6a – Cerisano FAMC Stringless Technology

Transcription

Stringless Paving, Where we are today
Anthony Cerisano
Vice President
Flores Automation & Machine Control
949.923.8966 / [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’s
Built engineering and management staff of 14 employees
Started Guntert & Zimmerman relationship in 2010
Currently programming S400, S600, S850SL, S1500, PS1200, & MP550
OEM engineering and programming that compliment FAMC controls
Currently performing paving machine retrofits for FAMC
Started Flores Automation & Machine Control in 2012
Current Leica paving dealer covering all of North America
Full services of training, support and service on your jobsites!
Machine control modeling services
S84 W18693 Enterprise Drive
Muskego, WI 53150
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…
Overview.
Difference between 2D and 3D
How many contractors in North America using
stringless paving?
When/where was the first time 3D paving was
used?
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”
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
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 Wire
Working 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
Reference
Point

“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…
Walk left 5ft!
Walk right 1ft!
Up a bit!
Down a bit!
STOP!
Reference
Point
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
•
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.
•
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.
•
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.
•
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.
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 wireline
through 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% crossslope
•
Who is paving stringless in North America?
ACME – Spokane, Wa
Acura Inc. – Bensenville, IL
Anthony Allega – Valley View, OH
Archer Western - Fort Lauderdale, FL
CC Myers – Rancho Cordova, CA
Cemex - Mexico
Cold Spring Construction – Akron, NY
Concrete Placing Company – Boise, ID
Emery Sapp – Springfield, IL
ET Simonds – Carbondale, IL
Flat Iron - Canada
Flynn Company – Dubuque, IA
Fred Weber - Maryland Heights, MO
Golden Triangle – Imperial, PA
Granite Construction Co - Texas
Hawkins Construction – Omaha, NE
Head Inc. - Louisiana
K-Five – Chicago, IL
Kiewit – Dallas, TX
Lindahl Brothers – Chicago, IL
McCarthy Improvement – Dubuque, IA
MCM – Dallas, TX
Milestone – Indianapolis, IN
Toebe Construction – Wixom, MI
WK Construction – Waterloo, IA
Zachry – North Carolina and Texas
Benefits of going 3D
Cost savings
Logistical advantages
Safety
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
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
Safety
Site Hazards
Walking hazard eliminated for workers near stringline
Vehicle hazard eliminated for driving near stringline
Overview of the different manufacturers for the
paving industry
Overview of the instrument technology types
offered and their applications
Overview of the support system for each
Overview of the different manufacturers for the paving industry
Overview of the instrument technology types offered and their applications
Total Station
accuracy +/-.01’
*line of sight
Millimeter GPS
accuracy +/-.01’
GPS RTK
accuracy +/-.1’
*with good satellite signal
*with good satellite signal
Slipform pavers
Trimmers
Placer/Spreaders
Milling Machines
Follow-up Machines
Curb & Gutter
Curb & Gutter Steering
Asphalt paving
Asphalt Paving Steering
Trimmers
Milling Machines
Curb & Gutter
Asphalt paving
Grading Market
Overview of the support system for each
Direct Paving Dealers
Same support personnel for all
paving applications in North
America
Manufacturer support for
FAMC
Local Machine Control Dealer
Network (Sitech)
Local Machine Control Dealer
Network
Manufacturer support for the
Sitech dealer
Manufacturer support for the
dealer
What infrastructure does a contractor need in
place to implement 3D technology?
Open-minded crew, adapt to change
Survey/Grade Checker resources
Ground-man, adjustments to machine
Data 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
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.
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
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.
What needs to happen once the 3D technology is
purchased and in place?
Defining roles
Proper training
Reasonable expectations of crew workload
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
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
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
Verify Survey Control - or - Request it properly
for what you need
Prepare 3D Model
Machine Calibration and Tunings
Plan Total Station Arrangements and hopping
patterns
Survey Control
CP105
Need to have a control point file to setup the total stations.
Fore each of the Control points we need the following:
1. Point Number
2. Northing
CP103
3. Easting
4. Elevation
CP104
Site Control Points…
Machine Control is only as good as the control!
CP101
CP102
With this information, we can
setup total stations anywhere we
want based on the survey
information provided.
CP100
37
Setting up the Total Stations...
Free Station Resections
Backsight Setup
on a Control Point
XYZ=?
XYZ 
± ?mm
3D Modeling Overview
Types of Models
3D 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 Models
3D 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 Models
3D 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 Linework or Surface File
Types of Models
3D 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 ?
Job_01_Surface.TTM
Job_01_Linework.DXF
Job_01_Road.RXL
What is a Model ?
Job_01_Surface.TN3
Job_01_Linework.LN3
Job_01_Road.RD3
Differences between grading and paving models
Grading Models
Paving Models
Grading uses GPS guided machines that are
Paving uses robotic total station guided machines that are
accurate to one tenth of a foot (+/- .1’)
accurate to one hundredth of a foot (+/- .01’)
3D line-work and surface files are used in the
Alignment based models are used in the paving market
grading market
How are Models Built ?
Skill Sets for a Good Model Builder
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
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
Available software packages used in the market for Trimble Modeling…
Trimble Terramodel
Trimble Business Center
Available software packages used in the market for Leica Modeling…
Leica iCON Office
Available software packages used in the market for Topcon Modeling…
Topcon 3D Office
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
What makes a good Model ?
Control of how many cross sections create the polylines paved on
True Vertical Curves  Improved Thickness/Smoothness, no “pin bumps”
Horizontal Curve
“Chording”
Levelling, “Eyeballing” &
Tensioning adds error
 Wastes
Concrete
Error Checking Procedures for surface and line-work files….
3D Polyline Editors
3D View Reference (looks good)
3D View Reference (looks like a problem)
Error Checking Procedures….
3D Road Report
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
Volume Reports!
Cut-Fill Plots Comparing 2 Designs…
Example: Existing VS Subgrade
Example: Subgrade VS Top of Concrete
Control your Yields.
Error Checking Procedures, for confidence and reference in the field….
3D Road Reports Per Alignment
Machine Calibration and Tunings
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
Settings on the Machine Controller
Usually 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
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.
Dry runs
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.
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
Thank you for your attention…
Time Permitting Question & Answers
Web References…
Positioning Manufactures:
www.leica-geosystems.com
www.trimble.com
www.topconpositioning.com
Machine Control Market Website:
www.machinecontrolonline.com
Software Manufacturers:
www.autodesk.com
www.carlsonsw.com
www.agtek.com
www.12d.com
www.bentley.com
www.hexagon.com/en/sbg.htm
www.vianovasystems.com/Products/NovapointDCM
www.liscad.com

6a – Cerisano FAMC Stringless Technology

Transcription

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