|Title of Invention||
MACHINE FOR ROAD MAINTENANCE AND REPAIR
|Abstract||ABSTRACT The invention in general related to a new mechanized hydro and pneumatic machine for maintenance and re co-conditioning work of concrete and bitumen roads. This machine is a four wheel mobile mechanical equipment with 2/4 wheel drive powered by 16 HP/20 HP diesel engines for achieving mobility and comprising steering system for steering feasibility, electrical equipment for activating and controlling the units, Hydraulic system for operating the front and rear buckets, pneumatic system for compressor for cleaning of pot holes and other accessories including tar boiler and tools etc. In the process of repair work, the machine is driven to the spot where the pot hole is identified and then pothole trimming is done by using pneumatic chipper and the pit is leaved out clean by pneumatic blower. Then the flame torch is used to dry the pit surface and mix is filled in the pit at the right temperature and then seal coat is filled and compacted well using pneumatic rammer and then the debris is removed and dumped in the debris bucket. Thus this one machine can carry out a perfect road reconditioning work,|
This invention in general relates to a machine for maintenance and repair of pot holes found in concrete and bitumen roads.
The transportation system depend mainly on good vehicles and good roads. Good roads play a vital role in enhancing and improving the transportation system, The criteria is not just ensuring laying of well designed and good quality roads, but it largely depends on the pattern and quality of continuous maintenance and improvement relevant to the traffic load and other environmental factors.
The wear and tear on the road surface is natural and inevitable. The damage is mainly on the top surface of the roads. The damage leads to uneven surface of the roads and pot holes on the road.
The main causes of the damage done to the road are;-
a. Due to excessive load on the road - which leads to cracks on the
b. Due to poor construction of the road Itself i.e. poor quality raw materials
and poor process of laying.
c. Due to debonding of top layer fi-om the bottom bearing layer.
d. Due to failure of the top bitumen mix layer.
e. Due to seepage of water underneath.
Hazards due to the existence of damaged roads and pot holes
a. High Accident rate due to the existence of potholes and uneven road
b. Mechanical damage to the vehicles - uneven wear and tear of the tyres,
c. Uncomfortable travel for the passengers due to jolting and random
d. Hampers traffic movement.
OBJECT OF THE INVENTION
The main object of the invention is to provide a new mechanised hydro and pneumatic system for maintenance and re co-conditioning work of concrete and bitumen roads.
It is another object of the invention to provide a product - which is mechanized - achieving high productively, better quality and less - labour dependent.
It is another object of the invention to provide a machine to repair and close the potholes on the roads>
It is another object of the invention to provide a machine, which is cost effective and mechanized system to maintain a pothole - free road surface.
SUMMARY OF THE INVENTION
Machine for road maintenance and repair - according to the present invention carried out for resolving the aforementioned problems and difficulties on road and road users, in which simple, mechanized steps are followed ;-
The machine for road maintenance repair - according to the present Invention consists of ;-
1. Thtt Machine
a. Is a four wheel mobile mechanical equipment with two wheel/four wheel
drive, powered by 15 HP/20 HP Diesel Engine.
b. The machine is fitted with a four speed gear box, three forward, neutral and
one reverse and fitted with a parking brake to be used while idling,
c. The engine is battery, key start and also hand crank start in the event of
d. The machine Is fitted with a mechanically actuated drum brake for all the
e. It Is basically a Hydro Pneumatic Equipment.
f. The maximum speed of the machine is about 15 Kms per hour.
g. The empty weight of the machine shall be about 1.5 tonnes.
2. Stcaring Syst«in
Mechanical steering by Rack and pinion. The machine has got a seat for driver and another seat for two workers.
3. Electrical Equipment
a. Electric 12 volts starting system, motor, battery, alternator and control panel
for the volt and ammeter.
b. The engine is specifically selected as air cooled to suit the Indian site
4. Hydraulic System
a. The front bucket(3) can hold 1.4 tonne and the rear 0.6 tonne.
b. The front bucket(3) and the rear half budcet(4) are operated hydraullcally
and the Hydraulic System is on whenever the Engine is running.
5. Pneumatic System
a. a compressor(5) of 6 Kg. Pressure and 5? cfm is provided for cleaning of pot¬holes, ramming the bitumen mix etc. and It can be activated by operating a lever.
6. Other Accessories
a. The machine is fitted with a tar boiler(9) to hold about 100 litres of bitumen
and it can be heated as and when required.
b. All the tools required to carry out the work can be accommodated In the
separate tool boxes provided.
The machine shall be constantly modified and Improved to be more use friendly.
The machine for road maintenance and repair according to the present invention - wortcs in the following sequence : -
i. Pot hole is identified on the road.
ii. The machine is droved to the Spot.
iii. Pothole size trimmed to the required geometric shape using the pneumatic chipper.
iv. the debris from the pits are removed by the shovel and also brushed clean and dust blown off by the pneumatic blower.
V. Pothole pits if wet are dried by Blow torch.
vL Hot molten bitumen at the right temperature is sprayed over the prepared surface as a tack coat from the Tar boller(9).
vii. The debris is not left over after filling the pothole, but collected and dumped in the Debris bucket.
viii. The bitumen mix to the required quantity is filled and after heating. If required, compacted and tamped well to the required level using Pneumatic rammer.
ix. Bitumen mix carrying bucket, pneumatic rammer, pneumatic blower, heating torch are all part of the equfpment/machrne.
X. Top seal coat is also laid immediately and tamped wall. Seal coat material is also carried in a Separate bucket as part of the equipment.
xi. The equipment is Hydro Pneumatic and requires three persons for operation and all the three can travel in the mobile machine.
The machine for road maintenance and repair - according to the Invention has the following salient characteristics and features combined with distinct advantages.
a. TRIMS pothole to required geometric shape, size and depth.
b. PROVIDES BUCKET for collection and disposal of debris.
c. BLOWS OFF dust from the prepared pothole pit.
d. DRIES pothole using flame torch.
e. FACILITATES SPRAYING molten bitumen at a right temperature as a tack
f. CARRIES bitumen mix of the right mix and quantity.
g. RAMS the bitumen mix firmly.
h. MOVES over to the next job conveniently carrying its team of just 3
operators and repair accessories and materials, j. COST effective.
The process of repair work - carried out on the road, using thB machine for road maintenance and repair according to the Invention consists of following steps:-
As can be done according to the invention.
1. Pothole trimming The entire surface is neatly trimmed to a geometric
shape using pneumatic chipper.
2. Pit cleaning Brushed clean manually and dust blown off using
pneumatic blower leaving a clean pit.
3. Pit surface Flame torch used to dry the surface. Tack coating
at the right temperature, carried out.
4. Compaction Mix filled in the pit at the right temperature or
heated if necessary using blow torch and compacted well using pneumatic rammer.
5. Seal coat Seal coat mix is carried in the bucket and can be
filled and compacted using pneumatic rammer.
6. Carting away of Debris Bucket is provided aiongwith to cart
the debris. away the debhs, and dump at the de signated
7.Econimics of the One machine and 3 workmen can carry out the
repair work job of 30 of labor wojlcmen in a more clean,
efficient and environment friendly performing manner.
EXISTING PRIOR ART AND THE PROBLEMS :-
For any country to grow, the four basic Infrastructures required are as follows:-
1. Good road and Transportation System
2. Good communication system
3. Good level of education
4. Awareness and application of the hygiene standards and energy system.
Of these, the invention, lays stress and Good Road, as this comes under Construction Industry's infrastructural needs.
Good road will ease and speed up the transportation system which is not only by adopting well designed good quality roads but also by continuous improvement and maintenance of roads as well. While laying of a good road is the responsibility (^ the owning authorities concerned, maintenance is one for which unfortunately In India neither do we have the right kind of machineries nor agency with pride, man power and attitude to maintain the roads in good condition. Unfortunately, even if there Is a "will* there is no proper modem mechanized system that can take care of
road maintenance as the road maintenance system that was followed 75 years before Is still being practiced even today, of course with a progressive degradation in following the standers of use of Material, Method and Man Power (The three Important Ms.)
While better materials can be sourced, unless better methods of using with good trained man power and practice, is put along with, the whole system will fail with roads full of potholes and craters.
Pffthffjg in Rftfliiff
The word must have come into use as a hole Is a pot renders the pot unfit and unsafe for use. Similarly, pothole in a road renders the road unfit and unsafe for use.
The f wwn for pfftholftt
Poverty among the population and potholes In roads are the two sore eyes and stumbling blocks for the growth of any country.
This occurs on the top surface of roads due to;
a. The debonding of top layer from the bottom bearing layer
b. Due to the failure of the top bitumen mix layer
c. Due to seepage of water underneath
d. Due to excessive load on road
e. Due to poor construction or due to any one of the above or other reasons.
Hftw it affocte the gmoffth utioft 9f th^ rgad iurfBCB
Driving over the pothole causes mechanical damage to the vehicles, tyre wear and tear and effects the health of the users and also damage to the road by extending the pothole size further to this slows down the traffic movement. If the driver suddenly spots the pothole and applies brake^^ there can be the danger of
i vehicle coming behind hitting and leading to accidents.
Why the pothoics should ba rapairad without much dalay
"A stitch in time save nine" is proverb and the repair of a pothole without much delay will save the damage to vehicles, accident and prevents the pothole reaching the size of a crater and allows smoother flow of traffic.
What ia tha normal oothoia ai»a
When potholes appear, they will be something of the size of about 1' x 1', about 1 or 2"deep and if left unattended quicldy shall reach the size of even 8' x 8' and 2' deep. There are potholes on the road surface in Tamiinadu, Karnataka and Goa of the above size requiring 6" to 8" size boulder soling to be filled to make up the level. This is only due to not attending to potholes on time. Also due to potholes, vehicles will move slowly using more fuel, wasting time and polluting the atmosphere.
How potholaa wara of iaaa aarioua oroblama in tha paat and now mora
fgrlffui of lato
In earlier days length of road was less, the quality of workmanship was better, vehicles using the road, the number, speed and laden weight etc., were less, the quality of maintenance was better, thus potholes never reached a dangerous level of attention in the past.
Nowadays, the length of road has increased, the quality of workman ship has decreased, the number of vehicles using the roads have increased and also the vehicle load carrying capacity and speed, thus leading to failure of road and more potholes and with less and improper maintenance it has reached a dangerous level of national debate and attention.
How it was prepared in the past, present and by the new system are being explained briefly below;
Z. r>OTHOLE TRIMMING
a) Earlier, In the manual system, the pothole pits used to be properly trimmed and cleaned.
b) Nowadays. In the manual system this is not being done and just some filling material of WBM or bitumen mix is filled In and Ijeft to the vehicles passing over to do the job of consolidation.
c) In our mechanical system, the pothole side surface and the bottom will be properly chipped with mechanical tools, brought to some proper geometric shape and made fit to receive further stages of work.
II. PIT CLEANING
a) In the earlier manual system, the pits were broomed and cleaned and the debris removed.
b) Presently, In the manual system, the same Is not being done due to lac) c) In our mechanical system the surface will be cleaned using cleaning brushes and the dust particles are removed using Pneumatic air blower, thus making the surface absolutely dean,
III. PIT'S SURFACE PREPARATION
a) In the earlier manual system, if the surface was wet there was no way to make it dry. Further, since bitumen will not stick to a wet surface, mud and jelly etc, will be filled and allowed to get compacted with vehicle movement.
b) Presently, in the manual system, cold bitumen mix is filled in pits and allowed to get consolidated with vehicle movement. Further this will not stick to the surface due to the present of moisture.
c) In our mechanical system, the surface shall be dried using flame torch,
heated and dried and brought to the perfect condition required for bonding of new bitumen/tack coat.
IV. PIT FILLING MATERIAL
a) In the older days, in the manual system, jelly and bitumen used to be mixed, heated to a warm condition, filled in pits and tamped to some level surface.
b) Presently, in the manual system, warm/cold asphalt mix Is filled and left for passing vehicle to do the job of consolidation. The warm/cold mix asphalt performances will not be as good as hot mix asphalt and will not stick to the old surface.
c) In our mechanical system, hot asphalt mix is carried to site and kept warm in the bucket. This shall be filled in the pit, heated with a flame torch and compacted using pneumatic rammers which does a perfect job, reaching compaction level similar to a Road Roller passing over the surface. The top surface can further be sealed using seal coat mix laid, heated and tamped mechanically, llius the top surface is well sealed.
This kind or thought has never applied In the past nor now to look into the problem that Is effecting the basic Infrastructure of the country.
The new mechanized hydro & pneumatic system can carry out a perfect road reconditioning work at 1/30* of the labor cost and thus productivity Is Increased by more than 30 to 40 times and the exact data and cost economics can be worked out for the needy users based on their inputs. However, it is beyond and doubts that since the system is a mechanized one, it requires less labor yiefding higher production and better quality standards and thus better roads.
The Idea of the above equipment Is Innovative and this Is the first equipment to be produced in the sub-continent including Pakistan, Bangladesh and far eastern countries. Now it is for the users, desirous of giving a good road surface for the
growth of the country to opt for the new system which is innovative, cost effective and right solution to have a pothole-free road surface.
ILLUSTRATION OF DRAWINGS
The invention is illustrated in Fig-1, the plan, elevation and end view of the invention. The Flg-2 shows all the accessories and unit fixed on the machine and the overall appearance of the machines as per the invention. The reference numerals in the drawings are as follows :-
1 - Power take unit
2- Hydraulic jacks
3- Front Bucket hot mix
4- Rear Bucket for debris
6- Compressor air Tank
7- Tool box
8- Hydraulic Tank
9- Tar boiler
According to the invention, a machine for road maintenance and repair of pot holes comprising ;-
a moveable drive carriage enclosing within,
a steering means,
a driver's seat,
plurality of co-worker's seats,
first tipping means including hydraulically operated bucket to
carry the bitumen mix,
second tipping means including hydraulically operated bucket also to
carry bitumen mix,
third bucket(3) to carry seal coat mix,
a tar boiIer(9) to heat the bitumen mix,
power means generating power for heating the tar in the tar boiler(9).
pneumatic chipper to trim the pot holes into geometric shapes, a compressor(5) for generating compressed air for the purposes of clearing the pot holes,
a pneumatic blower to blow the compressed air towards the pot holes, a flame torch means to dry the pot hole surface, a fourth bucket(4) to collect the debris fi-om the pot hole, a blow torch means to fill the pot holes with bitumen mix contained in the bucket,
a pneumatic rammer to compact the bitumen mix within the pot hole and to compact seal coat mix on to the pot hole, and a tool k.it(7) to store the tools and accessories,
such automotive drive carriage allowing the transportation of machine to location of repair of pot holes.
A machine for road maintenance and repair according to the invention, the technical specifications are as given below ;-
Dimensions in mm
Length : 2720 Breadth ; 1450
Empty weight 1250 Kg Carrying capacity 1600 Kgs, Volume 1 Cu.M.
Single / Double cylinder Aircooled 4 Stroke Diesel Engine - 10 / 12 Hp Engine of reputed Indian Make. Handle Start / Electric start
Driving Wheel 700x15 size Steering Wheel 600x16 size
Hydraulic pump with control value
Rolled steel section fully fabricated Section
Foot operated single plate dry Friction type
Foot operated, hydraulic brakes, hand brakes also provided.
Heavy duty synchromesh gear box
speed Control Driver's seat
Electric Equipment (Optional)
With 3 forward and 1 reverse drive
15 Kms / hour maximum
Jeep type foot controlled
Foam cushioned rubber Deluxe seat For drivers comfort, all round visibility and control.
12 volt Electric start. Head tight, Tail lamp SiHorn.
Ammeter, voltmeter and tool kit.
A machine for road maintenance and repair according to the invention, the main purpose and function of various accessories are as given below: -
1. Pothole size trimmed to the required geometric shape using Pneumatic Chippers, to the required depth, shape etc.
2. The debris from the pits are removed by shovel supplied along with and also brushed clean and dust blown off by pneumatic blower.
3. pothole pits if wet, are dried by Blow Torch,
4. Hot molten bitumen at the right temperature Is sprayed over the prepared surface as a tack coat. Tar boiler(9) is a part of the equipment.
5. The debris is not left over nearby and collected and dumped in the debris bucket.
6. The bitumen mix to the required quantity is filled and after heating, if required, compacted and temped well, to the required level using Pneumatic rammer.
7. Bitumen mix carrying bucket, pneumatic rammer, pneumatic blower, heating torch are all part of the machine.
8. Top seal coat is also carried in the separate bucket as a part of the equipment, carrying out the job of 30 workmen.
9. The equipment is Hydro pneumatic and requires three persons for operation and all the three can travel in the machine,
10. The machine is moderately priced and can be put to higher advantages, with high level of mechanization and high degree of quality achievement.
1, A machine for road maintenance and repair of pot holes comprising :-
a moveable drive carriage enclosing within,
a steering means,
a driver's seat,
plurality of co-worker's seats,
first tipping means having hydraulically operated bucket to
carry the bitumen mix,
second tipping means having hydraulically operated bucket also to
carry bitumen mix,
third bucket(3) to carry seal coat mix,
a tar boiler (9) to heat the bitumen mix,
power means generating power for heating the tar In the tar boller(9),
pneumatic chipper to trim the pot holes into geometric shapes,
a compressor(5) for generating compressed air for the purposes of
clearing the pot holes,
a pneumatic blower to blow the compressed air towards the pot holes,
a flame torch means to dry the pot hole surface,
a fourth bucket(4) to collect the debris fi-om the pot hole,
a blow torch means to fill the pot holes with bitumen mix contained in
a pneumatic rammer to compact the bitumen mix within the pot hole and to compact seal coat mix on to the pot hole, and
a tool kit(7) to store the tools and accessories,
such automotive drive carriage allowing the transportation of machine to location of repair of pot holes,
2, A machine for road maintenance and repair as claimed in claim 1 wherein
steering means comprises mechanical steering by rack and pinion.
3. A machine for road maintenance and repair as claimed in claim 1 , wherein
power means atleast comprising,
- a 12 volts electric starting means,
- a motor,
- a battery,
- an alternator,
- an engine and
- a control panel for controlling the voltage & current,
4. A machine for road maintenance and repair as claimed in claim 1,
substantially as herein before described and as Illustrated with reference to
|Indian Patent Application Number||884/MAS/1999|
|PG Journal Number||10/2005|
|Date of Filing||07-Sep-1999|
|Name of Patentee||KADAYAM RAMABHADRAN IYER SRINIVASAN|
|Applicant Address||SHANMUGA VILAS, # 3, 8TH CROSS, 5TH MAIN, KRISHNAPPA BLOCK, GANGANAGAR EXTN., BANGALORE 560 032|
|PCT International Classification Number||E01C023/18|
|PCT International Application Number||N/A|
|PCT International Filing date|