Machine, system and method for road construction

Abstract

A method of building a road using a binder and a reinforcement is disclosed. The method may include moving a machine over a surface on which the road is to be built, and generating a signal indicative of a texture of the surface during movement of the machine over the surface. The method may also include detecting a location of the texture on the surface, and determining, using a specially programmed processor, a positive amount of the binder to be applied to the location of the texture on the surface that varies based on the signal and on an embedment specification of the reinforcement. The method may further include automatically applying the positive amount of the binder to the location of the texture on the surface to build the road.

What is claimed is: 
     
         1 . A method of building a road using a binder and a reinforcement, the method comprising:
 moving a machine over a surface on which the road is to be built;   generating a signal indicative of a texture at the surface during movement of the machine over the surface;   detecting a location of the texture on the surface;   determining, using a specially programmed processor, a positive amount of the binder to be applied to the location of the texture on the surface that varies based on the signal and based on an embedment specification of the reinforcement; and   automatically applying the positive amount of the binder to the location of the texture on the surface to build the road.   
     
     
         2 . The method of  claim 1 , wherein:
 the texture corresponds to voids at the surface between existing reinforcements; and   the positive amount is sufficient to at least partially fill the voids and to embed newly added reinforcements by a minimum amount.   
     
     
         3 . The method of  claim 2 , wherein the positive amount is sufficient to completely fill a majority of the voids. 
     
     
         4 . The method of  claim 3 , wherein the positive amount is sufficient to overfill the majority of the voids. 
     
     
         5 . The method of  claim 4 , wherein the minimum amount is at least 40%. 
     
     
         6 . The method of  claim 5 , wherein the minimum amount is about 50-70%. 
     
     
         7 . The method of  claim 6 , wherein the minimum amount is about 60%. 
     
     
         8 . The method of  claim 1 , wherein:
 generating the signal includes generating the signal with at least one sensor mounted to the machine; and   automatically applying the positive amount of the binder includes causing the machine to automatically apply the positive amount of the binder in real or near-real time as the at least one sensor generates the signal.   
     
     
         9 . The method of  claim 1 , wherein generating the signal indicative of the texture includes generating a signal indicative of a distance between existing reinforcements to an upper surface of an existing binder holding the existing reinforcements in place. 
     
     
         10 . The method of  claim 9 , further including generating a virtual map of the surface based on the distance. 
     
     
         11 . The method of  claim 1 , further including:
 collecting at least one of environmental data or historical data for the different locations of the surface prior to application of the binder or reinforcement; and   selectively adjusting the positive amount according to the at least one of environmental data or historical data.   
     
     
         12 . The method of  claim 11 , wherein environmental data includes at least one of geographical information, climate information, weather information, or traffic information. 
     
     
         13 . The method of  claim 11 , wherein historical data includes information regarding historical performance of an existing road previously built at the location of the surface. 
     
     
         14 . The method of  claim 11 , further including selectively causing the machine to automatically apply at least one of a primer or a hardener to the surface based on the at least one of environmental data or historical data. 
     
     
         15 . The method of  claim 1 , further including:
 monitoring the positive amount of the binder being applied; and   selectively coordinating a rendezvous with a supply machine based on the monitoring.   
     
     
         16 . A method of building a new road over the top of an old road, the method comprising:
 moving a distributor over a surface of the old road;   generating a signal indicative of a texture at the surface during movement of the distributor over the surface;   detecting a location of the texture on the surface;   determining, using a specially programmed processor, a positive amount of asphalt to be applied to the location of the texture on the surface that varies based on the signal and based on an embedment specification of an aggregate;   automatically spraying the positive amount of asphalt at the location of the texture on the surface; and   applying the aggregate over the asphalt to build the new road.   
     
     
         17 . The method of  claim 16 , wherein:
 the texture corresponds to voids at the surface of the old road, between pieces of existing aggregate; and   the positive amount is sufficient to at least partially fill the voids and to embed newly applied aggregate by a minimum amount.   
     
     
         18 . The method of  claim 17 , wherein:
 the positive amount is sufficient to overfill the majority of the voids; and   the minimum amount is at least 40%.   
     
     
         19 . The method of  claim 18 , wherein the minimum amount is about 50-70%. 
     
     
         20 . A road building machine, comprising:
 a vehicle;   a distribution arrangement mounted to the vehicle and configured to distribute a binder on to a surface as the vehicle moves over the surface;   at least one sensor mounted to the vehicle and configured to generate a signal indicative of a distance between existing reinforcement at the surface to an upper surface of existing binder during movement of the vehicle over the surface;   a locating device configured to detect a location of the texture; and   a controller in communication with the distribution arrangement, the at least one sensor, and the locating device, the controller being specially programmed to:
 determine a positive amount of the binder to be applied to the location of the distance based on the signal and based on an embedment specification for reinforcement to be newly applied; 
 automatically cause the distribution arrangement to distribute the positive amount of the binder on to the surface at the location of the texture as the vehicle moves over the surface; and 
 embedding the reinforcement into the binder.