JP7623836B2 - How to recreate existing road shapes - Google Patents

Description

The present invention relates to a method for reproducing the shape of an existing road.

Conventionally, there are known so-called "bad roads" (existing roads) that are used as test courses for automobile companies, etc. An example of a bad road is a general paved road that has been in use for a long time and has developed unevenness on the pavement surface.

Here, patent documents related to the prior art include Patent Documents 1 to 4.

Japanese Patent Application Publication No. 2-74728 Japanese Patent Application Publication No. 6-166012 Japanese Patent Application Publication No. 9-131718 Japanese Patent Application Publication No. 11-269816

In recent years, however, there has been an increasing need to create (replicate) rough roads of the same shape as the rough road in multiple locations or to repair the rough road in order to make driving tests on rough roads more efficient. Here, in order to make driving tests on rough roads more accurate, it is important to accurately reproduce the rough road (the surface shape of the rough road).

However, there are cases where the above-mentioned rough roads have been created without using numerical data, or where the numerical data for the surface shape of the above-mentioned rough roads is no longer available, and in these cases it is very difficult to accurately reproduce the above-mentioned rough roads (surface shape of existing roads).

The present invention aims to provide a method for reproducing the shape of an existing road that can easily reproduce the surface shape of an existing road.

A method for reproducing the shape of an existing road according to an embodiment of the present invention includes a surface shape measuring step of measuring the surface shape of an existing road having unevenness, a mold creating step of creating a mold for reproducing the surface shape measured in the surface shape measuring step, a surface layer material forming step of forming a surface layer material using the mold created in the mold creating step, and a surface layer material installation step of installing the surface layer material formed in the surface layer material forming step on a base layer, wherein the unevenness causes the height position of the surface of the existing road to change not only in the extension direction of the existing road but also in the width direction of the existing road , and the surface shape measuring step measures the surface shape of an existing road that is slightly separated from the existing road in the width direction of the existing road. a laser length measuring device for measuring the surface shape of the existing road on the left side of the existing road, and a laser length measuring device for measuring the surface shape of the existing road on the right side of the existing road slightly away from the existing road in the width direction of the existing road, measuring the surface shape of the existing road with the left laser length measuring device, measuring the shape of parts of the surface of the existing road that cannot be measured with the left laser length measuring device because a convex portion of the existing road gets in the way with the right laser length measuring device, and complementing the measurement results by the left laser length measuring device with the right laser length measuring device .

In addition, in the method for reproducing the shape of an existing road according to this aspect of the present invention, the surface shape measurement process is performed using a laser length measuring device, and the laser length measuring device is freely rotatable and positioned around a first rotation center axis extending in a predetermined direction, and is freely rotatable and positioned around a second rotation center axis extending in a direction intersecting the predetermined first rotation center axis.

The method for reproducing the shape of an existing road according to this aspect of the present invention includes a planar shape division process for dividing the surface shape measured in the surface shape measurement process into a plurality of sections, and in the mold creation process, the mold is created for each section divided in the planar shape division process, and in the surface layer material forming process, a surface layer material is formed for each mold created in the mold creation process, and in the surface layer material installation process, the multiple surface layer materials formed in the surface layer material forming process are installed on the base layer so that the surface shape measured in the surface shape measurement process is reproduced.

In addition, in a method for reproducing the shape of an existing road according to an aspect of the present invention, the surface material formed in the surface material forming step is provided with a through hole penetrating the surface material in the thickness direction of the surface material, and the surface material installation step includes placing one surface of the surface material in the thickness direction, the surface having the unevenness, on the upper side, providing an adjuster between the base layer and the surface material installed on the upper side of the base layer for adjusting at least one of the position and attitude of the surface material, adjusting at least one of the position and attitude of the surface material, and after this adjustment, injecting fluid grout between the base layer and the surface material from the through hole, and allowing the grout to harden after this injection.

The present invention has the effect of providing a method for reproducing the shape of an existing road that can easily reproduce the surface shape of an existing road.

1 is a perspective view showing a surface shape of an existing road in a method for reproducing the shape of an existing road according to an embodiment of the present invention; 1A is a diagram for explaining a surface shape measuring process in a method for reproducing an existing road shape according to an embodiment of the present invention, and FIG. 1B is a view taken along the line IIB in FIG. 1A to 1C are diagrams illustrating a mold creation process in a method for reproducing an existing road shape according to an embodiment of the present invention. 1 is a diagram illustrating a surface layer material forming process in a method for reproducing an existing road shape according to an embodiment of the present invention. FIG. FIG. 2 is a diagram showing a surface layer material formed by a method for reproducing the shape of an existing road according to an embodiment of the present invention. 1 is a diagram illustrating a surface material installation process in a method for reproducing an existing road shape according to an embodiment of the present invention. FIG. FIG. 13 is a diagram showing a road obtained by a method for reproducing the shape of an existing road according to a modified example. FIG. 8 is a view taken along the arrow VIII in FIG. 7 . 11A to 11C are diagrams showing numerical data obtained in a surface shape measuring step in the method for reproducing the shape of an existing road according to the embodiment of the present invention. This is the formula for converting polar coordinates to Cartesian coordinates. 4 is a flowchart of a method for reproducing an existing road shape according to an embodiment of the present invention.

The method for reproducing an existing road shape (method for reproducing a rough road) according to an embodiment of the present invention is a method for reproducing an existing road 1 used, for example, as a test course for automobiles, by duplicating or repairing it. As shown in FIG. 11, the method for reproducing an existing road shape includes a surface shape measuring process S1, a mold making process S3, a surface layer forming process S5, and a surface layer installation process S7.

In the surface shape measurement process S1, the surface shape (shape of the upper surface 7) of the existing road 1, which has unevenness, is measured (see Figure 2). In the mold creation process S3, a mold 3 is created to reproduce the shape of the upper surface (road surface) 7 of the existing road 1 measured in the surface shape measurement process S1 (see Figure 3).

In the surface layer forming process S5, the surface layer 5 is formed using the mold 3 created in the mold creation process S3 (see Figures 4 and 5). In the surface layer installation process S7, the surface layer 5 formed in the surface layer forming process S5 is installed on the base layer 9 (see Figure 6). Note that it is desirable to remove foreign objects, etc. from the top surface 7 of the existing road 1 in a foreign object removal process before executing the surface shape measurement process S1.

For ease of explanation, one specific horizontal direction in space is defined as the x-direction, another specific horizontal direction perpendicular to the x-direction is defined as the y-direction, and a direction perpendicular to the x-direction and y-directions is defined as the z-direction. In this specification, the x-direction is the width direction of the road, the y-direction is the extension direction (longitudinal direction) of the road, and the z-direction is the up-down direction.

As shown in Figure 1, in an existing road 1 with unevenness, the shape of the upper surface (surface) 7 is an irregular surface with appropriate bumps and recesses that is not flat. To explain further, in an existing road 1 with unevenness, the height position of the surface 7 changes not only in the width direction (x direction) of the existing road 1 but also in the extension direction (y direction) of the existing road 1. In other words, the surface shape of the existing road 1 shown in Figure 2 (the shape of the wavy upper surface 7) changes not only in the x direction but also in the y direction.

In the surface shape measurement process S1, as shown in FIG. 2, a laser length measuring device 11 is used to measure the shape of the top surface 7 of the existing road 1. The laser length measuring device 11 is installed slightly away from the existing road 1 in the width direction of the existing road 1 and above the existing road 1 at a distance from the existing road 1.

Furthermore, the laser length measuring device 11 is freely rotatable and positionable around the first rotation center axis C1, and is also freely rotatable and positionable around the second rotation center axis C2, independent of the rotation positioning around the first rotation center axis C1.

The first rotation center axis C1 extends in a predetermined direction (for example, the extension direction of the existing road 1; y direction). The second rotation center axis C2 extends in another predetermined direction (up-down direction; z direction) that intersects with the first rotation center axis C1.

The laser measuring device 11 is designed to emit laser light 13 toward the surface 7 of the existing road 1, which is diagonally below.

In the surface shape measurement process S1, the angles θ and φ shown in Figure 2 are appropriately changed to measure the surface shape of the existing road 1 at as fine a pitch as possible. In other words, the coordinates of points on the top surface 7 of the existing road 1 are determined for as many points as possible. Furthermore, a cutoff process is performed to ignore the surface roughness of the top surface 7 of the existing road 1 and obtain only the undulations.

In other words, a cutoff process is performed on the raw data obtained in the surface shape measurement process S1 to remove short wavelengths in the surface shape of the existing road 1. For example, a planar shape of the existing road 1 is obtained that is represented by the trajectory of the central axis of a low cylinder (corresponding to a tire) with an outer diameter of about 400 mm when the cylinder is rolled on the existing road 1.

The method for reproducing the existing road shape also includes a planar shape division process for dividing the shape (surface shape) of the top surface 7 of the existing road 1 measured in the surface shape measurement process S1 into multiple sections. Then, in the mold creation process S3, multiple molds 3 are created for each section (surface shape section) divided in the planar shape division process.

In addition, in the surface layer forming process S5, multiple surface layers (surface layers divided into sections) 5 are formed for each of the multiple molds 3 created in the mold creation process S3. Furthermore, in the surface layer installation process S7, the multiple surface layers 5 formed in the surface layer forming process S5 are arranged in order on the base layer 9 so that the surface shape measured in the surface shape measurement process S1 is reproduced.

The surface layer material 5 formed in the surface layer material forming process S5 has a through hole (small diameter through hole) 15 (see FIG. 6) that penetrates the surface layer material 5 in the thickness direction (z direction) of the surface layer material 5. The inner diameter of the through hole 15 is set to a value that does not affect the waviness obtained by cutting off.

In the surface layer installation process S7, an adjuster 17 is installed between the base layer 9 and the surface layer 5. The adjuster 17 is, for example, a jack or a spacer, and is provided to adjust at least one of the height position of the surface layer 5 and the attitude of the surface layer 5. The attitude of the surface layer 5 is the rotation position around an axis extending in the longitudinal direction (y direction) of the regenerated road 19 and the rotation position around an axis extending in the width direction (x direction) of the regenerated road 19.

Furthermore, in the surface layer installation process S7, after adjusting the position and attitude of the surface layer 5, fluid grout 21 is injected between the base layer 9 and the surface layer 5 from the through holes 15, and the grout 21 is hardened after this injection. This results in a regenerated road 19 having the same shape of the upper surface 7 as the existing road 1.

Here, we will explain in more detail how to reproduce the existing road shape.

In the surface shape measurement process S1, the position of the measurement point P on the top surface 7 of the existing road 1 is determined in polar coordinates by the laser length measuring device 11. The laser length measuring device 11 is provided with a measurement reference point 23.

The laser length measuring device 11 is installed on a laser length measuring device installation section 25 provided on the outside of the existing road 1 in the width direction via a laser length measuring device support 27 such as a tripod. This defines the position of the measurement reference point 23 (the position of the measurement reference point 23 in the x-, y- and z-directions) of the laser length measuring device 11 relative to the existing road 1. The x, y, and z coordinates of the measurement reference point 23 are, for example, (0,0,0).

The laser length measuring device 11 can be rotated and positioned around the first rotation center axis C1 and the second rotation center axis C2 by the first rotation positioning unit (not shown) and the second rotation positioning unit (not shown), as described above. The first rotation center axis C1 passes through the measurement reference point 23 and extends in the y direction. The second rotation center axis C2 passes through the measurement reference point 23 and extends in the z direction.

The first rotation positioning unit and the second rotation positioning unit rotate the laser length measuring device 11 under the control of the control device 29 by an actuator such as a servo motor (not shown). The control device 29 is configured with a CPU 31 and a memory 33.

Furthermore, the rotation angle θ of the laser length measuring device 11 from the first reference plane L1 around the first rotation center axis C1 can be detected by a first rotation angle detection unit (not shown). Also, the rotation angle φ of the laser length measuring device 11 from the second reference plane L2 around the second rotation center axis C2 can be detected by a second rotation angle detection unit (not shown).

The first reference plane L1 is a plane (a plane extending horizontally) that includes the measurement reference point 23 and is perpendicular to the z direction, and the second reference plane L2 is a plane that includes the measurement reference point 23 and is perpendicular to the y direction.

Under the control of the control device 29, the laser length measuring device 11 emits a laser beam 13 toward a measurement point P on the top surface 7 of the existing road 1. Then, the distance r between the measurement reference point 23 and the measurement point P is calculated based on the time between when the laser beam 13 is emitted and when the laser beam 13 is reflected by the measurement point P and returns (the time it takes for the emitted laser beam 13 to return). At this time, the intersection angle θ between the laser beam 13 and the first reference plane L1 (rotation angle from the reference plane L1) and the intersection angle φ between the laser beam 13 and the second reference plane L2 (rotation angle from the reference plane L2) are calculated.

The distance r, rotation angle θ, and rotation angle φ thus determined are converted into Cartesian coordinates by the CPU 31 of the control device 29 and temporarily stored in the memory 33. The conversion from polar coordinates to Cartesian coordinates is performed using the conversion formula shown in FIG. 10. Furthermore, the origin of the coordinates of the measurement point P converted into Cartesian coordinates is the measurement reference point 23. The distance r, rotation angle θ, and rotation angle φ are also determined for a number of points on the top surface 7 of the existing road 1. For example, they are determined at a 5 mm pitch.

The raw data of the shape of the top surface 7 of the existing road 1 thus obtained is shown in Figure 9. Points P1, P2, P3, etc. shown in Figure 9 indicate the measured points on the top surface 7 of the existing road 1. This raw data is subjected to cutoff processing. The cutoff shape data (numerical data) of the top surface 7 of the existing road 1 is stored in the memory 33 of the control device 29. Note that data that has not been cutoff may be stored as is in the memory 33 of the control device 29.

However, there are cases where the measurement point at portion 35 shown in Figure 2(a) on the top surface 7 of the existing road 1 cannot be measured because it is shaded by the top 37 of the convex part of the existing road 1. In this case, a laser distance measuring device similar to laser distance measuring device 11 in Figure 2(a) can be installed on the right side of the existing road 1, and the laser distance measuring device installed on the right side of the existing road 1 can measure portion 35 to complement the measurement results of laser distance measuring device 11 installed on the left side of the existing road 1.

In the mold creation process S3 and the surface material forming process S5, for example, a mold 3 and a surface material 5 are created for each section divided in the extension direction (y direction) of the existing road 1 in the planar shape division process.

In the mold creation process S3, for example, as shown in FIG. 3, a general-purpose machine tool 39 is used to cut a material 41 made of synthetic resin such as polystyrene foam, wood, or other material to create the mold 3. The material 41 is, for example, a rectangular flat plate with a predetermined thickness. The mold 3 created in the mold creation process S3 is an inverted mold of the shape of the top surface 7 of the existing road 1. Note that in the mold creation process S3, the mold 3 may be created using a method other than cutting. For example, the mold 3 may be created using a 3D printer.

The machine tool 39 is configured with a table 43, a processing head 45, and a control unit 47. The control unit 47 is configured with a CPU 49 and a memory 51. The numerical data of the surface shape of the existing road 1 obtained in the surface shape measurement process S1 is transferred to the control unit 47.

A machining tool (e.g., an end mill) 53 is mounted on the machining head 45. The end mill 53 mounted on the machining head 45 rotates to cut the material 41.

The machining head 45 can be moved and positioned in the x-, y-, and z-directions relative to the table 43. Furthermore, the machining head 45 can be rotated and positioned about the A-axis and can also be rotated and positioned about the B-axis relative to the table 43. The A-axis is a specified axis that extends in the x-direction, and the B-axis is a specified axis that extends in the y-direction.

With the material 41 placed on the table 43, the end mill 53 is rotated under the control of the control unit 47 while the machining head 45 is moved appropriately, whereby one surface (upper surface) in the thickness direction of the material 41 is machined, and the mold 3 is created.

In the surface layer forming process S5, as shown in FIG. 4, the mold 3 is placed in a formwork 55 formed, for example, in a rectangular box shape. The flat surface of the mold 3 is in contact with the bottom surface of the formwork 55, and the uneven surface (uneven surface; irregular surface) that forms the inverted mold of the mold 3 faces upward.

After placing the mold 3 in the formwork 55, the reinforcing bars 57 are placed inside the formwork 55 and above the mold 3. After placing the reinforcing bars 57, pre-hardened concrete (e.g., cement concrete) 58 is poured into the formwork 55.

Then, the concrete 58 is hardened, and the hardened concrete 58 and the reinforcing bars 57 are removed from the formwork 55 to obtain the surface layer material (divided surface layer material; precast plate preparation) 5 with the framework of the reinforcing bars 57 inside, as shown in Figure 5. Note that the reinforcing bars 57 are not shown in Figure 5.

The position and posture of the surface layer 5 in the surface layer installation process S7 is adjusted using a laser length measuring device 11, for example, as shown in FIG. 6. For example, a laser beam 13 is emitted toward a specific point PA on the top surface 7 of the surface layer 5, and the coordinates of the specific point PA become the target coordinates (target coordinates for reproducing the existing road 1). At least three adjusters 17 are installed for each surface layer 5, appropriately spaced apart from each other, and there are at least three specific points PA for each surface layer 5, appropriately spaced apart from each other.

In the method for reproducing the shape of an existing road, the surface shape of the existing road 1 is reproduced using a surface shape measurement process S1, a mold creation process S3, a surface material forming process S5, and a surface material installation process S7. This makes it possible to easily reproduce the surface shape of the existing road 1 even if digitized data for the surface shape of the existing road 1 does not exist.

In the surface shape measurement step S1 of the method for reproducing the shape of an existing road, measurements are made using a laser length measuring device 11. The laser length measuring device 11 is also rotatable and positionable around an axis C1 extending in the y direction, and is also rotatable and positionable around an axis C2 extending in the z direction.

This makes it possible to measure the surface shape of the existing road 1 using a device with a simple configuration. Also, by installing the laser length measuring device 11 slightly away from the existing road 1 in the width direction of the existing road 1 and above the existing road 1 and away from the existing road 1, the installation of the laser length measuring device 11 is made easy.

In addition, in the surface layer forming step S5 of the method for reproducing the existing road shape, a surface layer material (divided surface layer material) 5 is formed for each mold (divided mold) 3 created in the mold creation step S3. In the surface layer installation step S7, the multiple surface layer materials 5 formed in the surface layer forming step S5 are installed on the base layer 9 so that the surface shape measured in the surface shape measurement step S1 is reproduced.

This allows the mass of each surface layer 5 to be reduced, making it easier to mold and install the surface layer 5.

In addition, in the surface material installation process S7 of the method for reproducing the existing road shape, an adjuster 17 is provided between the base layer 9 and the surface material 5 to adjust at least one of the position and posture of the surface material 5, and after this adjustment, fluid grout 21 is injected between the base layer 9 and the surface material 5 through the through hole 15 and allowed to harden.

This allows the divided surface material 5 to be accurately placed on the base layer 9, and even if the surface of the base layer 9 is slightly wavy, the surface shape of the existing road 1 can be accurately reproduced.

Incidentally, as shown in Fig. 7 and Fig. 8, the surface layer materials 5 may be arranged in two rows in the x direction. Then, an automobile tire 59 may be placed on each of the surface layer materials 5 arranged in two rows, and the automobile may be driven. Note that reference numeral 61 in Fig. 7 denotes a filler such as concrete. Also, in Fig. 7, the regulator 17 and grout 21 are omitted from illustration.

In addition, in the above description, the existing road 1 is a flat road that extends in a straight line, but the existing road 1 may extend in a curved manner, such as in an arc, may be a slope, or may have a bank.

In the above explanation, the shape of the top surface 7 of the existing road 1 is measured using a laser length measuring device 11 in the surface shape measurement process S1 (obtaining the uneven shape of the road surface 7 of the existing road 1), but the uneven shape of the road surface 7 of the existing road 1 may be obtained by other methods. For example, the uneven shape of the road surface 7 of the existing road 1 may be obtained by molding using a resin or the like. The mold obtained by this molding will be similar to the mold 3 described above, so for example, the mold obtained by the above molding can be used as is in the surface material molding process S5.

Although the present embodiment has been described above, the present embodiment is not limited to these, and various modifications are possible within the scope of the gist of the present embodiment.

REFERENCE SIGNS LIST 1 existing road 3 mold 5 surface material 9 base layer 11 laser length measuring device 15 through hole 17 adjuster 21 grout
C1: First rotation axis C2: Second rotation axis S1: Surface shape measurement process S3: Mold creation process S5: Surface layer material molding process S7: Surface layer material installation process

Claims (4)

A surface shape measuring process for measuring the surface shape of an existing road having unevenness;
a mold making step of making a mold for reproducing the surface shape measured in the surface shape measuring step;
a surface layer material forming step of forming a surface layer material using the mold created in the mold creating step;
a surface layer material installation step of installing the surface layer material formed in the surface layer material forming step on a base layer;
In the unevenness, the height position of the surface of the existing road changes not only in the extension direction of the existing road but also in the width direction of the existing road ,
The surface shape measuring step includes arranging a laser length measuring device for measuring the surface shape of the existing road on the left side of the existing road slightly separated from the existing road in the width direction of the existing road, and arranging a laser length measuring device for measuring the surface shape of the existing road on the right side of the existing road slightly separated from the existing road in the width direction of the existing road,
A method for reproducing the shape of an existing road, comprising the steps of: measuring the surface shape of the existing road with the left-side laser measuring device; measuring the shape of portions of the surface of the existing road that cannot be measured with the left-side laser measuring device because convex portions of the existing road get in the way with the right-side laser measuring device; and complementing the measurement results by the left-side laser measuring device with the measurement results by the right-side laser measuring device . The surface shape measuring step is performed using a laser length measuring device,
The method for reproducing an existing road shape as described in claim 1, wherein the laser length measuring device is capable of being rotated and positioned freely around a first rotation center axis extending in a predetermined direction, and is capable of being rotated and positioned freely around a second rotation center axis extending in a direction intersecting the predetermined first rotation center axis. a plane shape dividing step of dividing the surface shape measured in the surface shape measuring step into a plurality of sections;
the mold creation step is a step of creating the mold for each of the sections divided in the planar shape division step,
The surface layer material forming step is a step of forming a surface layer material for each mold created in the mold creating step,
3. The method for reproducing the shape of an existing road according to claim 1 or claim 2, wherein the surface layer installation process is a process of installing a plurality of surface layers formed in the surface layer forming process on the base layer so as to reproduce the surface shape measured in the surface shape measurement process. The surface layer material formed in the surface layer material forming step is provided with a through hole penetrating the surface layer material in a thickness direction of the surface layer material,
4. The method for reproducing the shape of an existing road according to claim 1, wherein the surface layer installation step is a step of placing one surface of the surface layer in the thickness direction, which surface has the unevenness , on the upper side, providing an adjuster between the base layer and the surface layer material installed on the upper side of the base layer to adjust at least one of the position and attitude of the surface layer, adjusting at least one of the position and attitude of the surface layer, injecting fluid grout between the base layer and the surface layer material from the through hole after this adjustment, and allowing the grout to harden after this injection.

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