Roadway Reports
Delineation Integrity — markers and signs
Markers
Automated Raised Pavement Markers — June 30, 2007
Paul Sherrill, George Burkett, Duane A. Bennett, and Steven A. Velinsky, "Design and Analysis of an Automated Mechanical System for the Replacement of Raised Pavement Markers", UCD-ARR-07-06-30-02, 206 pp, June 30, 2007.
Click here for pdf version of this report: UCD-ARR-07-06-30-02.pdf
Abstract — Raised pavement markers are used to delineate roadways because they provide excellent visual, tactile, and auditory feedback to drivers. However, over time markers can become dull or detach from the road, which necessitates their replacement. New markers must be placed relative to the existing installation, and this has traditionally been done by hand while riding in a specially-equipped truck.
In order to improve cost efficiency and worker safety, this report presents an alternative method of marker replacement. The alternative is a machine designed to automate the replacement process. The ultimate product is described in general terms, but the main focus of this report is to describe the current prototype stage.
The device will be carried by some vehicle. It is designed to allow for marker placement while the vehicle is in motion. To accomplish this, the primary installation equipment is mounted to a linear slide. The installation equipment is stationary with the road while placing a new marker, yet the vehicle can continue moving forward. A laboratory prototype has been developed and fabricated using a conveyor belt to simulate the relative motion of the road. The prototype can place a marker while the conveyor is at any speed up to 0.9 m/s (2 mph). The next stage of development will be a vehicle-mounted unit for field testing, and most of the current prototype can be transplanted for that purpose.
Automated Raised Pavement Marker Machine (Conveyor System)
Sun, Z. Sonja, David Ashuckian, Greg Reimers, Kendrick Mar, Shular Fischer, and Andrew A. Frank, "Automated Raised Pavement Marker Machine (Conveyor System)", UCD-ARR-92-06-30-01, 126 pp, June, 1992.
Abstract — This report summarizes a project directed towards the development of an automated machine for placing raised pavement markers. The report includes the basic design criteria established in the project and the various concepts considered to fulfill these objectives. The report also contains the detailed design, construction, testing, and evaluation of the automated Raised Pavement Marker (RPM) Applicator (conveyor belt) System. This machine was designed to apply reflective and non-reflective raised pavement markers with bituminous adhesive from a vehicle traveling up to 10 MPH. The results of this project show that a machine can be manufactured which has the ability to apply raised pavement markers and marker adhesive from a moving vehicle while allowing the operator to remain within the protective confines of the vehicle cab. The automated raised pavement marker machine (RPMM) was able to apply markers with pseudo-bituminous adhesive at speeds up to 5 MPH, making standard marker patterns or placing a single marker. The feasilibity of an automated raised pavement marker machine was clearly demonstrated.
Marker Adhesive Processes for Botts' Dots — Final Report
Sun, Z. Sonja, Greg Reimers, Shular Fischer, and Andrew A. Frank, "An Investigation of New Marker Adhesive Processes for Botts' Dots", UCD-ARR-94-01-31-01, 113 pp, January, 1994.
Abstract — In past few years, research efforts have been made to automate the marker placement process in order to increase operator safety and minimize traffic hazards caused by the current manual process. Several automatic raised pavement marker machine (RPMM) prototypes have been developed and tested. The concept of automating the marker placement process was proven. However, the bulk adhesive melting method was found to be difficult and almost incompatible with the automation of marker placement. The handling of liquid adhesive is messy and often contaminates and malfunctions robotic components or the end-effector. Delivery of hot bitumin at ca. 204.4 degrees C (440 F) also creates safety problems and causes unnecessary wear of mechanical parts. Hot bitumen displensing system is prone to high maintenance and easy failure, the resulting start-stop process requires a long down time, therefore lowers productivity.
In order to increase reliability and maneuverability of the automatic RPMM, a research has been conducted at University of California, Davis under the contract with Caltrans. This research investigates new marker adhesive processes aimed at eliminating the on-road bitumen melting and handling. With the proposed marker adhesive processes, markers are pre-attached with the adhesive layer on the bottom during manufacturing, laid onto road by the automated RPMM, and the adhesive layer will be then locally processed (with or without heating) to adhere to the pavement. The investigations performed were grouped into two categories, i.e., localized heating approach using bituminous adhesive and new adhesive material approach. New adhesive process methods and materials were investigated in close cooperation with Caltrans laboratories as well as adhesive and marker manufacturers including Stimsonite, Crafco, Davidson, Hellerbond, and RISI.
Marker Adhesive Processes for Botts' Dots — Supplement to Final Report
Sun, Z.Sonja, Andrew A. Frank, Alfred F. Leatherman, and Ronald E. Varosh, "An Investigation of New Marker Adhesive Processes for Botts' Dots: Supplement to Final Report", UCD-ARR-95-03-31-01, 41 pp, March, 1995.
Abstract — This report documents the extended work on the project "An Investigation of New Marker Adhesive Processes for Botts' Dots." The previous research had revealed that the induction heating and pyrotechnic heating methods were promising alternatives to the existing bitumen marker adhesive process. The two methods were further investigated during the extension with an attempt at further improving heating rate and bond strength of bituminous adhesive.
The results from the extension work showed that the induction heating method is very close to the practical application for an automatic RPM machine. However, several areas, such as arcing and damage on the reflective surface, need to be resolved prior to integration of induction heating technology into the automatic RPM machine. Further study on both induction and pyrotechnic heating is strongly recommended. It is suggested that the further investigation and development will be carried out directly by the private sector such as Hellerbond, an induction heating company, and RISI, a pyrotechnic company.
Stencils
Automated Stencilling — Completion Report: Prefabricated Target Layer
Broverman, Ian, "Completion Report for the Automated Stencilling Project: Prefabricated Target Layer", UCD-ARR-93-12-17-01, 141 pp, December, 1993.
Abstract — This thesis describes the design and construction of an automated prefabricated target laying device to be used for the installation of aerial survey markings on the shoulders of motor vehicle lanes. The goal of this work has been to produce a mochine that operates on simple principles, could be installed on a maintenance vehicle, and would be easy to operate. In the design of the system, a structured design methodology was used, which broke the design process into several steps: developing functional specifications, strawman concepts, feasibility studies, systems and component specifications, prototyping, integration with support systems, and field testing.
The prototype system used targets made out of 110 pound card stock and Screenrite semigloss black ink. They were stored in a paper tray and the top sheet was separated with a two stage suction system. The targets were positioned with a pick and place manipulator, made from two air cylinders. They were pressed to the ground with an end effector plate that would allow for sloped shoulders. The targets were glued down with a mastic, which was dispensed from three snuffer valves. The mastic was pressurized with a ram-mount pump. The target and mastic prototype were tested with an environmental exposure test and a wind loading test. The overall system was actuated pneumatically, using air-actuated spring-return solenoids to control flow. The system was controlled with a Z-World brand control board, using digital logic.
Automated Stencilling — Completion Report: Premark Mechanized Stencil
Daniger, David, "Completion Report for the Automated Stencilling Project: Premark Mechanized Stencil", UCD-ARR-93-12-24-01, 120 pp, December, 1993.
Abstract — This thesis provides information on the development of a machine directed towards the mechanization of the control point target stenciling process for aerial photogrammetry used in highway surveying. The information starts with brief descriptions of both aerial photogrammetry and the current method of application. The initial strawman concept shown at this point is used as the basis for preliminary testing. The thesis continues with a list of target specifications, functional requirements and the results of the preliminary testing. From here a list of design requirements is created and the final system design is drafted. The concluding results of this thesis are the construction and testing of a prototype system. From the final prototype testing, it has been determined that the system developed herein has a commercial value and the potential for improving worker safety and productivity.
Automated Stencilling — Final Report: The Big Articulated Stenciling Robot
Phillip Wing, Bahram Ravani, Richard Blank, Jeff Hemenway, Richard McGrew, "The Big Articulated Stenciling Robot (BASR)", UCD-ARR-98-01-15-01, January 15, 1998. Final report of contract RTA-65X936.
This system is designed to paint markings on the roadway pavement. Click here for pdf version of this report: UCD_ARR_98_01_15_01.pdf
Automated Stencilling — Refinements of a Robotic System
Ravani, Bahram, "Refinements of a Robotic System for Stenciling of General Roadway Markings", UCD-ARR-00-09-30-01, 347 pp, September 30, 2000.
Click here for pdf version of this report: UCD_ARR_00_09_30_01.pdf
Abstract — The purpose of work was to refine and evaluate the feasibility of using a long reach robotic arm for use in roadway markings and stenciling operations. This was part of an effort to minimize the traffic exposure for the working crew.
The scope of work involved testing of the system and research into modifications that would be needed before using a long-reach robot arm developed for highway applications. It was determined that the long reach robotic arm required modifications due to the coupling effects of the dynamics and the end point accuracy required for proper edge definition in painting of roadway markings. Modifications were performed in the hydraulic system and in the control algorithm to improve the performance of the robot. The results were experimentally demonstrated with the robot without an end-effector closely following roadway markings. In addition, the paper design of a new end-effector was completed that used an innovative tilt mechanism for the painting gun.
Photogrammetry Target Project Premark Painting System
Sprott, Ken S., Phillip W. Wong, Walter Nederbragt, Robert Olshausen, and Bahram Ravani, "A Description of the Photogrammetry Target Project Premark Painting System", UCD-ARR-94-09-09-01, 120 pp, July, 1994.
Abstract — This report presents a description of a premark painting system developed at UC, Davis. The system is designed to paint photogrammetry premarks used in the aerial survey of roadways. Overall system descriptions are given for the premark painting system. A detailed description is given for each of the major subsystems and the support equipment. The proposed system operation is described. Recommendations for future uses of the system are made along with recommendations for development into a commercial product.
Striping
Vision-based Low Cost Field Demonstrable Paint Restriping Guidance System
David C. Slaughter, Nelson Smith, Chris Gliever, Garrett Jones, and Justin Schlottman, "Vision-based Low Cost Field Demonstrable Paint Restriping Guidance System", UCD-ARR-01-09-14-02, 55pp, February 2002.
Click here for report in pdf format: UCD_ARR_01_09_14_02.pdf
This report describes a developmental feasibility study for the automatic guidance of a lane restriping system to automatically apply paint on top of worn traffic lane boundary striping with a lateral tolerance of +/-13mm and a longitudinal tolerance of +/-102mm for dashed lane striping. This system would assist the California Department of Transportation in their effort to enhance safety, reduce worker stress, improve restriping efficiency, and reduce traffic flow impacts of striping maintenance. Machine vision recognition systems employing both hardware and software based neural network lane stripe recognition were evaluated. Preliminary results show potential for automatic machine vision location of worn traffic lane boundary striping, however additional study is needed to fully evaluate the accuracy of this system. A non-contact radar displacement sensor was found to be an acceptable alternative to a traditional ground-driven encoded wheel sensor for longitudinal control of dash length.
Mobility Management
Operation Management
Litter and Debris
Prototype Telerobotic System for Debris Vacuum Positioning
Click here for report in pdf format: UCD_ARR_00_09_14_01.pdf
Development of a Prototype Telerobotic System for Debris Vacuum Positioning
Andrew A. Porterfield, Wilderich A. White, Steven A Velinsky, UCD-ARR-00-09-14-01, 102 pp, September 14, 2000.
This report describes the development of a telerobotic system for debris vacuum positioning: a remotely controlled articulated vacuum nozzle that is design to permit an operator to collect litter while seated in a vehicle cab.
Pavement Integrity — crack sealing / pavement repair
Crack Sealing
Development and Testing of a Crack Sensing System for a Tethered Mobile Routing Robot
Matsumoto, Lisa S., "Development and Testing of a Crack Sensing System for a Tethered Mobile Routing Robot", UCD-ARR-97-02-10-01, 116 pp, February 1997.
Abstract — As the number of vehicles driving over a particular highway increases, the deterioration of that highway accelerates. Degrading highways require costly maintenance and increase exposure of highway workers to cars traveling at speeds of 100km/h (65 mph) or higher. For purposes of road crew safety, prolonging the life of the highway, more efficient maintenance operations, and cost reduction, the notion of automating the maintenance tasks was conceived.
Through the joint effort of the California Department of Transportation (Caltrans) and the University of California at Davis, the Advanced Highway Maintenance and Construction Technology (AHMCT) Center has looked into automating the crack sealing process. The Tethered Mobile Routing Robot (TMRR) is designed to locate, rout, and seal cracks, similar to the manual crack sealing operation currently performed by highway maintenance workers.
Crack detection is the most important operation in the overall control scheme of the TMRR. Routing and sealing pavement without the knowledge of the crack's location will make this robot destructive and inefficient. Therefore, the purpose of this thesis is to develop and test a crack detecting algorithm for the TMRR. Based on the results of the tests, the crack finding algorithm demonstrates and validates its practicality for locating a crack in asphalt and concrete pavements. An effective means for tracking cracks in pavement is made possible through the accuracy of the LaserVision and linear positioning systems coupled with the competence of the crack finding algorithm.
Development of a High Resolution Sensing System for Automated Crack Sealing Machinery
Krulewich, Debra A., and Steven A. Velinsky, "Development of a High Resolution Sensing System for Automated Crack Sealing Machinery", UCD-ARR-92-07-31-01, 115 pp, July, 1992.
Abstract — Current methods for highway maintenance are both labor and cost intensive. In particular, the sealing of cracks costs the State of California over $10 million annually. Furthermore, the highway maintenance workers are exposed to the dangers of moving traffic.
Currently, research is underway at the Mechanical Engineering Department of the University of California, Davis to design and develop a crack sealing machine that will sense, prepare, and seal cracks in pavement. By developing this machine, the goals are to minimize the exposure of workers to the dangers of traffic, considerably increase the speed of operation, and improve the quality and consistency of the resultant seal. Improving the quality of the seal will result in extended time between major road rehabilitation. Furthermore, increasing the operation speed will reduce highway congestion due to lane closure.
The purpose of this paper is to develop the Local Sensing System that will detect cracks in pavement surfaces for the automated crack sealing machine. The Local Sensing System will locate crack position and measure crack width to an accuracy such that the crack preparation, sealant application and shaping of the seal can be performed through machine automation. A literature search was performed, which led to the development of the Local Sensing System. Recommendations and conclusions were made based on extensive testing of system performance. Based on the tests which were performed, it was concluded that the Local Sensing System met all requirements which are necessary to achieve a proper seal.
Development of Transfer Tank Longitudinal Sealer
Duane A. Bennett, Steven A. Velinsky, "Development of the Transfer Tank Longitudinal Sealer", UCD-ARR-05-12-31-01, 68 pp, October 6, 2006.
The Advanced Highway Maintenance and Construction Technology Center has designed and build the next generation of a highly successful line of longitudinal crack sealing machines which Caltrans maintenance crews use statewide to maintain highway pavements. These machines have consistently produced dramatic cost savings combined with improved safety and seal quality. This new machine development focuses on further increasing seal production capabilities and worker safety. To accomplish this goal, the Transfer Tank Longitudinal Sealer (TTLS), would seek to create a continuous hot sealant supply for high production sealing operation by developing a hot sealant transfer from nurse kettles scheme. The TTLS system consists of two separate machines that were developed simultaneously. The application truck is a self-contained high production highway longitudinal crack sealing machine. The transfer trailer serves the role of nurse kettle by providing large amounts of hot sealant and high speed transfer capabilities to quickly resupply the application truck. The development of both machines has been completed and initial highway testing of these machines has been conducted in conjunction with Caltrans maintenance crews. TTLS field testing results have proven the functionally of the equipment, but slow kettle heating times is ultimately preventing full deployment of this equipment. TTLS application truck kettle replacement will be necessary before field deployment can be accomplished.
Operator Controlled Crack Sealing Machine — Development of Long Arm and Control Unit
Todd Baker, Brian Hemmerlin, Xin Feng, Duane Bennett, Steven Velinsky, "Development of the Operator Controlled Crack Sealing Machine — The Long Reach Arm and Control Unit", UCD-ARR-99-06-30-02, 202 pp, June 1999.
Click here for report in pdf format: UCD_ARR_99_06_30_02.pdf
This report presents work leading towards the development of the first prototype Operator Controlled Crack Sealing Machine (OCCSM). This has included component subsystems as well as numerous critical machine components. The most important aspects of this phase were the design and fabrication of the Telescopic Manipulator, the development of the controller, and the integration of the two systems.
Fabrication and Testing of an Automated Crack Sealing Machine
Velinsky, Steven A., "Fabrication and Testing of an Automated Crack Sealing Machine", SHRP-H-659, 446 pp, August, 1993.
Abstract — This document reports on the development of a machine aimed at the automated sealing of cracks and joints in highway pavement. This machine is comprised of two independent machine systems: one for longitudinal cracks and joints that exist at the edge of the lane (e.g., construction joints), and the other for general (random or transverse) cracks/joints that may extend across a lane. The development effort has included a detailed feasibility analysis, development of machine concept, design and development of first and second generation machine components, and component testing, culminating in a first generation integrated automated machine. The machine is discussed in detail in this document along with market and cost analyses. The developed machinery appears commercially viable based on its potential for improving personnel safety and productivity while concurrently improving the quality and uniformity of the resultant seal.
Fabrication and Testing of Maintenance Equipment Used For Pavement Surface Repairs: Automated Crack Sealing Machine: Operation & Maintenance Manual
Velinsky, Steven A., "Fabrication and Testing of Maintenance Equipment Used For Pavement Surface Repairs: Automated Crack Sealing Machine: Operation & Maintenance Manual", UCD-ARR-93-05-31-01, 442 pp, May, 1993.
Abstract — This document presents information essential to the proper operation and maintenance of the Automated Crack Sealing Machine (ACSM) which was developed under the SHRP H-107A project. The ACSM is relatively complex, and thus, this document is intended to provide potential users with adequate information for the operation and maintenance of the ACSM. The ACSM is comprised of two independent machine systems, one for longitudinal cracks and joints that exist at the edge of the lane (e.g., construction joints), and the other for general (random or transverse) cracks/joints that may extend across the roadway. This report discusses non operational considerations for the ACSM including transport to and from the work zone and storage of the machine, possible system configurations for both longitudinal and general crack sealing operations, instructions that are common to both systems, details related to the set-up, deployment, operation and shutdown of each system, and finally, maintenance procedures for the various machine components.
On-Line Control On An Industrial Robot For Crack Sealing Using Proximity Sensing
Kahrl, Phillip A., and Bahram Ravani, "On-Line Control On An Industrial Robot For Crack Sealing Using Proximity Sensing", UCD-ARR-92-12-01-01, 155 pp, December, 1992.
Abstract — Each year, the state of California alone spends approximately $10 million on the sealing and filling of pavement cracks in order to retain structural integrity of roadways and extend time between major rehabilitations. The associated costs are approximately $1800 per lane mile with 66% attributed to labor, 22% to equipment and 12% to materials.
Currently, research is underway at the University of California, Davis to design and build a prototype Automated Crack Sealing Machine (ACSM). The subsystems of the ACSM will detect cracks and guide process equipment over the cracks to rout, heat, clean and seal. For transverse cracking, the process equipment will be manipulated with an industrial robot arm mounted on the rear of the ACSM support vehicle.
The purpose of this thesis is to develop and test algorithms for crack-following with a robot manipulator using the relative proximity sensor and to expand upon these algorithms to incorpoate data from the machine vision sytem as well. The result will be a flexible and robust control algorithm that will incorporate all available data for control and will be able to function with failures or errors in the machine vision system and associated subsystems.
Pavement Crack Cleaning and Heating System for Automated Sealing Machinery
Jazbec, Willikam C., and Steven A. Velinsky, "A Pavement Crack Cleaning and Heating System for Automated Sealing Machinery", UCD-ARR-92-03-26-01, 118 pp, March 1992.
Abstract — Currently, research is underway at the Mechanical Engineering Department of the University of California, Davis to develop prototype automated machinery that will sense, prepare, and seal (or fill) cracks and joints on pavement. As part of this overall project, this research reports on the design, testing and implementation of an automated pavement surface preparation unit that best meets crack sealing project goals in terms of feasibility, effectiveness, and efficiency. Specifically, means to improve upon and automate current crack cleaning and heating techniques are presented.
First, a feasibility study and literature search was performed to examine practical means of automating methods of crack cleaning and heating. Since the automated crack sealing machine being developed is a possible prototype for future commercialization, a heating system that will allow for traveling speeds faster than walking was necessary.
To best determine the relative differences between convective and radiant heating and to develop a design tool that could help in evaluating the pavement heating performance of available commercial equipment, finite difference heat transfer models were constructed using basic principles of classical heat transfer and experimentally formed hypotheses from literature. Verification of the accuracy of the models was then proven through comparisions with other author's experimental data and through testing of a commercial heater. Simulations using the developed models were then run resulting in the choice to discard radiant heating as a viable heating alternative since the lengthy heater that proved necessary would be difficult to articulate through turns.
After tests were conducted, formal design constraints were assembled and trade-off issues concerning the system to be selected for the crack sealing project were presented. Among these, general overall project goals, mechanical compatibility with the concept vehicle, performance of the heater, ability to integrate, and debris removal procurement and compatibility were identified as the important issues for design. Formalized specifications based on these criteria were then developed for purchasing and vendors with possible products meeting these specifications were contacted. The advantages and disadvantages of the available equipment were then discussed. Finally, the cleaning and heating system components selected for procurement and integration with the automated crack sealing machine were chosen, followed by recommendations for commercialization.
Cranes
Simulation of Cranes Using a Boom Support Vehicle
George Burkett, John McDonald, and Steven Velinsky, "Simulation of Cranes Using a Boom Support Vehicle", formerly titled "Crane Dolly Suspension Study for Dynamic Weight Distribution", UCD-ARR-02-06-30-03, 203 pp, June 2002.
Click here for pdf version of this report: UCD_ARR_02_06_30_03.pdf
This report describes the simulation of cranes using a boom support vehicle, with emphasis on dynamic road loads.
Pavement Surface
Fabrication and Testing of Maintenance Equipment Used For Pavement Surface Repairs: Final Report: Phase II - Part II
Velinsky, Steven A., "Fabrication and Testing of Maintenance Equipment Used For Pavement Surface Repairs: Final Report: Phase II - Part II", UCD-ARR-92-07-31-01, 90 pp, July, 1992.
