Apparatus and method for three-dimensional contouring

• US 20050147467A1
• Filed: 01/21/2005
• Published: 07/07/2005
• Est. Priority Date: 10/27/1998
• Status: Active Grant

• Current Assignee: Somero Enterprises Incorporated
• Original Assignee: Delaware Capital Formation Incorporated (Dover Corporation), Michigan Technological University
• Inventors: Kieranen, Carl B., Simula, Glen R., Waineo, James D., Ruonavaara, Nils P., Hallstrom, Charles A.
• Granted Patent: US 7,144,191 B2
• Time in Patent Office: Days
• US Class Current: 404/84.100
• CPC Class Codes: E01C 19/006 by laser or ultrasound
• CPC Class Codes: E01C 19/40 adapted to impart a smooth finish to the paving, e.g. tamping or vibrating finishers

Abstract

A contouring machine control system, contouring/smoothing method, and kit for enabling a contouring machine to automatically contour three-dimensional surfaces includes a contouring member, such as a screed or dirt grading blade, a target either attached to the contouring member or located at a remote location, a tracking device at the other of the contouring member or remote location that tracks the target and measures the position of the target in three dimensions, a proximity sensor adjacent one end of the contouring member to detect its height above a physical reference, and a controller/computer for controlling the height of the two ends of the contouring member. One of the ends is controlled as a function of a stored profile of the desired surface to be contoured and the target or tracking device position, while the second end is controlled as a function of the current height of the proximity sensor above the reference.

Claims

1. A contouring machine control system comprising:

a contouring member having first and second ends and able to be moved over an area to be contoured;

a target;

a tracking device that tracks the target and measures the position of said target in three dimensions as said contouring member is moved over the area to be contoured, one of said target and said tracking device positioned at said contouring member, and the other of said target and said tracking device positioned remotely from said contouring member;

said tracking device measuring the position of said target in three dimensions by emitting a laser beam that impinges on said target and is reflected back to said tracking device, detecting the reflected laser beam with said tracking device, computing the distance between said target and said tracking device, and determining the angular orientation of the emitted laser beam with respect to said tracking device;

a proximity sensor positioned adjacent one of the first or second ends of the contouring member, said proximity sensor able to detect its height above a physical reference at different positions with respect to the reference as the contouring member is moved over the area to be contoured, said reference being separate from the contouring member;

a stored profile of a desired surface to be contoured; and

a controller for controlling the height of said first and second ends of said contouring member, wherein said controller adjusts the height of said first end of said contouring member as a function of the stored profile and the three-dimensional position of the one of said target and said tracking device positioned at the contouring assembly, and said controller adjusts the height of said second end of said contouring member as a function of the current height of the proximity sensor above the reference.

2. The control system of claim 1 wherein said target is positioned at the contouring member and said tracking device is positioned remotely from said contouring member, said tracking device including a transmitter for transmitting the three-dimensional position information of said target to said controller.

4. The control system of claim 2 wherein said proximity sensor is an ultrasonic sensor.

6. The control system of claim 2 wherein said contouring member is able to contour uncured concrete.

7. The control system of claim 6 wherein said contouring member is able to vibrate.

8. The control system of claim 7 wherein said contouring member is an assembly including an auger positioned adjacent one side of a vibrating contouring beam, said auger oriented substantially parallel to said vibrating contouring beam.

9. The control system of claim 8 further including a plow positioned adjacent a side of said auger opposite said vibrating contouring beam such that said auger is intermediate said plow and said vibrating contouring beam, said plow oriented substantially parallel to said auger.

10. The control system of claim 9 further including a pivot axis oriented substantially parallel to said auger and a pivoting device for pivoting said vibrating contouring beam, said auger, and said plow about said pivot axis.

11. The control system of claim 10 further including a tilt controller that activates said pivoting device to tilt said vibrating contouring beam, said auger, and said plow about said pivot axis based upon said stored profile.

12. The control system of claim 2 wherein said controller includes a fluid cylinder for changing the height of said first end of said contouring member.

13. The control system of claim 12 further including a second fluid cylinder for changing the height of said second end of said contouring member.

14. The control system of claim 9 including a base having a cantilevered movable boom on which said contouring member is mounted;

said contouring member able to be moved toward said base on said boom for spreading and smoothing the uncured concrete.

15. The control system of claim 14 wherein said contouring member is telescopingly mounted to said base.

17. The control system of claim 2 wherein said target includes an infrared source and said tracking device includes infrared sensors for following said target whereby the angular position of said target is determined.

18. The control system of claim 2 further including a pivot adjustment mechanism that pivots said contouring member about an axis extending transverse to the direction of movement of said contouring member, said pivoting based on the stored profile of the surface to be contoured.

3. (canceled)

5. (canceled)

16. (canceled)

19-62. -62. (canceled)

63. A method for smoothing material to a desired shape, comprising:

providing a target having a reflector;

providing a contouring assembly for contouring said material over a given area, said contouring assembly having first and second ends and being supported in at least a first location;

providing a base upon which said contouring assembly is movably mounted;

providing a tracking device that tracks said target;

providing a proximity sensor adjacent one of the first and second ends of the contouring assembly, said proximity sensor being able to detect its height above a physical reference at different positions with respect to the reference as the contouring assembly moves over the given area, said reference being separate from the contouring assembly;

storing a profile of the desired shape of the material to be smoothed;

positioning one of said target and said tracking device at said contouring assembly and the other of said tracking device and said target remotely from said contouring assembly;

moving said contouring assembly over said material;

measuring the position of the target in three dimensions with said tracking device as said contouring assembly moves, said measuring the position of the target including emitting a laser beam from the tracking device so that the laser beam impinges on the reflection on the target, detecting the reflected laser beam with the tracking device, computing the distance between the target and the tracking device, and determining the angular orientation of the emitted laser beam, with respect to the tracking device with the tracking device;

adjusting the height of said first end of said contouring assembly as a function of the stored profile and the three-dimensional position of the one of said target and said tracking device positioned at the contouring assembly; and

adjusting the height of said second end of said contouring assembly as a function of the distance current height of the proximity sensor above the reference.

64. The method of claim 63 wherein said target is positioned at said contouring assembly and said tracking device is positioned remotely from said contouring assembly.

66. The method of claim 64 wherein said contouring assembly includes a longitudinal dimension, said method further including:

calculating a slope of the stored profile in the direction of movement of the contouring assembly;

moving said contouring assembly in a direction transverse to said longitudinal direction; and

tilting said contouring assembly about an axis parallel to the longitudinal dimension of said contouring assembly, said tilting based upon the calculated slope of the stored profile.

68. The method of claim 63 wherein said measuring of the position of the target further includes emitting an infrared signal from said target, detecting said infrared signal with said tracking device, and adjusting the direction in which said laser beam is emitted from said tracking device based on said detected infrared signal.

65. (canceled)

67. (canceled)

69-104. -104. (canceled)

105. A kit for enabling a contouring machine having a contouring member to automatically contour three-dimensional surfaces, said contouring member having first and second ends and able to contour material over a given area, said contouring machine further including a height adjustment mechanism able to adjust the orientation of said contouring member such that the first and second ends of the contouring member may be positioned at different heights, said kit comprising:

a target able to be attached to said contouring machine at a known position relative to said first end of said contouring member;

a tracking device that tracks said target as said target moves and measures the position of said target in three dimensions, said tracking device positionable remotely from said contouring machine at a known location, said tracking device measuring the position of said target in three dimensions by emitting a laser beam that impinges on said target and is reflected back to said tracking device, detecting the reflected laser beam with said tracking device, computing the distance between said target and said tracking device, and determining the angular orientation of the emitted laser beam with respect to said tracking device;

a proximity sensor able to be attached adjacent said second end of said contouring member, said proximity sensor able to detect its height above a physical reference as the contouring member is moved over the given area, said physical reference being separate from the contouring member;

a computer that operates said height adjustment mechanism and that includes a stored profile of a desired contour, said computer programmed to operate the height adjustment mechanism such that the height of the first end of the contouring member is adjusted based upon both the three-dimensional position of said target as measured by said tracking device and a desired height stored in said stored profile for the first end of said contouring member, said computer further programmed to operate the height adjustment mechanism such that the height of said second end of said contouring member is adjusted based on the current height detected by the proximity sensor of the second end of the contouring member above the physical reference.

106. The kit of claim 105 wherein said target emits an infrared signal and said tracking device detects said infrared signal and uses said detected infrared signal to aim said laser beam at said target.

107. The kit of claim 105 wherein said contouring member includes a blade that is able to grade dirt.

108. The kit of claim 105 wherein said contouring member includes a screed that is able to smooth uncured concrete.

109. The kit of claim 105 wherein said height adjustment mechanism includes a first fluid cylinder that is able to adjust the height of said first end of said contouring member and a second fluid cylinder that is able to adjust the height of said second end of said contouring member.