System and method for aligning entry snout of a barrier transfer machine with road barriers

A barrier transfer machine includes a moveable chassis, an entry snout, an exit snout, a conveyor system, and a control system that aligns the entry snout with road barriers before the road barriers are picked up. The control system includes a barrier position sensor; an entry snout position sensor; and a processing system.

BACKGROUND

Moveable road barrier systems are often placed on roadways to create traffic barriers between opposing lanes of traffic. Unlike permanent barriers, moveable road barrier systems may be picked up and repositioned by barrier transfer machines to make more efficient use of space, increase vehicle capacity, and reduce traffic congestion. For example, a barrier transfer machine may move a road barrier system back and forth between lanes of a roadway throughout the day to provide more lanes in directions of peak traffic and/or to create work zone space for construction crews.

A typical barrier transfer machine includes a moveable chassis; an entry snout supported on a forward end of the chassis for picking up road barriers from a road surface; an exit snout positioned on a rearward end of the chassis for placing the road barriers back onto the road surface; and a conveyor system positioned below the chassis for transporting the road barriers from the entry snout to the exit snout.

The entry snout must be aligned with and generally centered over the road barriers before they are picked up or else the barriers will rub against the carrier wheels on the entry snout, causing wear and damage to the entry snout and the barriers. To this end, an operator must steer the barrier transfer machine to align the entry snout with the barriers and simultaneously adjust the lateral position of the entry snout relative to the barrier transfer machine to precisely align it with the barriers. Unfortunately, these maneuvers are difficult in any situation and especially so when the barrier transfer machine is operating at high speeds and/or alongside heavy traffic or when it is driven by an inexperienced operator.

SUMMARY

The present invention solves the above-described problems and related problems and provides a distinct advance in the art of road barrier transfer machines. More particularly, the invention provides a road barrier transfer machine that includes a control system for aligning the machine with road barriers before the barriers are picked up.

A barrier transfer machine constructed in accordance with an embodiment of the invention broadly comprises a moveable chassis, an entry snout, an entry snout positioning mechanism, an exit snout, a conveyor system, and the above-mentioned control system.

The chassis has two ends and rides on wheels, belts, or other ground-engaging traction elements that are driven by conventional engines, transmissions, and associated mechanical and electrical components. The machine can be driven in either direction. In one embodiment, two operator cabs are supported on the chassis, one at each end of the chassis, but embodiments of the machine may have only one operator cab or even no cab at all. As used herein, the end of the machine currently picking up barriers is referred to as the “forward end” or “front end”, and the end of the machine placing the barriers back down is referred to as the “rear end”.

Either snout can pick up and drop off barriers, depending on the direction of travel of the machine. As used herein, the snout currently in front is referred to as the “entry snout”, and the snout currently in the back is referred to as the “exit snout”.

The entry and exit snouts include a blunderbuss that acts as a guide for the barriers as they enter or exit the machine and a number of bogey assemblies with carrier wheels that pick-up and carry the barriers towards the conveyor or place the barriers back down after being conveyed through the machine. The entry snout positioning mechanism is coupled with the entry snout for shifting the entry snout generally laterally with respect to the longitudinal axis of the chassis.

The conveyor system extends beneath the chassis and transports the road barriers from the entry snout to the exit snout.

In accordance with important aspects of the invention, the control system aligns the entry snout with the barriers before the barriers are picked up so that the barriers don't rub against the carrier wheels on the entry snout or otherwise cause wear and damage to the entry snout and/or the barriers themselves. An embodiment of the control system broadly comprises a barrier position sensor; an entry snout position sensor; and a processing system. The control system may be a stand-alone system or may be incorporated in other control systems of the barrier transfer machine.

The barrier position sensor senses a position of one of the road barriers (typically the forwardmost barrier) before the road barriers are picked up by the entry snout and generates corresponding barrier position data. In some embodiments, the barrier position sensor is a light detection and ranging (LIDAR) sensor and/or a radio detection and ranging (RADAR) sensor mounted on the entry snout. In other embodiments, the barrier position sensor may be a camera mounted on the entry snout or any other device or mechanism operable to sense the position or relative position of at least one of the barriers and generate corresponding position data. As used herein, the “position” of the barrier may be its geographical coordinates, its relative position with respect to the entry snout, and/or its angle with respect to the entry snout.

The entry snout position sensor senses a position of the entry snout before the road barriers are picked up and generates corresponding entry snout position data. In some embodiments, the entry snout position sensor is a proximity switch, a magnetic position sensor, a potentiometer, a mechanical resolver, a mechanical encoder, or any other sensor capable of sensing the position or relative position of the entry snout before the barriers are picked up. As used herein, the “position” of the entry snout may be its geographical coordinates, its relative position with respect to the barriers, and/or its angle with respect to the barriers.

The processing system compares the entry snout position data to the barrier position data to determine if the entry snout is aligned with the barriers before the barriers are picked up by the entry snout. In some embodiments, the processing system generates an alert if the entry snout is not aligned with the barriers and transmits the alert to a user interface in the barrier transfer machine so that an operator of the machine may correct any mis-alignment before the barriers are picked up. In other embodiments, the processing system controls the entry snout positioning mechanism to shift the entry snout laterally to correct any misalignment between the entry snout and the barriers before the barriers are picked up.

In still other embodiments, the processing system generates and transmits a steering signal to the user interface to prompt an operator to steer the barrier transfer machine to align the entry snout with the barriers. In other embodiments, the processing system generates and transmits a steering signal to an automatic steering mechanism to automatically steer the barrier transfer machine to align the entry snout with the barriers.

This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.

DETAILED DESCRIPTION

Turning now to the drawing figures, a barrier transfer machine10constructed in accordance with embodiments of the invention is depicted. As best shown inFIG. 6, the barrier transfer machine10is configured for picking up and repositioning a span1of interconnected road barriers12to provide more lanes in directions of peak traffic, to create work zone space for construction crews, or to otherwise make more efficient use of roadway space, increase vehicle capacity, and/or reduce traffic congestion. In accordance with important aspects of the present invention, and as described in more detail below, the barrier transfer machine includes a control system for aligning the machine with the barriers before the barriers are picked up to minimize or eliminate damage to the machine and/or the barriers caused by misalignments.

An exemplary span of road barriers12that may be picked up and repositioned by the barrier transfer machine10is depicted inFIG. 15. The span12may be any length and may include any number of fixed-length road barriers14and variable length barriers16. In some embodiments, the barriers14,16are connected end-to-end with steel pins and/or tensioning hinge mechanisms described in more detail below.

Examples of the fixed length barriers14are shown inFIGS. 10 and 11. The barriers14may be any type, shape, and size and may be formed of any suitable materials such as heavily reinforced concrete or high strength steel frames filled with concrete. In one embodiment, the barriers14have T-shaped tops18so they can be picked up and repositioned by bogey wheels of the barrier transfer machine as shown inFIG. 9and described below.

Returning toFIGS. 10 and 11, one side of each barrier14includes fixed, spaced apart, connection flanges20, and the opposite side includes spaced apart, spring biased, reactive tension elements22. A steel rod24may be inserted through holes in the flanges20and tension elements22of adjacent barriers when they are aligned to interconnect the adjacent barriers. The reactive tension elements22allow adjacent barriers to move longitudinally relative to one another when the barriers are under tension or compression. In other embodiments, the fixed length barriers may not have reactive tension elements, but instead may have larger holes in the connection flanges that create “sloppy hinges” to accommodate some longitudinal movement between adjacent barriers.

Examples of the variable length barriers16are shown inFIGS. 12-14. The barriers may be any shape and size and each has an outer frame26and an inner telescoping structure28that may move in and out of the outer frame26when the barrier is subjected to tension or compression forces. The variable length barriers also include connection flanges30that may be aligned with and interconnected to the connection flanges of adjacent barriers with a steel rod32. Movement of the telescoping inner structure28is resisted by internal hydraulic cylinders or other hydraulic or spring mechanisms.

FIG. 12shows a variable length barrier16in its fully retracted or compressed state when subjected to a compressive force of a magnitude sufficient to fully compress the hydraulic cylinders or other biasing mechanisms.FIG. 14shows the barrier16in its fully extended state when subjected to a tension force of a magnitude sufficient to fully extend the hydraulic cylinders or other biasing mechanisms.FIG. 13shows the barrier in its neutral or steady state when it is not subjected to a compressive or tension force. More details of exemplary embodiments of variable length barriers are disclosed in U.S. Pat. No. 6,439,802, which is incorporated into the present application by reference in its entirety.

Aspects of the barrier transfer machine10will now be described in more detail with reference toFIGS. 1-9 and 16. An embodiment of the barrier transfer machine10broadly comprises a moveable chassis34, an entry snout36, an entry snout positioning mechanism37, an exit snout38, a conveyor system40, a capstan system42, and a control system44for aligning the machine with road barriers before the barriers are picked up.

The chassis34has a forward end and a rearward end disposed along a generally longitudinal axis that is essentially parallel to a roadway over which the machine is driven. The chassis34rides on wheels46, belts, or other ground-engaging traction elements that are driven by conventional engines, transmissions, and associated mechanical and electrical components.

In one embodiment, the barrier transfer machine10is equipped with two cabs48,50, one at each end of the chassis34. The machine10can be driven in either direction, but typically only one operator in one of the cabs can be in charge of the key controls at any one time. Usually the cab in control is the cab at the end of the machine pointing towards the direction in which the machine is traveling. In some embodiments, the barrier transfer machine10may include various sensors and controls that provide autonomous operation without direct operator control or semi-autonomous operation with some operator control.

The entry snout36is mounted on a front end of the chassis and is configured for picking up the road barrier span from a first location on a road surface. Likewise, the exit snout38is mounted on the rear end of the chassis for placing the span back onto the road surface in a second location different from the first location. The snouts36,38act as guides for the road barriers as they are picked up and/or dropped off and can be moved and adjusted by operators of the machine to align the snouts with the incoming road barriers and the desired placement positions. Each snout36,38includes a blunderbuss assembly51and an array of bogey assemblies52. Each bogey assembly52comprises a number of carrier wheels54that pick up, carry, and/or lay down the barriers depending on the direction of travel of the machine.

The entry snout positioning mechanism37is shown schematically inFIG. 16and is operable to shift the entry snout36laterally from side-to-side with respect to the longitudinal axis of the machine10so as to align the entry snout with the barriers before they are picked up. An embodiment of the entry snout positioning mechanism37may include linear actuators, hydraulic cylinders, electric motors, or other mechanisms or combinations of mechanisms for shifting the blunderbuss51of the entry snout from side-to-side. In some embodiments, the entry snout positioning mechanism37may be controlled by a joystick or other control system in one or both the cabs of the machine. In other embodiments, the entry snout positioning mechanism may be controlled automatically by the control system44or by a remote operator via the remote control system74described below.

The conveyor system40extends beneath the barrier transfer machine and is configured for transporting the span of road barriers from the entry snout36to the exit snout38. The conveyor system40may be comprised of multiple assemblies and sections including straight sections, turn sections, and pickup/laydown sections connected to the snouts36,38. As best shown inFIG. 5, an embodiment of the conveyor system40comprises an S-shaped or otherwise curved structural frame56attached to the bottom of the machine and an array of bogey assemblies52supported to the frame. Each bogey assembly52comprises a number of carrier wheels54that pick up and carry the barriers through the machine during a barrier transfer operation.

The capstan system42is mounted alongside the conveyor system40and adjusts the tension or compression in the road barrier span12while it is being transported by the conveyor system in an attempt to keep the barrier span in its original longitudinal location relative to the road. As best shown inFIGS. 5 and 9, an embodiment of the capstan system42comprises a pair of large capstan wheels58on each side of the conveyor system, hydraulic cylinders, linkages, or other mechanisms60for urging the wheels against the road barriers as they pass by, and motors and pumps for driving the wheels so as to apply varying forward and rearward pressures on the road barriers. The capstan system42works by clamping the barriers with the capstan wheels58as they pass by on the conveyor system42and applying either forward or backward rotational pressure on the barriers. This alleviates excessive tension or compression in the span to reduce barrier migration and/or to reposition the barriers relative to one another.

Embodiments of the control system44will now be described in more detail with reference toFIG. 16. The control system44aligns the entry snout36with the barriers12before the barriers are picked up so the barriers don't rub against the carrier wheels on the entry snout or otherwise cause wear and damage to the entry snout and/or the barriers themselves. An embodiment of the control system broadly comprises a barrier position sensor62; an entry snout position sensor64; and a processing system66. The control system44may be a stand-alone system or may be incorporated in other control systems of the barrier transfer machine.

The barrier position sensor62senses a position of at least one of the road barriers12(typically the forwardmost barrier) before the road barriers are picked up by the entry snout36and generates corresponding barrier position data. In some embodiments, the barrier position sensor is a light detection and ranging (LIDAR) sensor and/or a radio detection and ranging (RADAR) sensor mounted on an extension arm66that extends forward of the entry snout. In other embodiments, the barrier position sensor62may be a camera mounted on the entry snout or any other device or mechanism operable to sense the position or relative position of at least one of the barriers and generate corresponding position data. As used herein, the “position” of the barrier may be its geographical coordinates, its relative position with respect to the entry snout, and/or its angle with respect to the entry snout.

The entry snout position sensor64senses a position of the entry snout36before the road barriers are picked up and generates corresponding entry snout position data. In some embodiments, the entry snout position sensor64is a proximity switch, a magnetic position sensor, a potentiometer, a mechanical resolver, or a mechanical encoder operatively coupled with the entry snout positioning mechanism37, but it may be any sensor or other mechanism capable of sensing the position or relative position of the entry snout before the barriers are picked up by the machine. As used herein, the “position” of the entry snout may be its geographical coordinates, its relative position with respect to the barriers, and/or its angle with respect to the barriers.

The processing system66is coupled with the barrier position sensor62and entry snout position sensor64by wired or wireless connections and receives and compares the entry snout position data to the barrier position data to determine if the entry snout is aligned with the barriers before the barriers are picked up by the entry snout. In some embodiments, the processing system comprises the entry snout position data to the barrier position data and determines the entry snout is not aligned with the barriers if the entry snout is not centered over a line extending through the length of the leading most barrier.

In some embodiments, the processing system66generates an alert if the entry snout36is not aligned with the barriers12and transmits the alert to a user interface68in the barrier transfer machine so that an operator of the machine may correct any mis-alignment between the entry snout and the barriers before the barriers are picked up. In some embodiments, the processing system66only generates an alert signal if it determines the misalignment between the entry snout and the road barriers is greater than a threshold amount. The threshold amount may be user-selected and may vary depending on a number of factors such as a speed of the machine, a position of the machine, and/or a position of the barriers. For example, the threshold may be greater when the machine is moving slower and/or the barricades are out of alignment due to a collision.

In other embodiments, the processing system66generates and transmits a control signal to automatically control the entry snout positioning mechanism37to correct any misalignment between the entry snout and the barriers before the barriers are picked up.

In still other embodiments, the processing system66generates and transmits a steering signal to the user interface68to prompt an operator to steer the barrier transfer machine to align the entry snout with the barriers. In other embodiments, the processing system66generates and transmits a steering signal to an automatic steering mechanism70to automatically steer the barrier transfer machine to align the entry snout with the barriers.

In other embodiments, the processing system66may both steer the machine10and controls the entry snout positioning mechanism37. For example, the processing system66may first generate and transmit a steering signal to the steering mechanism70to steer the barrier transfer machine to roughly align the entry snout with the barriers and then generate and transmit a control signal to the entry snout positioning mechanism37to more precisely align the entry snout with the barriers.

The control system44may also comprise a data transceiver72for transmitting the entry snout position data, the barrier position data, and other data to a remote control system74and for receiving control instructions and/or data from the remote control system so that the entry snout positioning mechanism37and/or the steering system70may be controlled remotely. The data transceiver72may be any device capable of transmitting and receiving data via wired or wireless connections. The data transceiver may be, or include, a wired or wireless network adapter or a wireless data transceiver for use with Bluetooth communication, radio frequency (RF) communication, near field communication (NFC), and/or with a mobile phone network, Global System for Mobile communications (GSM), 3G, or other mobile data network, and/or Worldwide Interoperability for Microwave Access (WiMAX) and the like.

In another embodiment, the relative position of the barriers versus the entry snout may be determined by a load cell or other force measuring sensor positioned in or near the snout that senses the magnitude and direction of forces applied on the entry snout by the incoming road barriers. The processing system monitors the output of the force measuring sensor to determine if the entry snout is aligned with the barriers and may also determine the direction and magnitude of the mis-alignment. In one embodiment, the processing system compares the current forces applied to the entry snout to a threshold force and determines the entry snout and barriers are out of alignment if the current forces exceed the threshold force. The threshold force may be determined by measuring the forces applied on the entry snout by the incoming road barriers during a “test run” during which the entry snout is aligned with the incoming road barriers. The direction of any misalignment may be detected by one or more force measuring sensors that sense the magnitude of forces applied to both sides of the entry snout by the incoming road barriers. If the processing system determines the forces applied to one side of the entry snout are greater than the forces applied to the opposite side, the processing system determines the entry snout needs to be moved toward the side with less forces applied to it.

Another embodiment of the invention is a method170of moving road barriers with a barrier transfer machine such as the one described and illustrated herein. The flow chart ofFIG. 17shows exemplary steps in an embodiment of the method170. In some alternative implementations, the steps or functions noted in the various blocks may occur out of the order depicted inFIG. 17. For example, two blocks shown in succession inFIG. 17may in fact be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order depending upon the functionality involved.

An embodiment of the method170comprises sensing a position of road barriers before they are picked up by a barrier transfer machine as depicted in box172. In some embodiments, the above-described barrier position sensor62senses the position of a leading one of the road barriers12before the road barriers are picked up by the entry snout36of the barrier transfer machine.

The method further comprises generating barrier position data corresponding to the position of the road barrier as depicted in box174.

The method further comprises sensing a position of the entry snout before the road barriers are picked up as depicted in box176. In some embodiments, the above-described entry snout position sensor64senses the position of the entry snout before the road barriers are picked up by the entry snout36.

The method further comprises generating entry snout position data corresponding to the position of the entry snout as depicted in box178.

The method further comprises comparing the entry snout position data to the barrier position data to determine if the entry snout is aligned with the barriers before the barriers are picked up by the entry snout as depicted in box180.

The method further comprises aligning the entry snout with the barriers to correct any misalignment as depicted in box182.

The aligning step may comprise generating an alert if the entry snout is not aligned with the barriers and transmits the alert to a user interface in the barrier transfer machine so that an operator of the machine may correct any mis-alignment between the entry snout and the barriers before the barriers are picked up.

Alternately, or in addition to, the aligning step may comprise controls the entry snout positioning mechanism to automatically shift the entry snout laterally to correct any misalignment between the entry snout and the barriers before the barriers are picked up.

Alternately, or in addition to, the aligning step may comprise generating transmitting a steering signal to the user interface to prompt an operator to steer the barrier transfer machine to align the entry snout with the barriers.

Alternately, or in addition to, the aligning step may comprise generating and transmitting a steering signal to an automatic steering mechanism to automatically steer the barrier transfer machine to align the entry snout with the barriers.

The method may also comprise transmitting the entry snout position data and the barrier position data and other data to the remote control system74and receiving control instructions at the processing system from the remote control system74.

The method may also comprise some or all of the following steps: picking up the road barriers from a road surface; transporting the road barriers in the barrier transfer machine; and placing the road barriers back onto the road surface.

Additional Considerations

In various embodiments, computer hardware, such as the processing system66, other processing elements, etc., may be implemented as special purpose or as general purpose. For example, the processing system66may comprise dedicated circuitry or logic that is permanently configured, such as an application-specific integrated circuit (ASIC), or indefinitely configured, such as an FPGA, to perform certain operations. The processing system66also comprise programmable logic or circuitry (e.g., as encompassed within a general-purpose processor or other programmable processor) that is temporarily configured by software to perform certain operations. It will be appreciated that the decision to implement the processing system as special purpose, in dedicated and permanently configured circuitry, or as general purpose (e.g., configured by software) may be driven by cost and time considerations.

Accordingly, the term “processing system” or equivalents should be understood to encompass a tangible entity, be that an entity that is physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein. Considering embodiments in which the processing system is temporarily configured (e.g., programmed), each of the processing elements need not be configured or instantiated at any one instance in time. For example, where the processing system comprises a general-purpose processor configured using software, the general-purpose processor may be configured as respective different processing elements at different times. Software may accordingly configure the processing element to constitute a hardware configuration at one instance of time and to constitute a different hardware configuration at a different instance of time.

Similarly, the methods or routines described herein may be at least partially processing element implemented. For example, at least some of the operations of a method may be performed by one or more processing elements or processing element-implemented hardware modules. The performance of certain of the operations may be distributed among the one or more processing elements, not only residing within a single machine, but deployed across a number of machines. In some example embodiments, the processing elements may be located in a single location (e.g., within a home environment, an office environment or as a server farm), while in other embodiments the processing elements may be distributed across a number of locations.