Asphalt 3-D controlled Milling Machine with Digital Upgrade in Rehabilitation
The digital upgrade using asphalt 3-D controlled for rehabilitation of highway section is an inevitable new technology innovation in the milling machine industry.
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Technological innovation combined with proven expertise. The milling cutters struck loudly in the old fashion; asphalt and rock could be seen, supported by protective fleece, with only gravel underneath. Such rigorous work means wasting 800 bits a day.
Digitally updated construction machines – The use of 3D-controlled asphalt milling machines reduces the workload of the construction site team: the machines are no longer adjusted manually; instead, they work completely automatically.
At the operator's station, several meters above the machine, the operator watched several screens. They show figures and digital images of construction sites.
Today, for the first time, a new digital technology is used here: the so-called Smooth Ride system. The app was developed by Topcon, a company specializing in geolocation and machine control.
This enables continuous measurement of the actual value through the side plate of the milling machine. By comparing the actual value with the target value from the 3D model, the precise milling depth can be automatically controlled.
STRABAG's subsidiary KAB has been cooperating with the leading milling machine manufacturers Topcon and Wirtgen for many years. Together, they test new developments in real situations – such as the 3D milling machine in this pilot project on the S33.
The first step is to use a digital scanner to record the entire road surface. The scanner, called Mobile Mapping, is installed on a car traveling at 80 km/h and can measure a 3-kilometer stretch of road.
The STRABAG team took about an hour to measure the three-kilometer test section on S33. This is a remarkable speed, as the comparison shows: usually two or three people are busy for a few days during this time, measuring cross-sections by hand on a regular basis.
In most cases, the highway may also have to be closed on one side. Accurate to the millimeter - the machine operator controls the work of the milling machine in 3D via on-screen controls.
High-precision images
This new technology provides detailed and highly accurate images of existing road surfaces. Compare the scans with the customer's planning data to determine how best to improve the uniformity of the road surface. Using this data, a 3D model for milling can be created.
The milling depth no longer needs to be marked on the road surface, but is controlled automatically. For example, it can be determined in advance how many trucks are needed to remove old material, and how much to grind.
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More sophisticated compaction techniques are now available, offering users a wide range of benefits.
While asphalt crushing techniques in North America and Europe vary widely, there are many similarities in the methods of compaction required. New developments in compaction rollers offer major quality advantages to contractors using North American and European style paving techniques.
According to Robert Holland, regional engineer at the Asphalt Institute, smart compaction technology represents the future of highway construction.
Horan presented a paper at the World Asphalt Conference and Expo in Orlando, Florida, in March on the benefits of smart compaction demonstrated by extensive research and field testing. Horan firmly believes that smart compaction will play an important role in future road construction projects.
For machine operators in the field, the new technology improves safety as they no longer have to leave the operator station or climb down to take manual measurements, which increases the risk of accidents.
According to KAB fleet manager Klaus Palle, the "only downside" is that the scanners and 3D machine controls don't work in subways and tunnels because there is no GPS signal.
Road machinery specialist Bomag held a two-day exhibition at its headquarters in Boppard, Germany. As part of the French Fiat company, the company presented its product range for the construction of asphalt pavements and demonstrated the capabilities of its machines for various jobs.
Around 200 customers from Europe, the Middle East and Africa showcased BOMAG's innovations and latest technologies, as well as other FAYAT Group companies such as asphalt mixing plants and asphalt spreaders.
Starting with the production of bituminous mixes, energy-saving technologies for hot mixes and the use of recycled materials were demonstrated, including an innovative top tower concept for production volumes below 200 t/h.
Attention then turned to milling, paving and asphalt compaction. The performance of the BOMAG product range is proven in a range of applications.
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The presentation concluded with an overview of BOMAG's wide range of services, one of the highlights being the online data feedback from other manufacturers' machine fleets using BOMAG TELEMATIC.
This fleet management program provides status tracking, capacity utilization and efficiency, and maintenance schedule reporting.
The BOMAG demo area showcases specific applications. Different machines were shown to customers; BM500/15 compact planer, new series of small twin roll rollers, new 4.5-ton BW138AD-5 twin roll roller, new BF800 dresser, BCM-Net, online networking of the site via WLAN connection.
Asphalt roller. The BM1500/15 was shown planing the damaged area to a depth of 210mm and using a BOMAG BF300P finisher to place and compact the asphalt surface.
At another site, a 100mm asphalt base was laid using BF800. To compact a road width of 10 m with the BOMAG BF800 finisher, two large tandem rollers work in parallel, a 10-ton BW174AP-AM pivot-steered tandem roller and a 10-ton articulated BW154 AD-AM.
Both rollers are equipped with Bomag Asphalt Manager II, which tracks asphalt hardness during compaction. Vibration is automatically controlled to apply optimal force without crushing the material.
When using multiple rollers, coordination is critical for high-quality results. BOMAG's solution is the BCM network, the tandem roller is equipped with a GPS receiver and connected via a WLAN network.
They send their location, compaction value and asphalt temperature to the server. This allows each roller operator to track his compaction progress as well as that of other rollers.
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