Roadway grinding/cutting apparatus and monitoring system

Abstract

An apparatus and method is provided for monitoring operation of a roadway grinding/cutting machine of the type configured to travel along a roadway while engaging and grinding the roadway with a grinding/cutting head. A first displacement sensor generates, during the travel, first distance data associated with a distance between a reference level and a location on the roadway ahead of the grinding zone. A second displacement sensor generates, during the travel, second distance data associated with a distance between the reference level and a location on the roadway behind the grinding zone. A processor captures and uses the first and second distance data to determine a depth of cut as grinding/cutting progresses.

1 . An apparatus for monitoring operation of a roadway grinding/cutting machine configured to travel along a roadway in a direction of movement, and having a grinding/cutting head displaceable relative to the machine to engage and grind the roadway at a grinding/cutting zone during the travel, the apparatus comprising:
 one or more first displacement sensors configured to generate, during said travel, first distance data associated with a distance between a predetermined reference level and a location on the roadway ahead of the grinding zone in the direction of movement;   one or more second displacement sensors configured to generate, during said travel, second distance data associated with a distance between the predetermined reference level and a location on the roadway behind the grinding/cutting zone in the direction of movement; and   a processor configured to capture and use said first and second distance data to determine a depth of cut during grinding/cutting operations.   
   
   
       2 . The apparatus of  claim 1 , comprising the machine including a ground engaging vehicle configured to travel along the roadway in the direction of movement, the head having a central axis and a plurality of circular blades spaced co-axially thereon, each blade having a plurality of abrasives circumferentially spaced thereon, and an engine configured to rotationally drive said head about said axis. 
   
   
       3 . The apparatus of  claim 1 , comprising one or more third displacement sensors configured to generate third distance data associated with a distance between a circumference of said head and a predetermined position relative to an axis of rotation of said head. 
   
   
       4 . The apparatus of  claim 3 , wherein said predetermined position is on said machine. 
   
   
       5 . The apparatus of  claim 3 , wherein said processor is configured to capture and use said third distance data to determine head wear. 
   
   
       6 . The apparatus of  claim 5 , wherein the head wear is determined during grinding/cutting operations. 
   
   
       7 . The apparatus of  claim 1 , wherein said sensors are disposed on said machine and said predetermined reference level corresponds to a position on said machine. 
   
   
       8 . The apparatus of  claim 1 , wherein said processor is disposed remotely from said machine. 
   
   
       9 . The apparatus of  claim 1 , wherein said head is vertically displaceable relative to said machine. 
   
   
       10 . The apparatus of  claim 1 , comprising coolant means for supplying coolant to said head at the grinding/cutting zone and for collecting said coolant after use. 
   
   
       11 . The apparatus of  claim 10 , comprising a pressure sensor configured to generate, during said travel, pressure data associated with pressure of said coolant. 
   
   
       12 . The apparatus of  claim 11 , comprising a temperature detector configured to generate, during said travel, temperature data associated with pressure of said coolant at a supply location and at a collection location. 
   
   
       13 . The apparatus of  claim 12 , wherein said processor is configured to capture and output said pressure and temperature data. 
   
   
       14 . The apparatus of  claim 1 , comprising a speed sensor configured to generate, during said travel, speed data associated with speed of travel along the roadway. 
   
   
       15 . The apparatus of  claim 14 , wherein said processor is configured to capture and output said speed data. 
   
   
       16 . The apparatus of  claim 2 , comprising an engine speed detector configured to generate, during said travel, engine speed data. 
   
   
       17 . The apparatus of  claim 16 , wherein said processor is configured to capture and output said engine speed data. 
   
   
       18 . The apparatus of  claim 1 , comprising a vibration sensor configured to generate, during said travel, vibration data associated with said machine. 
   
   
       19 . The apparatus of  claim 18 , wherein said processor is configured to capture and output said vibration data. 
   
   
       20 . The apparatus of  claim 1 , wherein said data is communicated wirelessly. 
   
   
       21 . The apparatus of  claim 1 , comprising a user interface configured to receive user input and display data outputted by said processor. 
   
   
       22 . The apparatus of  claim 21 , wherein said user interface is configured to display at least one of the parameters selected from the group consisting of: distance traveled; area of roadway ground; volume of material removed; abrasive cost per unit area of surface ground; speed of travel; head rpm; vibration; depth of cut; coolant pressure; coolant supply temperature; coolant collection temperature; head wear; and combinations thereof. 
   
   
       23 . The apparatus of  claim 1 , wherein the abrasive is a superabrasive selected from the group consisting of: cubic boron nitride; polycrystalline diamond; single crystal synthetic diamond; single crystal natural diamond; and combinations thereof with or without metal cladding. 
   
   
       24 . An apparatus for grinding concrete roadways, the apparatus comprising:
 a ground engaging vehicle configured to travel along the roadway in a direction of movement;   the vehicle supporting a grinding head thereon;   said grinding head having a central axis and a plurality of circular blades spaced co-axially thereon, each blade having a plurality of superabrasives circumferentially spaced thereon;   an engine configured to rotationally drive said grinding head about said axis;   said grinding head being displaceable relative to said vehicle, wherein said grinding head is configured to engage and grind the roadway at a grinding zone during said travel;   coolant means for supplying coolant to said grinding head at the grinding zone and for collecting said coolant after use; and   a grinding monitoring system including:
 one or more first displacement sensors configured to generate, during said travel, first distance data associated with a distance between a predetermined reference level and a location on the roadway ahead of the grinding zone in the direction of movement; 
 one or more second displacement sensors configured to generate, during said travel, second distance data associated with a distance between the predetermined reference level and a location on the roadway behind the grinding zone in the direction of movement; 
 one or more third displacement sensors configured to generate third distance data associated with a distance between a circumference of said blades and a predetermined position relative to said axis; 
 a pressure sensor configured to generate, during said travel, pressure data associated with pressure of said coolant; 
 a temperature detector configured to generate, during said travel, temperature data associated with said coolant at a supply location and at a collection location; 
 a vehicle speed sensor configured to generate, during said travel, speed data associated with speed of travel along the roadway; 
 a vibration sensor configured to generate, during said travel, vibration data associated with said vehicle; 
 a processor configured to capture and use said data to determine depth of cut and blade wear during grinding; 
 an output device coupled to said processor; 
 said processor configured to capture said data and display on said output device, during grinding operations, at least one of the parameters selected from the group consisting of distance traveled, area of roadway ground, volume of material removed, abrasive cost per unit area of surface ground, vehicle speed, grinding head rpm, vibration, depth of cut, coolant pressure, coolant inlet temperature, coolant outlet temperature, blade wear, and combinations thereof. 
   
   
   
       25 . An apparatus for grinding/cutting concrete roadways, the apparatus comprising:
 a ground engaging means for traveling along a roadway in a direction of movement;   the ground engaging means supporting a grinding/cutting means thereon;   said grinding/cutting means having a central axis and a plurality of circular blades spaced co-axially thereon, each blade having a plurality of abrasives circumferentially spaced thereon;   an engine means configured to drive said grinding/cutting means;   said grinding/cutting means being displaceable relative to said vehicle, wherein said grinding/cutting means is configured to engage and grind the roadway at a grinding/cutting zone during said travel; and   a monitoring means including:
 first displacement sensing means for capturing, during said travel, first distance data associated with a distance between a predetermined reference level and a location on the roadway ahead of the grinding/cutting zone in the direction of movement; 
 second displacement sensing means for capturing, during said travel, second distance data associated with a distance between the predetermined reference level and a location on the roadway behind the grinding/cutting zone in the direction of movement; and 
 processing means for capturing and using said first and second distance data to determine depth of cut during grinding/cutting operations. 
   
   
   
       26 . A method for grinding/cutting concrete roadways, the method comprising:
 (a) operating a ground engaging vehicle configured to travel along a roadway in a direction of movement, the vehicle supporting a head thereon, said head having a central axis and a plurality of circular blades spaced co-axially thereon, each blade having a plurality of abrasives circumferentially spaced thereon, an engine configured to rotationally drive said head about said axis, said head being displaceable relative to said vehicle, wherein said head is configured to engage and remove material from the roadway at a grinding/cutting zone during said travel;   (b) operating a monitoring system including:   one or more first displacement sensors configured to generate, during said travel, first distance data associated with a distance between a predetermined reference level and a location on the roadway ahead of the zone in the direction of movement;   one or more second displacement sensors configured to generate, during said travel, second distance data associated with a distance between the predetermined reference level and a location on the roadway behind the zone in the direction of movement;   a processor configured to capture and use said first and second distance data to determine depth of cut during grinding/cutting operations; and   (c) generating, during said operating (a) and said operating (b), at least one of the parameters selected from the group consisting of distance traveled, area of roadway ground, volume of material removed, abrasive cost per unit area of surface ground, vehicle speed, head rpm, vibration, depth of cut, coolant pressure, coolant inlet temperature, coolant outlet temperature, blade wear, and combinations thereof.