Stringless Paving, Where we are today...Slipform pavers Trimmers Milling Machines Curb & Gutter...
Transcript of Stringless Paving, Where we are today...Slipform pavers Trimmers Milling Machines Curb & Gutter...
Stringless Paving, Where we are today
Anthony CerisanoVice President
Flores Automation & Machine Control949.923.8966 / [email protected]
February 11, 2016
Presentation Outline…1. Flores Automation & Machine Control Introduction
2. What is 3D stringless paving?
3. Benefits of going 3D
4. What technology is currently in the market?
5. What infrastructure does a contractor need in place to implement stringless technology?
6. What needs to happen once the 3D technology is purchased and in place?
7. Workflow of Stringless Paving
Company History…CEO Frank Flores started Flores Automation in 2007
Specialized in industrial/mobile automation contracts to OEM’sBuilt engineering and management staff of 14 employees
Started Guntert & Zimmerman relationship in 2010Currently programming S400, S600, S850SL, S1500, PS1200, & MP550OEM engineering and programming that compliment FAMC controls
Currently performing paving machine retrofits for FAMC
Started Flores Automation & Machine Control in 2012Current Leica paving dealer covering all of North AmericaFull services of training, support and service on your jobsites!Machine control modeling services
We are North America’s resource to assist contractors in their transition to stringless paving. We provide services that are accountable, accurate, and accommodating of your contracts demands…
S84 W18693 Enterprise DriveMuskego, WI 53150
Presentation Outline…What is 3D stringless paving?
Overview.Difference between 2D and 3DHow many contractors in North America using stringless paving?When/where was the first time 3D paving was used?
What is 3D stringless paving?The technology of monitoring your paving machine’s position with surveying instruments, and comparing to a digital model to control the movements of steering and elevation
No Wires Onsite!
What is stringless paving?When a paving contractor goes “stringless” it means:
1. They no longer have to setup wirelines to guide the machines
2. They must have Survey Control Point Information
3. They must have a specifically prepared “MODEL”
What is 3D stringless paving?Difference between 2D and 3D controls for slipform paving
2D control is controlling the steering and elevation of the paving machine with the use of 5 volt based wand sensors
For Steering: 0 v – 2.5 v = Steer Left
2.5 v – 5 v = Steer right
For Elevation: 0 v – 2.5 v = Move Down
2.5 v – 5 v = Move Up
These sensors require a physical reference on the site to “follow” along. (Wire Line set to grade)
The wire line is set for steering and elevation reference by a surveyor
What is 3D stringless paving?Difference between 2D and 3D controls for slipform paving
3D control is controlling the steering and elevation of the paving machine with the use of CAN Network data. This data is derived from surveying instruments monitoring the machine, and comparing to a digital model for deviations.
Like the range of the wand sensors the onboard computer software creates an arbitrary range of numbers for the movements of the machine
For Steering: 265 to 465 = Steer Left
465 to 665 = Steer Right
For Elevation: 265 to 465 = Move Down
465 to 665 = Move Up
Total Station, GPS, or Laser Augmentation instruments monitor an X,Y, and Z of the paver
Workflow of Stringless Paving vs WireWorking with Stringline… Inspect design – calculate setting-out lists for each lane
Setup a total station, survey each hub or pin position with total station (or GPS if accuracy isn’t important!)
Hammer (or drill) in each pin, minimum 1 line for each lane of concrete/asphalt
Check pin alignment & adjust if required
Survey and set stringline height on each pin (min. 2 men)
Install & tension clamps and stringlines
“Eyeball” & adjust stringlines before paving
Move machine into position, set sensors to stringline
Check machine position relative to stringlines
Start Production, monitor machine position
Ensure (or hope!) nothing disturbs or damages stringlines during paving/milling…
ReferencePoint
Walk left 5ft!Walk right 1ft!
Up a bit!Down a bit!
STOP!
ReferencePoint
Leica Geosystems History…
• Kern & Co. was founded in 1819 in Aarau, Switzerland by Jacob Kern.• Company started with the manufacturing of drawing tools.
• Later, he became well known for his geodetic and astronomical instruments.
• In 1857, his sons, Adolf and Emil join the firm.• Adolf manager of Measuring Tools and Emil manager of Surveying
Instruments
Leica Geosystems History…
• In 1899 a trainee at Landestopographie named Heinrich Wild takes a company provided theodolite to the mountains of Switzerland to perform surveying tasks. Due to his bad experiences with the high mountain triangulation with conventional theodolite design, he starts redesigning in 1905.
• From 1905 to 1907, Heinrich was a member of the Swiss Military Commission charged with finding/developing new range finders.
• In 1908 Heinrich moves to Jena, Germany and is employed as the manager of the Geo department of Carl Zeiss.
Leica Geosystems History…
• In 1919, after WWI, Heinrich moves back to Switzerland and continues to work for Zeiss as a consultant.
• In 1921 Heinrich Wild started his own company in Heerbrugg, Switzerland, Wild Heerbrugg. In 1923 Heinrich produces the “Wild ThI”. With the production of the “Wild THl”, Heinrich Wild started what we know as modern surveying.
• 1935 Heinrich signs a contract with Kern to start manufacturing a line of theodolites, eventually buying Kern & Co.
Leica Geosystems History…• Over the last 200 years, Leica Geosytems has grown to become the world’s first in surveying innovation.
• The “Wild Thl” instrument was soon renamed "Wild T2" and would keep that name until production stopped in 1996.
• Total Stations have taken on a variety of looks over the years.
Leica Geosystems History…• Paving started with Leica on a project in 1996 with a stop and go machine .The first machine
automation test with robots was on a Wirtgen Test site in Windhagen, Germany 1997.
Leica Geosystems History…• In 1997 the German Railway Agency proposed a
project to 10 contractors to show new methods of building high-speed rail.• The Railway Agency required the contractor to
maintain the wireline through the length of the project. 5 contractors backed out due to not wanting to maintain 240 miles of wirelinethrough farmland.
• In 1998 A section from Berlin to Hannover was paved.
• QC was completed soon after paving operations and the first stringless project was conducted from Köln-Frankfurt on a ICE high speed-rail 120 Miles long.Complex high-speed rail geometry, up to 11% cross-slope
Who is paving stringless in North America?
ACME – Spokane, WaAcura Inc. – Bensenville, ILAnthony Allega – Valley View, OHArcher Western - Fort Lauderdale, FL CC Myers – Rancho Cordova, CACemex - MexicoCold Spring Construction – Akron, NYConcrete Placing Company – Boise, IDEmery Sapp – Springfield, ILET Simonds – Carbondale, ILFlat Iron - CanadaFlynn Company – Dubuque, IAFred Weber - Maryland Heights, MOGolden Triangle – Imperial, PA
Granite Construction Co - Texas Hawkins Construction – Omaha, NEHead Inc. - LouisianaK-Five – Chicago, ILKiewit – Dallas, TXLindahl Brothers – Chicago, ILMcCarthy Improvement – Dubuque, IAMCM – Dallas, TXMilestone – Indianapolis, INToebe Construction – Wixom, MIWK Construction – Waterloo, IAZachry – North Carolina and Texas
Benefits of going stringless…Cost Savings
Removes wire lines and conventional survey pins from the jobsite
Eliminates the drilling, pounding, & surveying in pins to base the wire elevation
Eliminates material costs and transport for posts, wire arms, and wire
Eliminates “bumps” to the wire during operation
The survey instruments included give the ability to measure before and after your paving for exact quality control
The stringline is virtually created, and put right on the machine computer
No waiting for surveying before production
Significantly reduces over-milling, over-pouring
Increases productivity, quality and performance bonuses
Benefits of going stringless…Logistical Advantages
Roadway is now open
Trucks no longer need to back up so far
No “Gates” in wireline needed
Better versatility moving through site
Wireline Clearance
Track grade is now the width of the actual machine
Benefits of going stringless…Safety
Site Hazards
Walking hazard eliminated for workers near stringline
Vehicle hazard eliminated for driving near stringline
Presentation Outline…What technology is currently in the market?
Overview of the different manufacturers for the paving industry Overview of the instrument technology types offered and their applicationsOverview of the support system for each
What technology is currently in the market?Overview of the instrument technology types offered and their applications
Total Station accuracy +/-.01’
*line of sight
Slipform paversTrimmers
Milling MachinesCurb & GutterAsphalt paving
Millimeter GPS accuracy +/-.01’
*with good satellite signal
TrimmersMilling Machines
Curb & GutterAsphalt paving
GPS RTK accuracy +/-.1’
*with good satellite signal
Placer/SpreadersFollow-up Machines
Curb & Gutter SteeringAsphalt Paving Steering
Grading Market
What technology is currently in the market?Overview of the support system for each
Direct Paving DealersSame support personnel for all paving applications in North
AmericaManufacturer support for
FAMC
Local Machine Control Dealer Network (Sitech)
Manufacturer support for the Sitech dealer
Local Machine Control Dealer Network
Manufacturer support for the dealer
Presentation Outline…What infrastructure does a contractor need in place to implement 3D technology?
Open-minded crew, adapt to changeSurvey/Grade Checker resourcesGround-man, adjustments to machineData prep resource
What infrastructure does a contractor need in place to implement 3D technology?
Open-minded crew, adapt to change
•Market as a whole is still new and changing often
•Software/Hardware updates are provided frequently
•Many procedures in the field are new until learning curve is complete
What infrastructure does a contractor need in place to implement 3D technology?
Survey/Grade Checker resources
•Many layout abilities are possible with the instruments
Any surveying experience is a benefit
•Accurate checks and adjustments need to be communicated to ground man
•Bridging the gap between data prep and field work benefits the crew as a whole, it is good for the Surveyor/Grade Checker to have this experience to help the communication between office and field.
What infrastructure does a contractor need in place to implement 3D technology?
Ground-man, adjustments to machine
•One man will usually monitor the corrections needed to keep quality of the paving
•This will usually be someone with paving experience of what to look for
•Good communication on what he is adjusting within the pave crew is ideal
What infrastructure does a contractor need in place to implement 3D technology?
Data prep resource
•The model now becomes as important to the spread as the wire would be
•The quality of these models is dependent on success of paving accurately
•Without this in-house ability, it is highly recommended to use a professional service to provide accountability
•Good support within the software products you use is crucial.
Presentation Outline…What needs to happen once the 3D technology is purchased and in place?
Defining rolesProper trainingReasonable expectations of crew workload
What needs to happen once the 3D technology is purchased and in place?
Defining roles
•Total Station - setups and care of equipment
•Groundman - for adjustments to machine
•Data Prep - resource in house or contracted
•QC and Staking - Grade Checking, Layout, and Topo
What needs to happen once the 3D technology is purchased and in place?
Proper training•Thorough understanding of operation and troubleshooting instruments
•Proper understanding of maintenance of instruments (calibrations)
•Initial training away from production
•Follow through training while in production
•Understanding of how to measure and report production
What infrastructure does a contractor need in place to implement 3D technology?
Reasonable expectations of crew workload
•Understand what your investment leaves you capable to handle
•One mainline system will not always be feasible to move between sites
•Production rates of stringless need to be established by how well the crew has accomplished the learning curve of the new workflow
•Management of the survey, modeling, and capable crew members must be taken into account
Presentation Outline…Workflow of Stringless Paving
Verify Survey Control - or - Request it properly for what you needPrepare 3D ModelMachine Calibration and Tunings Plan Total Station Arrangements and hopping patterns
Survey Control
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Site Control Points…Machine Control is only as good as the control!
Need to have a control point file to setup the total stations.Fore each of the Control points we need the following:1. Point Number2. Northing3. Easting4. Elevation
CP101
CP100
CP102
CP103
CP104
CP105
With this information, we can setup total stations anywhere we want based on the survey information provided.
Setting up the Total Stations...Free Station Resections
XYZ=?XYZ ± ?mm
Backsight Setup on a Control Point
Types of Models3D Line-work Models
Cad based format of elevated lines
All lines are selectable for reference to that line’s position and elevation
All alignments are tangent based, true curves not supported for alignments
Based on Northing, Easting, Elevation
Types of Models3D Surface Models
Full site coverage using Triangulation between known elevations
Usually not “seen” by the operator, but calculates corrections anywhere on the site in the background of your software
Used in combination with a 3D Line-work File for visibility
Based on Northing, Easting, Elevation
Types of Models3D Alignment Models -or- 3D Road Models
Built from Alignment Data, Profile Data, and Template Data
Support True Horizontal and Vertical Curves!
Can be exploded to be line-work/surface formats previously mentioned or bundled in XML for true road curves
Based on Station, Offset, and Elevation
Alignment Understands where horizontal
curves begin and end
Understands true curve
information
Understands the stationing
Profile Understands where vertical
curves begin and end
Understands true curve
information
Understands stationing
Templates Build other elevated lines
based upon the profile line
Base these other lines on
slope and distance
Outputs of these elements
results in having a 3D Line-
work or Surface File
Types of Models3D Alignment Models -or- 3D Road Models
= 3D Line-Work File= 3D Surface File= Job_01_Road.XML
What is a Model ?
Surface Model Formats: Job_01_Surface.DBX
Line-work Model Formats: Job_01_Linework.DBX
Alignment Based Formats: Job_01_Road.DBX
What is a Model ?
Surface Model Formats: Job_01_Surface.TTM
Line-work Model Formats: Job_01_Linework.DXF
Alignment Based Formats: Job_01_Road.RXL
What is a Model ?
Surface Model Formats: Job_01_Surface.TN3
Line-work Model Formats: Job_01_Linework.LN3
Alignment Based Formats: Job_01_Road.RD3
Differences between grading and paving models
Grading Models
Grading uses GPS guided machines that are accurate to one tenth of a foot (+/- .1’)
3D line-work and surface files are used in the grading market
Paving Models
Paving uses robotic total station guided machines that are accurate to one hundredth of a foot (+/- .01’)
Alignment based models are used in the paving market
How are Models Built ?
1. Thorough understanding of plan data and specifications
2. Experience in looking at and understanding engineer CAD data
3. Experience in the profiling process
4. Overall technically savvy with market standards
5. Field experience is invaluable
Skill Sets for a Good Model Builder
How are Models Built ?Available software packages used in the market for ENGINEERS…
1. Design Engineers software has different tools for creating 3D Data
2. These packages are for design engineers at Engineering houses or DOT’s, and are the formats we can receive to start our modeling process
How are Models Built ?Available software packages used in the market for Trimble Modeling…
Trimble Business CenterTrimble Terramodel
How are Models Built ?Available software packages used in the market for Leica Modeling…
Leica iCON Office
How are Models Built ?Available software packages used in the market for Topcon Modeling…
Topcon 3D Office
How are Models Built ?Available software packages used in the market 3rd Party for all Hardware
These packages export generic formats that the manufacturer software can recognize
Linework = .DXF Surface= .XML Alignment Models= .XML
What is a Model…Methods of Road Modeling
Step 1: Request all digital data the engineer will provide:
Alignments, Profiles, Templates
PDF of most recent version of approved plans
Step 2: Review what has been provided and decide if anything is useable in your software
Step 3: Start “KEY-ing” in the road elements
Start with alignments
Next input the profile information based on station, and curve info
Build the template information, and the sequence of transitioning
Step 4: Details of output formats
Control of how many cross sections create the polylines paved on
Levelling, “Eyeballing” & Tensioning adds error
True Vertical Curves Improved Thickness/Smoothness, no “pin bumps”
Horizontal Curve“Chording”
WastesConcrete
What makes a good Model ?
What makes a good Model ?Error Checking Procedures for surface and line-work files….
3D Polyline Editors
What makes a good Model ?Error Checking Procedures for surface and line-work files….
3D View Reference (looks good)
What makes a good Model ?Error Checking Procedures for surface and line-work files….
3D View Reference (looks like a problem)
What makes a good Model ?Is the model Smooth?, new procedures…
Convert an edge of paving to a TXT file of points, then import to PROVAL
Simulate ride scores on your smoothness specification
Check for frequencies of breaks in your profile
Once you know the ride score of your data, you can adjust what to expect from your AMES or SSI scores
What makes a good Model ?Volume Reports!Cut-Fill Plots Comparing 2 Designs…Example: Existing VS SubgradeExample: Subgrade VS Top of ConcreteControl your Yields.
What makes a good Model ?Error Checking Procedures, for confidence and reference in the field….
3D Road Reports Per Alignment
Workflow of Stringless Paving Machine Calibration... WHEN and WHY ??
• WHEN?• At First Installation• At EVERY subsequent change of the machine.
• After raising/lowering removing/mounting prism masts• After pan width changes
• WHY?• Prism Locations freshly measured relative to the paving kit.• Slope Sensors are freshly calibrated after measuring• Precise Paving, Good Practice• Optimal Machine Performance
• RISKS IF IGNORED?• Mis-matched slope sensors can cause machine “twisting” causing poor concrete
surface finish• Mis-alignment of track angles can cause a “Skew” in your steering alignment
Workflow of Stringless Paving
Settings on the Machine ControllerUsually performed with assistance of operator or machine setup crew
• Track Alignment / Swing Leg Alignment• Highly recommended you take the time to run stringline through the front and rear
track, adjust what is “straight” and null this value in the machines operator interface. If your machine runs a swing leg arrangement, you must square this and null as well.
• This will make the 3D steering as accurate as possible.• Steering and Elevation Gain Settings
• Advise the operator to adjust his elevational gain settings to a #1 value• Advise the operator to adjust his steering gains to a #1.
• Stringline tuning is usually much higher• Could cause irregular unexpected movements of the machine
• Steering and Elevation Control set to “3D”
Machine Calibration (without DBI)Step 1... Mark your points
• Raise the Machine for ability to mark 4 points on the pan• Measure forward .1’ from the back of the pan and 2’ in from the side on each
side of the pan• Measure forward 3.5’ from the back of the pan and 2’ in from the side on
each side of the pan
Workflow of Stringless Paving
Machine Calibration (with DBI)
• First Mark 4 points on the main paving pan.• Typically 2’ in from side edge, and .1’ forward from back edge on each side for tempA1 and
temp A2.• Typically 2’ in from side edge and 3.5’ forward from back edge for A3 and A4
• Stringline through your tempA1 and A3 back to find the location of where your A1 point will be on the OCB.
• Once you have string run, Level the OCB with the pan, then check all elevations with Total Station• * the OCB will shift back and forth, so once the calibration is checked and shot the point will
no longer be valid for calibration. • * the OCB needs to be on the EXACT plane that the front pan is on. If the front pan is level
and elevation 100.00 the OCB should read 100 as well. Adjustments to the elevation of the OCB are almost always necessary.
• Intersect the point you marked with string, and .1’ forward from the back edge, and mark your A1 and A2 point on the OCB.
Workflow of Stringless Paving
After model for paving production is loaded, dry run the machine to tune steering, elevation and ensuring model is correct. This ensures an added level of insurance as to a step being skipped or not done correctly.
Dry runsWorkflow of Stringless Paving
Total station hopping pattern
· Dry runs are a good time to envision total station layouts· Depending on truck routes, line-of-site objects (trees, signs, etc.)· Different jobs have limited options and distances between total stations
Workflow of Stringless Paving
Web References…Positioning Manufactures:www.leica-geosystems.comwww.trimble.comwww.topconpositioning.com
Machine Control Market Website:www.machinecontrolonline.com
Software Manufacturers:www.autodesk.comwww.carlsonsw.comwww.agtek.comwww.12d.comwww.bentley.comwww.hexagon.com/en/sbg.htmwww.vianovasystems.com/Products/NovapointDCMwww.liscad.com