Apparatus and method for asphalt control system

A system for controlling the production of an asphalt mix. The preferred system comprises a recycled asphalt pavement source, a recycled asphalt pavement sensor, a liquid asphalt cement source, a liquid asphalt cement meter, and a controller. The recycled asphalt pavement sensor communicates the amount of recycled liquid asphalt cement and the amount of RAP moisture contained in the amount of recycled asphalt pavement to the controller, the liquid asphalt cement meter communicates the amount of liquid asphalt cement provided by the liquid asphalt cement source to the controller, and the controller controls the amount of recycled asphalt pavement provided by the recycled asphalt pavement source and the amount of the liquid asphalt cement provided by the liquid asphalt cement source. A method comprising controlling the amount of recycled asphalt pavement and the amount of liquid asphalt cement provided to the asphalt mix substantially continuously and substantially in real time.

FIELD OF THE INVENTION

This invention relates generally to control systems used in connection with the production of mixtures, and particularly to control systems used in connection with the production of asphalt mixtures.

BACKGROUND AND DESCRIPTION OF THE PRIOR ART

It is known to use control systems in connection with the production of asphalt. Conventional control systems used in connection with the production of asphalt, however, suffer from one or more limitations. For example, conventional control systems used in connection with the production of asphalt do not accurately and precisely control the amount of liquid asphalt cement contained in the asphalt mix. More particularly, conventional control systems used in connection with the production of asphalt do not collect data relating to the amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement (RAP) substantially continuously and substantially in real time. Conventional control systems used in connection with the production of asphalt do not collect data relating to the amount of moisture contained in the amount of recycled asphalt pavement substantially continuously and substantially in real time. Conventional control systems used in connection with the production of asphalt do not collect data relating to the amount of moisture contained in the amount of aggregate material substantially continuously and substantially in real time. Conventional control systems used in connection with the production of asphalt do not collect data relating to the amount of liquid asphalt cement used in the asphalt mix substantially continuously and substantially in real time.

Consequently, conventional control systems used in connection with the production of asphalt result in material waste, excess cost, and less than optimal asphalt mixes.

It would be desirable, therefore, to provide an apparatus and method for a control system used in connection with the production of asphalt that would be adapted to accurately and precisely control the amount of liquid asphalt cement contained in the asphalt mix. It would be further desirable if such an apparatus and method for a control system used in connection with the production of asphalt could be provided that would be adapted to collect data relating to the amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement substantially continuously and substantially in real time. It would be still further desirable if such an apparatus and method for a control system used in connection with the production of asphalt could be provided that would be adapted to collect data relating to the amount of moisture contained in the amount of recycled asphalt pavement substantially continuously and substantially in real time. It would also be desirable if such an apparatus and method for a control system used in connection with the production of asphalt could be provided that would be adapted to collect data relating to the amount of moisture contained in the amount of aggregate material substantially continuously and substantially in real time. It would be further desirable if such an apparatus and method for a control system used in connection with the production of asphalt could be provided that would be adapted to collect data relating to the amount of liquid asphalt cement used in the asphalt mix substantially continuously and substantially in real time.

Additionally, it would be desirable if such an apparatus and method for a control system used in connection with the production of asphalt could be provided that would be adapted to reduce or eliminate material waste, excess cost, and less than optimal asphalt mixes.

ADVANTAGES OF THE PREFERRED EMBODIMENTS OF THE INVENTION

It is an advantage of the preferred embodiments of invention to provide an apparatus and method for a control system used in connection with the production of asphalt that accurately and precisely controls the amount of liquid asphalt cement contained in the asphalt mix. It is another advantage of the preferred embodiments of invention to provide an apparatus and method for a control system used in connection with the production of asphalt that collects data relating to the amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement (RAP) substantially continuously and substantially in real time. It is a further advantage of the preferred embodiments of invention to provide an apparatus and method for a control system used in connection with the production of asphalt that collects data relating to the amount of moisture contained in the amount of recycled asphalt pavement substantially continuously and substantially in real time. It is yet another advantage of the preferred embodiments of invention to provide an apparatus and method for a control system used in connection with the production of asphalt that collects data relating to the amount of moisture contained in the amount of aggregate material substantially continuously and substantially in real time. In addition, it is an advantage of the preferred embodiments of invention to provide an apparatus and method for a control system used in connection with the production of asphalt that collects data relating to the amount of liquid asphalt cement used in the asphalt mix substantially continuously and substantially in real time.

Additionally, it is an advantage of the preferred embodiments of invention to provide an apparatus and method for a control system used in connection with the production of asphalt that reduces or eliminates material waste, excess cost, and less than optimal asphalt mixes.

Additional advantages of the preferred embodiments of the invention will become apparent from an examination of the drawings and the ensuing description.

SUMMARY OF THE INVENTION

The apparatus of the invention comprises a system for controlling the production of an asphalt mix. The preferred system comprises a recycled asphalt pavement source that is adapted to provide an amount of recycled asphalt pavement to the asphalt mix and a recycled asphalt pavement sensor that is adapted to determine an amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement provided by the recycled asphalt pavement source and an amount of RAP moisture contained in the amount of recycled asphalt pavement provided by the recycled asphalt pavement source. The preferred system also comprises a liquid asphalt cement source that is adapted to provide an amount of liquid asphalt cement to the asphalt mix and a liquid asphalt cement meter that is adapted to determine the amount of liquid asphalt cement provided by the liquid asphalt cement source. The preferred system further comprises a controller that is adapted to communicate with the recycled asphalt pavement source, the recycled asphalt pavement sensor, the liquid asphalt cement source, and the liquid asphalt cement meter. In the preferred system, the recycled asphalt pavement sensor communicates the amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement and the amount of RAP moisture contained in the amount of recycled asphalt pavement to the controller, the liquid asphalt cement meter communicates the amount of liquid asphalt cement provided by the liquid asphalt cement source to the controller, and the controller controls the amount of recycled asphalt pavement provided by the recycled asphalt pavement source and the amount of the liquid asphalt cement provided by the liquid asphalt cement source.

The method of the invention comprises a method for controlling the production of an asphalt mix. The preferred method for controlling the production of an asphalt mix comprises providing a system for controlling the production of the asphalt mix as described above in this section. The preferred method further comprises controlling the amount of recycled asphalt pavement and the amount of liquid asphalt cement provided to the asphalt mix substantially continuously and substantially in real time.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Referring now to the drawings, the preferred embodiment of the control system in accordance with the present invention is illustrated byFIG. 1. As shown inFIG. 1, the preferred control system is adapted to collect data substantially continuously and substantially in real time. More particularly, the preferred control system is adapted to collect data relating to the amounts of the following ingredients of an asphalt mix: (i) virgin aggregate material; (ii) moisture contained in the virgin aggregate material; (iii) recycled asphalt pavement (RAP); (iv) moisture contained in the recycled asphalt pavement; and (v) recycled liquid asphalt cement contained in the recycled asphalt pavement. Using this substantially continuously and substantially real time collected data, the preferred control system determines and controls the injection rate of virgin liquid asphalt into the asphalt mix substantially continuously and substantially in real time.

Referring now toFIG. 1, a schematic view of the preferred embodiment of the control system in accordance with the present invention is illustrated. As shown inFIG. 1, the preferred control system is designated generally by reference numeral20. Preferred control system20comprises a system for controlling the production of an asphalt mix having recycled asphalt pavement source22. Preferred recycled asphalt pavement source22is adapted to provide an amount of recycled asphalt pavement to the asphalt mix via a conveyor or any other suitable device, mechanism, assembly or combination thereof adapted to convey recycled asphalt pavement to an asphalt mix. Preferably, recycled asphalt pavement source22is adapted to provide recycled asphalt pavement to the asphalt mix at a variable rate of tons per hour; however, it is contemplated within the scope of the invention that the recycled asphalt pavement source is adapted to provide recycled asphalt pavement to the asphalt mix at any suitable rate. Preferred recycled asphalt pavement source22comprises a container such as RAP bins24, RAP screen26, and a scale such as RAP belt scale28. Preferred RAP bins24are adapted to receive, store, and dispense recycled asphalt pavement. Preferred RAP screen26is adapted to screen recycled asphalt pavement. Preferred RAP belt scale28is adapted to weigh recycled asphalt pavement. WhileFIG. 1illustrates the preferred configuration and arrangement of the recycled asphalt pavement source, it is contemplated within the scope of the invention that the recycled asphalt pavement source may be of any suitable configuration and arrangement. It is also contemplated within the scope of the invention that the recycled asphalt pavement source may comprise any suitable device, mechanism, assembly, or combination thereof adapted to provide recycled asphalt pavement to an asphalt mix.

Still referring toFIG. 1, preferred control system20also comprises recycled asphalt pavement sensors30and31. Preferred recycled asphalt pavement sensors30and31are adapted to determine an amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement and determine an amount of RAP moisture contained in the amount of recycled asphalt pavement, respectively, provided by recycled asphalt pavement source22. Preferably, recycled asphalt pavement sensors30and31are adapted to determine the amount of recycled liquid asphalt cement contained in the recycled asphalt pavement and the amount of RAP moisture contained in the recycled asphalt pavement, respectively, at a variable rate of tons per hour or percentage by weight; however, it is contemplated within the scope of the invention that the recycled asphalt pavement sensors may determine the amount of recycled liquid asphalt cement contained in the recycled asphalt pavement and the amount of RAP moisture contained in the recycled asphalt pavement, respectively, at any suitable rate. Preferred recycled asphalt pavement sensors30and31are also adapted to communicate the amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement and the amount of RAP moisture contained in the amount of recycled asphalt pavement, respectively, to a controller such as microprocessor32. Preferably, recycled asphalt pavement sensor30communicates the amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement to the controller substantially continuously and substantially in real time. In addition, recycled asphalt pavement sensor31communicates the amount of RAP moisture contained in the amount of recycled asphalt pavement to the controller substantially continuously and substantially in real time. Preferred recycled asphalt pavement sensors30and31comprise an infrared sensor, a microwave sensor, and/or a radioactive material-based sensor. It is contemplated within the scope of the invention, however, that the recycled asphalt pavement sensors may comprise any suitable device, mechanism, assembly, or combination thereof adapted to determine the amount of recycled liquid asphalt cement and/or RAP moisture contained in the recycled asphalt pavement. WhileFIG. 1illustrates two separate recycled asphalt pavement sensors30and31, it is contemplated within the scope of the invention that fewer or more than two sensors may be provided to determine the amount of recycled liquid asphalt cement and the amount of RAP moisture contained in the recycled asphalt pavement.

Still referring toFIG. 1, preferred control system20further comprises liquid asphalt cement source40. Preferred liquid asphalt cement source40is adapted to provide an amount of liquid asphalt cement to the asphalt mix via a conduit or any other suitable device, mechanism, assembly, or combination thereof adapted to convey liquid asphalt cement to an asphalt mix. Preferred liquid asphalt cement source40comprises a container such as liquid asphalt cement tank42and a means for conveying liquid asphalt cement such as liquid asphalt cement pump44. WhileFIG. 1illustrates the preferred configuration and arrangement of the liquid asphalt cement source, it is contemplated within the scope of the invention that the liquid asphalt cement source may be of any suitable configuration and arrangement. It is also contemplated within the scope of the invention that the liquid asphalt cement source may comprise any suitable device, mechanism, assembly, or combination thereof adapted to provide liquid asphalt cement to an asphalt mix.

Still referring toFIG. 1, preferred control system20still further comprises liquid asphalt cement meter50. Preferred liquid asphalt cement meter50is adapted to determine the amount of liquid asphalt cement provided by liquid asphalt cement source40. Preferred liquid asphalt cement meter50is also adapted to communicate the amount of liquid asphalt cement provided by liquid asphalt cement source40to microprocessor32. Preferably, liquid asphalt cement meter50communicates to microprocessor32the amount of liquid asphalt cement provided by liquid asphalt cement source40substantially continuously and substantially in real time. WhileFIG. 1illustrates the preferred liquid asphalt cement meter, it is contemplated within the scope of the invention that any suitable device, mechanism, assembly, or combination thereof adapted to determine the amount of liquid asphalt cement provided by a liquid asphalt cement source to an asphalt mix may be used.

Still referring toFIG. 1, preferred control system20also comprises a controller such as microprocessor32. Preferred microprocessor32is adapted to communicate with recycled asphalt pavement source22, recycled asphalt pavement sensors30and31, liquid asphalt cement source40, and liquid asphalt cement meter50. Preferred microprocessor32is also adapted to collect data from recycled asphalt pavement source22, recycled asphalt pavement sensors30and31, liquid asphalt cement source40, and liquid asphalt cement meter50. Preferably, microprocessor32is adapted to collect data from recycled asphalt pavement source22, recycled asphalt pavement sensors30and31, liquid asphalt cement source40, and liquid asphalt cement meter50substantially continuously and substantially in real time. Preferred microprocessor32is further adapted to make calculations using the data collected from recycled asphalt pavement source22, recycled asphalt pavement sensors30and31, liquid asphalt cement source40, and liquid asphalt cement meter50. Preferably, microprocessor32is adapted to make calculations using the data collected from recycled asphalt pavement source22, recycled asphalt pavement sensors30and31, liquid asphalt cement source40, and liquid asphalt cement meter50substantially continuously and substantially in real time. Preferred microprocessor32is still further adapted to control the amount of recycled asphalt pavement provided by recycled asphalt pavement source22to the asphalt mix and the amount of the liquid asphalt cement provided by liquid asphalt cement source40to the asphalt mix. Preferably, microprocessor32controls the amount of recycled asphalt pavement provided by recycled asphalt pavement source22and the amount of the liquid asphalt cement provided by liquid asphalt cement source40substantially continuously and substantially in real time.

Still referring toFIG. 1, preferred control system20further comprises aggregate material source60. Preferred aggregate material source60is adapted to provide an amount of aggregate material to the asphalt mix via a conveyor or any other suitable device, mechanism, assembly, or combination thereof adapted to convey aggregate material to an asphalt mix. Preferred aggregate material source60comprises a container such as aggregate bins62, aggregate screen64, and a scale such as aggregate belt scale66. Preferred aggregate bins62are adapted to receive, store, and dispense aggregate material. Preferred aggregate screen64is adapted to screen aggregate material. Preferred aggregate belt scale66is adapted to weigh aggregate material. Preferably, aggregate material source60is adapted to provide virgin aggregate material to the asphalt mix at a variable rate of tons per hour; however, it is contemplated within the scope of the invention that the aggregate material source may provide aggregate material to the asphalt mix at any suitable rate. WhileFIG. 1illustrates the preferred configuration and arrangement of the aggregate material source, it is contemplated within the scope of the invention that the aggregate material source may be of any suitable configuration and arrangement. It is also contemplated within the scope of the invention that the aggregate material source may comprise any suitable device, mechanism, assembly, or combination thereof adapted to provide aggregate material to an asphalt mix.

Still referring toFIG. 1, preferred control system20still further comprises aggregate material sensor70. Preferred aggregate material sensor70is adapted to determine an amount of aggregate moisture contained in the amount of aggregate material provided by aggregate material source60. Preferably, aggregate material sensor70is adapted to determine the amount of aggregate moisture contained in the aggregate material at a variable rate of tons per hour or by a percentage of weight; however, it is contemplated within the scope of the invention that the aggregate material sensor may determine the amount of aggregate moisture contained in the aggregate material at any suitable rate. Preferred aggregate material sensor70is also adapted to communicate the amount of aggregate moisture contained in the amount of aggregate material to the controller. Preferably, aggregate material sensor70communicates the amount of aggregate moisture contained in the aggregate material to the controller substantially continuously and substantially in real time. Preferred aggregate material sensor70comprises an infrared sensor, a microwave sensor, and/or a radioactive material-based sensor, but it is contemplated within the scope of the invention that the aggregate material sensor may comprise any suitable device, mechanism, assembly, or combination thereof adapted to determine the amount of aggregate moisture in an amount of aggregate material.

Still referring toFIG. 1, preferred microprocessor32is adapted to communicate with aggregate material source60and aggregate material sensor70. Preferred microprocessor32is also adapted to collect data from aggregate material source60and aggregate material sensor70. Preferably, microprocessor32is adapted to collect data from aggregate material source60and aggregate material sensor70substantially continuously and substantially in real time. Preferred microprocessor32is further adapted to make calculations using the data collected from aggregate material source60and aggregate material sensor70. Preferably, microprocessor32is adapted to make calculations using the data collected from aggregate material source60and aggregate material sensor70substantially continuously and substantially in real time. Preferred microprocessor32is still further adapted to control the amount of aggregate material provided by asphalt material source60to the asphalt mix. Preferably, microprocessor32controls the amount of aggregate material provided by aggregate material source60substantially continuously and substantially in real time.

Still referring toFIG. 1, preferred control system20may also comprise dryer/mixer80, silos90, and baghouse100. It is also contemplated within the scope of the invention that other additives such as roofing shingles may be used to produce the asphalt mix. The preferred control system20is adapted to determine the amount of roofing shingles used in the asphalt mix, the amount of shingle moisture contained in the roofing shingles, and the amount of shingle liquid asphalt cement contained in the roofing shingles. It is further contemplated within the scope of the invention that mineral filler and lime may be used to produce the asphalt mix. Preferred control system20is adapted to determine the amount of mineral filler and the amount of lime used to produce the asphalt mix. Additives such as mineral filler and lime have no liquid asphalt cement content and negligible moisture content.

The invention also comprises a method for controlling the production of an asphalt mix. The preferred method comprises providing a system for controlling the production of the asphalt mix. The preferred control system comprises a recycled asphalt pavement source that is adapted to provide an amount of recycled asphalt pavement to the asphalt mix and a recycled asphalt pavement sensor that is adapted to determine an amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement provided by the recycled asphalt pavement source and determine an amount of RAP moisture contained in the amount of recycled asphalt pavement provided by the recycled asphalt pavement source. The preferred control system further comprises a liquid asphalt cement source that is adapted to provide an amount of liquid asphalt cement and a liquid asphalt cement meter that is adapted to determine the amount of liquid asphalt cement provided by the liquid asphalt cement source. The preferred control system still further comprises a controller that is adapted to communicate with the recycled asphalt pavement source, the recycled asphalt pavement sensor, the liquid asphalt cement source, and the liquid asphalt cement meter. In addition, in the preferred control system, the recycled asphalt pavement sensor communicates the amount of recycled liquid asphalt cement contained in the amount of recycled asphalt pavement and communicates the amount of RAP moisture contained in the amount of recycled asphalt pavement to the controller, the liquid asphalt cement meter communicates the amount of liquid asphalt cement provided by the liquid asphalt cement source to the controller, and the controller controls the amount of recycled asphalt pavement provided by the recycled asphalt pavement source and the amount of the liquid asphalt cement provided by the liquid asphalt cement source. The preferred method of the invention further comprises controlling the amount of recycled asphalt pavement and the amount of liquid asphalt cement provided to the asphalt mix substantially continuously and substantially in real time.

In other preferred embodiments of the invention, the method also comprises controlling the amount of aggregate material provided to the asphalt mix substantially continuously and substantially in real time. In yet other preferred embodiments of the invention, the method also comprises determining the amount of RAP moisture contained in the recycled asphalt pavement and the amount of recycled liquid asphalt contained in the recycled asphalt pavement substantially continuously and substantially in real time. In still other preferred embodiments of the invention, the method also comprises determining the amount of aggregate moisture contained in the aggregate material substantially continuously and substantially in real time.

In operation, several advantages of the preferred embodiments of the apparatus and method for a control system are achieved. For example, the preferred embodiments of the invention provide an apparatus and method for a control system used in connection with the production of an asphalt mix that accurately and precisely controls the amount of liquid asphalt cement, recycled asphalt pavement, and aggregate material contained in the asphalt mix substantially continuously and substantially in real time. The preferred embodiments of invention further provide an apparatus and method for a control system used in connection with the production of an asphalt mix that collects data relating to the amount of recycled liquid asphalt contained in the amount of recycled asphalt pavement substantially continuously and substantially in real time. The preferred embodiments of invention still further provide an apparatus and method for a control system used in connection with the production of an asphalt mix that collects data relating to the amount of RAP moisture contained in the amount of recycled asphalt pavement substantially continuously and substantially in real time. The preferred embodiments of invention also provide an apparatus and method for a control system used in connection with the production of an asphalt mix that collects data relating to the amount of aggregate moisture contained in the amount of aggregate material substantially continuously and substantially in real time. The preferred embodiments of invention further provide an apparatus and method for a control system used in connection with the production of asphalt that collects data relating to the amount of liquid asphalt cement used in the asphalt mix substantially continuously and substantially in real time.

Additionally, the preferred embodiments of invention provide an apparatus and method for a control system used in connection with the production of an asphalt mix that reduces or eliminates material waste, excess cost, and less than optimal asphalt mixes.

Although this description contains many specifics, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments thereof, as well as the best mode contemplated by the inventors of carrying out the invention. The invention, as described herein, is susceptible to various modifications and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.