Vögele Paving Training PDF

VÖGELE – Operators Guide Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Chapter 1 Topic Page Road Paver Chapter Topic Page 1.11 Screed Planning Angle (Angle of Attack) 36 1.1 Ge...

VÖGELE – Operators Guide Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Chapter 1 Topic Page Road Paver Chapter Topic Page 1.11 Screed Planning Angle (Angle of Attack) 36 1.1 General Information 9 1.12 Head of Material 37-38 1.2 Types of Paving 10 1.13 Connection: Tow Arms – Screed Frame 39 1.3 Design of as Road Paver 11 1.14 Connection: Tow Arms – Screed Frame 40 1.4 Drive Concept 12 1.15 Paver Operation 41-44 1.5 Product Palette of Vögele AG 13 1.16 Display Unit 45-46 1.6 Primary Paver Functions 14-19 1.17 Main Control Desk 45-62 1.6.1 Advance Drive 15 1.17.1 Start Screens “1.0” and “2.0” 47 1.6.2 Material Transfer 15 1.17.2 Warning Icons, Screen “0.1” 48 1.6.3 Material Conveyance 16 1.17.3 Machine Data, Screen “0.4” 49 1.6.4 Material Distribution 17 1.17.4 Screed Settings 50 1.6.5 Tow Point Adjustment 17 1.17.5 Tamper Settings, Conveyor Settings 51 1.6.6 Cylinder Functions 18 1.17.6 Vibration Settings, Auger Settings 52 1.6.7 Electrical Screed Heating 19 1.17.7 Pressure Bars, Automatic Steering 53 1.6.8 Compaction Devices 19 1.17.8 Engine, ECOplus and Diesel Particle Filter (DPF) 54 1.7 Self Levelling of a “Tracked” Road Paver 20 1.17.9 Autoset “Positioning Function” 55-56 1.8 Self Levelling of a “Wheeled” Road Paver 21 1.17.10 Autoset “Paving Function” 57 1.9 Explanation of Important Cylinder Functions 22 1.17.11 Electrical Screed Heating 58 1.9.1 Screed “Raising” 23 1.17.12 Service Area, Screed Crown Profile 59 1.9.2 Screed “Lowering” 24 1.17.13 Info Matrix, Info CAN 60 1.9.3 Forces on a Road Paver 25 1.17.14 Advanced Conveyor Setting 61 1.9.4 Screed “Float” 26 1.17.14 Advanced Auger Setting 62 1.9.5 Screed “Hold” 27 1.17.15 Traction Drive Mode “Manual”, Splitter Gearbox Clutch 63 1.9.6 Screed “Float Off” 28 1.17.16 “Language-Time-Date”, Display Brightness 64 1.9.7 Screed “Freeze” 29-30 1.9.8 Screed “Assist” 31-33 1.10 Tamper Speed vs. Paving Speed Joseph Voegele AG, Ludwigshafen/Rhein Germany 35 CTT Center for Training and Technology Chapter 2 Topic Screeds Page Chapter Topic Page 68-105 2.17.10 Submenu Calibration “Crown”, Conveyor Control 101 2.1 General Information 68 2.16.11 Description of NiveltronicPlus Screen 102 2.2 Product Palette of the Vögele AG 69-70 2.17.12 Start Screen NiveltronicPlus, Submenu: Parameters 103 2.3 Special Equipment 71 2.17.13 Calibration (Niveltronic), Sensitivity 104 2.4 Compaction Devices 72 2.17.14 Submenu: Advanced Settings, Working Window 105 2.5 Tamper (T) 73-75 2.6 Vibration (V) 76 2.7 Pressure Bars (P) 77 2.8 Screed Crown Profile 78 3.1 Levelling Sensors 109 2.9 Bolt-On Extensions 79-82 3.2 Fundamentals in Operation 110 2.10 Screed Side Plates (AB 500-3 and AB 600-3) 83 3.3 Mechanic Sensors 111-112 2.11 Electrical Screed Heating 84 3.4 Acoustic Sensors (Ultra Sonic) 113-124 2.12 Three-Point-Guidance System 85-87 3.4.1 Working Principals Ultra Sonic Sensors 113-116 2.13 Fixed Screeds SB 250-2 and SB 300-2 88 3.4.2 In-depth: Big Multiplex Ski 117-124 2.14 Design of a Fixed Screed 89 2.15 Compaction Devices on a Fixed Screed 2.16 2.17 Chapter 3 Topic Automatic Grade and Slope Control 109-127 Optical Sensor (Laser 125-126 90 3.5.1 Function Principle 125 Bolt-On Extensions for Fixed Screeds 91 3.5.2 Laser Receiver LS 300 126 Screed Operation 92-105 2.17.1 Switchover: Niveltronic – Paving Parameters 92 2.17.2 Tamper and Vibration Settings 93 2.17.3 Adjustment Pressure Bars and Balance P2 94 2.17.4 Screed Assist Pressure and Balance 95 2.17.5 “Screed Float Off “ , Paving Speed and Distance Counter 96 2.17.6 Matrix Screed Control, Socket for Grade Control 97 2.17.7 Electrical Screed Heating, Socket for Auger Sensor 98 2.17.8 Deflector Crawler Track, Auger Height Adjustment 99 2.17.9 Auger Control, Screed Crown Profile 100 Joseph Voegele AG, Ludwigshafen/Rhein Germany 3.5 Page 3.6 CTT Center for Training and Technology 3D Control (Navitronic) 127 Chapter 4 Topic Page Application 4.1 4.2 Chapter 5 Topic Page Service and Maintenance Paving Asphalt 131 5.1 Quick Reference Guide for Maintenance Work - Paver 165-166 4.1.1 Asphalt Layers and their Purposes 131 5.2 Information for Operators 167-172 4.1.2 Function of a Asphalt Base Course 131 5.2.1 167 4.1.3 Asphalt Binder Course 132 5.2.2 4.1.4 Asphalt Wearing Course 132 5.2.3 Centralized Lubrication System 168 4.1.5 Combined Asphalt Base and Surface Layer 133 5.2.4 Override of Hydraulic Valves 169 4.1.5 Checklist “Paving” 134 5.2.5 Fuses 170 4.1.6 Ten Steps Prior Paving 135 5.2.6 Aided Starting, Towing 170 4.1.7 Recommended Settings and Acronyms 136 5.2.7 Welding 171 4.1.8 Subgrade Preparation 137-139 5.2.8 Regeneration Chart Diesel Engine 172 4.1.9 Ten Steps after Paving 140 5.3 Traction Drive “Manual” , “Screed Float” Manually 167 Service on a “Dash 3” Paver 173-176 Paving and Checking Paved Result 141-145 5.3.1 Engine Oil 173 4.2.1 Manual Paving, Paving with Slope 141 5.3.2 Splitter Gear Box 174 4.2.2 Paving and Measuring Crown Profile 142 5.3.3 Crawler Track Chain, Auger Drive 175 4.2.3 Measuring Percentages 143 5.3.4 Conveyor Chains 176 4.2.4 Measuring Slope 144 5.4 Quick Reference Guide for Maintenance Work - Screeds 177-178 4.2.5 Using a Digital Spirit Level 145 5.5 Service on “Dash 3” Screeds 179-187 4.3 Influencing Parameters 146-147 5.5.1 Tamper Height 179 4.4 Sources for Paving Errors 148-150 5.5.2 Tamper Stroke, Wear Strip 180 4.5 Possible Faults Prior Paving 151-152 5.5.3 Screed Plates 181 4.6 Possible Faults During Paving 153 5.5.4 Tamper Shield 182 4.7 Possible Faults After Paving 154 5.5.5 Pressure Bar Adjustment 183-184 4.8 Summary of Potential Paving Faults 155 5.5.6 Screed Extension Adjustment 185 4.9 Frequent Errors when Paving 156-158 5.5.7 Planning Angle of the Screed Extensions 186-187 4.10 Segregation 159-161 4.11 Imprints 162 Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Chapter 1 Road Paver Aerial Photograph of the Joseph Vögele AG in Ludwigshafen/Rh. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 1.1 General Information A Road Paver is a construction machine, available either tracked or wheeled driven (depending on market or manufacturer also with rubber tracks), mainly used for laying asphalt, but also sand, gravel or concrete. Special Equipment, based on modified conventional pavers are also available such as “Spray Jet”, “InlinePave” or “Slope Paver”. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 9 1.2 Types of Paving Classical Paving Track Lanes / Special Profiles Placing all kinds of pavement layers for roadways and paths. Pavers are available in various performance classes and combine with varieties of screed options to handle these paving jobs. Extending Screeds can be set up for paving a large variety of special profiles thanks to their systems for adjustment. Special slip forms are available for paving farm tracks. When combining the height adjustment of the extensions with the crown profile adjustment, Mprofiles and W-profiles are possible. Layer thickness ranges from 20 mm to 500 mm. Paving Vertical Slope Special Formworks Apart from construction of conventional roads with gradients (uphill or downhill), road pavers can also be used for special applications, such as paving on a slope for dam construction, retaining walls, etc. In general, only slight conversion of the paver is required for handling these kind of jobs. For application under extreme conditions (steep slope), a special Slope Paver can be used. Banked Corners Paving Horizontal Slope As an alternative to paving in a vertical direction, pavers also work in a horizontal direction. In general such applications require no more than slight conversion of the paver. Paving work like this is also often found in the field of dam or canal construction. Joseph Voegele AG, Ludwigshafen/Rhein Germany By using special formwork, tracks for agricultural roads or rail track construction can be done. CTT Center for Training and Technology Even banked corners, like on race tracks, can be done with special formworks. In that case parabolic screeds can be used. 10 1.3 Design of a Road Paver 44 Paving Functions Paving functions like screed freeze, screed hold or screed assist are achieved by using the screed raising/lowering cylinders. 55 Screed Screed weight and compaction devices on the screed are affecting the pre-compaction of the laid material and profiling the new asphalt layer can be achieved. 1 2 3 4 5 6 7 8 9 66 Hopper The transfer of the material takes place between feeding lorry and hoppers in front of the paver. 77 Push Rollers 1 88 Paving depth can be controlled and irregularities in the base are reduced by changing the height of the tow point cylinders. Traction Drive 3 Two conveyors are used to bring the mix from the hoppers back to the screed (exception: SUPER 600/800 – only one conveyor) The truck wheels touch the push rollers and rotate during the paver pushes the truck forward. Height Adjustment via Tow Point Cylinders 22 By using adjustable hydraulic pumps, either tracks or wheels are driven. Joseph Voegele AG, Ludwigshafen/Rhein Germany Conveyors Spreading Augers Augers are used for uniform distribution of the mix in front of the screed. 99 Screed Heating To prevent the material from sticking to the screed, heating rods are fitted on the screed plates, tampers and pressure bars. CTT Center for Training and Technology 11 1.4 Drive Concept Advantages of a Tracked Paver Advantages of a Wheeled Paver   Driving in public traffic on its own axles, up to 20 km/h (larger contact area of the crawler track chains) - no need for a transportation truck  Steering movements won’t harm the base  Screed follows directly steering signals  Passover fresh laid base or binder course is possible  Single driven, hydrostatic rear wheel drive  Smooth running when laying asphalt wearing course  Highly manoeuvrable, tight turning radius (narrow or curved areas)  Permanent ground contact of at least two of three axles by the  Large paving width above 8,5 m, up to max 16 m  Use of high compaction screeds (TP2)  Use of SB screeds  Ideal or paving vertical slope (landfill site, water reservoir) (Large vertical and horizontal slope is possible) static 3-point support steering system (Irregularities in the base are transferred mitigated to the chassis) Joseph Voegele AG, Ludwigshafen/Rhein Germany High traction force  3D Levelling System can be used  Hopper Inserts (InlinePave; Feeders)  Electronically controlled directional stability (no permanent steering during paving)  Better access for service and maintenance work CTT Center for Training and Technology 12 1.5 Product Palette of Vögele AG SUPER Series Machine Class Mini Class Compact Class Universal Class Highway Class SUPER Series Weight Basic Width Maximum Width Maximal Capacity Machine Class Tracked Paver SUPER 700-3 5,9 t 1,2 m 3,5 m 250t/h Special Class Tracked Paver SUPER 800-3 6,1 t 1,2 m 3,5 m Tracked Paver SUPER 1100-3 8,5 t 1,8 m Wheeled Paver SUPER 1103-3 8,6 t Tracked Paver SUPER 1300-3 Weight Basic Width Maximum Width Maximal Capacity SUPER 1800-3 & SprayJet Module 20,8 t 2,55 m 6,0 m 700t/h 250 t/h SUPER 1800-2 Slope Paver 23,6 t 2,55 m 5,0 m 700 t/h 4,2 m 300 t/t SUPER 2100-2 IP Binder Paver 26,6 t 3,0 m 8,5 m 1100 t/t 1,8 m 4,2 m 200 t/h VISION Series 9,5 t 1,8 m 5,0 m 350 t/h Universal Class Weight Basic Width Maximum Width Maximal Capacity Wheeled Paver SUPER 1303-3 9,5 t 1,8 m 4,5 m 250 t/h Tracked Paver VISION 5100-2 15,5 t 2,45 m 5,8 m 700 t/h Tracked Paver SUPER 1600-3 18,4 t 2,55 m 8,0 m 600 t/h Wheeled Paver VISION 5103-2 14,9 t 2,6 m 5,8 m 700 t/h Wheeled Paver SUPER 1603-3 17,0 t 2,55 m 7,0 m 600 t/h Tracked Paver VISION 5200-2 19,4 t 3,0 m 8,6 m 1200 t/h Tracked Paver SUPER 1800-3 19,3 t 2,55 m 10,0 m 700 t/h Wheeled Paver VISION 5203-2 18,5 t 3,0 m 7,8 m 1200 t/h Wheeled Paver SUPER 1803-3 17,3 t 2,55 m 8,0 m 700 t/h Power Feeder Series Tracked Paver SUPER 1900-3 20,9 t 2,55 m 11,0 m 900 t/h Special Class Weight Basic Width Maximum Width Maximal Capacity Tracked Paver SUPER 2100-3 21,9 t 2,55 m 13,0 m 1100 t/h Power Feeder MT 3000-2 17,0 t 3,0 m - 1200 t/h Tracked Paver SUPER 3000-2 28,7 t 3,0 m 16,0 m 1600 t/h Power Feeder MT 3000-2 Offset 23,0 t 3,0 m - 1200 t/h Type Joseph Voegele AG, Ludwigshafen/Rhein Germany Highway Class CTT Center for Training and Technology Type Type Type 13 1.6 Primary Function of a Road Paver 1. Advance Drive 2. Material Transfer 3. Material Conveyance 4. Material Distribution Advance Drive to move the road paver is carried out either by crawler tracks or rubber wheels. Mix is dumped from the feed truck into the paver's material hopper. At the tracked paver, the two crawler tracks are driven independently. The wheeled pavers are equipped with three axles. Optional both front axles can be provided with front wheel assist. The feeding lorries are pushed by push rollers. From the hopper the mix is transferred longitudinal to the rear in front of the screed via two adjustable, separate conveyor chains (S 700/800 only one) Spreading the mix to both sides of the screed via two adjustable, separate augers. They can be operated manually or automatically with either mechanic or Ultra sonic sensors. Additionally the height of augers can be adjusted to fit to the paving depth. 6 5. Tow Point Adjustment Paving depth control and levelling out irregularities is done by adjusting the screed tow points in height, which is changing the screed angle of attack. Therefor hydraulic rams can be controlled either manually or automatically. Joseph Voegele AG, Ludwigshafen/Rhein Germany 5 8 8. Compaction Devices Weight of the screed and the energy of the compaction devices are significantly involved reaching the desired compaction. 3 1 4 6. Cylinder Functions 7. Electrical Screed Heating Screed Float, Screed Hold, Screed Freeze and Screed Assist are depending on the control of the „Screed Raising/Lowering Cylinders“. Heating to heat up the Screed Plates, the Tampers and (optional) the pressure bars to prevent the screed from sticky material CTT Center for Training and Technology Compaction is essentially influenced by:       Conveyors Augers Tampers Weight of Screed Pressure Bars Vibration 14 1.6 Primary Function of a Road Paver 2. Material Transfer 1. Advance Drive  Avoiding hard docking of the feed lorries (imprints in the surface)  Checking asphalt temperature  Keeping push rollers clean (guarantees directional stability)  Checking for segregation coming from plant or delivery  Obtain steering reference (Straight Joints!)  Reduce hopper movement  Constant Speed, matching with the material supply from the plant  Avoid spilling material  Push rollers can be changed in distance to match different truck sizes)  Keep track clean (using plough, if necessary) Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 15 1.6 Primary Function of a Road Paver 4. Material Distribution 5. Tow Point Adjustment  Setup of auger sensors  Ensure constant head of material  Ensure continuous flow of material  Feed ratio of conveyor and auger sensors  Reduce changing of tow points to achieve evenness  Setup right auger height   Avoiding segregation in the lateral areas  if necessary: use of auger extensions and tunnel plates Joseph Voegele AG, Ludwigshafen/Rhein Germany  Changing the tow points will change the screed angle of attack  Changing the screed angle of attack will change paving depth Tow arms fish plates can be changed in position for larger paving thickness CTT Center for Training and Technology 17 1.6 Primary Function of a Road Paver Additional Functions are:  Screed Float Is the condition of the screed normally used during paving. The screed is only connected to the tow point cylinders via the screed arms and is floating on the laid material.  Screed Hold / Float Off Prevents the screed from sinking when stopping during paving.  Screed Freeze Works against the floating up of the screed and therefore reduces possible „Start Up Bumps“ when resuming paving after a paving stop. 6. Cylinder Functions Main Function of the two rear mounted cylinders:  Screed Assist  Screed Raising and Screed Lowering Works against the floating up of the screed Screed lowering should not be carried out by and therefore reduces possible „Start Up using the screed float button on the two screed Bumps“ when resuming paving after a paving controls. stop. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 18 1.6 Primary Function of a Road Paver 7. Electrical Screed Heating 8. Compaction and Compaction Devices  Prevents material from sticking to the screed when paving  Wrong setup of material sensors can be negative for the bitumen bounded material pre-compaction of the asphalt  Insufficient heated up screed will influence the surface structure negatively and will lead to a poor float behaviour of the screed  Automatic temperature control is optionally available  Continuously, slow rotation of the augers  Tamper speed must be adjusted according to pave speed, stroke and shape of the tamper  Screed weight can be influenced by screed assist  Setup of pressure bars must be adjusted according to jobsite  Vibration can be used to improve surface structure Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 19 1.7 Self Levelling of a Screed – Tracked Pavers Short irregularities in the base are levelled out trough the self-levelling property of the floating screed. When passing over long irregularities, the height of the screed tow points changes automatically because the paver leaves its horizontal position. Chassis and tow points will raise, thus leading to a change in the layer thickness. Movement parallel to reference Depending on the screed angle of attack, more or less mix is packed under the screed as the paver advances, and the layer thickness gradually changes over a longer distance. The response of the screed to such changes depends on:  Paving speed  Change in height of the tow points  Screed angle of attack  Properties of the mix (compactability, bearing capacity) Deviation to reference Taking into account different length for the different paver types, consisting of tow arms length and the depth of screed plates, an average ratio about 5 : 1 results as far as compensation of short irregularities in the base is concerned. Long irregularities in the base can only be levelled out by actively controlling the height of the screed tow points. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 20 1.8 Self Levelling of a Screed – Wheeled Pavers Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 21 1.9 Cylinder Functions Hydraulic Circuits and Symbols Screed „Raising“ Screed „Lowering“ Tank 30 bar Tank max. 180 bar Screed „Freeze“ Screed „Assist“ Tank Example: SUPER 1800-3i 30 bar X max. 40 bar Screed „Floating“ Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Screed „Hold“/ „Not Floating“ Tank Tank Tank X 22 1.9 Cylinder Functions Hydraulic Circuitry Tank Symbol max. 180 bar Vertical Movement Push-button for raising the screed Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 23 1.9 Cylinder Functions Hydraulic Circuitry 2. Screed “Lowering” Symbol 30 bar Tank Push-button for lowering the screed  Lowering the screed is carried out with an aid pressure Vertical Movement of 30 bar on the rod side of the hydraulic cylinders  A One-way restrictor on the rod side of the cylinders allows an adjustable lowering speed  The screed is lowered “controlled” (no twisting of the screed and reduced risk for accidents)  Due to the use of the one-way restrictor a feeding of air or vacuum in the hydraulic system is avoided Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 24 1.9 Cylinder Functions Traction Force - Resistance The traction force of the paver must always be higher 3. Forces on a Road Paver than the resistance created by the material laying in front of the screed. When the screed is floating on the laid material, the following described forces are present. Changing the traction force (paving speed) or resistance (head of material) will lead to a change in the paving depth as well as the pre-compaction. The forces can influence the float behaviour of the screed and therefore pre-compaction and paving depth. Weight W Horizontal Forces Vertical Force R Resistance T Traction Force U Uplift Bearing Capacity – Screed Weight W As long as there is a equilibrium between bearing capacity and the screed weight, the screed will move parallel to the towing direction. Increasing the uplift force will result in an up-float of the screed until a new equilibrium is achieved. R T U Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 25 1.9 Cylinder Functions Hydraulic Circuitry 4. Screed “Float” Tank Symbol Tank v The Float symbol (≈) in the display of the screed controls or the Vertical Movement green LED in the screed float button are active as soon the screed is in “Float Position“.  „Screed Float“ is the circuitry of the hydraulic cylinders for raising/lowering, used for paving.  “Screed Float” means, the screed is floating freely on the laid material.  When “Screed Float” is active, the screed raising/lowering cylinders will not influence the uplift of the Screed positive or negative. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 26 1.9 Cylinder Functions Hydraulic Circuitry 5. Screed “Hold” Tank Symbol x “Pave” Mode Traction Main Switch „Neutral“ Vertical Movement “Pave” Mode Traction Main Switch „Paving“ Screed „Hold“ – in Pave Mode: When stopping the paver during paving “Screed Hold” is activated automatically. The function prevents the screed from sinking in the asphalt. When positioning the paver in “Pave Mode” with screed lifted and not locked, the screed will drop as soon the machine moves! Screed „Hold“ – not in Pave Mode The function allows the screed to be raised quickly for re-positioning of the paver. When positioning the paver locking the screed is not mandatory. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 27 1.9 Cylinder Functions Hydraulic Circuitry 5. Screed “Float Off” Tank Symbol F2 F4 x F6 F8 Display in Main Control Desk Vertical Movement Display in Lateral Screed Controls To prevent the screed from sinking when running out of material at the end of a path, the operator can push and hold the “Float off Key-switch”. As long the switch is pushed, screed float is deactivated. The paving thickness can be maintained even with less material under the screed. A loss of compaction, starting with activating the function, must be expected! Recommendation: Only on flat lanes/areas. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 28 1.9 Cylinder Functions Hydraulic Circuitry 6. Screed “Freeze” Symbol 30 bar Tank What is “Screed Freeze” ? The function involves a hydraulic function intended to minimize the upwards movement of the screed after a break in paving and thus the risk of a step in the pavement. The “Screed Float” is deactivated for a short time. How does it work? With a hydraulic pressure (30 bar) on the piston side of the cylinders (1) and the hydraulic locking by magnetic valves (2) on the rod side, the screed is locked hydraulically when “Screed Freeze” is activated. The screed tow point rams (3) are also locked for the period fixed. F4 Vertical Movement Vertical Movement F2 F6 F8 (Screen 1.1) for 500 mm or maximum 10 Seconds then „Screed Float“ Joseph Voegele AG, Ludwigshafen/Rhein Germany The automatic screed freeze function can be activated or deactivated in the display of the main control desk. CTT Center for Training and Technology 29 1.9 Cylinder Functions 6. Screed “Freeze” Symbol Hydraulic Components Hydraulic Circuitry When paving below 3m/min: Screed freeze is active for 10 seconds maximum, depending on the parameter setting in the protected area. 30 bar 30 bar Tank Tank When paving 3 m/min and above: Screed freeze is active for 0,5 m paving length. Afterwards, in both cases, „Screed Float“ will be automatically active. Note: When screed freeze is activated but not needed temporally, the function can be turned off by using the „Float Button“ on the screed control. When resuming paving after a following stop, the function is active again. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 30 1.9 Cylinder Functions 7. Screed “Assist” Hydraulic Components F2 Tank Symbol F4 F6 Adjustment System Pressure F8 Adjustment Balance Left-side/Right-side 0 - 40 bar Display Main Control Desk It is possible to provide both cylinders for screed raising/lowering with hydraulic pressure on the rod side , independently from each other. The pressure is influencing the weight force of the screed and will decrease the screed weight depending to the set assist pressure. Vertical Movement Vertical Movement Pressure-dependent Display Screed Control: Adjustment Balance lh/rh Display Screed Control: Adjustment System Pressure Left = Right Pressure-dependent Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 31 1.9 Cylinder Functions 7. Screed “Assist” Should the material bearing capacity not be sufficient, then this means, even with a high screed planning angle, the screed can not achieve the required level. Possible causes are:  Low pre-compaction from the tamper  Consistency of the material When paving mix with a poor bearing capacity the floating screed will sink in the material, recognizable at a high angle of attack.  Large paving depth( here: 400 mm HGT)  Poor bearing capacity ( observable at a very high angle of attack) When paving Profiles (e.g. Slope or levelling course) it can happen that on the “thicker” side a bigger angle of attack is needed or the angle of attack on the thinner side is getting negative. The screed assist function can be used when paving asphalt base course or asphalt binder course - but also for paving cemented material such as hydraulic threated base courses (abbr. CTB). Consequential: Different pre-compaction with eventual irregularities and, depending on the depth, even a twisting of the screed can occur. In that case screed assist can be applied on the “thicker” side. Side effect: When laying material with a poor bearing capacity the use of screed assist will optimize the angle of attack of the screed. Thereby the wear and tear of screed plates, tamper bars and pressure bare is reduced significant. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 32 1.9 Cylinder Functions 7. Screed “Assist” Less precompaction in the outside section of the curve Attention When using the hydraulic screed assist function, the float behaviour of a screed is actively influenced. When changing the screed assist pressure, the angle of attack and the paving depth must be observed. When paving less then the minimum paving width of the screed, usually cut-off shoes can be mounted to the screed. Alternatively screeds also can be filled with material on one side only in order to achieve a smaller paving width. The unfilled screed side, due to the missing uplift force, will sink in the Material. The one-sided use of screed assist pressure will prevent the screed from sinking. Important Recommendation Higher precompaction in the inside section Roundabouts / Tight Turns When paving tight turns (e.g. roundabouts) different speeds on both screed sides will be present: inner Radius = lower forward movement outer Radius = faster forward movement Due to that behaviour plus the equal tamper revolution across the screed width a different pre-compaction will occur. The lower uplift on the outside can be compensated by using the screed assist function. Additionally the reduced weight of the screed on the outside has a positive influence to the traction drive tracks or wheels – improvement of the traction force. Using screed Assist on thin layers is not recommendable. Due to the small tolerance area of the angle of attack there is the risk that the screed planning angle runs to flat and, in the worst case, the screed is paving in a “negative "position. That will lead inevitably to irregularities in the new layer. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 33 1.10 Tamper Revolution – Paving Speed General If the pave speed is increased without simultaneously increasing the tamper speed, the load bearing capacity of the mix will be reduced and the screed lay a thinner layer at a steeper angle of attack. Lower Pre-compaction Higher Pre-compaction Paving Speed Paving Speed After Compaction by Rolling Paving with Automated Grade and Slope Control If Automated Grade and Slope Control is used for paving, the desired elevation of the screed can be maintained by increasing the angle of attack, but pre-compaction will not remain constant. Joseph Voegele AG, Ludwigshafen/Rhein Germany When the roller passes over the mix, the amount of extra compaction will differ on account of varying pre-compaction and result in irregularities in the surface. CTT Center for Training and Technology 34 1.10 Tamper Revolution – Paving Speed Increasing the paving speed without matching the Tamper speed will result in a change of the uplift of the screed (uplift will drop) and therefore the paving depth will drop as well. Due to the increasing angle of attack a height offset will occur between main screed and extensions. Raising the tamper speed will result in an increase of the pre-compaction and therefore a change in the paving depth, as long there is no readjustment of other parameters such as the paving speed. Joseph Voegele AG, Ludwigshafen/Rhein Germany Recommendation To ensure an even pre-compaction following rule applies: when changing the paving speed, it is mandatory to adapt the Tamper revolutions. CTT Center for Training and Technology 35 1.11 Screed Planning Angle (Angle of Attack) Travel Direction Travel Direction 40 mm Positive angle of attack for 40 mm paving depth: between 40 und 80 mm on the Scale Joseph Voegele AG, Ludwigshafen/Rhein Germany Negative angle of attack for 40 mm paving depth: less than 40 mm on the Scale000 CTT Center for Training and Technology 36 1.11 Screed Planning Angle (Angle of Attack) An increased angle of attack will allow more material under the screed. As a result the paving depth will increase as long as the balance of screed weight and bearing capacity is achieved again. Raising the tow points relative to the ground will cause an increase of the screed angle of attack (⍺) and therefore the paving depth will also change. ⍺  For paving the angle of attack is set to a value on the scale between 0% and 100% bigger then the paving depth  The value indicated on the scale is summary of „paving depth“ plus „angle of attack“  That will guaranty the optimum efficiency of the compaction aggregates to the asphalt  Wear and tear on tamper, screed plates and pressure bars will be reduced  Optimum angle of attack = optimum position of the tamper  The screed weight has a good impact to the material Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 37 1.12 Head of Material  Overfilling of the screed should be avoided  changing head of material can influence the floating behaviour of the screed  Reducing the head of material leads to the screed sinking, increasing the head of material will lead to the screed raising  Head of material should be constant right from the beginning - during paving material flow can be controlled by sensors Attention! Changing head of material can lead to an up and down movement of the screed and therefore irregularities can appear. This should be avoided! Joseph Voegele AG, Ludwigshafen/Rhein Germany Recommendation: With a wheeled paver it is important to maintain a low and constant head of material to prevent the paver from lost of traction. CTT Center for Training and Technology 38 1.13 Connection: Tow Arm to Screed Frame Standard When the screed is mounted „deeper“ on the screed flanges, paving below the level of the paver crawler tracks is possible. A higher mounting of the screed to the flanges allows paving of thicker layers. When changing the tow arm lugs for thicker layers, the “0”-point is moved downwards. When adjusting the angle of attack the displayed value has to be reduced by that difference. Adjustment when the setting-range of the tow point cylinders is not enough to achieve the desired depth. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 39 1.14 Connection: Tow Arm to Tow Point Cylinder „Standard“ For common asphalt types. „Higher Angle of Attack“ When laying material with a poor bearing capacity it can happen that the tow points are not able to realize the required angle of attack. In that case the front part of the screed arms can be relocated to achieve a larger angle of attack. „Standard“ and „To the Rear“ Enlarged distance between Augers and screed. Can eliminate the eventual appearance of segregation when paving coarse-gained material or when the amount of binder is less. „Higher Angle of Attack“ and „To the Rear“ Combined with the “Higher Angle of Attack” when paving thicker layers (e.g. base course) the area in front of the screed and therefore the amount of material is increased. With additional material in front of the screed the resistance is getting bigger, more traction force is needed. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 40 1.15 Paver Operation The “Emergency Stop Button” is to stop the paver immediately in case of a dangerous situation! It is not its function to turn off the engine when the job is done! All “Emergency Stop Buttons” should be checked for function on a regular base. Tracked Paver: Reversing traction drive Crawler track Wheeled Paver: Pivot Steer in Positioning or Pave gear Tracked Paver: Deflector crawler tracks Wheeled Paver: Not available Joseph Voegele AG, Ludwigshafen/Rhein Germany Tracked Paver: No function Wheeled Paver: Road Mode On a wheeled paver additional switches for Indicators, Side lights, Head light and High beam are provided. CTT Center for Training and Technology 41 1.15 Paver Operation Operating and Setting Elements – Segment 1 1 2 3 4 5 6 1 12 o. 13 14 13 12 11 10 1. Hydraulic Auger Height Adjustment 2. Reversing Conveyors (0,5m) 9 8 11 o. 14 7 7. „Execute Button“ Autoset Functions All paving functions and paving parameters can be set either from the main control desk or the lateral screed controls. 3. Automatic Filling of the screed 8. Selecting Mode 4. Cleaning/Pre-heat Function 9. Parking brake Indicator 5. Reversing Crawler Tracks 10. Traction Main Switch 5. Pivot Steer (Wheeled Paver) 11. Auger, rh, Manual/Auto INFO 6. Setting Paving Speed 12. Conveyor, rh, Manual/Auto To ensure finishing a jobsite after occurrence of minor problems (e.g. failure of a screed control or sensors) the actuation of paving functions or setting of parameters is “redundant”. That means the functions can be set from different switches or screens. 13. Conveyor, lh, Manual/Auto 14. Auger, lh, Manual/Auto Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 42 1.15 Paver Operation Operating and Setting Elements – Segment 2 2 3 4 5 1 8 7 6 1. Electrical Screed Heating On/Off 2. Tow Point Cylinder, lh 1 5 3. Hydraulic Screed Lock 4. Tow Point Cylinder, rh 5. Hydraulic Screed Assist On/Off (Option) 6. Extend/Retract Screed, rh 7. Raising/Lowering Screed 2 4 8. Extend/Retract Screed, lh Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 43 1.15 Paver Operation Operating and Setting Elements – Segment 3 1 2 3 4 5 Truck – Dock Truck drives revers to paver. 6 Truck – Stop Truck shall stop or has docked (Signal from push-roller sensor). P A V Truck – Raise Dump Box Truck raises the dump box and Starting the transfer the material 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 12 11 10 9 8 Truck – Lower Dump Box Truck lowers the dump box Truck – Move Away Truck shall move away from the paver. O C K „Paver in Motion“ Deflector also can be operated from the screed control Joseph Voegele AG, Ludwigshafen/Rhein Germany D 7 Beacon Working Lights 24 Volt Screen Wiper / Cleaner (Option) Steering Trim Crawler Track Deflector 5 PaveDock Assistant Hopper Right Side Front Apron + Both Hopper Sides Hopper Left Side Steering Lever Horn Speed Adjustment Diesel Engine Start/Stop Diesel Engine E The signal is shown, when paver is moving in pave mode. The signal is displayed combined with the other signals. CTT Center for Training and Technology 44 1.16 Display Unit Navigation Block “Enter”, “Escape” and “Scrolling” push-buttons Coloured Display The three functions have status indicators. Push-buttons are active, when LEDs are illuminated. 4 Menu Push-buttons 8 Function Push-buttons Basically the screens of tracked and wheeled pavers are identical. Only a few differences must be considered. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 45 1.16 Display Unit Colored Display Travel speed in m/min (Pave Mode or Positioning Mode) Travel speed in km/h (Transportation Mode) Eco Plus Modus active Conveyor Material Level, left-hand side Conveyor Material Level, right-hand side Position Tow Point Cylinder, left-hand side Position Tow Point Cylinder,right-hand side Actual Page Number Actual Time Status Indicator – Pre-heating Diesel Particular Filter (DPF) Joseph Voegele AG, Ludwigshafen/Rhein Germany Activated Function Autoset „Paving Programs“ Fine Steering/ Radius Pre-selection CTT Center for Training and Technology Status Indicator Pave Dock Assistant 46 1.17 Display Screen Pages – Main Control Desk Start Screen “1.0” Start Screen “2.0” F1 Screed Settings F1 Engine Rpm, ECOplus, Regeneration Diesel Particle Filter F2 Tamper F2 Autoset Paving Functions F3 Conveyors F3 Electric Screed Heating F4 Vibration F4 - unassigned - F5 Spreading Augers F5 - unassigned - F6 Pressure Bars (Option) F6 - unassigned - F8 Automatic Steering (Option) F7 Service Area M1 Warning Icons F8 Display Brightness M2 - unassigned - M1 Warning Icons M3 - unassigned - M2 - unassigned - M4 Machine Data M3 - unassigned - [F7] Front Wheel Assist Joseph Voegele AG, Ludwigshafen/Rhein Germany wheeled Pavers only M4 Machine Data CTT Center for Training and Technology 47 1.17 Display Screen Pages – Main Control Desk Info Screen “0.1” – Warning Icons ! a b c d f g h i j k l m o p q r e Water Separator Full b Low Fuel Level c Alternator or „D+“ faulty d Low Grease Level (Centralized Lubrication System) e Clutch , Splitter Gearbox f Low Coolant Level g Coolant Temperature too High h Engine Oil Pressure i Low Engine Oil Level j Air Filter Clogged k Suction/return Filter Clogged l Leakage Oil Filter Clogged m Diesel Engine Fault / Stop Diesel Engine n False Software/Hardware recognized (No Engine Start!) o Automatic Steering / Brake Pressure too low p Emergency Stop Tripped q Fault in Regeneration System (Type „i“ Machines) r Interlock Regeneration System (Type „i“ Machines) n Information Instead of the warning “Automatic Steering Fault” (o) on a wheeled paver „Brake Pressure too low“ will appear in this field. Joseph Voegele AG, Ludwigshafen/Rhein Germany a CTT Center for Training and Technology 48 1.17 Display Screen Pages – Main Control Desk Info Screen “0.4” – Machine Data Following all displays for adjustments and applying are described. Valid for all screens: b a c d g e f Function deactivated Function activated a. Selected/Actual Travel Speed b. Revolution Diesel Engine c. Working Hours d. Temperature Diesel Engine e. Distance Counter (Pave Mode) f. Once icons are displayed besides F1-F8 the corresponding key buttons are active. Blank fields are indicating: key button not assigned. In the navigation block the key buttons Enter, Escape and scrolling are located. When the corresponding key switch is active, The respective LED is illuminated green. Fuel Level g. On-board Voltage Pushing key F7 will reset Distance Counter back to „0„ Joseph Voegele AG, Ludwigshafen/Rhein Germany Pushing Escape will switch back to the previous page, purpose of Scrolling/ Arrows is the selection or adjustment of values. To erase inactive fault messages in the fault memory or confirm a selection the enter key switch is used. CTT Center for Training and Technology 49 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “1.1” – Screed F2 Screed Freeze Button F2 activates the screed freeze function. When screed freeze is active, the rams for raise/lower screed are subjected to 30bar on the piston side and blocked on the rod side for 0.5m when starting up. The screed automatically switches to floating position after 0.5m, at least 1 second and not more than 10 seconds. Actuation of the tow point rams is likewise blocked both manually and by NiveltronicPlus during the blocking distance / time. This prevents the screed rising. When screed freeze is deactivated, the screed moves into floating position immediately when the paver starts up. F3 Auger Height With the function activated, the augers will raise automatically, simultaneously with Screed raising. F4 Floating position OFF (op) When F4 is pressed and held down, the solenoid valves on the rod side of the rams for raise/lower screed close and interrupt the float function. The screed is held in position. When the button is released, the screed resumes its floating position. LED indicators : Function active / inactive Values can be set at the navigation block using the arrow buttons Joseph Voegele AG, Ludwigshafen/Rhein Germany F6 Setting the screed assist pressure (option) The function must be activated via F6 for this purpose; the arrow buttons are enabled for adjustment as soon as the indicator lights up green. F8 Adjusting assist pressure balance, right and left The function must be activated via F8 for this purpose, as soon green LED is on the arrow buttons can be used to set values. CTT Center for Training and Technology 50 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “1.2” – Tamper Setting Tamper „Manual Mode“ Tamper rotates with the speed set by the arrow buttons, regardless to position of the traction main switch - displayed beside F6 Tamper „Automatic Mode“ Tamper rotates with the set speed, set by the arrow button, when traction main switch is set to “F”, respectively „Forward“ in Pave Mode. Joseph Voegele AG, Ludwigshafen/Rhein Germany Adjustment Screen “1.3” – Conveyor Setting F5 Adjustment Conveyor, left-hand side F6 Adjustment Conveyor, right-hand side With „F5“ for the left and „F6“ for the right conveyor the required side can be chosen. The values in percentage can be set by the arrow buttons. CTT Center for Training and Technology 51 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “1.4” – Vibration Setting F2 Vibration „Manual Mode“ Vibration rotates with the speed set by the arrow buttons Regardless to position of the traction main switch - displayed beside F6 F4 Vibration „Automatic Mode“ Vibration rotates with the revolutions , set by the arrow buttons, when traction main switch is set to “F”, respectively „Forward“ in Pave Mode. Joseph Voegele AG, Ludwigshafen/Rhein Germany Adjustment Screen “1.5” – Auger Setting F3 Reversing Auger, left-hand side F4 Reversing Auger, right-hand side The augers are reversed and deliver material inwards when buttons F3 / F4 are actuated. This is a non-locking function and cannot be activated permanently. Automatic mode is deactivated when the augers are reversed. Display „Auger position above the ground“ - besides F5 - CTT Center for Training and Technology 52 1.17 Display Screen Pages – Main Control Desk Adjustment Screen „1.6“ - Pressure Bars Adjustment Screen “1.8” – Automatic Steering F2 Pressure Bars „Manual Mode“ Functions works with the value set by the arrow buttons Regardless to the Traction Main Switch position. Automatic Steering F4 Pressure Bars „Automatic Mode“ Pressure Bars only work in „Pave Mode“ and Traction Main Switch actuated. Sonic steering sensor adjustment F6 Adjustment of the pressure for the system Adjustment with the arrow buttons Sensor selection (Option for tracked pavers only!) Steering control can be activated or deactivated by F2 When the sonic steering sensor is selected, button F7 is used to calibrate the steering sensor (Zeroed). Button F8 is used to choose between the mechanical and sonic steering sensors. F8 Balance P2 Adjustment of values with arrow switches (influences only the rear pressure bar P2, P1 will not be changed). Tracked Pavers only! Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Tracked Pavers only! 53 1.17 Display Screen Pages – Main Control Desk Adjustment Screen „2.1“ – Engine, ECOplus and DPF Splitter gearbox with clutch Pumps for traction, conveyors and augers as well as compaction are disengaged from the gearbox when the paver is stationary. Energy-optimized tamper drive The tamper motors are driven by a variable displacement pump instead of a fixed gear pump. The pump delivers as much oil as needed for the motor, thus preventing any loss of oil. Controlled hydraulic oil cooler The hydraulic oil only flows through the hydraulic oil cooler when its temperature exceeds 50°C. At a lower temperature the oil is bypassed to the hydraulic tank. In-depth: VÖGELE ECOplus Variable-speed fan A viscous coupling adjusts the fan speed in accordance with the engine data, the air intake temperature and the hydraulic oil temperature automatically. Less Fuel Consumption Less Emission Less Costs Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 54 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “2.2” – Autoset “Positioning Functions” M2 Save status / position of the functions The positions and status of the individual functions can be saved by pushing key button M2. Storing the values and settings possible in pave mode only. The functions are set to their limit position or to positioning position. The functions are set to their stored position for paving. Execute key switch AutoSet Positioning Functions (Main Control Desk) When the tick appears, the corresponding function has reached its positioning condition for job site movements or the stored position in pave mode. Function is selected for Autoset Function is not selected for Autoset When Execute Switch is operated, screen „2.2“ automatically appears Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 55 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “2.2” – Autoset “Positioning Functions” Screed raising/lowering Reversing conveyors Screed lock/unlock Front Apron up/down Augers up/down Deflector up/down  F2 Deflector up/down  F3 Augers up/down  F4 Front Apron up/down  F6 Screed lock/unlock  F8 Temporary reversing of the conveyors  Screed raising/lowering (not selectable)  Left and right tow point cylinder same position (not selectable) Joseph Voegele AG, Ludwigshafen/Rhein Germany With this function the paver is quickly prepared for repositioning on a job site. The adjustment of working positions will be stored. Therefore no data will get lost during the change between paving and positioning of the paver. CTT Center for Training and Technology 56 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “0.2” – Autoset “Paving Functions” Sub menu for selecting and opening of a stored F5 project F6 Sub menu to create a new project F6 Editing a Project F8 Storing a Project With this functions paving parameters and job sit conditions /information can be stored and, when needed on a similar, new jobsite, recalled and re-used.  Paving Speed  Tamper revolution / Stroke Those values are taken and Information like…  Pressure bar setting / stored from the actual paving  Project name Vibration revolution process and therefore available  Type of Layer such as base course, binder course or wearing course  Auger height for the next, similar job site.  Load class  Screed freeze on/off All data can be changed or  Grain size  Conveyor settings modified anytime in order to  Paving depth  Position Tow Point Cylinders compensate issues appearing  Paving width  Screed assist Pressure and Balance due to minor differences …can be stored via a pop-up menu Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 57 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “2.3” – Electric Screed Heating F2 Alternating mode, screed heating When alternating mode is active, the screed is permanently heated on both sides as long as the traction main switch is set to neutral. When the traction main switch is actuated in pave mode, the right and left-hand sides are heated alternately at 30 second intervals. Both sides of the screed are always heated permanently when the function is deactivated. F4 Temperature control, screed heating Activation of the function: temperature control, screed heating. The temperature is set via F6 Example: SUPER 1800-3i F6 Setting the screed temperature (option) Left-hand side, supplementary Right-hand side, supplementary The status indicator lights up green when F6 is actuated. The arrow buttons are now used to adjust the required screed temperature between 0° C and 180° C. Right-hand side Right-hand side Left-hand side F8 Actual screed temperature The actual temperature of the screed is indicated here. Left-hand side Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 58 1.17 Display Screen Pages – Main Control Desk Selection Screen”2.7” – Service Area Adjustment Screen “2.7.3” – Screed Crown Profile currently installed software version Adjustment of Screed crown profile Is also carried out in the Main desk display on screen “2.7.3, besides key switch F6. The required value can be set with the arrow switches of the navigation block (from -2,5% to +5,0%). F1 Display Info Pages F2 Advanced Conveyor Settings F3 Crown Adjustment F4 Advanced Auger Settings F5 Service Area (Password-protected) F6 Traction drive mode „manual“/ Emergency operation SGB Clutch F7 Error Messages, Service F8 Set of Date, Time and Language Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 59 1.17 Display Screen Pages – Main Control Desk Info Matrix The paver operator’s console is illustrated graphically here. Once a buttons on the console is actuated, the corresponding circle will turn black and indicates herewith the functionality of the switch. Key switches are shown as a black circle, locking switch keys are indicated, when actuated, with a cross in the centre. In the fields for traction main switch and steering lever values between 0 and 230 (digits) displayed. The value is changing depending on the position of the potentiometer dial. All key switches can be checked for functionality. Info CAN Displayed here the status of the CAN bus members. Therefor it can be checked whether the CAN bus member is recognized from the system or not. Meaning of the numeric „0“ and „1“ (ID): 1 = CAN Bus Member is operational 0 = CAN Bus Member is not recognized Additional errors in CAN O and Can 1 of the power PC are shown. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 60 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “2.7.2” – Advanced Conveyor Settings F5 Conveyor Adjustment, left-hand side The feed rate or respectively the speed in manual mode, can be set here. By pushing F5 the function is activated and can be used, when the green status LED is illuminated F6 Conveyor Adjustment, right-hand side The feed rate or respectively the speed in manual mode, can be set here. By pushing F6 the function is activated and can be used, when the green status LED is illuminated Emergency operation! On this page the operator can set advanced functions or emergency operations for paving, e.g. appearance of a failure with paddle sensor. F3 Conveyor Manual mode, left-hand side When the conveyor is switched to manual mode, it runs permanently and independently of the traction main switch at the speed set via F5. F4 Conveyor Manual mode, right-hand side When the conveyor is switched to manual mode, it runs permanently and independently of the traction main switch at the speed set via F6. Joseph Voegele AG, Ludwigshafen/Rhein Germany F7 Deactivating Conveyor Sensor left-hand side When the sensor is deactivated and manual mode is switched OFF, automatic mode ON, the conveyor runs at the speed set via F5 with the traction main switch set to “forward”. The Conveyor stop when the traction main switch is set to “neutral”. Emergency operation! F8 Deactivating Conveyor Sensor, right-hand side When the sensor is deactivated and manual mode is switched OFF, automatic mode ON, the conveyor runs at the speed set via F6 with the traction main switch set to “forward”. The conveyor stop when the traction main switch is set to “neutral”. CTT Center for Training and Technology 61 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “2.7.4” – Advanced Auger Settings By pushing the key switches F3 or F4, the corresponding function is activated and the augers are rotating reverse. F4 Revolution Auger, left hand side The feed rate or respectively the speed in manual mode, can be set here. By pushing F4 the function is activated and can be used, when the green status LED is illuminated F5 Revolution Auger, right hand side The feed rate or respectively the speed in manual mode, can be set here. By pushing F5 the function is activated and can be used, when the green status LED is illuminated Emergency operation! When the auger is switched to manual mode, it runs permanently and independently of the traction main switch at the speed set via F5. F7 Deactivating Auger Sensor left hand side When the sensor is deactivated and manual mode is switched OFF, automatic mode ON, the auger runs at the speed set via F5 with the traction main switch set to “forward”. The auger stop when the traction main Switch is set to “neutral”. F2 Auger, Manual Mode right hand side Emergency operation! When the auger is switched to manual mode, it runs permanently and independently of the traction main switch at the speed set via F6. F8 Deactivating Auger Sensor, right hand side When the sensor is deactivated and manual mode is switched OFF, automatic mode ON, the auger runs at the speed set via F6 with the traction main switch set to “forward”. The auger stop when the traction main Switch is set to “neutral”. F1 Auger, Manual mode left hand side F3 Reversing the Auger, left hand side F3 Reversing the Auger, right hand side Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 62 1.17 Display Screen Pages – Main Control Desk Sensor Bypass and Manual Operation of Splitter-Gear-Box-Clutch traction drive mode manual activated F2 F2 Traction Drive Mode „manual If the sensors of traction drive fail, the machine will come either to a complete stop or moves with a very low speed. In order to finish a job site, the sensors can be faded out. The paver is moving now with reduced speed, but unregulated! F4 Emergency Operation Splitter gear box clutch Pushing F4 the splitter gearbox clutch can be engaged manually. Attention Before engaging manual the function ECO Plus must be deactivated! Recommendation The required pressure of 20 bar must be controlled with a gauge! Wheeled Pavers only: Steering angle sensor and Brake pedal sensor signals are also faded out when they are out of the taught-in threshold values. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 63 1.17 Display Screen Pages – Main Control Desk Adjustment Screen “2.7.8” - Language, Time and Date F2 Language: After pushing F2 the language can be changed. F6 Time: F6 is activating the function to set the time Adjustment Screen “2.8” - Brightness F4 Brightness of Display To adjust the brightness, Switch F4 must be pushed. Now the green status LED is illuminated and the arrow buttons are active to adjust the brightness. „lighter“ F8 date: F8 is activating the function to set the date. „darker” Attention! These adjustments are only possible, when the diesel engine is off. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 64 Chapter 2 Screeds Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 2.1 General Information Screeds are available in two versions:  Extendable Screeds (AB)  Fixed Screeds (SB) Extendable Screed (AB) The purpose of the screed, which is the working tool of the paver, is to pre-compact the mix uniform across the complete paving width and create an evenly, homogeneous surface structure. The compaction devices of the screed should produce the highest as possible pre-compaction in order to reduce the influence to the rolling value, during the final compaction, when paving various paving depths. To gain pre-compaction various compaction aggregates can be provided to the screeds. Description and acronyms: T = Tamper (the tamper is brought to a vertical movement by an eccentric shaft). Fixed Screed (SB) V = Vibration (the vibration is realized with an unbalanced shaft, transverse to the direction of travel). P = Pressure bars (the pressure bars are pressed with a hydraulic frequency of ~ 68 Hz and a maximum pressure of ~ 130 bar into the mix). - P1 = Screed model with one pressure bar - P2 = Screed model with two pressure bars Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 68 2.2 Product Palette of Vögele AG Paving Width: Basic Width: Hydraulically adjustable: Bolt-on Extensions: Cut-off Shoes: Crown Profile: Compaction devices: 0,5 m – 3,5 m 1,2 m 0,75 m – 5 m 1,8 m AB 340-3 only for Compact-Class Paver Paving Width: Basic Width: Hydraulically adjustable: Bolt-on Extensions: Cut-off Shoes: Crown Profile: Compaction devices: 2,55 m – 8,5 m 2,55 m AB 500-3 for Pavers of the Universal and Highway Class Paving Width: Basic Width: Hydraulically adjustable: Bolt-on Extensions: Cut-off Shoes: Crown Profile: Compaction devices: AB 600-3 for Pavers of the Universal and Highway Class Paving Width: Basic Width: Hydraulically adjustable: Bolt-on Extensions: Cut-off Shoes: Crown Profile: Compaction devices: AB 220-3 for SUPER 700-3/800-3 Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology up to 2,2 m 0,65 m 0,5 m – 1,2 m -2% to + 4% Tamper, Vibration up to 3,4 m 25 cm, 40 cm (V), 55 cm (TV), 80 cm (TV) 52,5 cm -2,5% to + 4,5% Tamper, Vibration up to 5,0 m 25 cm, 75 cm, 125 cm -2,5% to + 5% Tamper, Vibration, Pressure bars 3 m – 9,5 m 3,0 m up to 6,0 m 25cm, 75 cm, 125 cm -2,5% to + 5% Tamper, Vibration, Pressure bars 69 2.2 Product Palette of Vögele AG SB 250-2 Paving Width: Basic Width: Bolt-on Extensions: Cut-off Shoes: Crown Profile: Compaction devices: 2,0 m – 13 m 2,5 m 25 cm, 50 cm, 100 cm, 150 cm 25 cm, 50 cm -2% to+ 3% Tamper, Vibration, Pressure bars SB 300-2 Paving Width: Basic Width: Bolt-on Extensions: Cut-off Shoes: Crown Profile: Compaction devices: 2,5 m – 16 m 3,0 m 25 cm, 50 cm, 100 cm, 150 cm 25 cm, 50 cm -2,5% to + 3 % Tamper, Vibration, Pressure bars Hydraulically extendable extension As an option, hydraulically extendable bolt-on extension (HEE) can be provided to the SB Screeds. With that add-on part the paving width can be infinitely adjusted from 0 to 0,75m on each side. Attention: It can not be attached directly to the main screed! At least a “1,0m” or a “1,5m” bolt-on extension must be placed between the main screed and the hydraulically extendable bolton extension. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 70 2.3 Special Equipment VF 500 Paving width: Basic width: Hydraulically adjustable: Bolt-on extensions: Crown profile: Compaction device: Gully Profile: Slope of Extension: 2,45 m – 5,95 m 2,45 m up to 4,75 m 30 cm und 60 cm -2% to + 5% Vibration 30 cm, 45 cm, 60 cm up to 10 % VF 600 Paving width: Basic width: Hydraulically adjustable: Bolt-on extensions: Crown profile: Compaction device: Gully Profile: Slope of Extension: 3,05 m – 7,75 m 3,05 m up to 5,95 m 30 cm, 45 cm, 60 cm -2% to + 5% Vibration 30 cm, 45 cm, 60 cm up to 10 % VR 600 Paving width: Basic width: Hydraulically adjustable: Bolt-on extensions: Crown profile: Compaction devices: Slope of extension: 2,55 m – 8,6 m 3,05 m up to 6,0 m 65 cm -2,5% to + 5% Vibration up to 10 % Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 71 2.4 Compaction Devices Tamper  The tamper provides the compaction of the mix.  Driven by an eccentric shaft the Tamper is pre-compacting the laid mix.  The better the pre-compaction done by the tamper, the better the screed floats on the laid mix. Joseph Voegele AG, Ludwigshafen/Rhein Germany Vibration Pressure Bars  The Vibrations brings the screed plates (SB Screed) or the screed frame (AB Screed) to vibrate and therefore achieving an optimum grain / bitumen distribution on the surface of the mix.  Pressure bars are driven by an “Impulse Generator”.  Vibration has a large impact to the surface structure, less to the pre-compaction.  Weight , is getting redensification. CTT Center for Training and Technology  With the pressure bars the mix, precompacted by tampers and screed 72 2.5 Tamper (T) Tampers, driven by an eccentric shaft, are provided to the screed to achieve pre-compaction in order to improve the bearing capacity of the mix – the screed can float on the mix. The better the float of the screed, the less angle of attack for paving is needed. Raising the tamper revolutions will result in a higher pre-compaction. Tamper Wear bar Screed plate Screed plate bottom Special profile Special Tamper profiles are available and can be used on screeds, e.g. for paving concrete or railway ballast. Also InlinePave requires a special tamper in order to meet the required high compaction. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 73 2.5 Tamper (T) 2 mm Tamper Stroke is usable for: Thin layers with a paving depth < 30 mm. 2 mm Stroke Bottom edge of Tamper & wear plate bottom flush at the lower dead centre of the eccentric shaft Tamper shaft Slot Clamping bolt Tamper stroke indication (engraved 2mm / 4mm / 7mm) Eccentric disc 4 mm Tamper Stroke usable for: All paving depth from 30 mm to 120 mm. 4 mm Stroke Bottom edge tamper must be 1 mm below the wear plate (on the lower dead centre of the shaft) On TP screeds the stroke of the tamper can be changed, on TV screeds it is available as an option. The tamper must be set across the complete screed width to the same stroke. 7 mm Tamper Stroke Usable for: Paving depth > 120 mm. 7 mm Stroke Bottom edge tamper must be 2.5 mm below the Wear plate (on the lower dead centre of the shaft) Joseph Voegele AG, Ludwigshafen/Rhein Germany Changing Tamper stroke: 1. Remove clamping bolt. 2. Rotate tamper shaft against eccentric disc , until the number of the desired stroke indication on the tamper shaft is located right besides the slot [2 on the eccentric disc. 3. Mounting clamping bolt. CTT Center for Training and Technology 74 2.5 Tamper (T) Tamper Shield Adjustment Lock nut Threated bolt Tamper shield Spring steel strip Mounting Spring steel strip Note  The spring steel strip closes the gap between tamper and tamper shield.  With a clearance too big, mix can penetrate between tamper and tamper shield. The proper adjustment of the tamper shield is achieved when the spring steel plate fits across the total width. Optimum is an even clearance of approx. 0,5mm. The rear of the tamper should flush with the wearing bar across its entire width.  With a clearance too less the tamper could be clamped. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 75 2.6 Vibration (V) The Vibrations brings the screed plates (SB Screed) or the screed frame to vibrate and therefore achieving a optimum grain distribution on the surface of the mix. Identically to the tamper the vibration frequency can be set by changing the revolutions of the drive shaft via the operating consoles. Gear-wheel to connect vibration to bolt-on extensions Shaft of unbalanced vibration Bearing for vibration shaft Note Comparatively to the tamper following rule applies: When paving thin layers with a small grain size a low speed (frequency) should be set or the vibration can even be turned off completely. Paving Tip: Turning off vibration when laying open porous material. Unbalanced weight Vibration shaft Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 76 2.7 Pressure Bars (P) On high compaction screeds, one (TP1) or two TP2) impulse-hydraulic driven pressure bars are attached to the screed. The pre-compaction of a TP1 screed is higher than with a TV screed but lower then with a TP2 screed. Screed frame with one pressure bar P1 The impulse pressure for the drive is infinitely adjustable from 40 to 130 bar. The Impulse frequency is set to approx. 68 Hz and should only be changed in exceptional circumstances. P1 P1 P2 P2 Screed frame with two pressure bars P2 The two pressure bars are differently shaped: P1= „Pointed“ (compaction) P2= „Flat“ (structure) On a „P1-Screed“ only the „Flat“ shape is used. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 77 2.8 Screed Crown Profile Example: AB 500-3/600-3: The spindles of the crown adjustment are driven by hydraulic motors. Controlling is carried out by the respective key buttons on the screed control or main control. Simultaneously the actual profile is displayed on the screen (in %). The adjustment mechanism allows profiles from - 2,5% up to + 5%. Hydraulic motor positive Crown profile Sensor Crown profile negative Crown profile Crown Display Crown „Calibration“ Crown Adjustment Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 78 2.9 Bolt-on Extensions Available sizes for Bolt-on extensions are: 0,25 m, 0,75 m und 1,25 m In terms of the design the bolt-on extension are identical to the main screed and extensions (tamper, vibration, pressure bars and heating elements). Joseph Voegele AG, Ludwigshafen/Rhein Germany Available bolt-on extensions are listed in the corresponding machine documentation. Also mentioned there are necessary accessories (e.g. deflector plates, bracing, tunnel plates ). At the „-3“ screed generation additional weight can be added. CTT Center for Training and Technology 79 2.9 Bolt-on Extensions  The quick-installation aid must be positioned horizontally.  Loosen locknut on eccentric bolt.  Check functionality of eccentric bolt.  Turn eccentric bolt lugs upwards.  Rest screed on wooden blocks.  Mount bolt-on extension using the quick-installation aid.  Fold the quick-installation aid down vertically.  Tighten locking pins up to the position of the head.  Attach flange to system.  Align the bolt-on extensions and screed plates with one another with the eccentric bolts. (see Sec. 6.3)  Adjust locknuts.  Tighten locking pins. Joseph Voegele AG, Ludwigshafen/Rhein Germany Use the eccentric bolt to adjust the bolt-on extensions so that the front edge of the screed plate is 0.5mm higher per mounted bolt-on extension. The rear edge must be flush across the full width. CTT Center for Training and Technology 80 2.9 Bolt-on Extensions Preparing the Curved Tooth Coupling  Push down on the fixing screw of the curved tooth coupling and slide the curved tooth coupling all the way back.  The arrow on the curved tooth coupling must be aligned with the positioning notch of the gearwheel. In order for the pressure bars of the bolt-on extension to be able to be lowered in parallel, they must be connected to the extending unit. Connect the pressure bars of the bolt-on extension with inner hex bolts and supporting blocks to the pressure bars of the extending screed. The pressure bars must be flush with the bottom and rear edges on the same level across the entire width. Locking the Curved Tooth Coupling  Once the bolt-on extensions have been adjusted, the curved tooth coupling has to be slid smoothly over the gearwheel until the fixing screw locks the coupling in place.  The coupling must display axial play. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 81 2.9 Bolt-on Extensions BE connected Without BE / outer BE Orifice Ø 0,8mm L Bleed Oil to Tank When mounting bolt-on extensions, the pressure lines of the pressure bars must be connected with one another. Additionally, the leakage oil line must be switched from the lower position to the upper position. The leakage oil line must be connected at the lower position on the outermost bolt-on extension or during removal. This ensures that the pressure bar can vent autonomously via the aperture. Pressure line L L Bleed Oil to Tank Orifice Ø 0,8mm Note: if the aperture is missing, the pressure bar can only reach a maximum pressure of P Bleed Oil from BE approx. 60 bar. P P Pressure line to BE Meaning of BE = Bolt-on Extension Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 82 2.10 Screed Side Plates AB 500-3 and AB 600-3 Mechanical Side Plate Hydraulical Side Plate Standard on AB 500-3 / AB 600-3 are mechanically adjustable side plates. These are adjusted in height by spindles. Optional hydraulically adjustable side plates can be mounted to the screed. In that case the height of the side plates can be set individually by a switch. The connection takes place by using hydraulic quick release couplings and electrical connectors. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 83 2.11 Electrical Screed Heating 1 Diesel Engine 2 Operators Desk 3 Switch or Fuse Box 4 Distribution Box 5 Generator 6 Tamper with heating rod 7 Screed plate with heating rod When the screed is heated up insufficiently, asphalt can stick on screed plates, tampers or pressure bars. In that case streaks Screed plate with heating rod and lines in the asphalt surface will appear when the, mostly fine parts/grains, fall off. Tamper with heating rod Pressure bar 2 with heating rod A change in the surface structure will also be visible. Until the screed is heated up to the desired temperature the Pressure bar 2 with heating rod screed float could change – which also can lead to a change in paving depth. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 84 2.12 Three-Point-Guidance System Telescopic Tube Main Screed Extension Extension Guidance tubes, inside Torque Restrain System Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 85 2.12 Three-Point-Guidance System 2 1 3 Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 86 2.12 Three-Point-Guidance System To ensure parallel extending and retracting, the extensions are „guided“ at three positions. Compared to the main screed, the extensions are located in the rear. Due to the necessary angle of attack Main screed and Extensions would pave different heights and leaving longitudinal offsets on the surface. As a prevention the height of the extensions can be changed. Joseph Voegele AG, Ludwigshafen/Rhein Germany To prevent the extensions from twisting, sliding blocks are used for limiting a possible, unwanted movement. Paving position: Compared to the main screed the extensions must be set higher in position. The height difference depends on the angle of attack. CTT Center for Training and Technology 87 2.13 Fixed Screeds – SB 250-2 and SB 300-2 Basic width of the fixed screed SB 250 is 2,50 m. By adding bolt-on extensions or hydraulically extendable bolt-on extensions, a maximum paving width of 13,00 m can be reached. Basic width of the fixed screed SB 300-2,made for the SUPER 3000-2 paver is 3,0 m. By adding bolt-on extensions or hydraulically extendable bolt-on extensions, a maximum paving width of 16,00 m can be reached. Width 2,5 m Width 3,0 m Depth 1,14 m Depth 1,14 m Weight 1,65 t (TV, T) Weight 2,26 t (TV, T) 1,88 t (TP1) 2,41 t (TP1) 2,02 t (TP2) 2,75 t (TP2) 2,1 t (TVP2) Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 88 2.14 Design of a Fixed Screed Tamper with heating rod Pressure Bar with heating rod Main Screed Fixed Bolt-on Extension Screed Plate with heating rod Unbalanced Vibration Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 89 2.15 Compaction Devices on SB Screeds TV Tamper and Vibration TP1 Tamper & one Pressure bar TP2 Tamper & two Pressure bars TVP2 Tamper, Vibration and two Pressure bars Recommendation All common Mixes Less compressible Materials or very thin courses Pre-compaction higher than TV Difficult compressible Materials also at large paving depth Less complexity necessary for redensification For RCC und PCC No redensification at PCC Application with preferably constant paving widths and large radii Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 90 2.16 Bolt-On Extensions for SB Screeds Sag When the Extensions are mounted to the screed on a levelled ground, the vertical bracing must be without strain. To compensate the bearing capacity on the outsides the screed should have (in raised position) a sag. How much sag depends on the paving width. Adjustable via the vertical bracing. Rear edge of the screed plates should be flash over the complete width. Front edge of the extensions should be 0.5mm higher per extension. To avoid bending caused by the force of the material in front of the screed a horizontal bracing should be mounted without strain on the rear of the screed. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 91 2.17 Screed Operation Switchover: NiveltronicPlus – Paving Parameter  The upper switch on the navigation block is used to switch between „Niveltronic Settings“ and „Paving Parameters“  The arrow buttons are used to scroll between the screens.  Using „Escape“ in a sub menu will call the previous screen. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 92 2.17 Screed Operation Tamper Settings Vibration Settings Option: Display Vibration Frequency Option: Display Tamper Revolutions F1 Selection Tamper „Automatic Mode“ F1 Selection Vibration „Automatic Mode“ F2 Selection Tamper „Manual Mode“ F2 Selection Vibration „Manual Mode“ F4 Decreasing Tamper Revolutions F4 Decreasing Vibration Revolutions F5 Increasing Tamper Revolutions F5 Increasing Vibration Revolutions Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 93 2.17 Screed Operation Adjustment of Pressure Bars F1 Selection Pressure Bars „Automatic Mode“ Balance Setting P2 F2 Increasing Pressure of P2 – max. 20bar F3 Reset Balance 1:1 F2 Selection Pressure Bars „Manual Mode“ F4 Decreasing Pressure of P2 – max. 20 bar F3 Submenu Balance P1 / P2 F4 Decrease of Pressure F5 Increase of Pressure Joseph Voegele AG, Ludwigshafen/Rhein Germany Note: Balance only influences the rear pressure bars (P2) ! CTT Center for Training and Technology 94 2.17 Screed Operation Adjustment: Screed Assist Pressure Adjustment: Balance Screed Assist F1 Selection Screed Assist: Automatic / Off F2 Left-hand side: decreasing screed assist pressure F3 Submenu „Balance“ Screed Assist F3 Reset Balance to 1:1 ( 0%) F4 Decreasing Screed Assist Pressure F4 Right-hand side: increasing screed assist pressure F5 Increasing Screed Assist Pressure +/- 50 % Screed Assist Pressure for the left-hand side or the right-hand side Pre-set assist pressure in %. max. 40 bar actual Screed assist pressure for both sides. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 95 2.17 Screed Operation Momentary “Screed Float Off” Info Screen: Paving Speed Paving Distance 233 m „push and hold“ F1 Screed „Not Floating“ As long F1 is pushed and hold, the screed float of the screed is deactivated and the screed is held. F1 Reset the Distance Counter F3 Submenu Service Display of the paving speed and a distance counter, which is counting the distance (in meter), covered in „Pave Mode“. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 96 2.17 Screed Operation Matrix Screed Control F1 Light bulbs / LED Function check Screed Control, Niveltronic Sensor, Auger Sensor Joseph Voegele AG, Ludwigshafen/Rhein Germany Pin Assignment of Socket “Grade Control” Service Screen „Automatic Grade Control“ All inputs and outputs of the levelling socket can be checked here CTT Center for Training and Technology 97 2.17 Screed Operation Pin Assignment of Socket “Auger Sensor” Service Screen Auger Sensor All inputs and outputs of the auger sensor socket can be checked here. Electrical Screed Heating Display of actual and set value of the screed plate temperature. F1 The electrical screed heating can be turned On or OFF via F1. Display „Set value“ (adjustable up to 200°C Display „Actual value“ Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 98 2.17 Screed Operation Float Position „Deflector Crawler Track“ Auger Height Adjustment With switch F1 the deflector plates of the crawler tracks can be lowered and raised. Shown is the distance between auger plate bottom and screed front bottom. When the function is activated, the deflectors are in „float position”. When the function is deactivated, the deflectors are in the upper end position. Rule of Thumb: Paving depth + 5 to 10 cm Adjustable at Screed Control or Main Control Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 99 2.17 Screed Operation Controlling the Augers Crown Profile Adjustment F1 Auger sensor ON/OFF Screed crown profile in % F3 Submenu „Calibration“ Adjustment is carried out via the Switches on the screed control Or In the display (service menu) of the Main control desk. F1 F3 Auger Sensor Adjustment Auger Sensor As soon as the auger sensor is activated, the display change and the operator can „calibrate“ the sensor via „F3“ (Actual value = Set value). Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 100 2.17 Screed Operation Submenu: Calibration of the Crown Profile Display F2 Decreasing displayed value F3 Set displayed value to „0“ F4 Increasing displayed value Controlling the Conveyors Adjustment of the material supply of the conveyors. When changing the value shown in the display, the switch-off point of the sensors will be moved. F4 Decreasing the material supply of the conveyor F5 Increasing the material supply of the conveyor Adjustment for the individual sides. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 101 2.17 Screed Operation Description of NiveltronicPlus-Screen Position tow point cylinder, l/h side Display Slope Status Screed Assist Position tow point cylinder, r/h side Set value Niveltronic l/h side Set value Niveltronic r/h side Actual value Niveltronic l/h side Actual value Niveltronic r/h side Sensor type r/h side Sensor type l/h side Calibration r/h side Calibration l/h side Submenu Settings Sensor selection l/h side Sensitivity l/h side Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Sensor selection r/h side Sensitivity r/h side 102 2.17 Screed Operation Start Screen “NiveltronicPlus” By pushing „F3“ the submenu „Parameters“ can be called. Submenu: Parameters F1 Sensor Calibration F2 Sensitivity F4 Advanced Parameter F5 Brightness Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 103 2.17 Screed Operation Submenu: Calibration “Displayed Value” F1 / F2 / F4 / F5 can be used to customize the displayed „Actual value“. By pushing the +/- switches together, the offset value will be reset. That means: the original sensor value is shown. The function is used to match the displayed value from the slope sensor with the „manual measured value“ of the slope of the application. Joseph Voegele AG, Ludwigshafen/Rhein Germany Submenu: Sensitivity Pushing F1 or F2 will change the sensitivity of the left-hand side. Pushing F4 or F5 will change the sensitivity of the right-hand side. Standard setting =5 Niveltronic „sluggish“ =0 Niveltronic „aggressive“ = 9 CTT Center for Training and Technology 104 2.17 Screed Operation Submenu: Advanced Settings Submenu: Working Window Using F1 or F2 will change the working window for the automatic grade control, left-hand side. Using F4 or F5 will change the working window for the automatic grade control, right-hand side. F1 Call Working Window Niveltronic Plus F2 „Locking“ Operation Side Operation of “NiveltronicPlus” and “Manual Tow Point Adjustment” can be blocked for the other screed console by pressing F2. If two screed consoles are shown, both sides can be operated, when only one is indicated means that only one side can be operated. The function can be activated and deactivated from either side. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 105 Chapter 3 Automatic Grade and Slope Control Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 3.1 Levelling Sensors In general linguistic usage Levelling means :  levelling something  planning something  to even something  bringing something to the same level Available Sensor types  Mechanical sensors  Contact-free, acoustic Sensors  Contact-free, optical Sensors  3D-System NavitronicPlus  getting differences out Mechanical Sensors Optical Sensors Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Acoustic Sensors 3D Control 109 3.2 Fundamentals in Operation Slope sensor The basic principle When sampling a reference the up and down movements of the screed will be transmitted to the mechanic grade sensor. Deviation between actual value and Set value will lead to an automatically control of the screed position carried out by the automatic levelling system. 1 Reference wire 2 Deviation to the Reference The automatic grade sensor recognizes a deviation in the adjusted reference. 3 Left hand side Control The height of the sensor facing the tow point cylinder is changing its position as long the grade sensor (3) is back in its initial position. 5 4 The other tow point cylinder will be only controlled, when the Slope sensor (4) determines a deviation to the set value. Right hand side Control The right tow point gets control signals as long the adjusted set value is reached. Initial situation: Left-hand side reference via a mechanical grade sensor, maintaining an adjusted slope, controlled by a slope sensor. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 110 3.3 Mechanic Sensors Advantages of a mechanic sensor:  Ground sampling with mechanic skis (0,3 m, 0,8 m or 2,0 m in length).  Insensitive against external influences such as moisture, wind, temperature  The “0,3 m” ski is suitable particularly for tight turns and roundabouts (the height level is copied with the short ski almost 1:1).  Measurement is carried out „visible“. That means, it is visible has the sensor a „stabile“ contact to the reference and it is „visible“ where at the reference the sensor has contact.  When only minor irregularities in the reference must be levelled out, the use of the 0,8 m or 2,0 m ski is recommended.  When bigger irregularities must be levelled out, the use of an average beam is useful. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 111 3.3 Mechanic Sensors The Slope Sensor can be combined with each available grade sensor Slope sensor The slope Sensor can be used, in combination with other grade sensors, for paving widths up to a maximum of 6 meter. The slope of the screed is measured with a fluid-filled sensor, comparable to a spirit level, and can measure slopes of +/- 10%. Mechanic wide range sensor Mechanic wide range sensor with LED display - only for „-3“ Paver! (Slope Sensor on the bar between the tow arms - shown enlarged ) Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 112 3.4 Acoustic Sensors Ultra Sonic Single Sensor Ultra Sonic Multiple Sensor The functional principle of acoustic sensors is identical: A ultrasonic signal is emitted, reflected and received again. The time between emitting and receiving is an indication about the distance to the used reference. Multiplex Big Ski Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 113 3.4 Acoustic Sensors Functional Principle Ground Mode String Mode The ultrasonic-single sensor is emitting one sound beam. Thereby the reference is transferred 1:1, without an averaging. Short irregularities can be levelled out by using an average value out of the 3 signals (in ground mode). The sensor is suited especially for: The sensor also can be used on a levelling wire or a tensioned string line. In that case 5 signals are used (string mode), but only the signal reaching the reference first is used for the Automatic Control.  Tight turns  Winding roads with small turning radiuses  When paving two lanes parallel (either „Hot-on-Hot“ or „Hot-on-Hold“)  Copying of speed humps or similar applications Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 114 3.4 Acoustic Sensors Functional Principle Distance measurement for temperature compensation Distance measurement for temperature compensation Reference At the ultrasonic-multi-sensor a sixth sonic signal is working in a similar way. Because Sound Waves move different at changing environment temperature, a compensation of this inconvenient behaviour is required. For compensation a reference point measurement with a defined distance takes place continuously. By using a metal bow, mounted in a fixed distance to the sensor cell, the measuring is carried out. Basically the first reflected signal is used for the temperature compensation, following reflected signals are used for levelling. Joseph Voegele AG, Ludwigshafen/Rhein Germany When the time from sending and receiving is changing due to a change in the environment temperature, the signal to the Niveltronic will be corrected. Info Sound Wave Speed at 0° C = 331 m/sec at 30° C = 349 m/sec CTT Center for Training and Technology 115 3.4 Acoustic Sensors Variable Working Range ( 250 – 650 mm ) Variable Working Range (250 – 650 mm –Niveltronic 250 – 1000 mm - BigSki ) Functional Principle String Min 2,5 mm X X X = 50 mm Working window ( + 25 mm / - 25 mm) „Ground“ – Mode Niveltronic Multiplex Bigski (Ground Mode) (Ground Mode)  3 active sensors  5 active sensors  Average determination  Average value out of  Adjustable working window „String“ - Mode Niveltronic and Multiplex BigSki (String Mode)  5 active sensors 3 signals  No average determination  First signal reflected back from reference (string) is utilized  Adjustable sensibility  Adjustable working window  Position: longitudinal to lane  (Niveltronic & Bigski!)  Adjustable sensibility  Adjustable working window  Position: longitudinal to lane Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 116 3.4 Acoustic Sensors In-depth: Big Multiplex Ski 1 2 3 P W IR T G E N G RO U P V ÖGE L E The extendible beam enables variable sampling lengths of 5 m to 13 m 1 2 3 P Three ultrasonic-wide-range sensors, each with five sensor cells to form an averaged value for the Niveltronic, are connected to the Big-Ski. W IR T G E N G RO U P V ÖGE L E Each sensor sends its measurement results to the central unit. In the control unit the 3 measured values are averaged. Obstacles, outside of an adjustable tolerance, will be ignored and not included in the average determination ( shuffle, big rocks,…). Note Possible configuration of a BigSki:  Sampling with 3 Sensors  String line sampling with only 1 Sensor Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 117 3.4 Acoustic Sensors In-depth: Big Multiplex Ski 2 1 3 P W IR T G E N G RO U P V ÖGE L E 1 2 3 Sensor connectors Analogue Sensor Connection Cable Standard Cable CAN Cable with 2x 120 Ohm Terminating Resistors Standard Cable Sonic-Ski CAN Sonic-Ski CAN Sonic-Ski CAN Connecting the Multiplex Bigski Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 118 3.4 Acoustic Sensors In-depth: Big Multiplex Ski Central Unit Big-Multiplex-Ski LCD Sensor Message LED Sensor Assignment LED Selection: Type of Sampling 1 2 3 P W IR T G E N G RO U P V ÖGE L E Changing Parameter Sensor Calibration Parameter Call Sensor detection Each Sensor station that is used the first time is first identified via LED. In addition sensor configurations or error messages are shown in the LCD display Calling Parameter (Working Window) Call „Working Window“. The value corresponds to the permissible measurement range of sensors around the calibration point (Value 6 = +/- 3cn) Change (in increments of 1cm between 4,0 and 20,0) or deactivate the range (bigger 20,0 = OFF). Joseph Voegele AG, Ludwigshafen/Rhein Germany Sensor Acknowledgement When the Big-Ski has been connected the first time or if the sensor combination has changed, the sensor detection must be acknowledged. The displayed numbers flashes before the confirmation. After confirmation ( pressing any key) the display is continuously on. Set Value Calibration The sensors must be calibrated before starting the first time or when fundamental changes in settings took place. When the “Set”-button is pressed, the calibration is done and “SET” appears in the display. CTT Center for Training and Technology 119 3.4 Acoustic Sensors In-depth: Big Multiplex Ski Sampling within the paving width Joseph Voegele AG, Ludwigshafen/Rhein Germany Sampling outside of the paving width CTT Center for Training and Technology 120 3.4 Acoustic Sensors In-depth: Big Multiplex Ski Installation Instruction for installation 1: „Distance A“ should be equal with „Distance B“! Distance A Distance B Instruction for installation 2: Pivot Point Paver Approved is also an approximation of the two pivot points / break over points of Paver and BigSki beam. Pivot Point BigSki Explanation: The pivot or break over point of the paver is approximately the position for the center sensor of the BigSki. The position also has a positive influence, e.g. when paving or sampling against an edge. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 121 3.4 Acoustic Sensors In-depth: Big Multiplex Ski Downward Motion Centre Sensor „Centric“ Upward Motion As long the system is working within the Working Window, the up and down movement of the BigSki beam will not influence the signals to the Tow Point Cylinders due to the centric installation of the center sensor. (Number of Sensors) Centre Sensor „Off- Center“ (no controlling done by the BigSki) Upward Motion Downward Motion Due to the “Off- center” position of the center sensor, false signals can occur and sent to the Tow Point Cylinders during up and down movements of the BigSki beam. (Number of Sensors) Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology (controlling by the BigSki) 122 3.4 Acoustic Sensors Application Tip – Paving towards an edge 1 Paving towards an edge (e.g. Bridge edge or milled edge) Screed Control „-3“ – Paver/Screed 2 Niveltronic OFF! Proceeding (Example Picture: Sampling „Bigski, left hand side): Before the first sensor reaches the edge: Turning off the Niveltronic on the screed control ! As soon the first sensor is on the new level, the new reference must be confirmed by pushing „F1“ and then the Niveltronic must be turned on again. This setting can be done without a paving stop! Niveltronic „Set Value“ Calibration Niveltronic ON! Joseph Voegele AG, Ludwigshafen/Rhein Germany NOTE No additional setting needs to be done on the central unit of the BigSki, as long the working window there is set to „Off“. CTT Center for Training and Technology 123 3.4 Acoustic Sensors Application Tip – Paving tight turns Application Tip – Paving Depression / Incline When paving crests or depressions, the first sensor sends a false signal or leaves the reference line. That behaviour can lead to false signals or even to an interruption of the sampling which would stop the automatic grade control. Installation Instruction for both cases: When paving turns it can happen that the front sensor leaves the optimum reference, as a result false measure values can occur. Joseph Voegele AG, Ludwigshafen/Rhein Germany For both paving examples the front sensor should be mounted besides the front edge of the crawler track or besides the first axle of a wheeled paver. CTT Center for Training and Technology 124 3.5 Optical Sensors (Laser) Functional Principle Laser Receiver Laser Transmitter The use of a laser receiver is especially applicable when paving large areas with a constant longitudinal and transverse slope such as Sport stadiums, parking lots or storage areas. Compared to Ultrasonic sensors the optical sensors are working with laser beams. Advantages:  Signals will not be influenced by wind or temperature  Large range of laser beams No height adjustment during paving is needed for the mast on the paver (bracket for laser receiver) due to the large measuring range. A laser transmitter is generating a “Plane” due to a rotating laser beam. The plane is determined by a receiver, attached to the paver. Attention Fog, Rain, Mirror Finished Building facades can influence the quality of the laser signal negative. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 125 3.5 Optical Sensors (Laser) Laser Receiver LS300 Display Meaning Positioning The laser receiver has just been switched on; no laser signal is reaching the receiver. In the long-distance range, the laser beam is targeting much too low; i.e. >105mm below the centre of the sensor Move Sensor downwards (or transmitter upwards) In the long-distance range, the laser beam is targeting too low; i.e. >90mm and 60mm and 60mm and 90mm and 105mm above the centre of the sensor Move sensor upwards (or transmitter downwards) Incorrect reflection respectively no explicit laser beam or electrical fault (e.g. defective amplifier). Proper measurements are impossible! No laser beam detected on the receiver! Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 126 3.6 3D Control (Navitronic) Functional Principle NavitronicPlus is a 3D-Machine Control System for reference-wire-less navigation of a Road paver. Controlling is carried out with a external computer, connected to the paver via an interface. Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 127 Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Chapter 4 Application Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 4.1 Paving Asphalt Asphalt Layers and their Purposes Function of a Asphalt Base Course: About technical and economical reasons, asphalt layers are subdivided  Within the scope of performing the construction, the base in different layers: - asphalt base course, course has to prevent the sub base from precipitation in order - asphalt binder course and to maintain the bearing capacity.  To get an even and stable base for the following layers such as - asphalt wearing course. Each layer has its special function and is needed, according Binder and Wearing Course. to its depth and position, to achieve the required bearing capacity of the complete construction.  During its service life the base course should be in a fixed bond with Binder and Wearing course to absorb the forces of traffic and derive them evenly to the sub base. Gradient of shearing stress due to moving traffic A strong and durable bond of the layers is required. Wearing Course Wear resistant and density Binder Course Shear Resistance Base Course Bearing Capacity Reference (Text in the following light-blue/red framed text boxes): German Asphalt Association (DAV) www.asphalt.de Joseph Voegele AG, Ludwigshafen/Rhein Germany CTT Center for Training and Technology 131 4.1 Paving Asphalt Asphalt Binder Course Asphalt Wearing Course At roads with heavier traffic (e.g. construction class III and higher, fully bonded pavement and special operational demands starting construction class IV) a binder course between base course and wearing course is mandatory. Asphalt wearing course is the top layer and therefore the most stressed area of the pavement and , thereby, subject to direct influence of traffic, weather and de-icing agent. Function of a Asphalt Wearing Course: Function of a Asphalt Binder Course:  Reducing existing irregularities in the base course to ensure the production of asphalt layers in uniform depths and required  As a “Use-surface” they shall provide a permanent, roadworthy and good passable or walkable surface.  As a “Sealing Layer“ the layers below shall be prevented from the evenness.  In particular the main function is to absorb the high shearing stress influences of weather