Patent Publication Number: US-2023139560-A1

Title: Paving material segregation detection and monitoring

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to paving materials, and more particularly to detecting and monitoring segregation within paving materials. 
     BACKGROUND 
     Particle segregation occurs in paving material when individual particles of similar size are grouped together within the paving materials. Asphalt created from segregated paving materials may create segregation within the paved asphalt. Particle segregation in paved asphalt may accelerate damage and decrease the life of the pavement. Particle segregation may occur at any point between an asphalt plant and the paving of a road. For example, when a haul truck is transferring paving material into the hopper of a paver machine, smaller and/or less dense paving materials may segregate to the bottom of the hopper below larger and/or denser paving materials. Traditionally, the paver machine operator or other paving workers must visually observe the paving material to detect particle segregation. 
     Chinese Patent Application No. CN 107341794 A (“the &#39;794 application”) discloses a real-time asphalt uniformity testing method where a static color image of an asphalt mixture is processed to create a model evaluation of particle distribution through the mixture, which is then transmitted to a remote control center for evaluation. The &#39;794 application discloses that the remote control center may then wirelessly transmit results of the evaluation to a separate computer. 
     The material segregation detection system and methods of this disclosure may solve one or more 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 
     A method and system for detecting paving material segregation in a paving material supply chain includes at least a paving material plant, a paving material haul truck, and a paver machine. The method and system further includes receiving segregation information from a plurality of cameras located in the paving material supply chain and identifying a location of segregation formation in the supply chain based on the received segregation information. 
     A method for detecting segregation in a paving material supply chain includes at least a paving material plant, a paving material haul truck, and a paver machine. The method includes receiving segregation information from a plurality of cameras located in the paving material supply chain; identifying a location of segregation formation in the supply chain based on the received segregation information; and providing a notification or alert based on the received segregation information. 
     A system for detecting paving material segregation in a paving material supply chain includes at least a paving material plant, a paving material haul truck, and a paver machine. The system further includes a central controller configured to receive segregation information from a plurality of cameras of the supply chain, detect segregation based at least in part on the segregation information and output at least one of segregation notice data, segregation alert signals, or remedial control signals to the supply chain based on the received segregation information. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    shows a paving material supply chain and segregation monitoring and detecting system according to aspects of the disclosure; 
         FIG.  2    shows a portion of the segregation monitoring and detection system on a paving material haul truck of the supply chain of  FIG.  1   ; 
         FIG.  3    shows a portion of the segregation monitoring and detection system on a paver machine of the supply chain of  FIG.  1   ; 
         FIG.  4    illustrates a schematic of the segregation monitoring and detection system of  FIG.  1   ; and 
         FIG.  5    illustrates a method of the segregation monitoring and detection system of  FIG.  4   . 
     
    
    
     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. Moreover, in this disclosure, relative terms, such as, for example, “about,” substantially,” “generally,” and “approximately” are used to indicate a possible variation of ±10% in the stated value. 
       FIG.  1    shows a paving material supply chain  100  and a paving material segregation monitoring and detection system  400 . As used herein, paving material will be referenced with respect to asphalt  102 , however, the disclosure herein may be applicable to any type of paving material that may be subject to segregation. Segregation is a lack of homogeneity in the paving material. In particular, asphalt segregation is a lack of homogeneity in a hot asphalt mix where coarse particles, such as larger rocks or aggregates of the asphalt mix, separate from finer particles or aggregate of the mix. As shown by a camera segregation identification view  408  in  FIG.  2   , large rocks or aggregates may separate from smaller rocks or aggregates within the asphalt  102 . The larger rocks or aggregates may be denser and/or weigh more than the smaller rocks or aggregates. As asphalt  102  moves in the supply chain  100 , the smaller rocks or aggregates may migrate below and/or otherwise apart from the larger rocks or aggregates based on the movement of the asphalt  102 . Thus, the larger rocks or aggregates may migrate down an asphalt pile existing within the supply chain  100 . Segregation is also based on fine particles such as sand flowing through gaps in the larger rocks or aggregates. Thus, as noted above, segregation can occur at any stage of the paving material supply chain  100  and may result in a decreased lifespan of a mat of asphalt  102 . 
     Paving material supply chain  100  may include, for example, an asphalt production and/or storage plant  104 , one or more asphalt haul trucks  106 , one or more paver machines  108 , and a central controller  406  in communication with one or more of the plant  104 , haul truck(s)  106 , and paver machine(s)  108 . The asphalt plant  104  may form the hot asphalt mix  102  (e.g., a mixture fine and coarse aggregates, such as sand, gravel, and rock, with bitumen) and store the asphalt in a silo  110 . The one or more asphalt haul trucks  106  may be loaded with asphalt  102  from the silo  110  of the asphalt plant  104 . The asphalt  102  may be received in a bed  112  of the haul truck  106 . The haul truck  106  may then deliver the asphalt  102  to the one or more paver machines  108  for laying a mat of asphalt  102 . In particular, the bed  112  may be raised as shown in  FIGS.  1  and  2    to urge the asphalt  102  out of a tailgate  114  of the haul truck  106  into a hopper  116  of the paver machine  108 . As best shown in  FIG.  3   , the paver machine  108  may form the mat of asphalt  102  by conveying the asphalt from the hopper  116  along a conveyor  120  to one or more augers  122 , and then to a screed  124  of the paver machine  108 . As will be discussed in more detail below, the hopper  116  may include side walls  126  that are actuated to fold inward to urge the asphalt  102  in the hopper  116  toward the conveyor  120 . Also, the speed of the conveyor  120  and the one or more augers  122  is controllable. 
     Referring again to  FIG.  1   , the paving material segregation monitoring system  400  may include a plurality of cameras  402  for capturing segregation information, transmitters  404  for sending and receiving information within the supply chain  100  to and from a central controller or hub  406 . For example, the transmitters  404  may wirelessly send segregation information from cameras  402  to central controller  406 , and central controller  406  may send information (e.g., data, signals, and/or commands) to other elements within the supply chain  100 . Alternatively, information exchange can be done in a wired manner. 
     Cameras  402  may be visible light or thermal cameras capable of distinguishing individual particles in paving material, such as the size and distribution of particles or aggregates making up the asphalt  102 . For example, cameras  402  may include one or more lenses, image sensors, digitization circuitry, and image processors for converting captured images (e.g.,  408 ,  FIG.  2   ) to a digital format and for processing the images, for example, to detect material segregation in the images. Cameras  402  may also include memory, for example in the form of read-only memory (ROM), random access memory (RAM), integrated circuitry memory, or a combination. Cameras  402  may include communication circuitry and be wired or wirelessly connected to transmitters  404  for communicating with controller  406 . Cameras  402  may include or be associated with clocks and GPS or other position sensors for identifying the time and where the images are captured. 
     As noted above, camera  402  may be a thermal camera configured to use, for example, Light Detection and Ranging (“Lidar”) to determine particle size and distribution within the asphalt. In such a camera  402 , a laser beam is emitted, and diffraction is received by the camera  402  to determine the size and distribution of particles in the asphalt. In particular, the large particles in the asphalt may scatter light at small angles relative to the laser, and small particles may scatter light at large angles relative to the laser. 
     In an alternative aspect, camera  402  may be a visible light camera that captures images of the individual particles in the paving material, and that image is sent to controller for analysis to determine size and distribution of particles or aggregates making up the asphalt  102 . Camera  402 , either as a visible light or thermal camera, will thus sense or capture information regarding particle size and particle distribution within the asphalt  102 . This information may form the segregation information sent to controller  406  for further processing and determinations regarding whether segregation exits. Alternatively, the sensed information by camera  402  may be processed within the camera  402  itself to determine whether segregation exits in asphalt  102 , and such processed information may be sent to controller  406  as the segregation information. 
     At least one camera  402  may be positioned at each location in supply chain  100  where the asphalt will be monitored. For example, one or more cameras  402  may be located at the plant  104 , the haul trucks  106 , the paver machine  108 , the mat of the asphalt  102 , and/or any other asphalt location of the supply chain  100 . In one aspect, one or more smart cameras  402  may be positioned at each of the plant  104 , the haul truck(s)  106 , and the paver machine(s)  108 . The cameras  402  may be positioned within these elements of the supply chain  100  to appropriately view the asphalt  102  for segregation determination. 
     For example, one or more cameras  402  may be positioned to view the asphalt delivery to, or stored in, silo  110  of plant  104  to determine segregation at the plant  104 . One or more cameras  402  may also be located on a haul truck  106 , such as in the bed  112  of the haul truck  106  to view the asphalt  102  stored therein.  FIG.  2    shows one such location of camera  402  to view the asphalt in the bed  112 , and a corresponding camera segregation identification view  408  of the asphalt  102  in the bed  112 . It is understood that more than one camera  402  may be used, and that the camera  402  associated with the haul truck bed  112  may be positioned and activated to view the receiving/moving of the asphalt into the bed  112  from the plant  104 , the static mound of asphalt in the bed  112 , and/or the dispensing/moving of the asphalt to the hopper  116  of the paver machine  108  from the bed  112  (as shown in  FIGS.  1  and  2   ). 
     The paver machine  108  may include one or more cameras  402  to view the asphalt in the hopper  116 , the asphalt on the conveyor, the asphalt at the auger  122 , and/or the pad of asphalt  102  created by the paver machine  108 . Similar to the haul truck cameras  402 , the cameras associated with the hopper  116  of the paver machine  108  may be configured (positioned and activated) to view the receipt/moving of the asphalt in the hopper  116  from the haul truck  106 , or view a static pile of asphalt in the hopper  116 . The one or more cameras  402  located at the conveyor  120  may be positioned anywhere along conveyor  120  to properly view the asphalt located on the conveyor  120  for detection of segregation. Similarly, the one or more cameras  402  at the auger(s)  122  may be positioned to properly view the asphalt located at the augers(s)  122  for detection of segregation. Finally, one or more cameras  402  may be located at a rear end of the paver machine  108  to view the mat of asphalt  102  for detection of segregation. It is understood that additional or alternative cameras  402  may be included about the supply chain  100 , such as a stationary camera  402  (not shown) adjacent mat of asphalt  102  for viewing the same. 
     Referring to  FIG.  4   , the material segregation monitoring system  400  may include inputs  410  to central controller  406 , and outputs  420  from central controller  406 . Central controller  406  forms a part of the supply chain  100  and may be located anywhere in communication with the plant  104  haul truck(s)  106 , and/or paver machines  108 . For example, the central controller  406  may be located at a monitoring station remote from the other elements of the supply chain  100 . Central controller  406  may embody a single microprocessor or multiple microprocessors that receive the inputs  410  and generate the outputs  420 . Central controller  406  may include a memory, a secondary storage device, a processor, such as a central processing unit, and/or any other means for accomplishing a task consistent with the present disclosure. The memory or secondary storage device associated with central controller  406  may store data and software to allow central controller  406  to perform its functions including the functions described with respect to  FIG.  5    and method  500  described below. Numerous commercially available microprocessors can be configured to perform the functions of central controller  406 . Various other known circuits may be associated with central controller  406 , including signal-conditioning circuitry, communication circuitry, and other appropriate circuitry. 
     The inputs  410  may include information from the one or more cameras  402 . For example, cameras  402  may include (n) number of cameras providing segregation information  412  to central controller  402 . As noted above, the segregation information  412  may include sensed or captured information from the cameras  402  (e.g., an image), or the sensed or captured information fully or partially processed for a segregation determination. The segregation information  412  may also include time and location information associated with the sensed information. For example, cameras  402  may include a global positioning type system and a clock for determining the location and time information of the segregation information. It is understood, however, that such time and location data may be provided by other sources than the cameras  402 , such as from the plant  104 , haul truck  106 , and/or paver machine  108 . The segregation information  412  may be provided continuously, at predetermined time or activity intervals, or upon request from central controller  406 . 
     The inputs  410  may also include supply chain information  414  received from the supply chain  100 . For example, the supply chain information  414  may include status, settings, and/or sensed or measured parameters from various elements of the supply chain  100 . Such supply chain information  414  may include status, settings, and/or measured information from the asphalt plant  104 , haul truck(s)  106 , and paver machine(s)  108 . With respect to the paver machine  108 , such supply chain information  414  may include hopper data, such as status of speed of the paver machine  108 , hopper actuation status and/or speed of hopper actuation, and/or speed the one or more augers  122  of the of the paver machine  108 . 
     The outputs  420  from central controller  406  may include segregation notice information  422  sent to one or more elements of the supply chain  100 . The segregation notice information  422  may include, for example, all or some of the bulk, raw segregation information  412  received from the cameras  402  at central controller  406 , all or some of the processed segregation information  412  from central controller  406 , and/or merely result based information indicating the existence or lack of existence of segregation in the asphalt  102 , including the time and location associated thereof. The segregation notice information  422  may be provided to, for example, the asphalt plant  104 , haul truck(s)  106 , paver machine(s)  108 , to a display associated with central controller  406 , and/or to a remote location. The segregation notice information  422  may be provided continuously, at predetermined time or activity intervals, or upon request from controller  406 . Further, the segregation notice information  422  may be stored, e.g. at central controller  406 , for further analysis and tracking. 
     The outputs  420  from central controller  406  may also include remedial actions when there is a determination that segregation exists in the asphalt  102 . The remedial actions may include, for example, alert signals  424  or control signals  426  sent to the supply chain  100 . For example, the alert signals  424  may include a visual and/or audible alert to a display and/or speaker associated with elements of the supply chain  100 . For example, the alert signal  424  may provide an alert on a display, speaker, alter light, etc. at one or more of the plant  104 , haul truck  106 , paver machine  108 , and/or display of the central controller  406 . The alert signals  424  may take the form of a mere notification of the existence of segregation and may include associated information (e.g., time and location), and/or may take the form of an alert to stop a particular process or component in the supply chain  100  in order to address the segregation. 
     Remedial action outputs in the form of control signals (or commands)  426  may include control signals to components of the supply chain  100  in attempts to minimize or discontinue the segregation detected. Such control signals may be signals to automatically stop particular processes in supply chain  100 , or may be control signals  426  to automatically adjust processes of supply chain  100 . For example, a control signal  426  may include a command to stop the paver machine  108  from paving, or the hopper  116  from actuating, or to adjust the speed of actuation of the hopper  116 , or the speed of the auger(s)  122  of the paver machine  108 . The adjustment may take the form of decreasing the speed of actuation of the hopper  116 , or the speed of the auger(s)  122  of the paver machine  108 . In another example, the remedial control signal  426  may include a new or revised route of the haul truck(s)  106  due to the determination that segregation is being caused by the current route of the haul trucks(s)  106 . It is understood that such remedial control signals  426  could alternatively take the form of recommended actions to operators of elements of the supply chain  100  to address or remedy the detected segregation. 
     In one aspect of this disclosure, the remedial action outputs (e.g. alert signals  424  and/or control signals  426 ) may be determined by a segregation remedy model  409  stored within central controller  406 . The segregation remedy model  409  may receive one or more of the segregation information  412 , supply chain information  414 , segregation determinations, results of remedial actions, weather information, and/or other information to estimate if segregation is more or less likely to occur, and then determine the most effective remedial action based on the various factors. The segregation remedial model  409  may include an optimization module receiving updated information during operation of the supply chain  100  so that the remedial action can be updated based on the additional information. This segregation remedial model  409  may be used to, for example, proactively avoid segregation by recognizing factors that lead to segregation and provide control signals or recommendations to address the factors before segregation happens or becomes more prevalent. Additionally or alternatively, the segregation remedial model  409  may use historical data to fine tune the remedial action provided or recommended to most effectively address determined segregation. Thus, the segregation remedial model  409  may assist in future supply chain planning, plant  104  operations, and haul truck  106  and paver machine  108  operations and deployment. 
     INDUSTRIAL APPLICABILITY 
     The disclosed aspects of the present disclosure may be used in any system where paving material segregation monitoring and detection may be useful. For example, the system of the present disclosure may be used at any stage in the supply chain of the paving material, or along the entire supply chain of the paving material to help avoid the detrimental effects of segregation in the paving material. 
       FIG.  5    shows an exemplary flowchart  500  for the operation of the material segregation monitoring system  400 . At step  502 , asphalt paving material  105  is monitored by one or more cameras  402  at one or more locations of the supply chain  100 . The monitoring may be achieved by central controller  406  and the segregation and supply chain information  412 ,  414  discussed above in connection with  FIG.  4   . The monitoring may include storing the segregation information  412  and segregation determinations to track the information received and determinations made at the central controller  406 . Step  504  may include determining whether segregation exist within the asphalt of the supply chain  100 , including where and when the segregation was formed. As noted above, this processing of sensed camera information may be partially or fully done at cameras  402  or at central controller  406 . The existence of asphalt segregation may be sent and/or stored as segregation notice data  422  to elements of the supply chain  100  and/or to an offsite location (Step  506 ). In addition, the identification of segregation may trigger taking a remedial action. As discussed above, the remedial action of step  506  may include providing alert signals  424  to elements of the supply chain  100  (e.g., display or speakers of the plant  104 , haul truck  106 , the paver machine  108 , and/or associated with the central controller  406 ) and/or to a remote location. The remedial action may also include providing control signals  426  to the supply chain  100 , or recommendations for adjustments to the supply chain  100 . For example, as noted above, such control signals may include commands or recommendations to stop certain actions of the supply chain  100 , and/or control signals or recommendation for adjusting routes of the haul truck(s)  106 , adjusting (e.g., decreasing) a speed of hopper  116  actuation, speed of an auger  122  of paver machine  108 , or the driving speed of the paver machine  108 . 
     The present disclosure may also assist in avoiding paving material segregation along various aspects of the paving material supply chain  100 , or along the entire supply chain  100 . In one example of the system  400 , if a haul truck  106  drives over particularly uneven roads on the route to deliver asphalt  102  to a paving site, the jolting movement of the haul truck  106  may cause asphalt segregation or increased asphalt segregation that can be determined by central controller  406 . Once determined, the system  400  can provide notifications, alerts, and/or recommended or actual control of the supply chain  100  to help avoid the determined segregation. For example, the system  400  can recommend or supply an alternative haul truck route, or adjustments to other processes of supply chain  100 . 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed system without departing from the scope of the disclosure. Other embodiments of the system will be apparent to those skilled in the art from consideration of the specification and practice of the material segregation detection system disclosed herein. For example, while the present disclosure describes the detection of segregation in paving material  105  in a paving supply chain  100 , it is contemplated that system may be used to detect and report abnormalities in any materials monitored in a supply chain. 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.