.

[0014] The first compacting drum 14 includes a first vibratory mechanism 26 that is operatively connected to a first motor 28. The second compacting drum 16 includes a second vibratory mechanism 30 that is operatively connected to a second motor 32. The first and second motors 28,32 are operatively connected, as by fluid conduits and control valves or electrical conductors and controls to the first power source 22. It should be understood that the first and second compacting drums 14,16 could have more than one vibratory mechanism per drum.

[0015] In as much as, the first compacting drum 14 and the second compacting drum 16 are structurally and operatively similar. The description, construction and elements comprising the first compacting drum 14, which will now be discussed in detail and as shown in FIG. 2, applies equally to the second compacting drum 16. Rubber mounts 36 vibrationally isolate the compacting drum 14 from the main frame 18. The first compacting drum 14 includes a propel motor 40 that is connected to the second power source 24. For example, the propel motor 40 is connected to the main frame 18 and operatively connected to the first compacting drum 14 in a known manner. The second power source 24 supplies a pressurized operation fluid or electrical current, to propel motor 40 for propelling the work machine 10.

[0016] Referring now to FIG. 2, the vibratory mechanism 26 is contained within a housing 46 that is coaxially supported within the first compacting drum 26 in a known manner. The vibratory mechanism 26 includes a first/inner eccentric weight 50 and a second/outer eccentric weight 52. An inner shaft 54 supports the inner eccentric weight and a pair of stub shafts 56 supports the outer eccentric weight 52. Motor 28 is connected to a drive shaft 58 that is connected to one of the stub shafts 56 to supply rotational power to the vibratory mechanism 26 so as to impart a vibratory force on compacting drum 14.

[0017] The outer eccentric weight 52 is mechanically coupled to shaft 54 so that it is directly rotated by the vibrator propel motor 28. The inner eccentric weight 50 is rotatably mounted concentrically with respect to the outer eccentric weight 52, and is driven along with the outer eccentric weight 52, via a torque limiting (slip) clutch 60 (see FIGS. 2 and 3) disposed between the inner shaft 54 and one of the stub shafts 56. Clutch 60 may be internal to the vibratory mechanism 26, as shown in FIG. 3 or external. The clutch 60 may be of a variety of types, such as but not limited to, a jaw type with spring tension, a ball ramp (such as shown in FIGS. 2 and 3), and a friction disk type. As shown in FIG. 3, the clutch 60 may be provided with a torque adjustment screw 62 and tension spring 64 for adjusting a clutch force.

[0018] As shown in FIG. 3, the inner weight drive shaft 50 is supported by bushings 70 within the stub shafts 56. In addition, the stub shafts 56 are supported by bearings 72 within the housing 46 of the vibratory mechanism 26.

[0019] Optionally, vibratory mechanism 26 may be modified to limit the rotation of the inner eccentric weight 50 within the outer eccentric weight 52 to 180 degrees with an internal stop mechanism, such as for example rubber covered stop pins 74 bolted through the stub shafts 56. Inner eccentric weight 50 contacts the stop pins 74 at two different positions. This insures a positive location of the minimum amplitude (could be zero, e.g., when the weights are 180 degrees apart) and the maximum amplitude (e.g., when the weights are 0 degrees apart) settings. The stop pins 74 are useful to simplify the control of the vibratory mechanism 26.

[0020] Typically, as shown in FIG. 4, a controller 80 is positioned on the work machine 10. Controller 80 receives input commands from an operator interface 120 and sends output commands to the first and second power sources 22, 24 for operating the vib motor 28 and propel motor 40 respectively. The operator interface 120 is defined as being any known device or combination of input devices such as touch screens, levers, rotary knobs, push buttons, joysticks and the like. The second power source 24 drives the propel motor 40, and is also controlled by the operator interface 120 and/or by controller 80.

[0021] The controller 80 can monitor drum acceleration via one or more accelerometers 84 mounted on a frame 18 and vibrator speed via one or more speed sensors 86 on the drive shaft 56 and control the output from the power sources 22,24 per a preprogrammed decision algorithm (see FIG. 5, for example). The operator inputs commands from the operator interface 82 to the controller 80 when vibration is needed and the controller 80 would respond with the appropriate signal command to the power source 22.

[0022] Industrial Applicability

[0023] During operation of the work machine 10, an operator actuates the propel motor/motors 40 such that the drums 14,16 rotate around a central axis in the desired direction. Rotating the drums 14,16 in this manner causes the work machine 10 to move in forward or reverse over the material 12 to be compacted. In addition, the operator actuates the motor/motors 28,32, which causes the drive shaft 58 (e.g., a cardan type flexible driveshaft shown in FIG. 2), along with the inner and outer eccentric weights 50,52, to rotate.

[0024] The position of the inner and outer eccentric weights 50,52, with respect to each other, determines the amplitude of the vibrations in the drum member. For example, if the inner and outer eccentric weights 50,52 are positioned 180° from each other, their weights counteract and zero amplitude (or a minimum amplitude) is obtained. If the inner and outer eccentric weights 50,52 are positioned 0° from each other, their weights combine and maximum amplitude is obtained. The inner and outer eccentric weights 50,52 can be positioned in an infinite number of positions, so that infinite vibration amplitude levels can be obtained.

[0025] During operation the vibratory mechanism 26 functions as follows:

[0026] When the work machine 10 is started the vibratory mechanism 26 is at rest with the inner and outer eccentric weights 50,52 at 180 degrees out of phase, so that the net amplitude is minimal or at zero. The operator signals for vibration from the operator interface 82. The controller 80 then increases the output from the power source 22, increasing the power supplied to the motor 28 at a relatively slow rate of speed. (2-8 seconds) In turn, the motor 28 accelerates the inner and outer eccentric weights 50,52 up to speed slowly enough that the slip clutch 60 does not activate (and therefore the amplitude does not change). At 90-100% of desired speed (or at some speed faster than frame resonance), the power source 22 suddenly surges to full output for a short period of time (20 milliseconds to 0.5 seconds estimated), which causes the clutch 60 to slip and increase the amplitude as the inner and outer eccentric weights 50,52 are moved out of 180 degree opposition. (Note: power source 22 output may be larger than what is required to drive the motor 28 at maximum frequency so that the amplitude adjustment can occur at a predetermined speed.)

[0027] The controller 80 monitors the response in the vibration of the drum 14 and may also determine the response of the material 12 being compacted via accelerometers 84 mounted on the drum 14 and frame 18. Conventional controllers 80 and other hardware (such as made by Geodynamik, for example) could be used for this application, which is in effect a compaction indicator combined with a compactor control system.

[0028] If the vibration sensed is not adequate for compaction, the amplitude is changed until the desired amplitude is reached. This is sensed by identifying the point (amplitude) at which de-coupling of the drum 14 from the surface of the material 12 being compacted occurs, and then backing off slightly.

[0029] The entire system can be monitored via the accelerometers 84 and/or the speed sensors 86. Normally, the accelerometers 84 could be used to determine the vibrator speed, but at low/no amplitude the speed sensors 86 may be needed.

[0030] Additionally, the computer controller 80 can monitor ground speed and based on input parameters, limit or control ground speed by controlling operation of power source 24 which drives the drive motor 40. This would be useful to control impact spacing for producing pavements with superior ride characteristics or to manage the compaction process to optimize the productivity of the machine.

[0031] When the vibratory mechanism 26 is stopped suddenly, the slip clutch 60 operates and allows the inner and outer weights 50,52 to rotate relative to each other to be 180 degrees out of phase and at zero amplitude. Stop pins 74 could be provided to limit the rotation of the inner and outer weights 50,52 to 180 degrees total rotation in either direction. This concept would also work with weight shafts that had continuous rotation capability, using a slightly more complex control theory.

[0032] The entire concept can also work if the orientation of the weights is reversed. That is, the vibrator decreases amplitude with sudden increases in speed and increases amplitude with sudden decreases in speed. From one perspective, this might work better as the vibrator could be suddenly turned on and it would go to zero or very low amplitude and high RPM. As the RPM was suddenly dropped, amplitude would increase and a new lower speed would be set at the same time. However, normally compaction could be expected to start at low RPM and high amplitude and increase RPM and decrease amplitude as the soil or asphalt mat was being compacted and got stiffer.

[0033] Shown and described are several embodiments of the invention, though it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. Therefore it is intended that the appended claims cover all such changes and modifications as fall within the true spirit and scope of the invention.

Claims

1. A vibratory mechanism comprising: a first eccentric weight rotatably supported within a housing; a second eccentric weight being coaxially rotatable with said first eccentric weight; and a clutch operatively connecting said first and second eccentric weights, said clutch being operative to index said first eccentric weight relative to said second eccentric weight to change a vibration amplitude of the vibratory mechanism.

2. The vibratory mechanism in claim 1, wherein said clutch is a torque limiting clutch, interposed said first and second eccentric weights, that slips to allow relative movement between said first and second eccentric weights.

3. The vibratory mechanism in claim 2, wherein said clutch is an adjustable clutch.

4. The vibratory mechanism in claim 1, including a motor for driving said first and second eccentric weights.

5. The vibratory mechanism in claim 4, including a shaft connecting said motor to said first and second eccentric weights.

6. The vibratory mechanism in claim 4, including a variable power source connected with said motor.

7. The vibratory mechanism in claim 4, wherein and an infinitely variable electric displacement controller controls said power source.

8. A work machine, comprising: a compacting drum supporting said work machine; and a vibratory mechanism as set for in claim 1.

9. A work machine comprising: a compacting drum supporting said work machine; a vibratory mechanism coaxially positioned within said compacting drum; said vibratory mechanism including: a first eccentric weight rotatably supported within a housing; a second eccentric weight coaxially rotatable with said first eccentric weight; and a clutch operatively connecting said first and second eccentric weights, said clutch being operative to index said first eccentric weight relative to said second eccentric weight to change a vibration amplitude of the vibratory mechanism.

10. The work machine recited in claim 9, wherein said clutch is a torque limiting clutch that slips to allow relative movement between said first and second eccentric weights with an abrupt increase or decrease in rotation speed.

11. The work machine recited in claim 10, wherein said clutch is an adjustable clutch.

12. The work machine recited in claim 9, further including means for limiting the phase difference between said first and second eccentric weights.

13. The work machine recited in claim 12, wherein said limiting means is a mechanical stop fixedly secured to the second eccentric weight, said first eccentric weight striking said stop at a predetermined relative position of the first and second eccentric weights.

14. The work machine recited in claim 9, further including a speed sensor that senses a speed of at least one of the first and second eccentric weights, and a computer controller that controls operation of said clutch based on an output of said sensor.

15. The work machine recited in claim 9, further including an accelerometer that senses an amount of acceleration created by said vibratory compactor, and a computer controller that controls said clutch based on an output of said accelerometer.

16. A method for controlling amplitude of a vibratory mechanism, the vibratory mechanism having first and second eccentric weights coaxially rotatably coupled by a torque limiting clutch operatively connecting, comprising: abruptly changing a speed of one of the first and second eccentric weights to cause the torque limiting clutch to slip, thereby causing the first and second eccentric weights to move farther apart or closer together to change the vibration amplitude.

17. The method recited in claim 16, including: determining at least an amount of vibration; and changing the vibration amplitude based on the detected vibration.

18. The method recited in claim 16, including repeating said speed changing step to arrive at a desired vibration amplitude.

19. The method recited in claim 16, including monitoring a vibration frequency, and controlling the vibrator so that a desired area of vibration frequency versus vibration amplitude is maintained.

20. The method recited in claim 19, wherein as the vibration frequency is increased, the vibration amplitude is decreased, and wherein as the vibration frequency is decreased, the vibration amplitude is increased.

21. The method recited in claim 16, including monitoring a ground speed of a vehicle that includes the vibratory compactor, and controlling the ground speed and the vibration amplitude relative to each other.