Patent Publication Number: US-2016222602-A1

Title: Systems and methods for guiding a compacting machine

Description:
TECHNICAL FIELD 
     The present disclosure generally relates to a compacting machine, and more particularly, to systems and methods for guiding a compacting machine. 
     BACKGROUND 
     The construction of road and highways typically involves a paving machine used to lay an asphalt mixture and a compacting machine (e.g., a roller machine) used to compact the mixture. The compactability of the asphalt mixture can be affected by environmental factors (e.g., ground temperature), mixture factors (e.g., composition properties), and construction factors (e.g., paving depth). A temperature of the asphalt mixture can also have an effect on its compactability. When the temperature of the asphalt mixture decreases, the mixture becomes more viscous and resistant to deformation, thus requiring higher compaction efforts. The composition of the asphalt mixture, which varies in dependence on expected loads caused by traffic and weather, also has an effect on its compactability. For example, mixtures that contain a high proportion of stones require high compaction efforts. 
     Traditional approaches rely upon operator judgment and perception, which require substantial operator training and preparation time. These approaches have the potential for human error and tend to be inconsistent in quality. Accordingly, when constructing long roads and highways, a significant number of pavement and rolling deficiencies appear. These deficiencies tend to increase construction time and cost. In recent years, several systems and methods have been developed for assisting operators of paving and compacting machines. 
     One method of improving the quality of paving operations is described in U.S. Pat. No. 6,749,364 (the &#39;364 patent) issued to Baker et al. on Jun. 15, 2014. The &#39;364 patent describes a pavement temperature monitoring system that can scan a material mat to be compacted. The &#39;364 patent also discloses a display device connected with a temperature sensor that can be viewed by the operator of the compacting vehicle. The display device provides the operator of the compacting vehicle with a temperature profile of the material mat. According to the &#39;364 patent, the pavement temperature monitoring system includes a “three light” indicator having a first light to indicate that the formed material mat is at the desired temperature, a second light to indicate that the formed material mat is at a higher temperature than the desired temperature, and a third light to indicate that the formed material mat is at a lower temperature than the desired temperature. This information may help the operator to adjust operational parameters of the compacting vehicle. 
     While the system of the &#39;364 patent may improve the traditional approaches of paving, the &#39;364 patent does not consider other factors that have an effect on the compactability of the asphalt mixture. In addition, the “three light” indicator disclosed in the &#39;364 patent can be a cumbersome way to provide guidance to the operator. Accordingly, the &#39;364 patent may provide an incomplete picture to the operator. 
     The disclosed systems and methods are directed to overcoming one or more of the problems set forth above and/or other problems of the prior art. 
     SUMMARY OF THE INVENTION 
     In one aspect, the present disclosure is directed to a guidance system for a compacting machine. The guidance system may include a data interface configured to receive real-time information indicative of at least one paving parameter, and to receive project-specific information indicative of at least one construction parameter. The guidance system may further include a locating device configured to determine a location of the compacting machine and at least one processing device in communication with the data interface and the locating device. The at least one processing device may be configured to use the real-time information and the project-specific information to determine a rolling pattern for the compacting machine. Based on the location of the compacting machine and the rolling pattern, the at least one processing device may be further configured to provide directional guidance to the compacting machine. 
     In another aspect, the present disclosure is directed to another guidance system for a compacting machine. This guidance system may include a data interface configured to receive real-time information indicative of at least one paving parameter. The guidance system may further include at least one image capture device configured to acquire real-time image data from an environment of the compacting machine, a display device located inside the compacting machine, and at least one processing device. The at least one processing device may be configured to use the real-time information to determine a rolling pattern for the compacting machine, and to present a visual representation of the rolling pattern integrated with the image data on the display device. 
     In yet another aspect, the present disclosure is directed to a software product stored on a non-transitory computer readable medium and including data and computer implementable instructions, which when executed by at least one processing device of a compacting machine cause the compacting machine to perform operations. The operations may include receiving real-time information indicative of at least one paving parameter. The operations may also include acquiring real-time image data from an environment of the compacting machine. The operations may further include using the real-time information to determine a rolling pattern for the compacting machine. The operations may additionally include displaying a visual representation of the rolling pattern integrated with the image data. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagrammatic illustration of a paving system according to one exemplary embodiment; 
         FIG. 2  is a side diagrammatic illustration of a compacting machine according to one exemplary embodiment; 
         FIG. 3  is a flow chart illustrating an exemplary disclosed method for guiding the compacting machine of  FIG. 2 ; and 
         FIG. 4  is an isometric illustration of a display device of the compacting machine of  FIG. 2 , showing a graphical user interface. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a diagrammatic illustration of a paving system  110  that includes at least one paving machine  112  and at least one compacting machine  114 . Paving machine  112  includes a frame  116  having a set of ground engaging wheels or tracks  118  mounted thereto, as well as a screed  120  for working paving material (e.g., an asphalt mixture) in a conventional manner. Paving machine  112  may further include a hopper  122  for storing paving material supplied via a supply machine  124  or another supply machine. The paving material may be transferred from hopper  122  to screed  120  via a conveyor system  126 . In some embodiments, paving machine  112  may include a receiver  128  configured to receive various electronic signals including position data, navigation commands, and paving-related information. The position data received via receiver  128  may include geographic position data such as GPS signals or local positioning signals, or position data indicative of the position of paving machine  112  relative to other machines of paving system  110 . The navigation commands received via receiver  128  may include alert commands, start commands, stop commands, machine speed commands, conveyor speed commands, travel direction commands, etc. The paving-related information received via receiver  128  may include information from other machines of paving system  110  including, for example, paving material temperature data as measured by compacting machine  114 . Paving machine  112  may also include a signaling device such as a transmitter  130  for outputting data signals or control signals to other machines. In addition, paving machine  112  may include a display device  132 , such as an LCD display device. In one embodiment, display device  132  may present a map of a work area, including icons representing one or more of the machines of paving system  110 . 
     In some embodiments, paving machine  112  may include a control system  134  for guiding and controlling paving machine  112 . Control system  134  may include a processing device  136  coupled with each of receiver  128 , transmitter  130 , display device  132 , and sensor  138 . The term “processing device” may include any physical device having an electric circuit that performs a logic operation on input or inputs. For example, the processing device may include one or more integrated circuits, microchips, microcontrollers, microprocessors, all or part of a central processing unit (CPU), graphics processing unit (GPU), digital signal processor (DSP), field programmable gate array (FPGA), or other circuits suitable for executing instructions or performing logic operations. In some embodiments, the at least one processing device may be associated with a software product stored on a non-transitory computer readable medium and comprising data and computer implementable instructions, which when executed by at least one processing device, cause paving machine  112  to perform operations. The non-transitory computer readable medium may include a memory, such as RAM, ROM, flash memory, a hard drive, etc. The computer readable memory may also be configured to store electronic data associated with operation of paving system  110 , for example, temperature data for paving material with which machines  112  and  114  interact, position data, time data, lift number data, and more. 
     In one embodiment, processing device  136  may receive real time information from sensor  138  during the paving operation. The real-time information may be transmitted to compacting machine  114 , such that a rolling pattern may be determined in real-time. Sensor  138  may be any type of sensor or sensor group configured to sense some parameter value that is indicative of, either directly or indirectly, the performance of paving machine  112 . Consistent with the present disclosure, sensor  138  may include, for example, a drum speed sensor, a temperature sensor, a speedometer, and more. In addition, sensor  138  may include one or more sensors unassociated with the performances of paving machine  112 . For example, sensor  138  may be an optical temperature sensor such as an infrared camera configured to measure the temperature of the paving material. Alternatively, sensor  138  may be a non-optical sensor such as a digital or analog sensor configured to provide data regarding the performance of paving machine  112 . 
     Compacting machine  114  may follow behind paving machine  112  and compact paving material distributed by paving machine  112  while the paving material is still relatively hot. Compacting machine  114  may include processing device  137  coupled with a receiver  129 , a transmitter  131 , a display device  133 , and sensor  139 . Receiver  129  may receive various electronic signals including position data, navigation commands, real-time information, and project-specific information. A detailed description of the information that receiver  129  may receive is provided below. Transmitter  131  may transmit position data indicative of a relative or geographic position of compacting machine  114 , as well as electronic data such as data acquired via one or more sensors  139 . Sensor  139  may measure various parameters, for example, the temperature of the paving material that compacting machine  114  is interacting with. In some embodiments, compacting machine  114  may include a control system  135  for guiding and controlling compacting machine  114 . For example, control system  135  may determine a recommended rolling pattern and display the rolling pattern to the operator of compacting machine  114 . In another embodiment, control system  135  may communicate directly with control system  134  in order to share processed electronic data generated during operation of paving system  110 . 
     Consistent with exemplary embodiments of this disclosure, the control, monitoring, and/or data recording of paving system  110  may take place from a variety of locations, either onboard of machines  112 ,  114 , or at a separate command center. It is contemplated that, for at least certain paving jobs, paving system  110  may be used with one or more control stations separate from each of the respective machines. A control station  140  may be a part of paving system  110 . For example, control station  140  may include a computer monitored by a paving foreman, technician, etc., and may receive signals from any or all of the machines of paving system  110  and output control commands. Control station  140  may serve as an alternative or supplemental command center where personnel can monitor paving progress, view maps of the work area, etc. To this end, control station  140  may also include a receiver  142 , an electronic control unit  144 , a memory  146  and a transmitter  148 . Electronic control unit  144  might also comprise a memory writing device  150  configured to record electronic data from any of machines  112 ,  114 , or  124  on memory  146 . 
     Control station  140  may also be configured to communicate with supply machines and/or even an asphalt plant to speed up or slow down paving material production, delivery, etc., based on progress of paving system  110 . It should be appreciated that any or all of the control and data recording aspects of paving system  110  might take place at control station  140 , via a laptop computer, a PDA, cell phone, etc. Typically, control station  140  will be in two-way communication with at least some of the machines of paving system  110 , and also in one-way or two-way communication with machines and personnel associated with a supply chain for paving material. Additional stations (not shown), such as a quality control station and a validation station, may also be used. In some instances, a quality control station may be used to record data relating to comparisons between pre-established paving specifications and actual paving parameters. The quality control station could also be used to make any necessary changes in system operation between paving process stages. The quality control changes might take place via computer or by a technician. A validation station may also be set up at a work site to record information relating to paving specifications and paving quality, etc., for access by personnel other than paving contractors. 
       FIG. 2  illustrates compacting machine  114  in greater detail. Compacting machine  114  may include a first frame unit  212 , a second frame unit  214 , and an operator cabin  216  having therein a navigation device  218 , such as a steering wheel. As shown in  FIG. 2 , processing device  137  may be coupled with a data interface  220  that is connected to sensor  139  via a communication line  222 . Data interface  220  may be also connected with receiver  129 , display device  133 , an image capturing device  224 , a locating device  226 , and navigation device  218  via at least communication line  228 . 
     In one embodiment, compacting machine  114  may include an articulation joint  230  coupling first and second frame units  212  and  214 , and may further include a steering system  232  to steer compacting machine  114  during operation. To this end, navigation device  218 , or an autonomous driving module associated with processing device  137 , may communicate steering control signals via yet another communication line  234  to steering system  232 . In one specific embodiment, steering system  232  may include one or more steering actuators  236 , such as hydraulic cylinders, having one or more control valves  238  coupled therewith. Steering control signals may be used to adjust a position, speed, direction, etc., of actuators  236  to control travel of compacting machine  114 . In some embodiments, compacting machine  114  may also be equipped with an electronically and/or operator controlled throttle (not shown), and possibly other control features such as a vibratory apparatus (not shown) associated with one or more compacting drums  240  and  242 . Additionally or alternatively, compacting machine  114  may include apparatus for sensing a smoothness and/or stiffness of paving material over which compacting machine  114  is travelling. Transmitter  131  may be equipped to transmit data that includes smoothness and/or stiffness information for use in system control and/or contract validation, etc. 
     Compacting machine  114  is shown as having dual drums  240  and  242 . However, other types of compacting machines may be suitable for use in the context of the present disclosure. In non-articulated versions of compacting machine  114 , for instance, a different type of steering system may be used. Further, belted compacting machines or compacting machines having a single rotating compacting unit, or more than two compacting units, are contemplated herein. Rather than a self-propelled compacting machine as shown, compacting machine  114  might be a tow-behind or pushed unit configured to couple with a tractor (not shown). An autonomous compacting machine is also contemplated herein. 
     Sensor  139  may be any type of sensor, or sensor group, which is configured to sense some parameter value that is indicative of, either directly or indirectly, a compaction response of the paving material in the work area. Sensor  139  may be separate from or integral with compacting machine  114 . Positioning of sensor  139  on compacting machine  114  can provide real-time information that may be used for determining the rolling pattern. For example, sensor  139  may sense a relative rolling resistance of the paving material as compacting machine  114  moves across the work area. In response, sensor  139  may output the sensed values to processing device  137 , via communication line  222 . Descriptions herein of “paving material” should not be construed in a limiting sense. Soil, sand, gravel, concrete, asphalt, landfill trash, mixtures including any of the foregoing, etc., are all contemplated as paving materials suitable for compaction via the methods and apparatuses described here 
     In one embodiment, compacting machine  114  may use a single image capturing device to acquire real-time image data for input to processing device  137 . Alternatively, compacting machine  114  may use a plurality of image capture devices to acquire the real-time image data. The term image capture device refers to any type of device suitable of detecting and converting optical signals in the near-infrared, infrared, visible, and ultraviolet spectrums into electrical signals. The term image data includes any form of data retrieved from optical signals, for example, the image data may include video streams and/or images. In one example, image capturing device  224  may be positioned in operator cabin  216 . Alternatively, a first image capturing device  224  may be mounted to first frame unit  212  and a second image capturing device  224  may be mounted to second frame unit  214 . 
     In some embodiments, locating device  226  may determine the location of compacting machine  114  and/or the relative position of compacting machine  114  within the work area. The determination of the location and/or the relative position of compacting machine  114 , together with the determination of a paving material compaction response, may enable processing device  137  to determine the rolling pattern for compacting machine  114 . The rolling pattern may be provided to guide compacting machine  114 . For example, the rolling pattern may identify regions wherein supplemental compaction of the paving material is desired. In addition, the rolling pattern may identify regions where supplemental compaction effort will be futile, such that wasted effort is avoided. 
       FIG. 3  is a flow chart illustrating an exemplary process  300 . Exemplary process  300  describes how processing device  137  can guide compacting machine  114  using a rolling pattern determined based on information retrieved from one or more sources.  FIG. 4  is an isometric illustration of display device  133  showing a graphical user interface. The graphical user interface illustrates how a visual representation of the rolling pattern may be integrated with captured image data. 
     INDUSTRIAL APPLICABILITY 
     The disclosed guidance system may be applicable to any compacting machine. The above capabilities of control system  135  may be embodied in exemplary process  300  for guiding a compacting machine. Exemplary process  300  is to be construed as non-exclusive. Specifically, the steps of exemplary process  300  may be modified in any manner, including by reordering steps and/or inserting or deleting steps. It is intended, therefore, that exemplary process  300  be considered as illustrative only. 
     At step  302 , system  135  may receive real-time information indicative of at least one paving parameter. In some embodiments, system  135  may include a data interface (e.g., data interface  220 ) configured to receive the real-time information. The term “data interface” includes any device configured to receive digital data from one or more sources. The disclosed embodiments are not limited to any particular data interface configurations or protocol. In some embodiments, system  135  may receive real-time information from the sensors associated with compacting machine  114  (e.g., from sensor  139 ), and sensors associated with paving machine  112  (e.g., from sensor  138 ). As mentioned above the real-time information may be indicative of at least one paving parameter. Consistent with embodiments of this disclosure, the at least one paving parameter may be part of a group of parameters that includes temperature-related parameters. This may include, for example, the temperature of the paving material as measured at paving machine  112 , the temperature of the paving material as measured at compacting machine  114 , the ground temperature, the air temperature, the predicted cooling rate, ambient temperature, etc. The at least one paving parameter may also include paver-related parameters, for example, the velocity of paving machine  112 , the paving rate, the paving material depth, etc. In addition, the at least one paving parameter may also include compactor-related parameters, for example, the velocity of compacting machine  114 , the frequency of drums  240 ,  242 , the amplitude of drums  240 ,  242 , etc. 
     At step  304 , system  135  may receive project-specific information indicative of at least one construction parameter. System  135  may receive the project-specific information from a data interface (e.g., data interface  220 ). In some embodiments, system  135  may communicate with a paving machine co-located at a common worksite (e.g., paving machine  112 ), with a work site management center, and with a remote control station (e.g., control station  140 ). The data interface may receive the project-specific information from one or more input devices associated with at least one of compacting machine  114 , paving machine  112 , and remote control station  140 . As mentioned above, the project-specific information may be indicative of at least one construction parameter. In some embodiments, the at least one construction parameter may be part of a group of parameters that includes mixture-related parameters, for example different characteristics of the paving material: composition, chemical properties, physical properties, amount, graduation, size, shape, etc. The at least one construction parameter may also include machine-related parameters, for example the types of the machines being used, the models of the machines being used, the machines&#39; status, etc. In addition, the at least one construction parameter may include job-related parameters, for example, a required width of lane to compact, a required length of lane to compact, a type of paving project, etc. 
     At step  306 , system  135  may determine a location of compacting machine  114 . According to some embodiments consistent with the present disclosure, system  135  may include a locating device (e.g., locating device  226 ) for determining the location of compacting machine  114 . The term locating device refers to any geographical locating device, regardless of whether it receives a signal from a separate receiver (e.g., receiver  129 ), or has an internal receiver configured to receive signals from a wireless network, e.g., a satellite network or a cellular network. In some embodiments, the locating device may be further configured to determine the relative position of compacting machine  114  to other machines within a work area. 
     At step  308 , system  135  may acquire real-time image data from the environment of compacting machine  114 . In some embodiments, system  135  may include at least one image capture device (e.g., image capture device  224 ) configured to acquire real-time image data from an environment of compacting machine  114 . Processing device  137  may be configured to retrieve information from the image data from the environment of compacting machine  114 , and use the information retrieved from the image data in determining a rolling pattern. In some embodiments, the information retrieved from processing the image data may include identifying objects in the path of compacting machine  114 , for example, vehicles, pedestrians, road signs, and more. 
     At step  310 , system  135  may determine a rolling pattern for compacting machine  114 . System  135  may determine the rolling pattern using information from one or more sources. Specifically, processing device  137  may use a combination of any of the information received and/or determined in steps  302 - 308 . In a first example, processing device  137  may use the real-time information to determine the rolling pattern. In a second example, processing device  137  may use the real-time information and the project-specific information to determine the rolling pattern. In a third example, processing device  137  may use the real-time information, the project-specific information, and the location of compacting machine  114  to determine the rolling pattern. In a fourth example, processing device  137  may use the real-time information and information retrieved from processing the image data to determine the rolling pattern. In addition to the information received and/or determined in steps  302 - 308 , supplemental information from various sources may be used (e.g., from a weather forecast). 
     In some embodiments, determining the rolling pattern includes determining at least one of a vibrational amplitude of compacting machine  114 , a vibrational frequency of compacting machine  114 , and a required number of passes that compacting machine  114  should make (e.g., five passes or seven passes). Consistent with disclosed embodiments, the rolling pattern may identify a first mixture area having compacting priority over a second mixture area. The first mixture area and the second mixture area may be adjacent to each other and may be undistinguishable to an ordinary observer. However, identifying the first and second mixture areas enables processing device  137  to guide compacting machine  114  to the first mixture area before the second mixture area. In some cases, the rolling pattern may depend on the location of compacting machine  114  relative to the first mixture area to be compacted. For example, assuming the first mixture area to be compacted is on the right of compacting machine  114 , after compacting machine  114  has turned to the right, the first mixture area to be compacted would be in front of compacting machine  114  and the rolling pattern would change accordingly. 
     At step  312 , system  135  may provide directional guidance to compacting machine  114 . In one embodiment, processing device  137  is configured to provide directional guidance based on the location of compacting machine  114  and the rolling pattern. In case compacting machine  114  is an autonomous machine, the directional guidance may be provided to a navigation module. The navigation module may then guide compacting machine  114  to compact an area without operator intervention. Alternatively, the directional guidance may be provided to the operator of compacting machine  114  via a display (e.g., display device  133 ), a speaker, a tactile device, and/or any other devices for providing output information to a user. In some embodiments, the directional guidance may include guidance to the first mixture area identified as having a compacting priority over the second mixture area. In addition, processing device  137  may further provide guidance regarding at least one of: a velocity of compacting machine  114 , the vibration amplitude of drums  240  and  242 , and the frequency of drums  240  and  242 . Thus, the operator of compacting machine  114  would know where to compact and what compacting parameters to apply. 
     At step  314 , system  135  may present a visual representation of the rolling pattern integrated with the image data. In some embodiments, display device  133  may present the real-time image data acquired at step  308  to the operator, and processing device  137  may show a visual representation of the rolling pattern integrated with the image data on display device  133 . Specifically, the visual representation may provide guidance to a first mixture area and to the second mixture area. In one embodiment, presenting the visual representation of the rolling pattern integrated with the image data includes overlapping the visual representation on top of the image data. 
     Consistent with disclosed embodiments, non-transitory computer-readable storage media that may store one or more software products is provided. When a software product is executed by processing device  137  it may cause compacting machine  114  to perform any or all steps of exemplary process  300 . 
     An illustration of how the visual representation of the rolling pattern may be integrated with the image data is illustrated in  FIG. 4 . Display device  133  may take the form of a portable device including a screen  410  configured to display a graphical user interface  412 . Graphical user interface  412  may display a visual representation  414  of the rolling pattern integrated with the image data  416 . Graphical user interface  412  may further display two dashed lines representing the center of image data  416 , and a left arrow indicating that compacting machine  114  needs to turn left. Consistent with exemplary embodiment of the present disclosure, visual representation  414  may include a dotted area representing the area to compact first, e.g., the first mixture area. Also, image data  416  may be a live video stream capturing the moving direction of compacting machine  114 . Display device  133  may also include one or more keys  418  to input data, for example, to input project-specific information. Alternatively, screen  410  maybe a touchscreen enabling the operator to input data. In some embodiments, the visual representation changes according to the movement of compacting machine  114 , such that when the operator of compacting machine  114  looks at display device  133 , he/she would immediately understand which way to steer compacting machine  114 . 
     In some embodiments, graphical user interface  412  may include information regarding the velocity of compacting machine  114 . In other embodiments, graphical user interface  412  may include information regarding the vibration amplitude and/or the frequency of drums  240  and  242 . The information may be presented after the operator presses one of keys  418 . For example, graphical user interface  412  may display one or more bar charts (not shown) illustrating the current velocity of compacting machine  114  compared to the recommend velocity, the current vibration amplitude of drums  240  and  242  compared to the recommend vibration amplitude, and/or the current frequency of drums  240  and  242  compared to the recommend frequency. Graphical user interface  412  may further display a representation of the compacting process progress  420 . The representation of the compacting process progress indicates the current pass number out of the total passes determined for the job. In one embodiment, the dotted area representing the first mixture area in visual representation  414  of the rolling pattern may have the same color (or dots density) as the current pass number in representation of the compacting process progress  420 . 
     It will be apparent to those skilled in the art that various modifications and variations can be made to system  135 . Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed system. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.