Presentation Overview

Transcription

1 Stringless Concrete Paving STRINGLESS CONCRETE PAVING ACPA BUS TOUR AUGUST 5, 2015 Presentation Overview 1) Manufactures 2) Components needed for Stringless Paving 3) Conventional Methods VS Stringless Methods 4) How it works? 5) Questions 1

2 MANUFACTURES OF STRINGLESS PAVING COMPONENTS There are multiple manufactures that developed Stringless Technology. Leica Was the first to develop stringless concrete paving. Late 1990 s Wirtgen-2010 Trimble Topcon Mainline Slipform Paving 2

3 TYPES OF STRINGLESS APPLICATIONS Mainline Slip-forming Curb & Gutter, Barrier Milling MAINLINE PAVING 3

4 CURB & GUTTER & OFFSET PAVING MILLING APPLICATIONS 4

5 WHAT IS LEICA PAVESMART 3D? External Control system developed by Leica Geosystems specifically for stringless concrete paving. Works with a variety of Concrete Paver Manufactures Gomaco Guntert and Zimmerman Power Curbers Wirtgen Vogele Controls the steering and elevation of the concrete paver by the use of 3D models and robotic total stations. SYSTEM BENEFITS... Removes stringlines and conventional survey pins from the jobsite Eliminates the drilling, pounding, & surveying in pins to base the string elevation Eliminates material costs and transport for posts, wands, and string Eliminates bumps to the string during operation Increases jobsite safety & Opens up truck routes within work area The survey instruments included give the ability to measure before and after your paving for exact quality control 5

6 The stringline is virtually created, and put right on the machine computer Create 3D Models in all Major CAD Software packages No waiting for surveying before production Significantly reduces over-milling, over-pouring. (during overlay projects) Increases productivity, quality and performance bonuses Controls Machine height, slope, steering automatically Allows for digitally fine tuning your machine to move as you want Allows for you to override automatics and change alignment or profile on the fly Improves material yields Posted system accuracies of.01 SYSTEM BENEFITS CONT. Typical Mainline Paver System (5) 1 Robotic Total Stations 3-4 are typically dedicated to tracking the machine. Need at least 2 to operate the machine. 1 is typically utilized as a checking tool behind the machine (4) Backsight Setups that sit over control points that set up total stations (1) Grade Checking Rod with Hand-held controller that checks grade, and measures points. It also reports station, offset, and cut/fill information (1) Machine Computer/Software Rugged on-board computer with PaveSmart3D Software (1) Machine Installation Kit-incl. cables/paver prisms/slope sensors 6

7 SYSTEM MAIN COMPONENTS ROBOTIC TOTAL STATIONS LEICA VIVA TS15 (TRACKING THE MACHINE OR GRADE CHECKING) 1 total station Used For all Surveying & Machine Control applications 12Hz measurement rate Tracking accuracy 1/8 at 300 ft (±3mm at 100m Typical working Range 300ft (± 100m ) (600ft/200m total) Synchronized EDM/Hz/V data Fully robotic operation Automatic prism tracking Runs VIVA Software interface same as Data Collector SYSTEM MAIN COMPONENTS CONT. Leica CS15 Data Collector Runs VIVA Software for Data Collection, Surveying, or Grade Checking Runs on Windows Mobile Operating System SD, CF, and USB Ports available Full VGA display i.mx ARM core processor Antenna Radio communication with the LRBT Radio Handle, which makes this control any TS15 Total Station Internal Digital Camera for site photos Docking/Charging Station Lemo Port on bottom for USB Connection to PC, or direct connect to GPS Receivers 7

8 SYSTEM MAIN COMPONENTS LEICA MPC1310 MACHINE COMPUTER Rugged Housing SVGA Colour Touch screen Microsoft Windows Embedded Operating Temp. Range -20 C to +60 C MilSpec connectors Remote Access via Internet Power max 2A, 9-30VDC CE & FCC approved IP65 Housing Daylight-readable display Freewave Radios USB Port 4 x RS232 Ports CANBus & Power System Main Components Layout of Stringless Components Computer & Radios Prisms Slope Sensors Secondary Total Station Primary Total Station Leica PaveSmart 3D v3.0 Jan

9 System Main Components Layout of Stringless Components Prism Prism Machine Computer and Radios Slope Sensors Leica PaveSmart 3D v3.0 Jan System Main Components On-Machine Components 1.) Rugged 360deg Prisms 2.) On-Machine Computer w/ PaveSmart3D 3.) Dual Axis Slope Sensors Leica PaveSmart 3D v3.0 Jan

10 Workflow for String-Line Conventional Paving... Survey uses a total station to set pins with fill values to the top of concrete every 25 outside of the pave lane Then drilling, and pounding in stakes, and installing tension clamps/wands for line and measuring up to grade to set the string at each survey pin Fine tune string by eye for smoothness Set machine in place and adjust wand sensors into position to trace the string line Contractor is ready to pave to the string line with breaks every 25! Ensure (or hope!) nothing disturbs or damages string lines during paving Leica PaveSmart 3D v3.0 Jan Leica PaveSmart 3D v3.0 Jan

11 Leica PaveSmart 3D v3.0 Jan Stringline VS CAD Based Road Models... Stringline = approximation True Vertical Curves Improved Thickness/Smoothness, no pin bumps Levelling, Eyeballing & Tensioning adds error Horizontal Curve Chording Wastes Concrete Leica PaveSmart 3D v3.0 Jan

12 Workflow for String-Less Paving... BEFORE PROJECT BEGINS: Contractor Builds a 3D model of the concrete edge lines (Virtual Stringline) Surveyor Sets Control Points every of each side of the road Contractor Calibrates the Paver ON PAVE DAY: Contractor sets up (2) total stations backsights the instruments based on the surveyors control points and tracks the (2) Masts on the machine (15 minutes) Contractor is ready to Pave. Automatically! ** Contractor sets up (2) total stations every 500 and leap-frogs to each setup as the paver gets there throughout the pave day Leica PaveSmart 3D v3.0 Jan Leica PaveSmart 3D v3.0 Jan Paver Calibration 12

13 How to Build the Model... All major CAD platforms produce files for Leica PaveSmart 3D Most Modeling Software Packages can generate a.dxf file of the long-slope lines of the road. You load this dxf file into the data collector and it converts it to a.dbx format which can be staked for Station, Offset, and Cut Fill to top of concrete, great info! Leica PaveSmart 3D v3.0 Jan How to Build the Model... All major CAD platforms produce files for Leica PaveSmart 3D CAD System Leica PaveSmart 3D v3.0 Jan

14 Site Control Points MACHINE CONTROL is only as good as the PROJECT SURVEY CONTROL CP 5 Need to have a control point file to setup the total stations. Fore each of the Control points we need the following: CP 4 1. Point Number CP 6 2. Northing 3. Easting 4. Elevation CP 2 CP 3 CP1 With this information, we can setup total stations anywhere we want based on the survey information provided. Leica PaveSmart 3D v3.0 Jan Setting up the Total Stations... Free Station Resections C L XYZ=? XYZ ± 0.01 Backsight Setup on a Control Point Leica PaveSmart 3D v3.0 Jan

15 Survey Control & System Accuracy Leica PaveSmart 3D v3.0 Jan Machine Control is only as accurate as the Survey Control! High-order, well-braced network essential. ±0.01ft in Z & ±0.03 ft XY is our published accuracy for slipforming ±0.02 ft in Z & ±0.03 ft in XY is our published accuracy for milling Dependent on Accurate Survey Control Insist control is available for 3- or 4-point Resections anywhere on the project When setting up instrument, always use at least two control points from the previous setup. Always need line of sight to the paver prisms. Be aware of truck routes and other obstructions that may block sight from total station. The Working Screen... Dashboard (Status & Warnings, Troubleshooting) Production Monitoring Position Control Outputs Project Plan View (click for string selection) Operator Menu Clean, simple, machine-like user interface All essential production information available at-a-glance Varies according to application requirements (asphalt/milling/concrete) Leica PaveSmart 3D v3.0 Jan

16 Once the contractor is paving stringless There are not reference points (survey pins) all over the site indicating where the line and grade of the concrete should be 2. Tape measure will only tell how thick the slab is How do you check what s going on? Is the slab where it should be Horizontally? Is the slab at the right elevation? Leica PaveSmart 3D v3.0 Jan The answer is to use the same technology... Total Station Road Stakeout 16

17 Questions?? 17