3D Milling. Tom Abell

Transcription

1 3D Milling Tom Abell

2 Trimble & 3D Milling as Part of the Resurfacing Process Design Measure Resurfacing From initial survey to finish surface Mill Compact Pave

3 Content Data acquisition Creating data models Trimble PCS900 Paving Control System v2.1 for Milling Machines Milling operations Accuracy aspects Benefits of 3D milling

4 Advantages of 3D Milling 1. Increased production and lower cost Only mill what needs to be milled 2. Increased smoothness Smoothness harder to achieve at the paving stage 3. Decreased material usage No filling of low spots 4. Mill complex designs

5 Data Acquisition / Data Model

6 Data Aquisition of Existing Surface Wavy Road Universal Total Station (UTS)/ rover rod Compactor with UTS 3D scanning

7 Static 3D Scanning Example 3D Data Collection 3D Design

8 Mobile Scanning with 25mph - MX8 Simultaneous collection of laser point cloud and digital images 2 x laser scanners 4 x 5 MP digital cameras Applanix integrated GNSS + IMU Signal point measurements with total station, GNSS and precise leveling Trimble Trident

9 New Optimized Road Design New horizontal / vertical alignment and cross-section profiles based on: Meeting road design specification parameters Minimum cutting / filling Visualization of cut and fill areas

10 Create Design and Corridor in Business Center - HCE Import roading design points or alignment data Create corridor Same design for Trimble SCS900 Site Controller Software and GCS900 How to check if a design is smooth 3D view and design drive through IRI calculation in Business Center - HCE!

11 PCS900 v2.1 for Milling Machines

12 PCS900 - Control System Overview PCS900 Full 3D position Relative to design Up/Down Left/Right Corrections Contact Sensors Sonic Sensors Wire Rope Sensors 2D position only 2D OEM Control System Machine Hydraulics (Leg Control)

13 Portable Kitting Option New installation box Radio PM400 Main harness Access holes for Target/GS420 cable Display cable Remote antenna cable And more

14 System Architecture - Wirtgen

15 UTS - Management Single screen for UTS activities Provides all pertinent information Available for asphalt and slipform pavers also

16 Dual Elevation Control With a single target, we allow the user to make adjustments on the slope side as an elevation Much easier to make adjustments based on grade checker feedback 2D system is configured for dual 3D elevation Mill-only feature

17 UTS Operational Tips 3D mill speed up to 15m/min and more Try to do several parallel lanes with 1 UTS Refraction Limit shot distances to m ( ), hot weather < 130m (425 ) Avoid shots close over hot surfaces You hunt mm s with a 40 ton machine! Need best surveying practices UTS calibration before any mill job Grade check accuracy to be in mm s Make sure your tools are wright

18 Masts Manual extendable masts Fixed (dozer) masts

19 Dual Mast Setup Allows measure-up of left and right masts Still only using one side for machine control Makes switching over from one side to another fast Same feature that exists on asphalt pavers

20 Project Results

21 Review of Accuracy Result of 250m Study Section - CZ State before reconstruction Road elevation compared to design before 3D milling In tolerance + 1cm (60%) Out of tolerance + 1 cm (16%) Out of tolerance - 1 cm (24%) Road elevation compared to design after 3D milling In Tolerance +- 1cm (98.4%) Road elevation compared to design after 3D milling and 2D paving Outside Tolerance +1cm (0.2 %) Outside Tolerance -1cm (1.4%) In Tolerance +- 1cm (99.6%) Legend: Elevation difference actual versus design (m) Outside Tolerance +1cm (0,1%) Outside Tolerance -1cm (0,3%)

22 Benefits of 3D Milling

23 Advantages of 3D Milling 1. Increased production and lower cost Only mill what needs to be milled 2. Increased smoothness Smoothness harder to achieve at the paving stage 3. Decreased material usage No filling of low spots 4. Mill complex designs

24 Advantages of 3D Milling Increased smoothness + material savings The issue of differential compaction when paving Previous 3D milling takes away the issue:

25 Advantages of 3D Milling Mill Complex Designs Variable depth and slope milling enables milling of: Transitions Super-elevated curves Variable drainage slopes Longitudinal waves in the road Guide Policy for Geometric Design of Freeways and Expressways - NAASRA 1976

26 3D Milling Job Study

27 The Job Milling For a white topping overlay 4.5 miles of Interstate 70 Near Mack, Colorado Milled in half-mile stretches, averaging about three inches, across the entire 4.5 mile stretch of Interstate-70

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29 Scope of Job Began in June, 2013 Survey crew was hired to take a topographic profile of the existing road An intended profile was then determined from the topography Worked with SITECH Rocky Mountain on the operation of the PCS900 system as well as setting up control points at 700 spacing

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31 Scope of Job Operators completed one pass on the outside edge, then turned and came back on the opposite edge of the roadway Milled in a round robin fashion to cover the 38 wide roadway with no tracking in reverse Utilized a multiple UTS setup to cover 2000 segments at a time. Grade checks were performed throughout the milling to ensure proper tolerance

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33 Why Trimble? Needed to eliminate overrun of concrete and provide an exact profile for the white topping Determined that the advantages of the PCS900 for Milling Machines was a musthave. Highly accurate milling at variable depth and slope Owners of the road wanted it to be milled to an exact profile No stringlines!

34 Results, Achievements, Recognition Successfully milled the entire stretch of roadway in 18 days, nine days per side. Shaved 3 days off the project timeline and delivered significant manpower savings over the scope of the project More competitive bidding for future road mill projects with Trimble Grade Control 3D Milling helped meet ride incentives from CDOT and others that provide extra compensation for completed roadways with extremely smooth rides

35 QUESTIONS?

36 THANK YOU