US20070116519A1 - Systems and Methods for Milling Paving Material with Increased Stability, Support, and Power - Google Patents

Systems and Methods for Milling Paving Material with Increased Stability, Support, and Power Download PDF

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Publication number
US20070116519A1
US20070116519A1 US11/564,710 US56471006A US2007116519A1 US 20070116519 A1 US20070116519 A1 US 20070116519A1 US 56471006 A US56471006 A US 56471006A US 2007116519 A1 US2007116519 A1 US 2007116519A1
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cutting head
milling
milling apparatus
self
powered
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US11/564,710
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J. Haroldsen
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Asphalt Zipper Inc
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Asphalt Zipper Inc
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Publication of US20070116519A1 publication Critical patent/US20070116519A1/en
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    • EFIXED CONSTRUCTIONS
    • E01CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01CCONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C23/00Auxiliary devices or arrangements for constructing, repairing, reconditioning, or taking-up road or like surfaces
    • E01C23/06Devices or arrangements for working the finished surface; Devices for repairing or reconditioning the surface of damaged paving; Recycling in place or on the road
    • E01C23/08Devices or arrangements for working the finished surface; Devices for repairing or reconditioning the surface of damaged paving; Recycling in place or on the road for roughening or patterning; for removing the surface down to a predetermined depth high spots or material bonded to the surface, e.g. markings; for maintaining earth roads, clay courts or like surfaces by means of surface working tools, e.g. scarifiers, levelling blades
    • E01C23/085Devices or arrangements for working the finished surface; Devices for repairing or reconditioning the surface of damaged paving; Recycling in place or on the road for roughening or patterning; for removing the surface down to a predetermined depth high spots or material bonded to the surface, e.g. markings; for maintaining earth roads, clay courts or like surfaces by means of surface working tools, e.g. scarifiers, levelling blades using power-driven tools, e.g. vibratory tools
    • E01C23/088Rotary tools, e.g. milling drums

Definitions

  • the present invention relates to systems and methods for milling paving material. More particularly, the present invention relates to systems and methods that provide increased stability, support and power while grinding paving material.
  • Asphalt milling is a technique currently employed to remove asphalt pavement for reconstruction or resurfacing, and for accessing buried utility lines.
  • the technique involves the removal of asphalt pavement through the use of a cold planer, which can remove up to approximately two inches of pavement surface during a particular pass.
  • a cold planer typically includes a barrel-like attachment, referred to as a mandrel, and a variety of bits (e.g., 40) that are affixed to the exterior surface of the mandrel. Coupled to the cold planer is a vehicle (e.g., a bobcat or skid-steer) that is used to propel the cold planer.
  • a vehicle e.g., a bobcat or skid-steer
  • the mandrel rotates and is pushed into the pavement by the hydraulic system of the vehicle, causing the bits to grind up the asphalt pavement.
  • the vehicle pushes the cold planer as the mandrel rotates to grind a trench in the asphalt pavement that is typically up to 24 inches wide.
  • the process is further delayed by the requirement of having to push the cold planer at an extremely slow rate.
  • Much of the power from the skid-steer is used to rotate the mandrel. As such, limited power is available to push the cold planer forward.
  • the cold planer creates a trench by grinding the pavement at a rate of up to 1 ⁇ 2 mph.
  • the process is further hampered by instability.
  • the vehicle used to propel the cold planer typically loses traction and has a tendency to shake.
  • a loss in pressure between the actions of providing pressure on the cold planer and lowering the mandrel also yields to instability.
  • a procedure of edge milling typically requires the removal of supporting structures of the cold planer, triggering further instability.
  • the present invention relates to systems and methods for milling paving material. More particularly, the present invention relates to systems and methods that provide increased stability, support and power while grinding paving material.
  • Implementation of the present invention takes place in association with a self-powered milling system for use in milling or grinding asphalt and is configured for coupling to a vehicle (e.g., a bobcat, steer-skid, or other vehicle) that selectively pushes or pulls the milling system in a desired direction.
  • the milling system includes a cylindrical mandrel, having a variety of bits attached thereon, which spins on an axis to break up and mill the asphalt.
  • the mandrel is powered by a milling system motor that speeds up production and enables milling of very thick asphalt (e.g., 8 inch thick asphalt) in a single pass.
  • a breaker bar of the milling system is continuously located at or near ground level during the milling process to hold the asphalt down as it tries to lift up during the process. The breaker bar further assists in breaking up the milled asphalt aggregate.
  • the milling system includes a carriage that follows the contour of the ground.
  • the carriage provides stability during the milling process, allowing only the mandrel or cutting head to move during the process.
  • the carriage may be selectively adjusted to provide cuts at various angles.
  • the carriage is designed to include a flush side to enable use of the milling system in performing precise edge milling of the asphalt.
  • FIG. 1 illustrates a perspective view of a representative embodiment of the present invention
  • FIG. 2 illustrates a front view of the embodiment of FIG. 1 ;
  • FIG. 3 illustrates a perspective view of a representative cutting head that may be used in association with the embodiment of FIG. 1 ;
  • FIG. 4 illustrates a side view of the embodiment of FIG. 1 ;
  • FIG. 5 illustrates a top view of the embodiment of FIG. 1 .
  • the present invention relates to systems and methods for milling paving material. More particularly, the present invention relates to systems and methods that provide increased stability, support and power while grinding paving material.
  • paving material shall refer to any material that may be used to pave a road, path, sidewalk, parking lot, driveway, thoroughfare, or any other similar surface.
  • paving materials include asphalt, tarmac, pavement, cement, clay, stone and dirt.
  • Embodiments of the present invention take place in association with a self-powered milling system for use in milling or grinding paving material, and which may be configured to be coupled to a vehicle (e.g., a bobcat, steer-skid, back hoe, excavator or other vehicle) that selectively pushes or pulls the self-powered milling system in a desired direction.
  • the milling system includes a cutting head, such as a cylindrical mandrel that includes a variety of bits attached thereon. The mandrel spins on an axis to break up and mill the paving material, and is powered by a milling system motor that speeds up production and enables the milling of very thick paving material (e.g., 8 inch thick asphalt) in a single pass.
  • Embodiments of the present invention further embrace a milling system having a carriage that follows the contour of the ground.
  • the carriage provides stability during the milling process, allowing only the cutting head to move during the process, and may be selectively adjusted to provide cuts at various angles.
  • the carriage includes a flush side to enable performance of precise edge milling.
  • a breaker bar is coupled to the carriage.
  • the breaker bar is continuously located at or near ground level to hold the asphalt down as it tries to lift up during the milling process.
  • the breaker bar is further employed to assist in the breaking up the milled asphalt aggregate.
  • embodiments of the present invention take place in association with a self-powered milling system that may be used to mill or grind paving material, and that may be configured to be coupled to a vehicle (e.g., a bobcat, steer-skid, back hoe, excavator or other vehicle), which selectively pushes or pulls the self-powered milling system in a desired direction.
  • a vehicle e.g., a bobcat, steer-skid, back hoe, excavator or other vehicle
  • FIG. 1 a representative embodiment of a self-powered milling system is illustrated as milling system 10 , which includes cutting head 12 having bits 14 attached thereon, motor 16 , carriage 18 , wheels 20 , and vehicle coupler 22 .
  • milling system 10 is configured to be coupled to a vehicle using vehicle coupler 22 .
  • vehicle coupler 22 is adjustable to allow for a coupling of milling system 10 to any type of vehicle.
  • the vehicle (not shown) may be operated by a user to selectively push or pull milling system 10 in a particular direction.
  • Milling system 10 comprises a motor 16 , which is separate from the motor of the vehicle. As such, milling system 10 is self-powered to enable the grinding or milling of paving material. More specifically, motor 16 is dedicated to the actuating of cutting head 12 in order to grind or mill paving material under milling system 10 .
  • FIGS. 2 and 3 The use of cutting head 12 is more fully illustrated in FIGS. 2 and 3 .
  • FIG. 2 a front view of milling system 10 is provided.
  • Cutting head 12 is actuated by motor 16 and spins on an axis. As cutting head 12 is spinning, milling system 10 is pushed by a vehicle coupled thereto and mills paving material that passes underneath cutting head 12 .
  • cutting head 12 is a barrel-like attachment, known as a mandrel.
  • the mandrel spins and is pushed into the paving material.
  • Bits 14 affixed to the exterior of the mandrel engage and grind up the asphalt. Once ground, the asphalt may be easily removed and replaced.
  • approximately forty bits are located on the exterior surface of cutting head 12 .
  • the bits 14 are scattered and patterned along the mandrel in a way that optimally enables pulverization and are exposed to the asphalt when the mandrel is in operation.
  • six bits are located at each end of the mandrel. The end bits prevent the mandrel from wedging into the paving material and from becoming stuck, and are known as “inside end bits.”
  • Each bit 14 has a hardened or carbide tipped end, a stem, and a flat end at the bottom of the stem.
  • the bits 14 are attached to a mandrel by their insertion into channels or blocks of the mandrel.
  • the stem of a bit 14 has a spring collet surrounding it. When the bit is forced into a channel of a bit block and pressed down through the shaft, the spring collet squeezes against the stem to tightly fit the stem within the channel.
  • An annular space on the bit that engages a lipped section of the top end of the bit shaft and locks the bit into the shaft is located between the bit stem and the tipped end of the bit. This annular space prevents the tip from leaving the shaft.
  • a bit 14 may be removed, such as when it has become tipped out, by pounding on the exposed flat end of a bit 14 seated within the shaft, and drive the bit 14 from the shaft.
  • the bit is removable because despite its secure fit within the shaft, when the flat end is impacted, the spring collet is forced inward to contract and pass by the lip of the shaft and is released from the annular space within the bit block.
  • bits require replacement. For example, when an operator of milling system 10 hits a manhole, bits may become tipped out and need replacement. The need for replacing bits 14 arises frequently, therefore time efficient and cost effective techniques for replacing bits is greatly desired.
  • a bit access is provided to facilitate bit removal from a top-level or a top portion of milling apparatus 10 .
  • the bit access is illustrated as removable cover 30 , which is hinged to a casing that covers cutting head 12 .
  • removable cover 30 is mechanically removable. Cover 30 provides access to bits 14 and facilitates access by eliminating the traditional requirement of having to access bits 14 from underneath a cold planer.
  • removable cover 30 removes a top portion from a casing that covers cutting head 12 as well as a portion of either side of the casing. As such, in one embodiment, the top 60° to 90° of the cutter head 12 is exposed when removing removable cover 30 . Since a portion on each of the sides of the casing is removable, access to the inside end bits is facilitated.
  • motor 16 to drive cutting head 12 eliminates the need of traditional practices to steal power from the vehicle motor (not shown).
  • the use of motor 16 exponentially speeds up production (it is approximately 4-6 times faster than traditional methods) since it enables the vehicle motor to be dedicated to moving system 10 and further enables up to approximately 8 inches of paving material to be milled in a single pass, as opposed to 2 inches by traditional methods. As such, the time required for an operator to perform the milling of paving material is greatly reduced since up to 8 inches can be milled with each pass.
  • a traditional cold planer that claims it can mill up to 6 inches deep actually requires three separate passes, where each pass mills 2 inches of the paving material, in order to mill the total 6 inch deep paving material.
  • a traditional milling head requires approximately 72 hp to run effectively.
  • An average skid-steer motor doesn't generally produce more than 72 hp, which must be used to spin the milling head and to push the cold planer. Therefore, since so much of the power is required to spin the milling head, the amount of power available to push the cold planer is limited and results in an extremely slow process.
  • the traditional cold planer is only able to mill up to about 2 inches deep and is only pushed at 1 ⁇ 2 mph.
  • power e.g., 72 hp or another amount of power
  • an additional amount of power e.g., another 72 hp or another amount
  • the increased power yields increased efficiency in performing a milling job.
  • Embodiments of the present invention further increase the ability to mill paving material by providing a belt-driven system to power a cutting head.
  • vehicles used to power a traditional cold planer are powered through the utilization of a hydraulic system, which yields a high efficiency loss.
  • a hydraulic system is typically about 60% efficient.
  • 72 hp is available to both move a traditional cold planer and to spin a cutting head
  • the actual power available due to the hydraulic system is 43.2 hp (72 hp multiplied by 60% efficiency is 43.2 hp).
  • the other 28.8 hp is lost in heat.
  • embodiments of the present invention embrace the use of a belt-driven system 34 , which provides 90% to 95% efficiency.
  • milling system 10 is actually placing 64.8 (72 hp multiplied by 90% efficiency is 64.8 hp) on spinning cutting head 12 .
  • the belt-driven system 34 is additionally illustrated in FIGS. 4 and 5 , which are respectively a top view and a side view of milling system 10 , and includes a belt and a transmission 64 ( FIG. 5 ).
  • the belt couples shaft 42 ( FIG. 3 ) of cutting head 12 with motor 16 to cause motor 16 to rotate shaft 42 and cause cutting head 12 to spin.
  • system 10 further includes a belt tensioning system 60 ( FIG. 5 ), such as an automatic or manual tensioner, that keeps the belt of the belt-driven system taut.
  • the belt-tensioning system 60 includes a pneumatic air cylinder 62 ( FIG. 5 ). As such, the belt may be set and aligned with low to no tension and locked into place. The belt-tensioning system 60 may then be engaged to apply tension to the belt in order to keep the belt taut. In one embodiment, the tension automatically adjusts to pressure. Therefore, when the system 10 hits, for example, an object while in use, the belts are automatically kept taut.
  • milling system 10 provides a carriage 18 , which sits near the ground and provides support. In one embodiment, carriage 18 sits approximately one-half inch above the ground. In the illustrated embodiment, wheels 20 are coupled to carriage 18 . Carriage 18 provides pressure on cutting head 12 .
  • Carriage 18 includes a flush side 26 that enables edge milling of paving material. For example, when milling system 10 is used to mill paving material that is located up against a vertical surface, milling system 10 is pushed along the vertical surface with the flush side 26 near the vertical surface. As such, the paving material may be milled within three to four inches of a vertical surface without touching the sides of milling system 10 . The remaining portion of paving material may then be knocked off with a shovel. In contrast, traditional techniques required disassembly of a cold planer, which has caused instability in using the cold planer. The use of carriage 18 further allows for carriage 18 to potentially bump the vertical surface rather than cutting head 12 , which would damage the vertical surface.
  • Carriage 18 is configured to be selectively adjusted to enable milling system 10 to be used in such a way as to cut on a particular angle or taper.
  • Embodiments of the present invention embrace the ability to manually or hydraulically adjust the height of wheels 20 .
  • Milling system 10 maintains traction and support by allowing carriage 18 to follow the ground while cutting head 12 follows the set angle. In contrast, traction is lost in traditional techniques.
  • Milling system 10 may be manually or hydraulically tipped through the use of a cylinder, such as cylinder 28 .
  • cylinder 28 is locked for safety reasons while moving milling system 10 .
  • cylinder 28 which allows cutting head 12 to raise and lower, may be manually or hydraulically actuated to allow cutting head 12 to move back and forth.
  • cutting head 12 is allowed to float, which allows equal traction for the vehicle used.
  • cutting head 12 is allowed to adjust to whatever angle it needs to in order to adjust and follow the contour of the ground. As such, multi-vector positioning of cutting head 12 is made possible.
  • Embodiments of the present invention embrace an improved method for entering the ground in order to mill paving material.
  • the vehicle is locked up in a home position and the arms of the vehicle are locked down with the tilt locked back. In this manner, nothing shakes or vibrates.
  • Pressure is provided onto cutting head 12 by cylinder 28 , and motor 16 engages cutting head 12 to allow for the milling to occur.
  • embodiments of the present invention may be dropped into any asphalt or paving material and pulverize the paving material into a fine gravel, similar to a road base.
  • a first cylinder illustrated as cylinder 28 , holds cutting head 12 down into the ground, pulling between carriage 18 and cutting head 12 .
  • a second cylinder controls the tilt that is enabled by milling system 10 and has the extra option of allowing cutting head 12 to float while in use to enable a more effective milling.
  • system 10 pivots about pivot point 52 .
  • a third cylinder is utilized to shift the vehicle hook-up.
  • a bearing 32 faces outward and is protected from any debris, such as rocks, that may be spinning around.
  • a mound sets bearing 32 inside cutting head 12 , but facing out to provide access to grease bearing 32 .
  • a user may pop bearing 32 out and remove it without disassembling any other portion of milling system 10 .
  • the cutting head 12 may be dropped out from system 10 and replaced with another cutting head.
  • bearing 32 is placed inside the cutting head 12 , facing out where it is still protected.
  • a well mount or a gear reduction planetary that is mounted to one side of the drum and to the frame.
  • an outboard shaft is mounted with an outboard bearing support to help the cutting head ride. This increases the life span of the gearbox and virtually provides an unlimited life span of the gear reduction planetary.
  • a remote control system is utilized to provide control of the various cylinders in order to guide or steer milling system 10 .
  • the remote control system utilizes a radio control system, such as an RF frequency, to provide the control.
  • the system has an E-stop with a continuous transmission. If an operator gets far enough away from milling system 10 , the system shuts down automatically.
  • milling system 10 includes an extended drive input.
  • a shaft with a flex coupling that includes a couple of bearings that have two pilot tubes that bolt up to cutting head 12 and support the belt enable the engine to be flush on side 26 rather than having to overhang approximately 12 inches.
  • Embodiments in the present invention further embrace a large frame that holds still, just allowing the cutter head to move up and down.
  • the vehicle frame is extended 10 feet or longer by the use of the carriage of the milling system.
  • a breaker bar illustrated as breaker bar 24 is continuously located at ground level to hold the pavement down as it tries to lift up and is used to help break up the aggregate that has been milled.
  • the embodiments of the present invention embrace systems and methods that provide increased stability, support and power in milling paving material.
  • the present invention may be embodied in other specific forms without departing from its spirit of essential characteristics.
  • the described embodiments are to be considered in all respects only al illustrative and not restrictive.
  • the scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mining & Mineral Resources (AREA)
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  • Civil Engineering (AREA)
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  • Road Repair (AREA)

Abstract

Systems and methods that provide increased stability, support and power while grinding paving material. A self-powered milling system, which is coupled to a vehicle to selectively move the milling system, is used to mill paving material. The milling system includes a cutting head, such as a cylindrical mandrel that includes a variety of bits attached thereon and spins on an axis, to mill the paving material. The cutting head is powered by a milling system motor that speeds up production and enables the milling of very thick asphalt (e.g., 8 inch thick asphalt) in a single pass. A milling system carriage follows the contour of the ground, provides stability during the milling process, and may be selectively adjusted to provide cuts at various angles. In one embodiment, the carriage includes a flush side to enable precise edge milling. In a further embodiment, a breaker bar is located at or near ground level to hold the paving material down as it tries to lift up during the milling process, and is employed to assist in the breaking up of the milled aggregate.

Description

    RELATED APPLICATIONS
  • This application claims priority to U.S. Provisional Application Ser. No. 60/348,063, filed Jan. 9, 2002, and entitled, “Systems and Methods for Milling Paving Material with Increased Stability, Support, and Power,” which is incorporated by reference herein.
  • BACKGROUND
  • 1. Field of the Invention
  • The present invention relates to systems and methods for milling paving material. More particularly, the present invention relates to systems and methods that provide increased stability, support and power while grinding paving material.
  • 2. Background of the Invention and Related Art
  • Asphalt milling is a technique currently employed to remove asphalt pavement for reconstruction or resurfacing, and for accessing buried utility lines. The technique involves the removal of asphalt pavement through the use of a cold planer, which can remove up to approximately two inches of pavement surface during a particular pass.
  • A cold planer typically includes a barrel-like attachment, referred to as a mandrel, and a variety of bits (e.g., 40) that are affixed to the exterior surface of the mandrel. Coupled to the cold planer is a vehicle (e.g., a bobcat or skid-steer) that is used to propel the cold planer. The mandrel rotates and is pushed into the pavement by the hydraulic system of the vehicle, causing the bits to grind up the asphalt pavement. The vehicle pushes the cold planer as the mandrel rotates to grind a trench in the asphalt pavement that is typically up to 24 inches wide.
  • While this technique enables the creation of a trench that is up to 2 inches deep, various problems exist. For example, traditional cold planers stall out upon attempting to grind 2-3 inches of asphalt pavement. Thus, when desiring to mill a depth of 6 inches of pavement, at least three passes of the cold planer must be conducted. Furthermore, the milled asphalt composite left behind in the wake of the cold planer must be removed between each pass. As a result, this process has proven to be time consuming.
  • The process is further delayed by the requirement of having to push the cold planer at an extremely slow rate. Much of the power from the skid-steer is used to rotate the mandrel. As such, limited power is available to push the cold planer forward. Typically, the cold planer creates a trench by grinding the pavement at a rate of up to ½ mph.
  • The process is further hampered by instability. The vehicle used to propel the cold planer typically loses traction and has a tendency to shake. A loss in pressure between the actions of providing pressure on the cold planer and lowering the mandrel also yields to instability. Moreover, a procedure of edge milling typically requires the removal of supporting structures of the cold planer, triggering further instability.
  • Thus, while the traditional technique of asphalt milling enables the creation of a milled trench that is up to 2 inches deep, the technique has proven to be instable and time consuming. Accordingly, it would be an improvement in the art to augment or even replace existing techniques to enable a trench to be milled in asphalt pavement at a quicker rate and/or to provide increased stability to the milling process.
  • SUMMARY AND OBJECTS OF THE INVENTION
  • The present invention relates to systems and methods for milling paving material. More particularly, the present invention relates to systems and methods that provide increased stability, support and power while grinding paving material.
  • Implementation of the present invention takes place in association with a self-powered milling system for use in milling or grinding asphalt and is configured for coupling to a vehicle (e.g., a bobcat, steer-skid, or other vehicle) that selectively pushes or pulls the milling system in a desired direction. The milling system includes a cylindrical mandrel, having a variety of bits attached thereon, which spins on an axis to break up and mill the asphalt. The mandrel is powered by a milling system motor that speeds up production and enables milling of very thick asphalt (e.g., 8 inch thick asphalt) in a single pass. A breaker bar of the milling system is continuously located at or near ground level during the milling process to hold the asphalt down as it tries to lift up during the process. The breaker bar further assists in breaking up the milled asphalt aggregate.
  • In one implementation, the milling system includes a carriage that follows the contour of the ground. The carriage provides stability during the milling process, allowing only the mandrel or cutting head to move during the process. The carriage may be selectively adjusted to provide cuts at various angles. Furthermore, the carriage is designed to include a flush side to enable use of the milling system in performing precise edge milling of the asphalt.
  • While the methods and processes of the present invention have proven to be particularly useful in providing increased stability, support and power in the area of milling asphalt, those skilled in the art shall appreciate that the methods and processes can be used to mill a variety of different surfaces.
  • These and other features and advantages of the present invention will be set forth or will become more fully apparent in the description that follows and in the appended claims. The features and advantages may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. Furthermore, the features and advantages of the invention may be learned by the practice of the invention or will be obvious from the description, as set forth hereinafter.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • In order that the manner in which the above-recited and other advantages and features of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
  • FIG. 1 illustrates a perspective view of a representative embodiment of the present invention;
  • FIG. 2 illustrates a front view of the embodiment of FIG. 1;
  • FIG. 3 illustrates a perspective view of a representative cutting head that may be used in association with the embodiment of FIG. 1;
  • FIG. 4 illustrates a side view of the embodiment of FIG. 1; and
  • FIG. 5 illustrates a top view of the embodiment of FIG. 1.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, and represented in FIGS. 1 through 5, is not intended to limit the scope of the invention, as claimed, but is merely representative of the presently preferred embodiments of the invention.
  • The presently preferred embodiments of the invention will be best understood by reference to the drawings wherein like parts are designated by like numerals throughout.
  • The present invention relates to systems and methods for milling paving material. More particularly, the present invention relates to systems and methods that provide increased stability, support and power while grinding paving material.
  • In the disclosure and in the claims the term “paving material” shall refer to any material that may be used to pave a road, path, sidewalk, parking lot, driveway, thoroughfare, or any other similar surface. Examples of paving materials include asphalt, tarmac, pavement, cement, clay, stone and dirt.
  • Embodiments of the present invention take place in association with a self-powered milling system for use in milling or grinding paving material, and which may be configured to be coupled to a vehicle (e.g., a bobcat, steer-skid, back hoe, excavator or other vehicle) that selectively pushes or pulls the self-powered milling system in a desired direction. The milling system includes a cutting head, such as a cylindrical mandrel that includes a variety of bits attached thereon. The mandrel spins on an axis to break up and mill the paving material, and is powered by a milling system motor that speeds up production and enables the milling of very thick paving material (e.g., 8 inch thick asphalt) in a single pass.
  • Embodiments of the present invention further embrace a milling system having a carriage that follows the contour of the ground. The carriage provides stability during the milling process, allowing only the cutting head to move during the process, and may be selectively adjusted to provide cuts at various angles. In a further embodiment, the carriage includes a flush side to enable performance of precise edge milling.
  • In one embodiment, a breaker bar is coupled to the carriage. The breaker bar is continuously located at or near ground level to hold the asphalt down as it tries to lift up during the milling process. The breaker bar is further employed to assist in the breaking up the milled asphalt aggregate.
  • As provided above, embodiments of the present invention take place in association with a self-powered milling system that may be used to mill or grind paving material, and that may be configured to be coupled to a vehicle (e.g., a bobcat, steer-skid, back hoe, excavator or other vehicle), which selectively pushes or pulls the self-powered milling system in a desired direction. With reference to FIG. 1, a representative embodiment of a self-powered milling system is illustrated as milling system 10, which includes cutting head 12 having bits 14 attached thereon, motor 16, carriage 18, wheels 20, and vehicle coupler 22.
  • In FIG. 1, milling system 10 is configured to be coupled to a vehicle using vehicle coupler 22. In the illustrated embodiment, vehicle coupler 22 is adjustable to allow for a coupling of milling system 10 to any type of vehicle. Once coupled to milling system 10, the vehicle (not shown) may be operated by a user to selectively push or pull milling system 10 in a particular direction.
  • Milling system 10 comprises a motor 16, which is separate from the motor of the vehicle. As such, milling system 10 is self-powered to enable the grinding or milling of paving material. More specifically, motor 16 is dedicated to the actuating of cutting head 12 in order to grind or mill paving material under milling system 10.
  • The use of cutting head 12 is more fully illustrated in FIGS. 2 and 3. In FIG. 2, a front view of milling system 10 is provided. Cutting head 12 is actuated by motor 16 and spins on an axis. As cutting head 12 is spinning, milling system 10 is pushed by a vehicle coupled thereto and mills paving material that passes underneath cutting head 12.
  • With reference now to FIG. 3, a perspective view of cutting head 12 is illustrated. In FIG. 3, cutting head 12 is a barrel-like attachment, known as a mandrel. The mandrel spins and is pushed into the paving material. Bits 14 affixed to the exterior of the mandrel engage and grind up the asphalt. Once ground, the asphalt may be easily removed and replaced.
  • In one embodiment, approximately forty bits are located on the exterior surface of cutting head 12. The bits 14 are scattered and patterned along the mandrel in a way that optimally enables pulverization and are exposed to the asphalt when the mandrel is in operation. In addition to the bits on the exterior of the mandrel, six bits are located at each end of the mandrel. The end bits prevent the mandrel from wedging into the paving material and from becoming stuck, and are known as “inside end bits.”
  • Each bit 14 has a hardened or carbide tipped end, a stem, and a flat end at the bottom of the stem. The bits 14 are attached to a mandrel by their insertion into channels or blocks of the mandrel. In one embodiment, the stem of a bit 14 has a spring collet surrounding it. When the bit is forced into a channel of a bit block and pressed down through the shaft, the spring collet squeezes against the stem to tightly fit the stem within the channel. An annular space on the bit that engages a lipped section of the top end of the bit shaft and locks the bit into the shaft is located between the bit stem and the tipped end of the bit. This annular space prevents the tip from leaving the shaft.
  • A bit 14 may be removed, such as when it has become tipped out, by pounding on the exposed flat end of a bit 14 seated within the shaft, and drive the bit 14 from the shaft. The bit is removable because despite its secure fit within the shaft, when the flat end is impacted, the spring collet is forced inward to contract and pass by the lip of the shaft and is released from the annular space within the bit block.
  • Unfortunately, due to wear and tear, bits require replacement. For example, when an operator of milling system 10 hits a manhole, bits may become tipped out and need replacement. The need for replacing bits 14 arises frequently, therefore time efficient and cost effective techniques for replacing bits is greatly desired.
  • In the illustrated embodiment, and with reference back to FIG. 1, a bit access is provided to facilitate bit removal from a top-level or a top portion of milling apparatus 10. The bit access is illustrated as removable cover 30, which is hinged to a casing that covers cutting head 12. In another embodiment, removable cover 30 is mechanically removable. Cover 30 provides access to bits 14 and facilitates access by eliminating the traditional requirement of having to access bits 14 from underneath a cold planer.
  • In the illustrated embodiment, removable cover 30 removes a top portion from a casing that covers cutting head 12 as well as a portion of either side of the casing. As such, in one embodiment, the top 60° to 90° of the cutter head 12 is exposed when removing removable cover 30. Since a portion on each of the sides of the casing is removable, access to the inside end bits is facilitated.
  • The use of motor 16 to drive cutting head 12 eliminates the need of traditional practices to steal power from the vehicle motor (not shown). The use of motor 16 exponentially speeds up production (it is approximately 4-6 times faster than traditional methods) since it enables the vehicle motor to be dedicated to moving system 10 and further enables up to approximately 8 inches of paving material to be milled in a single pass, as opposed to 2 inches by traditional methods. As such, the time required for an operator to perform the milling of paving material is greatly reduced since up to 8 inches can be milled with each pass.
  • Thus, for example, a traditional cold planer that claims it can mill up to 6 inches deep actually requires three separate passes, where each pass mills 2 inches of the paving material, in order to mill the total 6 inch deep paving material. Furthermore, a traditional milling head requires approximately 72 hp to run effectively. An average skid-steer motor doesn't generally produce more than 72 hp, which must be used to spin the milling head and to push the cold planer. Therefore, since so much of the power is required to spin the milling head, the amount of power available to push the cold planer is limited and results in an extremely slow process. Typically, the traditional cold planer is only able to mill up to about 2 inches deep and is only pushed at ½ mph.
  • In contrast, in accordance with the present invention, power (e.g., 72 hp or another amount of power) from the vehicle motor is provided to selectively move/push the milling system 10, and an additional amount of power (e.g., another 72 hp or another amount) is provided to spin the cutting head 12. The increased power yields increased efficiency in performing a milling job.
  • Embodiments of the present invention further increase the ability to mill paving material by providing a belt-driven system to power a cutting head. Traditionally, vehicles used to power a traditional cold planer are powered through the utilization of a hydraulic system, which yields a high efficiency loss. For example, a hydraulic system is typically about 60% efficient. Thus in the example above, where in a traditional procedure 72 hp is available to both move a traditional cold planer and to spin a cutting head, the actual power available due to the hydraulic system is 43.2 hp (72 hp multiplied by 60% efficiency is 43.2 hp). The other 28.8 hp is lost in heat.
  • In contrast, embodiments of the present invention embrace the use of a belt-driven system 34, which provides 90% to 95% efficiency. Thus, where motor 16 provides 72 hp, milling system 10 is actually placing 64.8 (72 hp multiplied by 90% efficiency is 64.8 hp) on spinning cutting head 12. The belt-driven system 34 is additionally illustrated in FIGS. 4 and 5, which are respectively a top view and a side view of milling system 10, and includes a belt and a transmission 64 (FIG. 5). The belt couples shaft 42 (FIG. 3) of cutting head 12 with motor 16 to cause motor 16 to rotate shaft 42 and cause cutting head 12 to spin.
  • In one embodiment, system 10 further includes a belt tensioning system 60 (FIG. 5), such as an automatic or manual tensioner, that keeps the belt of the belt-driven system taut. In a further embodiment, the belt-tensioning system 60 includes a pneumatic air cylinder 62 (FIG. 5). As such, the belt may be set and aligned with low to no tension and locked into place. The belt-tensioning system 60 may then be engaged to apply tension to the belt in order to keep the belt taut. In one embodiment, the tension automatically adjusts to pressure. Therefore, when the system 10 hits, for example, an object while in use, the belts are automatically kept taut.
  • With reference back to FIG. 1, milling system 10 provides a carriage 18, which sits near the ground and provides support. In one embodiment, carriage 18 sits approximately one-half inch above the ground. In the illustrated embodiment, wheels 20 are coupled to carriage 18. Carriage 18 provides pressure on cutting head 12.
  • Carriage 18 includes a flush side 26 that enables edge milling of paving material. For example, when milling system 10 is used to mill paving material that is located up against a vertical surface, milling system 10 is pushed along the vertical surface with the flush side 26 near the vertical surface. As such, the paving material may be milled within three to four inches of a vertical surface without touching the sides of milling system 10. The remaining portion of paving material may then be knocked off with a shovel. In contrast, traditional techniques required disassembly of a cold planer, which has caused instability in using the cold planer. The use of carriage 18 further allows for carriage 18 to potentially bump the vertical surface rather than cutting head 12, which would damage the vertical surface.
  • Carriage 18 is configured to be selectively adjusted to enable milling system 10 to be used in such a way as to cut on a particular angle or taper. Embodiments of the present invention embrace the ability to manually or hydraulically adjust the height of wheels 20. Milling system 10 maintains traction and support by allowing carriage 18 to follow the ground while cutting head 12 follows the set angle. In contrast, traction is lost in traditional techniques.
  • Milling system 10 may be manually or hydraulically tipped through the use of a cylinder, such as cylinder 28. For example, cylinder 28 is locked for safety reasons while moving milling system 10. Once milling system 10 is in use, cylinder 28, which allows cutting head 12 to raise and lower, may be manually or hydraulically actuated to allow cutting head 12 to move back and forth. In other words, cutting head 12 is allowed to float, which allows equal traction for the vehicle used. While milling, cutting head 12 is allowed to adjust to whatever angle it needs to in order to adjust and follow the contour of the ground. As such, multi-vector positioning of cutting head 12 is made possible.
  • Embodiments of the present invention embrace an improved method for entering the ground in order to mill paving material. In one embodiment, the vehicle is locked up in a home position and the arms of the vehicle are locked down with the tilt locked back. In this manner, nothing shakes or vibrates. Pressure is provided onto cutting head 12 by cylinder 28, and motor 16 engages cutting head 12 to allow for the milling to occur. As such, embodiments of the present invention may be dropped into any asphalt or paving material and pulverize the paving material into a fine gravel, similar to a road base.
  • Thus, a first cylinder, illustrated as cylinder 28, holds cutting head 12 down into the ground, pulling between carriage 18 and cutting head 12. A second cylinder controls the tilt that is enabled by milling system 10 and has the extra option of allowing cutting head 12 to float while in use to enable a more effective milling. In one embodiment, as illustrated in FIG. 4, system 10 pivots about pivot point 52. A third cylinder is utilized to shift the vehicle hook-up.
  • With reference back to FIG. 1, a bearing 32 faces outward and is protected from any debris, such as rocks, that may be spinning around. In one embodiment, a mound sets bearing 32 inside cutting head 12, but facing out to provide access to grease bearing 32. Alternatively, a user may pop bearing 32 out and remove it without disassembling any other portion of milling system 10. Alternatively, the cutting head 12 may be dropped out from system 10 and replaced with another cutting head. Thus, bearing 32 is placed inside the cutting head 12, facing out where it is still protected.
  • Also inside cutting head 12 is a well mount or a gear reduction planetary that is mounted to one side of the drum and to the frame. On the other side of the drum an outboard shaft is mounted with an outboard bearing support to help the cutting head ride. This increases the life span of the gearbox and virtually provides an unlimited life span of the gear reduction planetary.
  • In a further embodiment, a remote control system is utilized to provide control of the various cylinders in order to guide or steer milling system 10. In one embodiment, the remote control system utilizes a radio control system, such as an RF frequency, to provide the control. The system has an E-stop with a continuous transmission. If an operator gets far enough away from milling system 10, the system shuts down automatically.
  • In a further embodiment, milling system 10 includes an extended drive input. A shaft with a flex coupling that includes a couple of bearings that have two pilot tubes that bolt up to cutting head 12 and support the belt enable the engine to be flush on side 26 rather than having to overhang approximately 12 inches.
  • Embodiments in the present invention further embrace a large frame that holds still, just allowing the cutter head to move up and down. In other words, the vehicle frame is extended 10 feet or longer by the use of the carriage of the milling system. Furthermore, a breaker bar illustrated as breaker bar 24, is continuously located at ground level to hold the pavement down as it tries to lift up and is used to help break up the aggregate that has been milled.
  • Thus, as discussed herein, the embodiments of the present invention embrace systems and methods that provide increased stability, support and power in milling paving material. The present invention may be embodied in other specific forms without departing from its spirit of essential characteristics. The described embodiments are to be considered in all respects only al illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims (41)

1-42. (canceled)
43. A self-powered milling apparatus, said apparatus comprising:
a carriage configured to be selectively coupled to a vehicle;
a cutting head coupled to said carriage for use in milling paving material, wherein the cutting head in flush with a side of the carriage to provide precise edge milling; and
a milling system motor coupled to said carriage, said milling system motor dedicated to driving said cutting head.
44. The self powered milling apparatus of claim 43, further comprising an extended drive input coupled to the frame, wherein the extended drive input includes a shaft with a flex coupling that includes one or more pilot tubes that couple to the cutting head and support a belt to enable the motor to be flush with a side of the frame.
45. The self-powered milling apparatus of claim 43, wherein said vehicle coupler is adjustable to accommodate any type of motorized vehicle.
46. The self-powered milling apparatus of claim 43, wherein said cutting head comprises a mandrel.
47. The self-powered milling apparatus of claim 43, wherein said cutting head comprises a plurality of removable and interchangeable bits affixed thereto and arranged in an identified manner to optimize exposure to said paving material and pulverization of said paving material.
48. The self-powered milling apparatus of claim 47, wherein said plurality of bits each comprise a stem portion, a tip removably coupled to said stem portion, and a flat end at the base of said stem portion, said plurality of bits capable of being removably coupled and secured to said cutting head within a plurality of respective matching bit blocks arranged about said cutting head, said bit blocks comprising a channel through which said bits are secured within.
49. The self-powered milling apparatus of claim 48, wherein said plurality of bits further comprise a spring collet surrounding said stem portion, said spring collet securely holds said bits in place within said channel.
50. The self-powered milling apparatus of claim 48, wherein said tip further comprises an annular space that engages a lip formed on said shaft portion to removably couple said tip to said shaft.
51. The self-powered milling apparatus of claim 47, wherein said frame further comprises a bit access to provide quick top-level access to said bits and facilitate and provide for removal of said bits.
52. The self-powered milling apparatus of claim 51, wherein said bit access comprises a removable cover that exposes from 60 to 90 degrees of said cutting head when removed.
53. The self-powered milling apparatus of claim 43, wherein said motor allows from 0 to 10 inches of paving material to be milled in a single pass, thus significantly reducing overall milling time.
54. The self-powered milling apparatus of claim 43, wherein said motor powers said milling apparatus via a belt-driven system, said belt-driven system increases the efficiency of each milling job by transferring between 80 and 95 percent of said power to said cutting head, thus allowing a greater amount of said paving material to be milled in a single pass.
55. The self-powered milling apparatus of claim 54, wherein said belt-driven system comprises a belt and a transmission, said belt couples a shaft of said cutting head with said motor to cause said motor to rotate said shaft, which subsequently causes said cutting head to rotate about an axis of rotation.
56. The self-powered milling apparatus of claim 55, wherein said belt-driven system further comprises a belt tensioning system designed to maintain proper tensioning of said belt.
57. The self-powered milling apparatus of claim 56, wherein said belt tensioning system automatically adjusts the tension of said belt.
58. The self-powered milling apparatus of claim 57, wherein said tension is adjusted automatically in response to external forces encountered by said milling apparatus.
59. The self-powered milling apparatus of claim 43, further comprising a carriage coupled to said frame, said carriage comprising a portion located in close proximity to the ground to provide tracking means and support to said milling apparatus, said carriage also providing pressure to said cutting head.
60. The self-powered milling apparatus of claim 59, wherein said carriage comprises a flush side portion to allow edge milling of said paving material.
61. The self-powered milling apparatus of claim 59, wherein said carriage is adjustable to allow said cutting head and said milling apparatus to perform tapered milling and milling on an identified angle.
62. The self-powered milling apparatus of claim 43, further comprising means for tipping, wherein said milling apparatus is allowed to adjust to any necessary angle to properly track and follow the contour of the ground.
63. The self-powered milling apparatus of claim 62, wherein said means for tipping comprises a cylinder, said cylinder allowing said cutting head to move up and down, said cylinder also capable of being actuated to allow back and forth movement of said cutting head.
64. The self-powered milling apparatus of claim 62, wherein said means for tipping is selected from manual, mechanical, electromechanical, hydraulic, electric, and pneumatic actuation.
65. The self-powered milling apparatus of claim 43, wherein said milling apparatus comprises a pivoting point by which said cutting head rotates about.
66. The self-powered milling apparatus of claim 43, wherein said cutting head is coupled to said frame using a removable bearing, said bearing having a portion partially exposed to provide easy access for maintenance and removal purposes.
67. The self-powered milling apparatus of claim 43, wherein said cutting head comprises a gear reduction planetary mounted to said cutting head and said frame.
68. The self-powered milling apparatus of claim 43, further comprising a remote control system to provide steering and guiding control of said milling system.
69. The self-powered milling apparatus of claim 43, further comprising a first cylinder to hold said cutting head into the ground.
70. The self-powered milling apparatus of claim 43, further comprising a second cylinder to control any desired tipping and tilting of said milling apparatus.
71. The self-powered milling apparatus of claim 43, further comprising a third cylinder to shift said motorized vehicle hook-up.
72. The self-powered milling apparatus of claim 43, further comprising an extended drive input.
73. The self-powered milling apparatus of claim 43, wherein said frame is extended and stationary to allow said cutting head to just move up and down.
74. The self-powered milling apparatus of claim 43, further comprising a breaker bar to hold the unmilled portion of said paving material down to facilitate the milling operation and to help break up the milled paving material.
75. A method for milling paving material, said method comprising the steps of: obtaining a milling apparatus, said milling apparatus comprising:
a carriage configured to be selectively coupled to a vehicle;
a cutting head coupled to said carriage for use in milling paving material, wherein the cutting head in flush with a side of the carriage to provide precise edge milling;
a milling system motor coupled to said carriage, said milling system motor dedicated to driving said cutting head;
coupling said milling apparatus to a motorized vehicle;
utilizing said motorized vehicle to maneuver and position said milling apparatus; and
employing said motor of said milling apparatus to drive said cutting head to mill said paving material.
76. The method of claim 75, further comprising the step of adjusting said cutting head to conform to the contour of the ground.
77. The method of claim 75, further comprising the step of removably coupling a plurality of bits to said cutting head.
78. The method of claim 75, further comprising the step of actuating said cutting head via said motor using a belt-driven system, said belt-driven system comprising a belt tensioning system.
79. The method of claim 75, further comprising controlling said milling apparatus using a remote control system.
80. The method of claim 75, further comprising the step of accessing said cutting head from a top-level using a bit access.
81. The method of claim 75, further comprising the step of removably coupling one or more bits to said cutting head.
82. The method of claim 75, further comprising the step of allowing multi-vector positioning of said cutting head.
US11/564,710 2002-01-09 2006-11-29 Systems and Methods for Milling Paving Material with Increased Stability, Support, and Power Abandoned US20070116519A1 (en)

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US8556536B2 (en) 2009-01-02 2013-10-15 Heatwurx, Inc. Asphalt repair system and method
US8562247B2 (en) 2009-01-02 2013-10-22 Heatwurx, Inc. Asphalt repair system and method
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US9022686B2 (en) 2009-12-31 2015-05-05 Heatwurx, Inc. System and method for controlling an asphalt repair apparatus
US9416499B2 (en) 2009-12-31 2016-08-16 Heatwurx, Inc. System and method for sensing and managing pothole location and pothole characteristics
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US20210230819A1 (en) * 2020-01-28 2021-07-29 Caterpillar Paving Products Inc. Milling machine having pivot arms offset from engine output shaft
US11136732B2 (en) * 2020-01-28 2021-10-05 Caterpillar Paving Products Inc. Milling machine having pivot arms offset from engine output shaft
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US20030127905A1 (en) 2003-07-10

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