Three-dimensional bridge deck finisher

Abstract

A bridge paving machine and method for paving a 3D design without vertical profile rails includes converting a desired design into a 3D surface model to account for certain factors known to cause deviations in the paving processes and paving the 3D surface model in the expectation that factors will cause the 3D surface model to deflect into the desired design. An on-board computer system adjusts the 3D surface model in real-time to correct for on-site variables. The on-board computer system receives data from various external sensors, including deflection sensors fixed to girders in the bride structure, and paving machine-based sensors, and uses various predictive models to predict surface deflection based on the sensor data. The 3D surface model is continuously updated based on the predictive models and actual measured deflections.

What is claimed is: 
     
         1 . A carriage of a bridge paving machine, the carriage comprising:
 a finishing tool, wherein the carriage is configured to engage a superstructure of the bridge paving machine, wherein the carriage is configured to move linearly along a span of the superstructure and move vertically to apply a crown to a paving surface, wherein the carriage applies the crown using the finishing tool;   a forward sensor platform, wherein the forward sensor platform comprises a non-contact sensor; and   a mast comprising a tracking device, wherein the tracking device is configured to locate the carriage in three-dimensional space.   
     
     
         2 . The carriage of  claim 1 , wherein the finishing tool comprises a cylinder finisher. 
     
     
         3 . The carriage of  claim 1 , wherein the forward sensor platform is disposed on a surface of the carriage oriented in a forward direction during a paving process, wherein the carriage moves along the span and moves vertically to apply the crown during the paving process, wherein the forward direction is orthogonal to the span. 
     
     
         4 . The carriage of  claim 3 , comprising a rearward sensor platform, wherein the rearward sensor platform is disposed on a second surface of the carriage which is oriented in a rearward direction opposite to the forward direction, wherein the rearward sensor platform comprises an additional non-contact sensor. 
     
     
         5 . The carriage of  claim 4 , wherein the mast is disposed between the finishing tool and the rearward sensor platform, wherein the mast extends above the forward sensor platform, the finishing tool, and the rearward sensor platform. 
     
     
         6 . The carriage of  claim 3 , comprising a lateral sensor platform, wherein the lateral sensor platform is disposed on a second surface of the carriage which is oriented in a lateral direction corresponding to movement along the span, wherein the lateral sensor platform comprises an additional non-contact sensor. 
     
     
         7 . The carriage of  claim 1 , wherein the non-contact sensor is configured to measure a distance in front of the carriage. 
     
     
         8 . The carriage of  claim 1 , wherein the non-contact sensor comprises at least one of a sonic or ultrasonic sensor. 
     
     
         9 . The carriage of  claim 8 , wherein the non-contact sensor is configured to map a plurality of underlying reinforcing elements in the paving surface before the paving surface is finished by the finishing tool. 
     
     
         10 . The carriage of  claim 1 , wherein the non-contact sensor comprises a laser sensor. 
     
     
         11 . The carriage of  claim 1 , wherein the non-contact sensor comprises an image capture device. 
     
     
         12 . The carriage of  claim 1 , wherein the tracking device is one of a laser target or a total station target. 
     
     
         13 . A bridge paving machine comprising:
 a superstructure;   a plurality of tracks, wherein the plurality of tracks support the superstructure;   a carriage comprising:
 a finishing tool, wherein the carriage engages the superstructure of the bridge paving machine, wherein the carriage is configured to move linearly along a span of the superstructure and move vertically to apply a crown to a paving surface, wherein the carriage applies the crown using the finishing tool; 
 a forward sensor platform, wherein the forward sensor platform comprises a non-contact sensor; and 
 a mast comprising a tracking device, wherein the tracking device is configured to locate the carriage in three-dimensional space; and 
   at least one paving processor in data communication with a memory storing processor executable code for configuring the at least one paving processor to:
 correlate data collected from the non-contact sensor with a location determined from the tracking device of the mast. 
   
     
     
         14 . The bridge paving machine of  claim 13 , wherein the carriage is coupled to the superstructure by one or more hydraulics. 
     
     
         15 . The bridge paving machine of  claim 13 , wherein the at least one paving processor is configured to correlate data collected from the non-contact sensor to beam deflection data received from a plurality of beam deflection sensors. 
     
     
         16 . The bridge paving machine of  claim 13 , wherein the at least one paving processor is configured to:
 cause the carriage to pave the paving surface according to a three-dimensional model;   monitor actual deflections of the paving surface, wherein the actual deflections are determined, at least in part, using the data collected from the non-contact sensor;   compare the actual deflections to expected deflections to identify one or more deviations; and   modify the three-dimensional model according to the one or more deviations as the carriage is paving the paving surface according to the three-dimensional model.   
     
     
         17 . The bridge paving machine of  claim 13 , wherein the at least one paving processor is configured to:
 receive a desired design for the paving surface;   determine a set of corrections relating to one or more structural features of the paving surface to corresponding deviations in the desired design, wherein the corresponding deviations are determined, at least in part, using the data collected from the non-contact sensor;   incorporate the set of corrections into a design profile to reduce an optimized three-dimensional surface model; and   execute the optimized three-dimensional surface model with the carriage.   
     
     
         18 . The bridge paving machine of  claim 13 , wherein the at least one paving processor is configured to:
 receive a desired design for the paving surface;   determine deflection data from a plurality of deflection sensors;   continuously compare the deflection data to the desired design;   apply a correction to compensate for deformation; and   incorporate the correction into a design profile to produce an optimized three-dimensional surface model.   
     
     
         19 . A system comprising:
 a bridge paving machine comprising:
 a superstructure; 
 a plurality of tracks, wherein the plurality of tracks support the superstructure; 
 a carriage comprising:
 a finishing tool, wherein the carriage engages the superstructure of the bridge paving machine, wherein the carriage is configured to move linearly along a span of the superstructure and move vertically to apply a crown to a paving surface, wherein the carriage applies the crown using the finishing tool; 
 a forward sensor platform, wherein the forward sensor platform comprises a non-contact sensor; and 
 a mast comprising a tracking device, wherein the tracking device is configured to locate the carriage in three-dimensional space; and 
 
 at least one paving processor in data communication with a memory storing processor executable code for configuring the at least one paving processor to:
 correlate data collected from the non-contact sensor with a location determined from the tracking device of the mast; and 
 
   one or more total stations, wherein the one or more total stations and the tracking device generate the location.   
     
     
         20 . The system of  claim 19 , comprising a plurality of deflection sensors, wherein the plurality of deflection sensors are configured to couple to a plurality of beams of a bridge, wherein the non-contact sensor is configured to measure a plurality of points in the paving surface, wherein the plurality of points correspond to the plurality of deflection sensors, wherein the at least one paving processor is configured to analyze the plurality of points for a vertical deviation using the non-contact sensor.