3D printer and autonomous carrier system integration

InfraRob, a pioneering research initiative funded by the European Commission's Horizon 2020 program, is committed to revolutionizing road infrastructure maintenance through autonomous robotic solutions and modularization. At the core of this mission is the rapid and effective repair of small potholes, crucial for preserving road integrity, reducing maintenance costs, and extending pavement service life.

 Developing an Autonomous Pothole Repair System

Task 3.1 focuses on the development of a specialized 3D printer capable of extruding a specific mixture to fill small cracks and potholes. This innovative printer will integrate into an existing small autonomous carrier, creating an autonomous repair system. By minimizing worker exposure to traffic and heavy machinery, this system not only enhances safety but also optimizes the cost-effectiveness of routine maintenance tasks.

Phases of Development

The development of the 3D printing system and its integration into the autonomous carrier spans four essential phases:

1. Defining Carrier Constraints: Understanding operational limitations imposed by the autonomous carrier.

2. Optimizing System Parameters: Determining ideal parameters for the 3D printer and the repairing mixture to ensure effective pothole repair.

3. Printer Design and Construction: Designing and constructing the 3D printer prototype tailored to project specifications, considering payload capacity and integration space.

4. Integration with Autonomous Carrier: Seamless integration of the 3D printer with the autonomous carrier to form a functional autonomous repair system.

Optimal Mixture Development

The selection of an appropriate repairing mixture crucially depends on both the printer's capabilities and the pothole's characteristics. Preliminary studies explored various materials, including Hot Mix Asphalt (HMA), Cold Mix Asphalt (CMA), Bituminous Mastics, and synthetic compounds. After rigorous testing, a 100% Reclaimed Asphalt Pavement (RAP) blended with a Multifunctional Chemical Compound (MCC) emerged as the optimal choice. This cold mixture:

• Does not require a heating system, facilitating direct integration with the small robotic system.

• Exhibits excellent extrudability and performance metrics.

• Is self-compacting, enabling immediate reopening of road sections to traffic post-repair without sticking to vehicle tires.

• Allows for pothole repairs without prior operations like asphalt cutting and cleaning, enhancing efficiency.

• Represents a sustainable "green solution" by utilizing 100% reclaimed materials, thereby conserving natural resources.

To read the full detailed report of Task 3.5 click here.

Future Directions

Moving forward, the project anticipates implementing an automatic longitudinal crack sealing system using a bituminous mastic casting system. These innovations aim to further streamline road maintenance processes and enhance infrastructure resilience.

InfraRob exemplifies Europe's leadership in leveraging advanced technologies for sustainable infrastructure management. By integrating autonomous robotics with innovative 3D printing solutions, the project sets a precedent for efficient, cost-effective, and environmentally conscious road maintenance practices.