Patent Publication Number: US-10787773-B2

Title: Calibration system and method for a spraying machine

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority from the U.S. Provisional Application No. 62/716,112, filed on Aug. 8, 2018, which is incorporated by reference herein in its entirety 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to a road construction machine, and more particularly, to a system and method for calibrating emulsion fluid delivery in a spraying machine. 
     BACKGROUND 
     The present disclosure relates to paving machines that are used in road surface construction and repairs. Paving machines are typically utilized to lay asphalt or other paving material. Paving often includes delivering (e.g., spraying) a pre-coating tack, emulsion fluid, or other treatment fluid on the ground or road surface to aid in the bonding of the new pavement. Paving machines aim to spray a constant amount of treatment fluid to the ground surface. Different paving operations may involve different treatment fluids, and different treatment fluids may have different properties, including density, viscosity, etc. The different properties of the treatment fluid may affect the delivery rate and/or the spray area of the treatment fluid. 
     U.S. Pat. No. 9,845,579, issued to Pembleton et al. on Dec. 19, 2017 (“the &#39;579 patent”), describes a pavement coating system having a shiftable spray bar. The &#39;579 patent discloses a pavement coating system that uses a pump to deliver one or more pump counts of coating material into a container. The container may then be weighed or otherwise measured to produce a calibration scale factor, which may then be input into the control system in order to correlate a pump count with the output mass or volume of the coating material. The control system of the &#39;579 patent also is coupled to one or more speed sensors, and adjusts a pump rate in light of the sensed ground speed to maintain a predetermined application rate. The &#39;579 patent discloses calibrating the mass or volume of coating material delivered, but the control system does not take into account, among other things, a spray area of one or more nozzles. Accordingly, the control system does not adjust a spray rate to maintain a desired amount of coating material over an area of the ground surface. The paving machine of the present disclosure may solve one or more of the problems set forth above and/or other problems in the art. The scope of the current disclosure, however, is defined by the attached claims, and not by the ability to solve any specific problem. 
     SUMMARY 
     In one aspect, a paving system may include a paving machine, including a paving material delivery assembly, including a hopper, a conveyor assembly, an auger, and a screed. The paving machine may also include an emulsion fluid delivery assembly including a plurality of spray bars, wherein each spray bar includes one or more nozzles. The paving system may also include a controller and a display interface. The controller may be configured to receive inputs from the display interface indicative of a mass and an area of emulsion fluid delivered from one active nozzle in order to calibrate the emulsion fluid delivery assembly. 
     In another aspect, a control system for a paving machine may include a plurality of spray bars coupled to the paving machine to deliver an emulsion fluid to a ground surface, wherein each of the spray bars includes one or more nozzles. The control system may also include a controller and a display interface. The controller may be operatively coupled to the display interface and to each spray nozzle on the plurality of spray bars to calibrate a delivery of emulsion fluid through the nozzles based on an inputted mass of the emulsion fluid and an inputted area of a spray pattern through one active nozzle. 
     In a further aspect, a method of calibrating an emulsion fluid delivery system for a paving machine may include selecting an active nozzle, with the active nozzle being one of a plurality of nozzles on one or more spray bars mounted on the paving machine, delivering an emulsion fluid through the active nozzle for a spray duration, measuring a mass of the emulsion fluid delivered through the active nozzle over the spray duration, and inputting the measured mass of the emulsion fluid delivered through the active nozzle over the spray duration into a user interface. The method may also include delivering a spray pulse of the emulsion fluid through the active nozzle, measuring a length and a width of a spray pattern of the emulsion fluid delivered during the spray pulse, and inputting the measured length and width of the spray pattern of the emulsion fluid delivered during the spray pulse into the user interface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an illustration of portions of an exemplary machine, according to aspects of this disclosure. 
         FIG. 2  is an illustration of an exemplary spray nozzle and a corresponding spray pattern of the exemplary machine of  FIG. 1 . 
         FIG. 3  provides a flowchart depicting an exemplary method for calibrating the delivery of emulsion fluid, according to aspects of this disclosure. 
         FIG. 4  is an illustration of an exemplary display interface of the exemplary machine of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” “having,” “including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. 
     For the purpose of this disclosure, the term “ground surface” is broadly used to refer to all types of surfaces that form typical roadways (e.g., asphalt, cement, clay, sand, dirt, etc.) or upon which paving material may be deposited in the formation of roadways. In this disclosure, relative terms, such as, for example, “about,” “substantially,” and “approximately” are used to indicate a possible variation of ±10% in a stated value. Although the current disclosure is described with reference to a paving machine, this is only exemplary. While the present disclosure will be discussed in connection with a paving machine, it is understood that the current disclosure can be applied as to any machine, such as, for example, a paver finisher, a tanker truck, an asphalt finisher, any other machine used in the paving process, or any other machine that includes a spraying system where calibration would be beneficial. 
       FIG. 1  illustrates a bottom view of portions of an exemplary paving machine  10 , according to the present disclosure. Machine  10  may be any size paver with any paving width. In one aspect, machine  10  may be a small paver, for example, with a maximum paving width of approximately 5.5 meters. Machine  10  includes a frame  12 , a hopper  14 , and an auger  16 . Machine  10  also includes a screed  18 , which may be extendible to vary the paving width. Machine  10  may also include a conveyor assembly (not shown) to deliver paving material from hopper  14  to the ground surface below auger  16 . The paving material may be spread, smoothed, tamped, etc. by auger  16  and screed  18 . Although not shown, machine  10  is coupled to a supply of emulsion fluid, either mounted on machine  10  (e.g., via a tank located to the rear of hopper  14 ), or connected to machine  10  (e.g., carried by a supply tanker ahead of machine  10 ). Additionally, one or more spray bars  20  with nozzles  22  are coupled to machine  10  to deliver the emulsion fluid to the ground surface. Spray bars  20  may be fixed on machine  10 , or may be movable (e.g., raised or lowered, pivotable, extendable, telescoping, etc.). Individual spray bars  20  or individual nozzles  22  may be activated via a controller, for example, an emulsion control module (or “ECM”)  24 , and ECM  24  may be in communication with one or more control panels, for example, an operator display interface  26 . Display interface  26  may be used to control or monitor one or more aspects of machine  10  via ECM  24 . 
     Although not shown, machine  10  may also include an operator station or cab, from which an operator may maneuver and control machine  10 . Machine  10  may also include one or more operator positions, for example, positioned on screed  18  from which an operator may monitor or control aspects of machine  10 . One or more display interfaces  26  may be positioned in the operator station or in one or more operator positions on screed  18 . Alternatively or additionally, one or more display interfaces  26  may be remote from machine  10 . 
     In one aspect, the one or more spray bars  20  include a plurality of spray bars  20 , each including a plurality of nozzles  22 . Each of the nozzles  22  on each spray bar  20  may be selectively opened to deliver emulsion fluid to a ground surface, ahead of delivery of the paving material to the ground surface. For example, machine  10  may include two side spray bars  20 A, two rear spray bars  20 B, and a central spray bar  20 C. The two side spray bars  20 A may each include four nozzles  22  and may be pivotable relative to machine  10 . The two rear spray bars  20 B may each include two nozzles  22  and may be positioned to the rear of frame  12 , for example, to the rear of ground-engaging elements or tracks  28  and forward of auger  16 . Central spray bar  20 C may include four nozzles  22  and may be a forward-most spray bar. For example, central spray bar  20 C may be positioned between ground-engaging elements or tracks  28  and rearwardly of hopper  14 . Each spray bar  20  and individual nozzles  22  may be electronically coupled to ECM  24 . Moreover, display interface  26  may be coupled to ECM  24  to control and monitor the status of spray bars  20  and nozzles  22 . 
     ECM  24  may include a computer or computer readable memory storing computer executable instructions to control delivery of emulsion fluid through spray bars  20  and nozzles  22 . ECM  24  may be configured to selectively control the delivery of emulsion fluid from the supply by controlling a pump coupled to the supply and spray bars  20  via one or more hoses. ECM  24  may also be operatively coupled to nozzles  22  to open or close individual nozzles  22 , for example, by controlling the opening and closing of one or more pneumatic valves associated with each nozzle  22 . Additionally, ECM  24  may be configured to receive data from one or more sensors, for example, one or more sensors measuring the speed or direction of machine  10 . In one aspect, one or more sensors  29  may be in communication with elements driving each track  28  to measure a speed or direction of each track  28 . For example, one sensor  29  may be coupled to a drive wheel  28 A or idler  28 B of each track  28  to measure the speed of each track  28 . Sensors  29  may be wired or wirelessly coupled to ECM  24 , and ECM  24  may calculate a speed and direction for machine  10  based on the information received from sensors  29 . Accordingly ECM  24  may also be configured to determine a distance traveled by machine  10 . ECM  24  may further be configured to receive user commands or information from a user input device, for example, from display interface  26 . ECM  24  may be wired or wirelessly connected (e.g., via Bluetooth®, WiFi, or other connection protocol) to nozzles  22 , display interface  26 , sensors, and other components of machine  10 . 
     As discussed in greater detail with respect to  FIG. 4 , display interface  26  includes a display with a series of display and input options. Display interface  26  may be operable to control the delivery of emulsion fluid by opening or closing one or more internal valves and/or by controlling the operation of emulsion pumps, for example, via ECM  24 . Furthermore, the functions and capabilities of display interface  26  may be combined into a touch screen user interface. As noted above, one or more display interfaces  26  may be positioned on machine  10  or may be remote from machine  10 , for example, on a smartphone, tablet, or laptop. In either aspect, one or more display interfaces  26  may be wired or wirelessly connected to ECM  24 . 
       FIG. 2  illustrates an exemplary spray pattern  30  from one nozzle  22 . In one aspect, all of nozzles  22  on spray bars  20  are identical, and thus deliver a common spray pattern  30 . Nozzle  22  delivers the emulsion fluid to the ground surface to form spray pattern  30  on an area of the ground surface. Spray pattern  30  has a length L and a width W. Spray pattern  30  is shown as being substantially rectangular, but this disclosure is not so limited, as spray pattern  30  may take other shapes depending on the particular type of nozzle. Because nozzles  22  on spray bars  20  are the same type of nozzle, testing one nozzle  22  to determine an area of spray pattern  30  may be used to determine the area of spray patterns  30  for all of nozzles  22  and to calibrate the delivery of emulsion fluid for machine  10 . Alternatively, machine  10  may include two or more types of nozzles  22 , and each type of nozzle  22  may be measured and calibrated. 
       FIG. 3  provides a flowchart depicting an exemplary method  100  for calibrating the delivery of emulsion fluid. Method  100  includes determining a mass of delivered emulsion fluid per an area of ground surface (i.e., kg/m 2 ), which may then be used to calibrate the delivery of a particular emulsion fluid during a paving operation. As mentioned, different emulsion fluids, or the same fluid under different conditions (e.g., temperature, humidity, or altitude variations), may exhibit different densities, viscosities, or other properties that may affect the delivery rate and/or the spray area of the particular emulsion fluid. Accordingly, method  100  may be performed before initiating a particular paving operation, and the performance of method  100  may be prompted and/or assisted by ECM  24  and display interface  26 . 
     Method  100  includes an initial step  102  of selecting one spray nozzle  22  to be used for the calibration process. Display interface  26  may be used to select the particular nozzle  22 , for example, by placing the particular nozzle  22  in an active configuration with the remaining nozzles  22  in an inactive configuration. In one aspect, an outer-most nozzle  22  on one of side spray bars  20 A may be used as the active nozzle  22  to allow for easier access for a user to position a receptacle under the active nozzle  22 . Step  104  includes setting a duration for the selected spray nozzle  22 . For example, a user may input a duration of, for example, five seconds for the active nozzle  22  to deliver emulsion fluid. Step  106  includes placing a receptacle of known weight underneath the selected spray nozzle  22 . In one aspect, a cup, a bucket, or other receptacle may be weighed when empty in order to measure the weight of the receptacle, and then the receptacle may be positioned underneath the selected nozzle  22 . Step  108  of method  100  includes activating the selected spray nozzle  22  for the selected duration. Depending on machine  10 , the delivery of the emulsion fluid during the duration may be continuous, or may be delivered in intervals. In this step, the delivered emulsion fluid is collected in the receptacle. Next, step  110  includes weighing the receptacle, and step  112  includes subtracting the known weight of the receptacle to determine a mass of the sprayed emulsion fluid delivered in the set duration. In step  114 , the mass of the sprayed emulsion fluid may be input into the display interface  26 . As such, ECM  24  may determine a mass of emulsion fluid delivered as function of time. Additionally, because the duration of each spray pulse is known, ECM  24  may determine a mass of emulsion fluid delivered for each spray pulse. 
     Method  100  further includes step  116  that includes activating the selected spray nozzle  22  for one or more spray pulses. The one or more spray pulses may be one spray pulse, two spray pulses, etc., and the number of spray pulses delivered in step  116  may be set or adjusted on display interface  26  ( FIG. 4 ). For example, spray pattern  30  may be clearer or more easily measured if two or more spray pulses are delivered to the ground surface compared to a single spray pulse. Step  116  may include an initial step of placing a large piece of paper, plywood, or other material on the ground surface below the selected spray nozzle  22  such that the material receives the delivered emulsion fluid. Alternatively, spray pattern  30  may measured directly on the ground surface. Next, step  118  of method  100  includes measuring a length of spray pattern  30  delivered by the one or more spray pulses ( FIG. 2 ). Step  120  includes measuring a width of spray pattern  30  delivered by the one or more spray pulses. Then, step  122  includes inputting the measured length and width of spray pattern  30  into display interface  26 . The length and width of spray pattern  30  may be entered individually such that ECM  24  may determine an area of spray pattern  30  formed by the one or more spray pulses, or the user may use the measured length and width to determine an area of spray pattern  30 , which may then be entered into display interface  26 . 
     It is noted that different measurements may be taken and input into display interface  26  if spray pattern  30  is a non-rectangular shape. Although not shown in the figures, display interface  26  may include a shape input, in which a user may input or select the shape of spray pattern  30 . Similarly, display interface  26  may include one or more inputs for the user to input various measurements of spray pattern  30  for ECM  24  to determine an area of spray pattern  30 . 
     Using method  100 , ECM  24  may use the inputted measured mass of the sprayed emulsion and area of the spray pattern to determine a delivery rate (e.g., mass per area in kg/m 2 ) of emulsion fluid sprayed by nozzle  22 . ECM  24  may apply the determined delivery rate to each nozzle  22  on spray bars  20 , and ECM  24  may modify active nozzles  22  and/or the frequency of spray pulses as necessary during a paving operation in order to deliver the appropriate (desired or stored) amount of emulsion fluid to the appropriate portions of the ground surface. For example, ECM  24  may be coupled to one or more speed or direction sensors of machine  10  (i.e., sensors  29 ) that detect a speed or direction of machine  10 , and ECM  24  may modify which of nozzles  22  are active and/or the frequency of spray pulses based on the detected speed or direction of machine  10  in order to maintain a consistent delivery of emulsion fluid to the ground surface. Moreover, ECM  24  may be coupled to one or more sensors that determine a width of screed  18 , and ECM  24  may modify which of nozzles  22  are active and/or the frequency of spray pulses based on the detected width of screed  18 . 
       FIG. 4  illustrates an exemplary control panel display  32  that may be displayed on display interface  26 . Control panel display  32  may be a touch screen (e.g., an iPad®, tablet, etc.), or may instead include a display or a plurality of displays and one or more pushbuttons, switches, a keyboard, etc. Control panel display  32  displays a plurality of measured values, user input options, and other information to an operator of machine  10 . 
     Control panel display  32  may include a plurality of display screens, which may be selectable via a plurality of tabs  34 A- 34 L on a tool bar  36 . For example, tool bar  36  may include a home tab  34 A and a variety of other tabs  34 B- 34 L to allow a user to toggle between a variety of other input and/or monitoring screens, which may include accessing corresponding settings or actuation control screens.  FIG. 4  illustrates control panel display  32  being in a nozzle calibration mode or screen, for example, with tab  34 F being active and the corresponding icon  38  being displayed on control panel display  32 . 
     Nozzle calibration mode may include displaying a plurality of sensor values on control panel display  32 . For example, control panel display  32  may display one or more of a compressor pressure  40 , an emulsion fluid volume  42  in a supply, an emulsion fluid level  44  in the supply, and an emulsion fluid temperature  46  in the supply. Control panel display  32  may also display an emulsion fluid pump rate  48  and/or an emulsion fluid pressure  50 . The aforementioned values and indications may be based on a plurality of sensors positioned on or within portions of machine  10  and wired or wirelessly coupled to ECM  24 . 
     Nozzle calibration mode includes displaying a plurality of nozzle controls  52  and nozzle indicators  54 . Nozzle controls  52  may allow a user to control (i.e., activate or deactivate) individual nozzles  22 . Nozzle indicators  54  may illuminate or change color to indicate the operational status of individual nozzles  22  or sets of nozzles  22 . The configuration of nozzle controls  52  and nozzle indicators  54  on control panel display  32  may correspond to, or be indicative of, the relative positioning of nozzles  22  along spray bars  20  on machine  10 . In one aspect, nozzle controls  52  and nozzle indicators  54  may be combined into pushbuttons, switches, or touch screen icons to control nozzles  22 . 
     Nozzle calibration mode also includes a plurality of displays and inputs that may be used in method  100 . In one aspect, control panel display  32  may include a nozzle selection input  56  that includes a numerical indication of an active nozzle for the calibration method. The active nozzle may be adjusted via a down button  58  and an up button  60 . For example, machine  10  may include sixteen nozzles  22  on spray bars  20  (as in  FIG. 1 ), with each nozzle  22  being designated by a number between one and sixteen. The left most nozzle  22  on left side spray bar  20 A may be nozzle number “1,” and the right most nozzle  22  on right side spray bar  20 A may be nozzle number “16.” Although not shown, the active nozzle  22  may also be indicated with nozzle indicator  54  being illuminated, circled, or otherwise identified. Additionally, in the nozzle calibration mode, nozzle controls  52  may be inactive such only that nozzle selection input  56  controls which individual nozzle  22  is active for the calibration. 
     Nozzle calibration mode further includes a spray duration input  62  through which a user may set a duration for the selected spray nozzle  22 , for example, in step  104 . Spray duration input  62  may include a time display  64 , a down button  66 , an up button  68 , and an activate button  70 . A user may set the duration using down button  66  and up button  68 , and may press activate button  70  once the receptacle has been positioned below the selected nozzle  22  in order to activate the selected nozzle  22  for the set duration in step  108 . The user may then input the measured mass of the sprayed emulsion fluid, as in step  114 . For example, control panel display  32  may include a mass input  72 , which may include a down button  74  and an up button  76  to allow the user to input the measured mass of the sprayed emulsion fluid. 
     Nozzle calibration mode also includes a spray pulse input  78  through which a user may set a number of spray pulses, for example, before step  116 . Spray pulse input  78  may include a pulse display  80 , a down button  82 , an up button  84 , and an activate button  86 . A user may set the number of spray pulses using down button  82  and up button  84 , and may press activate button  86  to activate the selected spray nozzle for the set number of spray pulses in step  116 . The user may then input the measured spray pattern  30 . For example, control panel display  32  may include a length input  88  and a width input  90 , each of which may include respective up and down buttons. 
     It is noted that the inputs shown in  FIG. 4  are merely exemplary, and display interface  26  and control panel display  32  may include any number of displays and inputs. For example, nozzle calibration mode may include a numerical keypad. In one aspect, selecting nozzle selection input  56 , spray duration input  62 , mass input  72 , spray pulse input  78 , length input  88 , or width input  90  may activate the keypad such that the user may input the appropriate numerical value. Moreover, rather than measuring a mass of emulsion fluid delivered in steps  110  and  112 , method  100  may include measuring a volume of emulsion fluid delivered, for example, in a measuring cup. Display interface  26  may then include the appropriate inputs for a user to input the measured volume, and ECM  24  may determine a volume of emulsion fluid delivered over the area of spray pattern  30 . Display interface  26  and control panel display  32  may also include a plurality of alarms and notifications based on the plurality of sensors associated with machine  10 , and the alarms or notifications may be displayed on display interface and control panel display  32  regardless of the selected mode or current operation in order to advise the user. Furthermore, control panel display  32  may include additional inputs to allow a user to input information for a non-rectangular spray pattern and/or for multiple types of nozzles  22  coupled to machine  10 . 
     INDUSTRIAL APPLICABILITY 
     The disclosed aspects of machine  10  may be used in any machine to assist in delivery of sprayed fluid, and in particular, to assist in the spraying of emulsion in a paving machine. During operation, spray bars  20  may deliver emulsion fluid to the ground surface traversed by machine  10  ahead of the delivered paving material to aid in the binding of the paving material to the ground surface. However, different paving materials may necessitate different emulsion fluids, and different emulsion fluids may include different properties, such as, for example, density, viscosity, etc. that may affect the delivery rate of the emulsion fluid. Furthermore, different paving conditions (e.g., temperature, humidity, altitude, etc.) may affect the flow and delivery rate of an emulsion fluid. The disclosed aspects of machine  10  may be used to allow a user to calibrate the delivery rate of a particular emulsion fluid to be delivered under the particular conditions of a specific paving operation. 
     For example, before beginning a paving operation, the user may select the nozzle calibration mode on display interface  26 , which may prompt the user to perform method  100 . For example, display interface  26  may prompt the user to select one nozzle  22 , and to set a duration for the selected nozzle  22  using nozzle selection input  56  and spray duration input  62 . The user may collect a mass of the emulsion fluid delivered through the selected nozzle  22 , and input the mass of emulsion fluid into display interface  26 . The user may also deliver a number of spray pulses to a ground surface or material on the ground surface to determined the area of spray pattern  30 . The user may measure the spray length L and spray width W of spray pattern  30 , and input length L and width W into display interface  26 . ECM  24  may then determine a emulsion fluid delivery rate via nozzle  22  as a ratio of mass (kg) of emulsion fluid to the area of spray pattern  30  (m 2 ). Additionally, because the duration of each spray pulse is known, ECM  24  may determine a mass (kg) of emulsion fluid delivered for each spray pulse. ECM  24  may then use the measured delivery rate to calibrate each of nozzles  22  during the paving operation. For example, ECM  24  may compare the measured delivery rate to a target delivery rate and adjust one or more parameters of the emulsion fluid delivery. Additionally, based on changes in the speed and/or direction of machine  10 , or in the width of screed  18 , ECM  24  may adjust the active nozzles  22 , the frequency of spray pulses (i.e., increase or decrease the frequency of spray pulses), and other parameters of the emulsion fluid delivery in order to maintain a consistent delivery rate of emulsion fluid to the ground surface. As such, ECM  24  may more accurately or efficiently deliver emulsion fluid to the ground surface, which may increase the binding of the paving material to the ground surface. 
     If the conditions or the type of emulsion fluid change during a paving operation, the user may repeat method  100  to recalibrate the emulsion fluid delivery rate. Similarly, if the target emulsion fluid delivery rate changes during the paving operation, the steps of method  100  may be repeated to help ensure the emulsion fluid delivery rate is in line with the target delivery rate. Method  100  may be performed as many times as necessary during the paving operation, and selecting the nozzle calibration tab  34 F on display interface  26  and control panel display  32  may prompt the user to perform the calibration steps. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed machine without departing from the scope of the disclosure. Other embodiments of the machine will be apparent to those skilled in the art from consideration of the specification and practice of the control system for a paving machine disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.