Note: Descriptions are shown in the official language in which they were submitted.
CA 02609763 2013-12-06
TITLE
INSPECTION OF ASPHALT DURING MANUFACTURING
BACKGROUND OF THE INVENTION
[0002] The present
invention relates generally to an apparatus for detecting
taggants and, in particular, to a system for monitoring the ratio of mixtures
formed from two or more parts.
[0003] Two-part adhesives, mixed at the time of use, are well known and are
used throughout many industries to bond components together. Such adhesives
exhibit a faster dry time, longer shelf life, and stronger adhesive
characteristics
than typical one part adhesives. One requirement of two-part adhesives is to
keep the mixture of the parts at the correct ratio to obtain a reaction that
will
correctly form the adhesive. It often is difficult to monitor the mixing ratio
in a
production setting where the adhesive parts are being mixed and dispensed as
needed on a manufacturing line.
[0004] A system and a method for monitoring the proportional volume of
constituents provided to an adhesive mixture are shown in the U.S. Patent No.
5,831,151. Ferromagnetic tagging material particles are suspended in one of
the two constituent parts used in the mixture. A first tagging material sensor
is
utilized to monitor the flow of the tagged part to the mixing area and a
second
tagging material sensor is utilized to monitor the mixed parts as they flow to
a
dispenser nozzle. A monitor calculates the volumetric ratio of the two
1
CA 02609763 2007-11-06
,
constituents based upon the concentration of the tagging material and a
warning is given when the calculated ratio exceeds predetermined limits.
=
Although the preferred embodiment of the present invention is discussed in
terms
=
of a two component mixture, this system can be used with more than two
component mixtures.
SUMMARY OF THE PRESENT INVENTION
(40051 The present invention concerns a ferrous magnetic taggant system for
monitoring a ratio of at least two components being combined in a mixture. The
system comprises: a first sensor for generating a first sense signal
representing
= an amount of ferrous taggant particles per unit volume of a first
component
flowing adjacent the first sensor; a second sensor for generating a second
sense
- signal representing an amount of ferrous taggant particles per
unit volume of a
. mixture of the first component and a ferrous taggant particle
free second
component flowing adjacent the second sensor; and a control means
= responsive to the first and second sense signals for calculating a ratio
of the
. i
; volumes of the first and second components n the mixture. The
first and
= second sensors have a generally tubular body with a central passage
through
which material flows, an inner sense coil extending about a circumference of
the
; passage, a drive coil extending about a circumference of the
inner sense coil, and
an outer sense coil extending about a circumference of the drive coil. The
: inner and outer sense coils each generate a coil signal in
response to the
= presence of the ferrous taggant particles. The system includes an
instrumentation amplifier connected to the inner and outer sense coils for
= t=
generating a sense signal represonting a difference between the coil signals,
the
sense signal being one of the first and second sense signals. The control
; means is connected to an information processing device and
generates an
= output signal representing the ratio of the volumes to the information
processing
device.
= 190061
The system includes a master for calibrating the first and second
=
. sensors, which each have a passage through which material flows.
The
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master has a body with a smaller diameter end sized to fit into the passages
and a larger diameter end sized for use as a handle. The body further having
a core formed from a filler material and a predetermined percentage of the
ferrous taggant particles.
=
= (0007] The present invention also relates to a method of
monitoring a -=
volume ratio of at least two components mixed together comprising the steps
of:
.
providing a first sensor for generating a first sense signal representing an
amount
I of
ferrous taggant particles per unit volume of a first component flowing into a
,
mixing device; providing a second sensor generating a second sense signal
representing an amount of ferrous taggant particles per unit volume of a
mixture
of the first component and a ferrous taggant particle free second component
= I
flowing in the mixing device; and providing control means for calculating a
ratio of
the volumes of the first and second components in the mixture. The method
further includes a step of operating the control means to compare a value of
L
the first sense signal with a value of the second sense generated after a !
predetermined delay representing a time required for a portion of the first
=
: component to travel from the first sensor to the second sensor.
= DESCRIPTION OF THE DRAWING
(0000] The
above, as well as other advantages of the present invention, will
= . become readily apparent to those skilled in the art from the
following detailed
description of a preferred embodiment when considered in the light of the
accompanying drawings in which:
[0009]
Fig. 1 is a schematic view of a magnetic taggant system in
accordance with the present invention;
tpoio]
Fig. 2 is cross sectional view of a sensor used in the system shown in Fig.
1;
.=
(0011] Fig. 3 is a circuit schematic for the sensor shown in Fig.
2;
(00123
Fig. 4 is a wave form diagram of the sampling of the current signal
generated by the circuit shown in Fig. 3;
[0013] Fig. 5 is the wave form of Fig. 4 with the DC offset
removed;
= =
= 7422
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CA 02609763 2007-11-06
tom Fig. 6 is a circuit schematic of the drive amplifier shown
in Fig. 3; =
1003.5] Fig. 7 is a cross sectional view of a master for the system
shown in Fig. 1;
[p016] Fig. 8a is a schematic view of a magnetic taggant system
according to
the present invention for mixing asphalt;
0017] Fig. 8b is a perspective view of a portion of the system
shown in Fig. 8a;
[018] Fig. 9 is a view of a checking system according to the
present invention for
verifying the asphalt mixture forming the road;
=
($191 Fig. 10 is a schematic view of a paint mixing system;
= [0020] Fig. 11 is a schematic view of a magnetic taggant
system for controlling
= the mixing of the paint in the system shown in Fig. 10;
= 00211 Fig. 12 is a top and side view of a temperature
sensor of the present
; invention;
[p0221 Fig. 13 illustrates different sensor types for the preferred
method of the
! present invention;
[130233 Figs. 14-16 illustrate a magnetic flux tagging sensor used
in conjunction
with distance sensor;
=
00241 Fig. 17 illustrates an MFT sensor viewing the volume below
the roads
surface;
00251 Fig. 18 illustrates a typical laboratory specimen;
(0261 Fig. 19 illustrates a preferred embodiment of the MFT
TESTING
; EQUIPMENT of the present invention;
(i)027] Fig. 20 illustrates a preferred method of batch testing and
inspection of
=
the present invention;
.= 6)028] Fig. 21 illustrates placing a sample of final asphalt
mixture inside of a
container;
[0291 Fig. 22 illustrates Magnetic Flux tagging sensors placed on
a finished
=
surface and used to monitor the asphalt below the surface; =
[D030] Figs. 23-27 illustrate laboratory test results;
= 0033.1
Fig. 28 illustrates an actual laboratory equipment arrangement;
.
(032] Figure 29 illustrates a flow chart providing a description
of testing;
.=
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CA 02609763 2013-12-06
[0033] Fig. 30 illustrates a Sensor configuration at the liquid asphalt
manufacturing plant;
[0034] Fig. 31 illustrates a two tier hopper with optional reducers for
thorough
test of flowing material and with heated feed screw and reducer for more
controlled flow of asphalt;
[0035] Fig. 32 illustrates attachments for permanent mounting on various
mixing
equipment. A free flow attachment and controlled feed screw. Other constant
flow devices such as piston loaded cylinders could replace the feed screw;
[0036] Fig. 33 illustrates attachment for truck which could incorporate any of
the
sensors previously described;
[0037] Fig. 34 illustrates a square hopper for easy dumping at a construction
site.
Portable mix ratio tester;
[0038] Fig. 35 illustrates an optional piston delivery system with similar
results
as feed screw;
[0039] Fig. 36 illustrates a batch mixer and sensor;
[0040] Fig. 37 illustrates a manufactured asphalt flow diagram; and
[0041] Fig. 38 illustrates a portable compactor for testing small samples.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0043] The present invention concerns a system for monitoring the mixing of
two or more constituents to form a mixture in a desired ratio of the
components.
Although a two-part adhesive, a component "A" and a component "B", is used
as an example in the following description of the invention, other mixtures of
three or more components that either normally include or can have added
thereto a metallic component that affects a magnetic field can be used with
the
system according to the present invention. A system 10 according to the
present
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r.
P.
invention is shown in Fig. 1 as monitoring a two component mixing and
dispensing apparatus 11. The apparatus 11 includes a component "A" source
12 through which flows the component "A" in the direction of an arrow 13.
= The apparatus 11 also includes a component "B" source 14 through which
flows the component "B" in the direction of an arrow 15. The sources 12 and 14
are connected to a mixing tube 16 wherein the two components mix and through
which the mixture flows In a direction of an arrow 17 to a dispensing nozzle
a 18. Although not shown, a conventional mixing element is positioned
inside
the mixing tube 16.
=
00441
The system 10 includes a control means such as an electronic
'
instrument 20 connected to two sensors referred to as sensor "A" 21 and sensor
"B" 22. The sensor "B" 22 is mounted in such a manner that the component "B",
carrying a constant known amount of ferrous taggant particles per unit volume,
= flows through the center of the sensor "B" 22. Thus, the sensor "B" 22
determines that a desired amount of taggant particles is flowing. The =
component "A" has no ferrous particles. When the two components are mixed in
#
the Mixing tube 16, the mixture of "A" + "B" results and flows through the
center
. of
the sensor "A" 21 to the dispenser nozzle 18. The instrument 20 can be
connected to one or more information processing devices such as a personal
computer PC 19, a programmable logic controller PLC 23 and a diagnostic
. ;
display 24, These devices provide information as to the Operation of the
=
: apparatus 11 and can use the information generated by the instrument
20 In a
feedback control system to automatically adjust the flow of the "A" and "B"
= components from the sources 12 and 14 respectively.
[00451
The passage of the ferrous taggant particles is detected by the sensors
21 and 22 which each send a sensor signal to the electronic instrument 20.
After
demodulation of the sensor signal from the coil "B", a linear output signal
proportional to the amount of ferrous taggant particles is generated by the
= electronic instrument 20. A delay representing the time required for the
portion of
=
the component "6" previously measured with the sensor "B" 22 to move within
=
the sensor "A" 21 is required. This delay allows the taggant component "B" to
1742?
6
=
CA 02609763 2007-11-06
1
. ;
e
:
i
,
Imix with the non-taggant component "A" and move within the sensor "A" 21.
This
I
i
will assure testing of the adhesive before and after it is mixed_ The change
in ' It
electrical response has been determined to be linear with respect to amount of
:
,
taggant. This simplifies the ratio equations. Using a deviation from a desired
,
=
ratio will further eliminate errors due to different mixtures of
the component "B". i
= If for instance the mixture has been reduced by ten percent, the readings
of both
. 1
the sensor "A" 21 and the sensor "B" 22 will be reduced proportionally. Thus,
the mixture will still have the correct ratio. The absolute reading of the
sensor
1
. "B" 22 also is monitored to assure the mixture is held within a certain
percent. ,
;
10461 EQUATIONS:
,
,
,
:
E . 047] EQUATION OF THE LINE: %TAGGANT = M x X + B
. [0048] M: slope of a line. This is adjusted with each system.
. .
,
( 049] X: amplitude of the sine wave response from the A/D
converter. This ,
. ,
. .
.
.
could also be the phase.
.
,
'
. = ri)050] B: offset. This is affected by the external environment.
This effect is t.
cancelled when the coil is positioned on a production system.
.
= [1051] R = %A / %B
,
10521 RATIO (DEVIATION FROM NOMINAL) =100(((RAR-1).5)-1)
. r 053] The constant ".5" is dependent on the desired mix ratio_ A
".5" constant
. 1 indicates two parts of the component "A" for every one part of
the taggant "B". .
i The above formula is specific to a 2:1 mixture and would be
varied according to ,
I the mixture ratio be measured.
.
C'054] One method for making the small taggant particles is
practiced by 3M, St. '
i
. _ Paul, Minnesota. Small plastic balls 40 (Fig. 2) are plated with
a ferrous material.
I
This plating is noticed by an alternating magnetic field. Two effects occur:
1) the
flux lines of the magnetic field are altered proportionally to the amount of
the balls , !
,
40; and 2) small eddy currents are created within each ball 40 wherein these
eddy currents oppose the initial magnetic field and affect the return response
of =
the sense windings of the sensors 21, 22. Another Source Of taggant material
is
the Coat-it company.
'
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,
,
CA 02609763 2007-11-06
00551 The sensors "A" 21 and "B" 22 are made as similar as
possible to
= cancel out variations due to the environment. By mathematically ratioing
the
effect to the magnetic field, the two coils cancel many common environment
' changes.
=
[00563 The present technology uses the small plated balls 40.
Other taggant
material may be possible. Any material affecting the magnetic field has the
= . = potential to be used.
[0057) There is shown in Fig. 2 a sensor 26 that is suitable for
use as the
. sensors 21 and 22. The sensor 26 is tubular in cross section
with a hollow
= =
interior passage 26a through which the material carrying the balls 40 flows.
Extending about a circumference of the interior passage 26a is an inner sense
. coil 27. Extending about a circumference of the inner sense
coil 27 is a drive
=
= coil 32. Extending about a circumference of the drive coil 32 is an outer
sense
coil 28.
= E00581 The drive coil 32 creates an AC magnetic field. The two
sense windings
=
= 27 and 28 are designed so signals from the inner sense coil 27 cancel
signals
from the outer sense coil 28 when only air is present in the passage 26a. When
= material enters the passage 26a, the Inner sense coil 27 receives a
larger
signal than the outer sense coil 28. The difference between the signals is
detectable through electronics. The effect of the plated balls 40 is
proportional to
: the amount of the balls within the sensor 26_ The material used
to hold the three
windings 27, 28, 32 in place can be one of Delrin, ceramic, nonmagnetic
= .= stainless, and titanium. Typically, three bobbins are
made, one for each coil, and
= ! tightly fit together.
(OS] As an alternative, the sensor windings 27 and 28 can be
replaced by other =
=
types of sensors such as Hall Effect devices. =
(0060] The electronic circuit connected to the sensor coil 26 is
shown in
Fig. 3. A microprocessor controlled AC sine wave oscillator 25 generates a
=
sine wave signal to a current drive amplifier 33 connected to the drive coil
. 32. The microprocessor can be a separate unit (not shown) or
can be a
microprocessor in one of the information processing devices 19, 23, 24. The
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CA 02609763 2007-11-06
1 oscillator also provides synchronized square wave signals of
frequencies "f"
and "nf'. The current drive 26 will ensure constant current on the drive side.
= =
Changes due to the taggant 40 will occur on the sense side. The two sense
' windings 27 and 28 are situated in such a manner that in air
there is no signal, F
When the metallic particles 40 are positioned inside of the coil 26, the inner
sense coil 27 is more affected then the outer sense coil 28. The coils 27, 28
are
; connected to inputs of an instrumentation amplifier 29 that
measures the
difference between the two sense winding signals. A difference signal
generated
=
by the amplifier 29 is filtered by a filter 30, AG coupled and directed to an
analog
= to digital converter 31. The signal from the oscillator 25 having the
frequency "nr,
typically four times a frequency of the signal "f, is applied to the converter
31.
= 0061) Similar circuitry 34 is provided for a current
signal from the oscillator 33.
=
The current should be very stable. However, even small changes in the current
=
due to power supply variation can cause variation in the return
information. These =
effects are cancelled by normalizing the sense signal from the filter 30 with
a
return. The "4? frequency signal which is synchronized at four times the sine
wave frequency will provide the AID conversion start pulses. Sampling is
every 90 degrees to obtain four points for each sine wave as shown in Fig. 4
as
points "p1" through "p4", Two AID conversions, one fora current signal "lain"
and one for the sense signal "SENSE", sample at precisely the same time.
The four points are used to remove any DC information and accurately calculate
- the amplitude and the phase of the "kin" signal and the sense
sine waves. The
; sense signal is divided by the current "kin". This compensates
for any deviation
due to the power supply. This normalized amplitude and phase result in an
electronic number proportional to the percent of taggant 40 (metallic
particles) in
the coil 26. It has been found that the percent of taggant 40 inside the coil
26
varies linearly. Now, the percent taggant can be calculated based on an
absolute reading. The amount of taggant used and called 100% was empirically
determined, This provided the starting point. To obtain a 50% mixture, 50% of
the
ferrous particles are mixed. Any percentage can be mixed and predicted.
However, the less the taggant, the smaller the electronic signal.
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CA 02609763 2007-11-06
=
=
=
=
(0062.1 Although four points per sine wave are shown in Fig. 4, the
number of
. sampling points can be increased for additional harmonic
information.
Furthermore, other techniques such as quadrature demodulation could be used.
=
Also, the phase of the signal can be used instead of the amplitude.
0063] Extreme care is involved to keep the integrity of the sense
signal. This
includes the coils 27, 28 being designed differentially. They only return
signals =
that are information. They are zeroed in air. They return signals proportional
to
the amount of the taggant filler 40. The two sensor coils "A" and "B" 21, 22
are
! designed physically the same. The two sensor coils 21, 22 are
positioned as
close as possible to each other so they both encounter the same changes in
;
environment without being effected by the magnetic field of the other coil,
= (p064) Two twisted pair of wires route the signal from
the drive and from the
difference of the two senses. Each twisted pair has its own shield. The two
wires
=
=
; will see the same external events such as noise coupling etc.
These two wires :
are fed into the instrument amplifier 20 subtracting the outer sense from the
=
inner sense and eliminating any common mode noise. The electronics are
, mounted on a board with a printed circuit that routes the signals
differentially. =
. Special ground plane and shielding is used.
Wes] Special care is taken to remove electrical noise. Analog
filters remove a
=
, considerable amount of noise. A notch filter is designed to
remove the 60 Hz
noise. High pass and low pass filters remove the aliasing type noises and
=
t
unwanted frequency noise. Software filters further remove noise which has been
= ,-
= picked up on the circuit board or at the last stage before the ND
conversion.
These Weis Hrtl optimized for a pticular fiequenc.-y_
E006611 A special 60 Hz filter algorithm has been developed to
remove all 60 Hz
= noise. By selecting a frequency multiple of 60 Hz, it is possible to
completely
remove any 60 Hz related noise. 120 Hz noise is a common problem when
considering high gain circuits. First, select a frequency at "n" times the
test
frequency. Example: 16 x 60 e 960. Gather four points (90 degrees apart) for
=
. = =
16 sine waves. Note these 16 sine waves correspond to 60 Hz since the
= =
frequency was defined as 16 x 60 = 960 Hz, Subtract the first point from the
third
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CA 02609763 2007-11-06
point and the second point from the fourth for each of the sixteen 960 Hz sine
waves. Now there are two points for each sine wave. This has removed all of
the
DC and there are sixteen pairs of points. By averaging the first of these
points
and then averaging the second for each of the sixteen 960 Hz sine waves, the
60 ;
= Hz noise is removed. Also improved is the variance by 1/sqrt(n) by
averaging. Now
the two points can be converted to the amplitude and phase of the signal.
=
E0061] Using the above techniques, the DC offset is removed from
each sine
wave. Averaging sixteen waveforms has the effect of reducing the variance due
to
random noise byl/sqrt (16). Because the frequency was chosen to be a multiple
of 60 Hz, also removed is the effect of both 60 Hz and 120 Hz. In Europe, a
=
multiple of 50 Hz will be chosen.=
.
[pose) The waveform of sixteen sine waves shown in Fig. 5 has the
DC
. offset removed and includes both 60 Hz and 60 x 16 960 Hz. As
previously
=
explained, four points are sampled for each 960 Hz waveform. Then
the first, = N
=
=
= . ; second, third and fourth points are averaged. This
averaging will remove the
60 Hz, and the 120 Hz, the 240 Hz.... until Nyquest sampling theory of less
than
= two samples/cycle is reached. At this point other filters are removing
the noise.
(0069] Automatic determination of offset: in the past the
procedure would be to
= . remove offsets caused by change in environments by
manually adjusting the
= offset. In the system according to the present invention, the operator
turns off the
= component "A" supply and the same material will flow through both coils
21, 22.
. The percent taggant should read the same for both coils. A
simple calibrate
offset button will remove any of the offsets. No adjustments by the operator
are '
required.
L0070] Spacial and volumetric filter: In the past filters were
all related to the
frequency. The frequency has no meaning to the operator. This new algorithm
=
, will set up the filters based on the acceptable missing
adhesive. For example, if
one inch of missing adhesive is acceptable then a spatial filter will
determine
== software and hardware filtering. If the operator wishes to
monitor the volume
flow, a volumetric filter will relate the flow rate to the frequency sampling
rate
etc. No knowledge of sampling theories etc, will be required.
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CA 02609763 2007-11-06
,
,
:
100711 The sampling will be related to volume flow of material
or the rate of
dispensing; ultimately to how much missing adhesive is allowable.
=
00721 Monitoring absolute coil reading: Special algorithms will
study :
' multiple frequencies and use these frequencies to eliminate the
effect of ..
. temperature. This may require fft's and regression equations to
ignore
temperature variation.
.
. 16073] By monitoring the voltage on the output of the amplifier
33, see Fig. 6, it
l
can be determined if clipping is being approached. Harmonic analysis can be
. used to determine if clipping is beginning. This can be used to
detect changes .
. . in a malfunctioning drive.
,
b074] By adding analog switches, the sense windings can be
turned on and =
,
oft These switches can be added to apply voltages to the sense windings and
'
. . detect changes in coil windings, broken wires and missing
cables, These
: voltages will be used to determine if the secondary coils are
correctly working. .
:
,
1:00751 When switching on/off the drive, extreme transients can
occur
. .
. . resulting in wasted time before accurate data can be taken. In
the past,
;
.
the turn on/off circuitry was synchronized with the oscillator frequency. The
.
; actual energy causing transients occur at non-related times
based on delays in
i
' circuitry, coil resistance, capacitance and inductance. A
programmable delay will .
:
.
. .
.
, .
. . switch the power on or off at the minimum transient time. This
will be determined .
.
.
,
. by analyses of the transients (fft's, wavelets). Removing the
delay optimizes ;
,
the data gathering. As shown in Fig. 3, a "D" flip flop 35 is clocked by the
"1" .
,
. frequency signal from the oscillator 25.
;
r0076) In the past, complicated masters were made using two
ferrite adjustable ,
cores. They required very stable ceramic material which was very breakable. it
. was sensitive with the absolute position. With the above
design, the passage ;
. - 26a can be filled with a master made with material similar to
that used for the ,
adhesive. In Fig. 7, there is shown a master 36 having a body with a larger
,
diameter end 37 and a smaller diameter end 38. A core 39 extends from end
. .
' to end along a longitudinal axis of the body of the master 36.
The body of the .
master 36 can be made from a suitable material such as Delrin. The core 39 is
, .
. .
,
:
:.=
1 ;
:
, 17422
12
.
1
:
,
CA 02609763 2007-11-06
formed of a predetermined percentage of the taggant material 40 and a filler
= material,
0077] The smaller diameter portion 38 is sized to fit into the
passage 26a of the
sensor 26 being used as the sensor 22 for the component "8" material. The
=
. larger diameter portion 37 can be used as a handle and the
smaller diameter ,
=
portion 38 is inserted up to the adjacent end of the larger diameter portion
37
= which functions as a stop. The larger diameter portion 37 is sized to fit
into the
passage 26a of the sensor 26 being used as the sensor 21 for the mixture.
The smaller diameter portion 38 can be used as a handle and the larger
diameter
' portion 37 is inserted up to the adjacent end of the smaller
diameter portion 38
' which functions as an indicator. Typically, the diameters of the
passages 26a
are sized proportionally to the percentage of the component "B" in the
mixture.
(0078] The magnetic taggant system according to the present
invention can be
used to achieve the proper mixing of the constituents of paving and building
.
.
materials such as asphalt, cement and concrete. For example, Fig. 8a is a
.
schematic view of a magnetic taggant system 50 according to the present
;
invention for mixing asphalt. A taggant material is supplied from a first
source 51
and a material "A" is supplied from a second source 52 to a first mixer 52.
The
. combined materials from the first mixer 52 flow through a first
conduit 53 to a =
second mixer 54 where a material "El" is added from a third source 55. The
=
materials are mixed to form asphalt which flows from the second mixer 54
; through a second conduit 56. A first sensor 57 is provided at the
first conduit 53
. - and a second sensor 58 is provided at the second conduit 56. The
sensors 57
i and 58 are operated in a manner similar to the sensors 21 and 22
of Fig. Ito
generate signals representing the mixture ratio of the materials "A" and 13".
The
=
computer system 19 can respond to the signals to generate an indication of the
=
mixture ratio and to control the flow of the taggant material and the "A" and
"B"
=
materials.
[00791 Fig. 8b is a perspective view of a portion of the system
shown in Fig, 8a. The
asphalt flowing from the second mixer 54 can be used to pave a road 59, for
example.
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CA 02609763 2007-11-06
r,
(0080) Fig. 9 is a view of a checking system 60 according to the
present
: invention for verifying the asphalt mixture forming the road
59. The system 60
includes a computer 61, typically a portable computer, connected to one or
more :
sensors 62 that detect the taggant material. The system 80 can be used to spot
check the road 59 or be mounted on a moving vehicle (not shown) to scan the
road. In this manner, the asphalt mixture can be verified and the depth of the
asphalt can be determined.
00911 The magnetic taggant system according to the present
invention can
- be used to achieve the proper mixing of the components required
to produce a
desired paint color. Fig. 10 is a schematic view of a system 70 for mixing
paint
having, for example, three sources of paint color constituents. A red paint
color
source 71, a green paint color source 72 and a blue paint color source 73
have outlets connected to flow controls Vr, Vg and Vb respectively. A
taggant material source 74 is connected to an inlet of a first mixer 75 having
. .
an outlet connected to a first conduit 76. The first conduit 76 is connected
to
an inlet of a second mixer 77 having an outlet connected to a second conduit
78. The second conduit 78 is connected to an inlet of a third mixer 79 having
an
outlet connected to a dispenser 80.
t0082] The paint sources 71, 72 and 73 are connected to
respective inlets of the
' first mixer 75 by valves SRI, SG1 and SB1 respectively. The
paint sources 71, 72
and 73 are connected to respective inlets of the second mixer 77 by valves
=
SR2, 502 and 582 respectively. The paint sources 71, 72 and 73 are connected
=
to respective inlets of the third mixer 79 by valves 5R3, SG3 and S83
respectively. The dispenser 80 dispenses the mixed color paint by, for
example,
spraying the paint on a car body 81 or filling a paint can 82.
=
=
(0083] Fig. 11 is a schematic view of a magnetic taggant system
90 for controlling =
=
=
the paint mixing in the system shown in Fig. 10. A first sensor 83 is
provided at =
the first conduit 76, a second sensor 84 is provided at the second conduit 78
and a third sensor 85 is provided at the third conduit 80. The sensors 83, 84
and
85 generate signals to a computer system 86. Based upon the signals from the
sensors 83, 84 and 85 and information about the desired color mix, the
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CA 02609763 2007-11-06
=
=
computer system 86 controls the operation of a plurality of devices 87 in the
= system 70 which includes the flow controls Vr, Vg and Vb for regulating
the
= flow rate and the valves SRI, SG1, SB1, SR2, 802, SB2, SR3, 803 and SB3
for turning on and off the flow.
= (0084]
Additional technologies are explained below as related to
Ferromagnetic = =
=
Tagging (FMT). Magnetic Flux Tagging (MFT) is a more generalized I
=
=
description of this technology. FMT is a subset of MFT when ferrite powders
are used.
=
(0085] I. LAB EQUIPMENT ¨ for measuring mix ratios:
r0086] 1. Equipment will monitor the mixing of multiple
components. A
tagged material will be added to component "A". As this chemical is mixed with
other materials the mix ratio will be calculated and displayed.
(0087] 2. A second component "B" could also be mixed and
monitored.
,
=
Components "A" and "B" will have unique mix ratios. Components "A" and
"B" can be mixed and its ratio can be calculated. As an example if component
=
= "A" = 80% and component "Er = 40 % a 1:1 mixture should result in a
reading
=
of 60%.
[0088] 3. Equipment will have a method to normalize any
materials
=
= ; through mathematics. One possibility will be a linear
prediction by measuring
=
the mix ratio of two known ratios with known percentages of tagged material
and =
then calculating a gain and offset to linear predict the mix ratio of other
mixtures.
(00891 4. Equipment will have the ability to monitor a time
constant of the
separation of the magnetically tagged material and then predict the time
constant of separation of various other materials. As an example, if the mass
=
and specific gravity is known for the tagged material various non-metallic
=
materials with known mass and specific gravity should have similar time
constants for separation.
=
(00901 5. Various other laboratory aids will be included. The
ability to
download (or store) data at various times; for example, to monitor the
separation
= = ; of ferrite over time. Another possibility is to monitor a
chemical; as air is
17422
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CA 02609763 2007-11-06
= removed the materials mixture will change (example - more tagged material
per
unit volume).
[00911 II. MONITORING OF MIXING ¨ with chemicals which already have
a
percent of metal present:
;
[0092] Mixtures may naturally have metallic powders or metallic
powders
are added because they provide a desired chemical effect. This will provide
the
=
= same magnetic effect as the tagged material. Additional mixing of these
materials can be monitored.
[0093] III. 100% INSPECTION - of one component materials:
[0094] 1. One component materials such as a one component adhesive
can
= be 100% inspected. One component is manufactured by mixing several
=
= ; components. Each mixture (or critical mixtures) can be
monitored. After each
= mixture is monitored an average value and standard deviation will
describe the
' content of the new material shipped. The customer who dispenses
this material
'
will also monitor the dispensing to ensure the mixture has not changed.
(0095] 2. The addition of thixitrope (suspension stabilizer) could
also be added in '
a known amount to allow the tagged material to separate at a known time. This
= '
would be detected by the FMT technology notifying the dispensing equipment the
= shelf life has been exceeded avoiding dispensing out of spec adhesives.
=
= (00961
IV. PHASE INFORMATION: .=
=
[00971 By adding a two materials such as a ferrite and aluminum
adds phase =
=
information.
= 0098] This may allow unique footprint for the new
mixture_
00993 V. IN LINE TAGGING:
.
=
rimi] Add a tagging mechanical mixer to mix the tagged powder with
one of the
;
two chemicals to be mixed. This would simplify retrofitting to existing
systems
=
; and would not require the chemical manufacturer to add the tagged
chemical.
(002] VI. PORTABLE OR LIGHT INDUSTRIAL OR HOBBIST EQUIPMENT:
[0031 This technology can be easily adopted for portable, light
industrial and
=t= hobbyist use. Low cost electronics is presently available, The design
could
=
= be minimized to a cost effective way to monitor mix ratios.
=
=
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CA 02609763 2007-11-06
[004] VII. ADD FERRITE - (or other magnetic powder) to monitor the
flow
rate of fluids (example, flow rate of hydraulic fluid):
E 0051 1. Add hard ferrite (or any powder which can be magnetized)
to monitor
flow with non-contact sensor. In previous papers we discussed detection of
flow
rate by magnetizing a group of particles then detecting them at a known
distance
from the magnetization source allowing us to determine flow rate.
=
=
[6067 2. Magnetize the powder as it passes. Use a sensor placed at
a .
;
known distance. Perhaps a differential coil. Record the time between
magnetizing and sensor detection. If the tube is round the volume rate will be
pi ;
x r2 x distance/delta time.
[007] 3, By adding two sensors it may provide a more accurate
measurement.
Magnetize with a slow sine wave varying frequency. Then use the sensor to
measure the phase. This will be the delta time required for volume
calculations.
=
(0081 Monitoring the mix ratio of asphalt has been problematical,
resulting in
; major expenses when constructing roads parking lots etc. A new
technology
mixes tagged materials into the asphalt during the manufacturing process
allowing
= Magnetic Flux Tagging, MET equipment to accurately inspect the mix ratio.
As the
' tagged material is mixed and other components are added the
percent volume of r
tagged material is reduced. Using MFT sensors we can monitor these changes
, which accurately represent the mix ratio.
(0091 Various sensors have been developed which provide inspection at
all
stages of the asphalt manufacturing. In the laboratory we 100% inspect the
batch
mixing of liquid asphalt and various other components, stones, stone chips and
sand as they are added. This provides us with reference information useful
during the manufacturing process. Tagging allows us to 100% inspect the batch
= manufacturing. We can continue to examine the asphalt as it is dispensed
on the
roads. The finished roads can be studied for mix ratio quality with
nondestructive
test sensors. The same non-destructive sensors can be used on older roads to
study the change of mix ratios as the concentration of stones in the asphalt
began
, to change their position.
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c
17
CA 02609763 2007-11-06
f.:
i
= s
,
. i.,
= (610]
Presently there is no simple technology to monitor the mix ratio
of asphalt. 1.
.
.
= Often, weeks or months after a road is installed the road must be torn
out and
.
. i
=!
replaced. The present technology requires removing samples of the road as the
.
,
; asphalt is poured at preset distance increments. These samples
are sent to the ' ,t
department of transportation for evaluation. The evaluation is a lengthy
process <,
, further complicated by the enormous amount of construction
during the busy
,
= . = i summer months. Various test perform at the department of
transportation ;
. determine whether the quality of the road is within
specification. By adding the ;
.
i
= 7
Magnetic Flux Tagging Technology all steps of the manufacturing, laboratory
.
.
i
. development, asphalt manufacturing, road construction and
nondestructive testing
r,
1
. of finished roads. The roads profile and historical data can
now be accumulated for , 1
.
t
=
=
. . preventative maintenance and traceability.
i
. 1
-
= 011] With reference to Figure 12, the sensor of the
present invention is there
.
i
=
shown and is defined as follows. .
,
r
. (0121 SENSOR: A sensor is composed of a drive and sense winding. The
drive
, winding generates an AC magnetic field. Tagged material such as
ferrite powder or
various metal powders are mixed with one of the components before mixing.
i
i
' . Various sensors will be discussed. The encircling sensor has a foot
print slightly , i=
' larger then the volume within its cylinder. If additional
material is mixed within this
,
volume the percentage of tagged material is reduced. The reduction of material
= !
' = i affects the mix ratio. If the sizes of particles are small then
the mix ratio varies
linearly with the sensors response. Large components such as stones have a
= i
similar effect by replacing tagged material with non-tagged voids.
Other non- .
,
. .
' tagged voids are created when air is locked into this same
volume. Other = .
.
:
=
. : sensors will monitor the mix ratio by being placed on top of
the tagged asphalt or .
. tagged material under test. A different type sensor can be
placed within the = .
: material and monitors the material around it. Alternate
techniques such as using Hall
= , Effect sensors to monitor the field are also available. By
adding a temperature
:
.
: sensor variations in information caused by temperature variation
can be . .
=
,
.
.
= -
: compensated for.
liD131 Magnetic Flux Tagging equipment for mixing of asphalt
'
i
.
,
. . 17422
,
!
=
18
:
.
_
= .
i
.
CA 02609763 2007-11-06
0141 1. Magnetic Flux Tagging laboratory equipment which
provides an
accurate method to ensure the mix ratio of asphalt is accurately mixed,
[015] 2. Magnetic Flux batch mixing equipment which ensures the batch
mixture is
correctly mixed for production. 100% inspection, control limits etc.
0161 3. Magnetic Flux Tagging for periodic testing of batch
mixture.
(0111 4. Magnetic Flux Tagging with portable equipment to
periodic inspect as
material is dispensed on roads etc.
=
(018) 5. Magnetic Flux tagging for monitoring the finished
asphalt after in use with =
a sensor that can be positioned on top of the asphalt.
(919] 6. Magnetic Flux tagging which ensures the mixing of polymers
with liquid
asphalt is accurately mixed. This can also be used for subsequent mixing
= operations.
ION The following description refers to Figure 13, Sketches 1-3 and
Figures
14-22:
(021.] 1. A sensor encircles the material and determines if the
material within the
: sensor is properly mixed. SEE SKETCH #1 of Figure 13.
= (0221 2. A sensor positioned on the material looks into the
material and =
determines if the various components of the mixture are properly mixed. SEE
SKETCH #3 of Figure 13.
0233 3. A sensor which can be placed inside the material to determine
if the
material around the sensor is properly mixed. SEE SKETCH #2 of Figure 13.
0)24] 4. A temperature sensor can be added to any of the above
magnetic flux
: tagging sensors to provide temperature compensation information
when
= monitoring asphalt at elevated temperature. SEE SKETCH #1, 2, 3 of Figure
13.
025] 5. By adding a tagged material to the liquid asphalt (binder) we
can
monitor each additional component as it is mixed. The sensor responds to the
; magnetic field proportionally to the amount of tagged material
within its footprint.
= z This varies linearly with the mix ratio when the binder +
sand + tagged powder
are mixed. Also changes caused by the addition of larger items such as stones,
stones chips effectively replace the tagged powder with nonmetallic material
which
appears as void to the magnetic field and react differently the tagged
material.
17422
19
=
CA 02609763 2007-11-06
i
T
. 1
t
.
f-
=
,
,
Within the foot print less tagged material is present. This reduction in the
i.
;
percentage of tagged material per unit volume is detected.
t
i
.=
- r 26] 6. Another method is to accurately volumetrically
measure each
:
,.
component, add a tagged material then batch mix. The final volume will provide
a
= percent value for the mbctures content which represents the quality of
the mixture. Any
- = deviation from this number indicates the material within the
footprint is off ratio. Only the
:
correct mixture of sand+ binder tagged material + stones + stone chips will
provide a i
,
,
=
. unique number.
;
. 1 271 7. Control limits can be placed on the displayed results
to signal the operator
,
. the mix ratio is out of specification.
[ 28] 8. Distance sensor #1, #2, #3: These three sensors
measure the 1
distance above the road the Magnetic Flux Sensor is. An MFT instrument
. f
,
calculates the volume between the sensor and the surface. This volume is
. subtracted from the volume of the foot print below the MFT
sensor_ This sensor is
.
.
,
,
= optimized for looking at fields below the sensor. See Figure 14.
" rD2g1 9. With reference to Figures 14-15, a distance sensor is
positioned in i
center MFT sensor to calculate the distance to the road surface, volume of
air, .
= rl 301 etc.
i
;
10. Spacers are positioned with the MFT sensor providing a constant
i distance to the road surface. The volume of air below the
sensor can be .
1
=
.
i
' calibrated out. See Figure 16.
..
. [ 31] 11. MFT sensors view the volume below the roads surface.
The air ,
i space volume can be calculated and subtracted from the total
volume of the MFT i
. .
,
!
. : sensors foot print. As we analyze the road we know the mix
ratio of 100% binder +
)
! sand + tagged material_ The large stones and stone chips
replace the tagged
.
. i
! material with voids which are effectively spaces without tagged
material. These
.
,
,
I
i voids reduce the mix ratio in a direct relation of the percent
total volume. A
;
!
i stone of lec's placed into a footprint of 10 cc's will reduce
the MFT displayed
, value to 90%. See Figure 17.
,
i
,
-
1
,
,
t 7422
20
.
,
.
1
CA 02609763 2007-11-06
,
= ,
(0321 12. Various sensors such as ultrasonic, laser sensors
can be used
with moving vehicles for continuous testing of a road. Many other measuring
.
.=
transducers are also available.
..
.
.
. t0331 13. The distance information can be used to adjust the
drive current of the
,
=
primary drive coil which creates the magnetic field we are
studying. Also =
= changing the gains of the return signal will improve the quality of the
signals.
= .
.
.
0341 14. Wearing of road due to compacting of the materials
used is also
i
i detectable through monitoring changes in the percentage of MFT
per unit volume
: of the foot print.
,i [035] 15. With reference to Figure 18, Sketch #4, LABORATORY
.
i=
'i
' SPECIMEN: Laboratory specimens are manufactured in laboratories
by mixing
. : liquid asphalt with stones, sand, other minerals and tagged
material. They are :
' 155mm in diameter by 155mm high. They are shaped as large
pucks. All
. laboratory testing is performed through these specimens. By
tagging these .
.
.
. .
.
.=
. specimens various mix ratio information can be immediately
realized. These same =
=
. .
,
,
=
specimens can be further utilized to calibrate equipment used to
100% monitor the :
. : manufacturing of asphalt for final product inspectiOn.
i
.
.
,
. t0361 With reference to Figures 19, Sketch #5-8, a preferred
embodiment of the
,
. MFT TESTING EQUIPMENT of the present invention is there shown,
where:
=
.
=
Op371 SKETCH #5: Binder + sand + ferrite create a specimen which
reads 100% =
i . with MFT.
1,0381 SKETCH #6: Adding stones reduces the percentage of tagged
material
! : within the foot print.
6339] SKETCH #7, #8: Off ratio or incorrect mixtures display off
ratio values.
:
1040] 1. A typical asphalt mixture is a combination of sands,
stones, stone chips,
liquid asphalt and occasionally polymers are mixed with the liquid asphalt
(binder). i
' ! SEE SKETCH #6.
6041] 2. By mixing various sands and binders we can establish a
reference =
,
=
, material. By mixing a tagged material such as ferrite we can
use the Magnetic i
=
i Flux Tagging to monitor the mixing process. One method is to
add a tagged
,
.
material to one of the components and monitor now it changes after it is mixed
with .
,
;
.
.
;
.
!
, .
!
17422
, = 1 21
, i.
CA 0 2 6 0 9 7 6 3 2 0 0 7 - 11 - 0 6
. each additional component. Another method is to accurately
calculate the
õ.
volume of each component then mix with a known amount of tagged material and
: calculate the expected percent. For instance it is known that 2%
volume of ferrite
= will cause the MFT system to display 100%. If we take a known volume of
various materials to be mixed and add 2% of the total volume of ferrite our
equipment displays100%.
= E
=
(0421 3. Two masters can be manufactured by adding 2% tagged
material to
master "A" (sand + binder + tagged material) the total volume and then add 1%
of
= the total volume to second master "B". After thoroughly mixing both
masters
master A would read 100% while master B will read 50%. These two masters
can be used to calibrate the electronics. These two masters will be used to
determine the gain and offset necessary to calibrate an accurate reading in
the
Magnetic Flux Tagging system.
[e43] 4. Once calibrated the laboratory equipment can monitor various
mixtures. The variation of the display output will provide information on the
=
= volumetric mix ratio and the percent volume of the stones and stone chips
has
been added. When an incorrect mix ratio or volume of stone is detected the
= control limit will notify the operator the mixture is off ratio or the
stones are not
= mixed. Sketch #6 is accurately mixed, Sketch #7 and #8 are inaccurately
mixed.
[0443 5. A temperature sensor provides information to correct the
readings at
elevated temperatures. Normal batch mixing will occur at temperatures over 100
- degrees C. SEE Figure 13, SKETCH #1, #2, #3.
=
(045] 6. Analyzing of the material while compacting before and after
provides an =
accurate change of concentrated material. Air voids are replaced with tagged
material.
[046] 7. Height sensors can be used to calculate the total
compression of a
=
specimen when compacted. The total volume of compacted stone + tagged
. materials represents the total concentration of the mixture. The
concentration of
material within the sensors footprint monitors the mixture as it is compacted_
An
out of mix ratio specimen will react differently then correctly mixed asphalt.
1 7422
22
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=
CA 02609763 2007-11-06
(9471 8. MFT provides accurate concentration information by
dividing the
percentage mix ratio by the volume of the sensors footprint. Studying the
= , compacting qualities of a mixture is important for road
construction.
=
= (0481 9. MET will monitor the relation of compacting
force vs. change in
=
concentration useful in the construction of roads.
[049] 10. Measurements of the compacting force, change in overall
height and
= change in percent mix ratio per foot prints volume are all related to the
final
; asphalt products specification.
1650] 11. The non-compacted mix ratio can be used as a reference for
the batch
manufacturing process inspection
051] BATCH TESTING EQUIPMENT, 100% INSPECTION AND PERIODIC
INSPECTION:
=
052] With reference to Figure 20, a preferred method of batch testing and
= inspection of the present invention is there shown.
(4531 The binder + tagged powder are mixed. Sensor A monitors the
mixing
=
ensuring a constant mix ratio. The concentrated tagged binder will
be mixed with .
! the binder when passing through static mixer #1, The mix ratio from
sensors B/A is
100% inspected. Alternately a sensor F can determine when mixer #1 is
thoroughly mixed. Polymers or other additives can be mixed with static mixer
#2
= and monitored with sensor C. The ratio of sensor C/B is the mix ratio of
polymer
to binder. This is 100% inspected. The liquid asphalt or binder is typically
== manufactured at an oil refinery then shipped to the batch mixer where
the dry
=
= ; mixtures are mixed with the binder. The sensor D inspects
the incoming mixture for
; consistency' and mix ratio content Pre-measured volumes of
various mineral
components such as sand, stone chips are added to the batch mixer. During
. mixing the sensor E help determine when the batch mixture is
ready. Alternatively
material can be pumped through an encircling sensor and returned to the multi
ton
batch mixer (not shown). When the mixing is complete the final mixture can be
monitored for consistency and mix ratio by passing a continuously flowing
final
mixture through sensor F. The material is then transported to a construction
site
i for instillation. Additional testing can be performed in the
laboratory by utilizing
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CA 02609763 2007-11-06
WT. laboratory equipment. Another technique for periodic testing of the final
.=
= batch material involves removing a sample of the final mixture and using
. specially designed canister with encircling coil to evaluate the
sample of
material. It may require pre-compacting the material to a known value to
ensure
the consistency is the same from periodic test to test.
= [054]
POLYMER MIXING TEST EQUIPMENT: For high quality asphalt the =
binder is sometimes mixed with polymers. Typically a static mixer is provided
at
=
=
=
; the liquid asphalt manufacturer. By tagging either the polymer or
liquid asphalt
the mix ratio can be 100% inspected. Ensuring the more expensive polymer mix
is
accurately mixed.
.
= 0551
Polymer or other additives can accurately be added to the binder through =
, static mixer #2.
=
0563 TAGGING THE LIQUID ASPHALT: One example, liquid asphalt (binder)
can be tagged by mixing the tagged material with a known amount of binder
using
a batch mixer. The addition of two sensors A and B will ensure the final
binder is
=; properly tagged.
= 057] TAGGING BY VOLUMETRIC CALCULATION OF BATCH MIXER: If we
add tagged material as a percentage of the final mixture we can study the
mixture
=
=
with sensor E and then 100% inspect the material with sensors A and F as it is
=; dispensed. The average MET value and standard deviation represent the
quality
=
, of the mixture.
058] PERIODIC ROAD TEST: With reference to Figure 21, placing a
sample of
; final asphalt mixture inside of a container as shown and pre-
compacting as
=
determined with laboratory testing the sensor will monitor the mix ratio under
a
known condition. The compacting can be a manual or automatically applied.
i
(9591 SENSORS INSIDE THE MIXTURE: Provide mix ratio information as the
material is mixed. SENSOR E.
= - 060] ABOVE SURFACE SENSORS FOR REVIEWING THE FINISHED
PRODUCT: With reference to Figure 22, Magnetic Flux tagging sensors can now
I
t
; be placed
on a finished surface and used to monitor the asphalt below the :
surface. A periodic test gathers information for preventative maintenance. As
the
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74
. I
CA 02609763 2007-11-06
=
heavy loads alter the concentration of material the information will be
gathered
and used to prevent failures. A finished road or parking lot can be
nondestructively tested by positioning a sensor on the surface and monitoring
the
material below the surface.
(061] ASPHALT SPECIMEN TESTING
[062] Our laboratory testing demonstrates the value of using
Magnetic Flux
Tagging of the present invention for inspection of asphalt specimens. By Using
this technology the operator will immediately know if the specimen under test
is
' properly mixed without destroying the specimen. A profile of the
specimens mix
ratio is immediately available without laboriously melting and separating the
components to obtain the volumes of various components, stones, sand etc.
Plastic and elastic characteristics can be viewed in real time as the specimen
is
= I compressed. The position of the off ratio can aid in
understanding failures_
[463] We have developed a method for manufacturing temporary specimens
which for purpose of these laboratory experiments allows us to accurately
, calculate the volume and mix ratios. By using gelatin and marbles
we can
accurately and quickly test the various mix ratios of specimens. The use of
marbles allows us to accurately measure the volume 4/31rr3, and use the result
to
" determine the accuracy of the mix ratios. Various gelatin
specimens will be
, demonstrated.
=
= 0641 We are also interested in working with asphalt
manufacturers in adapting
i our sensor to the actual manufacturing process_ The encircling
sensor we =
' presently use can be used for 100% inspection with the final
mixture as it is
=
loaded into trucks and transported to the construction site. The addition of
=
! tagged material will also allow us to analyze below the surface
of a finished road.
We use an above surface sensor which monitors the tagged material below the
surface monitoring any changes in the mix ratio, without destroying the road.
The profile can be used to monitor changes in the road and to help in
preventative maintenance.
(Q65] Figures 22-28 illustrate a preferred method and test results
for asphalt
= testing specifically.
= 17422
CA 02609763 2007-11-06
66/ Laboratory testing demonstrates the value of using Magnetic
Flux Tagging
of the present invention for inspection of asphalt specimens. By using this
technology the operator will immediately know if the specimen under test is
properly mixed without destroying the specimen. A profile of the specimens mix
ratio is immediately available without laboriously melting and separating the
.
4
components to obtain the volumes of various components, stones, sand etc.
Plastic and elastic characteristics can be viewed in real time as the specimen
is
compressed. The position of the off ratio can aid in understanding failures.
ti/671 In a preferred embodiment, a method for manufacturing temporary
specimens has been developed for the purpose of these laboratory experiments
allows us to accurately calculate the volume and mix ratios. By using gelatin
and
marbles we can accurately and quickly test the various mix ratios of
specimens.
The use of marbles allows us to accurately measure the volume 4/3m3, and use
;
the result to determine the accuracy of the mix ratios. Various gelatin
specimens
will be demonstrated.
[068) The method may also be adapted for use of a sensor in the
actual .
, .
manufacturing process. The encircling sensor presently used can be used for
100% inspection with the final mixture as it is loaded into trucks and
transported
to the construction site. The addition of tagged material will also allow us
to
analyze below the surface of a finished road. An above surface sensor may be
Used to monitor the tagged material below the surface monitoring any changes
in
the mix ratio, without destroying the road. The profile can be used to monitor
changes in the road and to help in preventative maintenance.
e6e) With reference specifically to Figure 23, Laboratory Test #1
results are ;
;
illustrated. The two masters are used to calibrate the sensor which varies
linearly
with the amount of tagged material. As stones sand etc. replaces the tagged
,=
asphalt the percentage varies linearly with the amount of asphalt replaced.
The '
yellow profile results from filling a specimen with 1" diameter marbles and
the
100% tagged asphalt. This represents the base line of the mixed marbles and
' asphalt.
;
17422
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CA 02609763 2007-11-06
=
=
070) In order to verify in our laboratory a gelatin was used in
place of the liquid
= asphalt. This enabled the technician to quickly reproduce the specimens
with
various mix ratios. The same results are expected when mixed with the liquid
asphalt. In this instance, marbles are used in place of stones to more easily
and
;
' accurately calculate their volume, 4/3Trr3.
= 10723 BASELINE: Figure 24 illustrates the master filled with 1"
marbles will be . I
used as for comparing the various specimens.
= [072] With reference to Figure 25, the actual variation within the
1" marble
master specimen can be amplified to further study how the mix ratio varies
within
: the specimen. Note: This is an amplified profile; the full scale
covers about 4%
=
total variation of the mix ratio.
= 10731 With reference to Figure 26, three specimens have
been manufactured by
= adding different percentages of stone. The specimens are made of five
sections.
. The red profile has five sections of equal number of marbles, two
sizes. The
= slight dip can be accounted for by the spacing between the marbles which
are
separated with 100% tagged material. The blue profile has only one section
With
marbles. The dip at approximately 6" is caused by this section of marbles. The
yellow profile has two sections with reduced marble count. At 4" 15% of the
marbles are removed, at 5* 26% of the marbles are removed. Again we see an
; increase in mix ratio as the tagged material replaces the marbles.
At 6" the
marbles are returned to their original count. Ihe profile returns to its
original
percentage before the edge affect occurs.
With reference to Figure 27, the specimen was filled with marbles of equal
size then filled with 100% tagged liquid asphalt. The slight ripple at the top
indicates slight variations in the mixture at these positions.
16751 Figure 28 illustrates an actual laboratory equipment arrangement.
In this
example, the jar is filled with 1" diameter marbles, each marbles volume is
4/3m3= .52cubic inches each marble will require lcublc inch of space, .48
cubic
inches of empty space will be filled with 100% tagged material. The ratio of
, tagged material is .48/1.00=48%. The actual displayed values
varied from 49%
to 52%.
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27
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CA 02609763 2007-11-06
I
:
076] We have accurately demonstrated the use of magnetic Flux
Tagging when
=
=
=
manufacturing specimens in the laboratory. We can adopt this
technology to ;
. =
=
=
= 100% inspect the manufacturing of asphalt by using a similar sensors to
monitor
the finished asphalt as it is dispensed into the trucks for shipment to a
, .
construction site. We have additional sensors which can be used above the
! . roads surface to obtain the horizontal profile of the finished
road mix ratio. The
;
=
use of marbles and gelatin have aided in the laboratory experiment. Repeating
this test with stones, aggregate liquid asphalt will substantiate these
results.
. , Magnetic Flux Tagging of the present invention monitors the
mixing of liquid
= asphalt with polymers then monitors the amount of liquid asphalt replaced
by
stone + sand + aggregate mixtures. The profile of laboratory test specimens,
manufactured asphalt and finished roads will all benefit with 100% inspection
=
using Magnetic Flux Tagging as described above.
077] With reference to Figures 29-38, a preferred embodiment of
the present
'
invention is there shown and illustrates a method and apparatus for the
inspection of asphalt during the manufacturing process. This describes the
= particular requirements Of asphalt manufacturing but can be extended to
various
other manufacturing processes such as cement, concrete and other similar
manufacturing processes of mixtures,
(rn) Occasionally liquid asphalt is mixed with polymer. If
liquid asphalt is by =
=
. itself or mixed with polymer it is referred to as the binder.
Asphalt is the
combination of binder + stones + sand + aggregate +etc.
0791 1. Sensors developed for monitoring the mix ratio of
asphalt. Made up of
:
a sinusoidal driven magnetic field, A detection sensor which monitors changes
In
flux as the flux changes in proportion to the percent tagged material. The
tagged =
material which varies in proportion to the volumetric percentage of the
mixtures
that is tagged. Sensors can be encircling, above surface or submergible.
Temperature compensation will allow the operation of the sensor above 200
degrees Centigrade, typical temperatures of asphalt manufacturing.
(1080] 2. Figure 30: Sensors specifically designed to monitor the
mixing of liquid
; asphalt with polymer, and for verification of the amount of
tagged material. = =
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28
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.
=
CA 02609763 2007-11-06
1
: Nan 3. Figure 30: Sensors and process used at the liquid
asphalt
manufacturing plant to mix liquid asphalt and polymer and to ensure the proper
amounts of polymer and tagged material is added and properly mixed.
se821 4. Figures 36 and 37: An incoming sensor located at the asphalt
manufacturing plant to ensure the correct binder mixture is received.
V0831 5. Figure 32: Sensor and mounting hardware which 100%
inspects the
manufactured asphalt as it leaves the mixer.
6. Figure 31 and 34: A portable test system which monitors the quality of
the mix ratio a batch mixer or asphalt manufacturer is making. Figure 34- A
portable feedscrew is illustrated for testing quality of a batch mixer Tagged
=
.
=
particles are either previously mixed with the liquid asphalt or added
separately =
= directly in the mixer with sand, binder, stones, etc. The heated
feedscrew
;
=
=
= f provides a constant flow of hot asphalt mixtures of stone
+ sand + etc. The
=
sensor monitors the mix ratio of the batch material. This will test the
quality of the
mixture. Various other methods of feeding a constant flow of asphalt through
the
=
= sensor are possible. The feed screw assembly can be directly attached to
the
=
output spout of the giant batch mixer. Potentially, this method may be used
to = =
= .
test asphalt as it is dispensed on the road with the addition of a
gas or electric =
, generator and an added dispensing track. Truck fill the hopper
at the construction= =
site. The material is 100% inspected as it is transferred to the road
dispensing
= ; hopper. FHWA could test batch mixers by adding .2% by
total volume and
; monitor how accurately is mixed ¨perhaps before accepting a
dnlivery. The .
; addition of a generator enables portable usage.
085] 7. Figure 30 and 37: A process of 100% inspection by the
addition of
. tagged material binder. Tagged material can be added at the
onset to the =
manufactured liquid asphalt (the binder) and be evaluated at every step in the
manufacturing process of asphalt. Figure 31 -Any mixing process which occurs
after the tagged material is added can be 100% inspected. At the liquid
asphalt
. plant Sensor "A" will 100% inspect the liquid asphalt after it
is mixed with tagged =
=
material ensuring it is properly mixed and record the actual
percentage. Sensor ,
= "B" 100% inspects the final mixture of polymer and liquid asphalt. If
polymer is
17422
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29
= .
=
CA 02609763 2007-11-06
=
=
not added sensor "B"= sensor '`A" The ratio of NB is the
manufacturing plant. =
= The absolute value of "B" will be recorded and sent to the asphalt
manufacturer.
=
The standard deviations of the sensor "A" and sensor "B" must be within
specification for accurately mixed asphalt. Figure 37- The batch mixer is
filled
with stones, sand, aggregate, etc. (the components of asphalt). Sensor "A"
monitors the incoming binder and verifies it matches the mixture shipped form
=
=
the liquid asphalt (binder) manufacturer. Sensor "C" notifies the operator the
asphalt is mixed with a submerged sensor or by pumping the asphalt through an
encircling coil. Sensor "B" 100% monitors the finished asphalt mixture as ti
is
dispensed into A truck for delivery to the construction site. The standard
deviation
= = of sensor "C" determines if the mixture is accurately mixed.
The average value is
the actual mixture. By dividing C/A the actual mix ratio is calculated. This
ratio
- can be mathematically determined by knowing the volume of
materials.
(01116) 8. A process of adding the tagged material directly to the
mixer. It can
: also be added to a sub mixture for example testing the mixing of
sand and
Manufactured sand before it is mixed with the stone aggregate. Any mixing
process which Occurs after the tagged material is added can be 100% inspected.
r 087] 9. Sensors mounted within a hopper or inside a transporting
truck for
monitoring segregation. The occurrence of segregation will be detected,
notifying
the operator of the out of specification material before it is dispensed on
the road.
Mal 10. Figure 31 and 34: Portable mix ratio equipment to 100%
inspect or
partially inspect by sampling the delivered asphalt to a construction site as
it is .
dumped into a road compacting hopper.
=
.=
[0139] 11. Figure 31 and 34: Portable mix ratio equipment mounted on a
truck or
trailer which can load asphalt directly from the mixer. Move the asphalt out
of the
loading dock. Then perform mix ratio testing.
tOgO1 12. Figure 38: Various other known test can also be
performed at this ,
. . time for example compacting could also be tested by removing a
sample,
compacting to a known force and comparing to a known compacted mix ratio. In
this illustration, a portable asphalt specimen is monitored. Asphalt is loaded
into
the mold until the desired weight is reached. After loading, a Force is
applied to
=
=
= 17422
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CA 02609763 2007-11-06
=
; the asphalt through the piston type compactor. The material will
be compacted to
a known force and compared to a similar test performed in the laboratory. The
force is applied through a lever arm or other motorized mechanism, It is a
i comparative test to quickly determine if the sample is within
specification.
0911 13. Figure 32: Sensor and mechanical assembly, attached to the
mixer
testing the free falling asphalt as it exits the mixer.
0921 14. Figure 32: Sensor and mechanical assembly, attached to
the mixer
=
testing the free falling asphalt as it exits the mixer and uses a reducer to
provide
an evenly flowing dispensed material.
=
1993] 15. Figure 32: Mechanical assembly, attached to the mixer. A feed
screw
or various techniques to provide a constant flow of material through the
sensor
for accurate mix ratio monitoring,
=
(694J 16. Figure 30: Mechanical assembly performing the same test
as 13...15.
Designed to attach on top of a truck or various other asphalt transporting
=
; vehicles,
=
rpm 17. Figure 31 and 34: The portable equipment as described
above for = =
= =
? testing the quality of the mixture manufactured. The portable
tester can be used
; to verify proper mixture before it is loaded onto the
transporting truck. The
= portable tester verifies mixing equipment is correctly mixing. The same
equipment can be used by organizations such as the Federal Highway
Association to inspect the mixing equipment.
E696] 18. Figure 37: Submerged sensors located inside of the mixer for
monitoring the mixture as it is mixed. Other option is to pump a small sample
of
, asphalt through an encircling sensor that will feed back into the
mixer. This will
detect when the mixing is completed. It can be used to notify the operator
mixing
= is complete.
;
(0971 19. Figure 31 and 34: The test equipment will be built on a
trailer allowing
T us to quickly download a sample of the asphalt from the giant
batch mixers, After
the asphalt is loaded the vehicle can be transferred outside of the loading
dock
s where analyses of the mix ratio can be performed. This will avoid
interfering with
normal function of the asphalt facility. Asphalt will be dumped into the
portable
=
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31
=
CA 02609763 2007-11-06
! hopper. We will first study the affect of free falling asphalt through a
sensor. A
= second hopper is positioned below the first hopper. This will collect the
asphalt
=
as it flows out of the first hopper. A feed screw will be positioned below the
= second hopper providing the ability to reload the hopper #1 with asphalt
for
;
= ' further examination by recycling the same asphalt. The feed
screw will also be
=
designed with its own inspection equipment which will again analyze the mix
ratio
. . as the material is pumped out of hopper #2. The feed screw
will provide a
t
= constant flow for more accurate analyses of mix ratios. The feed screw
will
= provide a means for removing the test material from the portable test
trailer. This
is a test of the mix ratio with a controlled flow of asphalt and will provide
a
'
== solution for monitoring the mix ratio if the free flowing material is
not acceptable.
[PM 20. Figure 35 illustrates an optional piston delivery system with
similar
results as the feedscrew described above. The cylinder is preferably filled
with
asphalt. The piston pushed the asphalt out at a constant speed for monitoring
the
mix ratio. Optionally, the material will freely flow through the piston.
; =
[099] A portable construction vehicle will allow us to perform
our test with ,
= I
=
= minimal disturbance to the asphalt facility. This portability provides us
with the
capability of testing various facilities.
Linobj FOUIPMENT: We will need to build a two tier hopper system.
Hopper #1
= will be located above the hopper #2. Hopper #1 will be designed to
collect
! manufactured asphalt directly from the mixer used at the asphalt
manufacture
facilities. A control lever will be positioned below the funneled thruway
preventing
= the asphalt to pass through to the second hopper. A MFT sensor will be
. positioned below the control lever to 100% inspect the mixture as it
falls through
the sensor. The second hopper will collect the asphalt and funnel the asphalt
to a
motorized feed-screw. When activated, the material will be delivered through a
, pipe which will deliver the asphalt back to hopper for retesting or to an
external
: vehicle.
(01013 TASK #1, #2: STUDY FREE FALL, TAPERED FREE FALL, FEED
SCREW DELIVERY WITH AND WITHOUT REDUCER:
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32
=
CA 02609763 2013-12-06
[102] Fill hopper #1 with manufactured asphalt. Monitor the flowing of
material as
the control lever is opened. Study the average value and standard deviation,
observe and record dispense rate. Determine if any fluctuation in readings is
caused by the delivery system or are actually variations in mix ratio.
Transfer from
hopper #2 back to hopper #1 while studying the results of sensor #2 located
after
the feed screw. Modify the sensor #1 by adding tubing which limits the flow of
material due to the smaller diameter. The backup of material may improve the
resulting data from sensor #1. Again use the feed screw to reload the hopper
#1.
Insert a diameter reducer after sensor #2. Study if this improves the
repeatability
of the data from sensor #2
[103] TASK #3: Redesign the portable equipment for testing the manufacturing
of
asphalts. Task #2 will provide us with the necessary information on how to
manufacturer the portable test station. If sensor #1 provides us with the
quality
information the second hopper will still be necessary to remove the asphalt.
However this may simplify the feed-screw. We will still need to deliver the
asphalts at high through puts when this equipment is used at construction
sites.
[104] Task #4: Develop software, electronics, and hardware for portable use at
construction sites. Sample test the material delivered.
[105] TASK #5: If free flow is repeatable then design a sensor which fits
above the
vehicle which will 100% inspect the finished mix ratio as it is dumped into a
truck. This same sensor can be adopted to fit various mixers, batch mixers as
used
at the asphalt manufacturing facility. If the free flow is not acceptable then
design
a sensor which includes the feed screw. Two types of sensors, one that fits on
the
batch mixer and another that fits on the truck. Software, electronics and
hardware
will be developed.
[106] TASK #6: Develop electronics, hardware and software that will help
test if mixing time or mixing revolutions are adequate. Develop testing
procedures
which will evaluate the mixer.
[001] In accordance with the provisions of the patent statutes, the
present
invention has been described in what is considered to represent its preferred
embodiment.
33
