Surface Systems & Instruments, Inc.

CS9500 Full-Lane Survey-Profiler

Full lane width scanning

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At a Glance

The CS9500 Survey Profiler combines the point-to-point precision of a high-speed inertial profiling system, data from a tactical grade IMU sensor to eliminate the impact of vehicle dynamics), and corrected GPS positions. The resulting outputs feature open area or roadbed topographies with accurate cross-slopes and elevations approaching total stations accuracy (with control point merger).  Use the data for road design (optimized for smoothness) and variable depth machine control. 

The CS9500 Survey-Profile system is both a DOT certified inertial profiler and high resolution mobile surveying system.  The CS9500 can simultaneously measure IRI (longitudinal profile), transverse profile and 2D/3D surface scans for land surveying and machine control applications.  The survey side of CS9500 system has been end-user validated as more accurate than any commercial scanning system.  This device does full 3D scanning and can be simultaneously (or separately) used for IRI testing and full lane transverse profiles (for rutting, lane edge change and more under AASHTO PP69-10 & 70-10).  The surface survey data can be adjusted with a merge in of control points for very accurate 3D elevation content. 

The CS9500 system can also be used for 2D scanning for pavement rehabilitation work that does not involve paving to grade.  SSI’s software includes a Profile Design module for configuring slope and cut/fill parameters for a design output optimized for best IRI results.  The data can be exported to machine control systems, including 2D grade control systems such as Paveset/Pavesmart devices.

The CS9500 system has these core features:

  • Scalable: Start with dual track profile, add Cross-Slope, Transverse & 3D Scanning
  • Supports full lane width 3D scanning and rut measurement
  • Merges RTK GPS or control points for precise 3D elevations
  • Generate surface designs for best smoothness & machine control 
  • Configurable slope, cut/fill parameters, optimized for IRI
  • DOT Certified inertial profiler for IRI Testing
  • Simultaneously collects road profile and dense 2D surface scans or 3D topographies down to 1” spacing longitudinally and transversely.
  • Attaches to industry standard pickup trucks or vans.
  • Outputs data in CAD and LIDAR formats (e.g.) PNEZD, PLLHD, GPGGA, LAS and configurable TXT.
  • Reusable container for storing costly sensors off-vehicle.

  

 

Features & Benefits

 

Proven Accuracy in Measuring Cross-Slopes

Cross-slopes are obviously critical to accurate surface topographies.  The CS9500 has a unique and robust cross slope measurement system.  The instrumentation, proprietary to SSI, combines inertial profiler sensors with a vehicle dynamics measuring IMU.  As proof, below are repeatability and accuracy comparisons for CS9500 cross slope measurements.  The results are based on 20 same-surface data collections (10 runs in one direction and 10 the reverse direction).  The random test surface is 500ft long and included readings with reference data established by smart-level (with 0.1% resolution) every 10 ft (2 readings per spot flipping the level around and averaging). As depicted below, comparing every single spot on all 20 runs, the maximum difference in CS9500 slope measurements was -0.175%. Thus on the test surface the CS9500 was within 0.2% slope accuracy 100% of the time. 96% of all of the CS9500 are were within 0.1% of smart level readings.

 

Forward Direction Cross-Slope Measurements (Reported at 10 Foot Intervals for 500 Feet)

 

Accuracy of CS9500 Cross-Slope: (Comparison with Smart Level)
100% of comparisons within 0.175%. 96% of comparisons within 0.1%. 
Repeatability of CS9500 Cross-Slope: (Comparison of 10 Same Surface Runs)
Average Difference (% gradient): -0.01716087 
Overall % of measurements within 0.1 (% gradient): 0.960869565
Minimum/Maximum Differences (% gradient): -0.055 (min) -0.175 (max)

 

Reverse Direction Cross-Slope Measurements (Reported at 10 Foot Intervals for 500 Feet)

 

Accuracy of CS9500 Cross-Slope: (Comparison with Smart Level)
100% of comparisons within 0.175%. 96% of comparisons within 0.1%. 
Repeatability of CS9500 Cross-Slope: (Comparison of 10 Same Surface Runs)
Average Difference (% gradient): -0.016445652 
Overall % of Measurements within 0.1 (% gradient): 0.956521739
Minimum/Maximum Differences: -0.08 (min) -0.149 (max)

 

Create 3D Topos with Near Total Stations Accuracy Using Control Point Merger

The CS9500 system collects full lane width scans at highway speeds.  Unlike a competing survey manufacturer’s scanning system, there is no need to do repeat collections to rely on the average of several runs to “fix” issues within the individual ones.  3D surfaces are created in SSI’s post-processing engine, and for improved elevation accuracy, control points can be added using the SSI CAD software (see below).  The resulting surface can then be output (at configurable longitudinal and transverse intervals) to CAD and LIDAR formats for use in third party applications for pavement design and machine control. 

 

Example of CS9500 Data with Control Points Merged 
(Visualization Using SSI CAD Software)

 

The survey elevations within the CS9500 data can be improved to near total stations accuracy by adding known control points to the surface data.  SSI supplies the software to do just that and regenerate the adjusted surface.  The table below characterizes the improved surface elevation accuracy when control points are added at the indicated spacing.  The data is from a test pavement with independently collected total stations control points.  As shown, the CS9500 data with control points merged at any spacing between 100-500ft produced a surface accurate to within 7 mm 100% of the time.

 

Control Data Merger:  Accuracy Based on Separation Interval

 

The figure below shows the improved elevation accuracy when control points are merged at shorter spaced intervals.  While the CS9500 data shows improved elevation content with control merged at any point along the test surface, the elevation accuracy is nearest to total stations accuracy when merged at tighter spacing. 

 

CS9500 Increased Accuracy Based on Control Data Merge Interval

 

Generate Smoothness Based Surface Designs for Variable Depth Machine Control

After raw surface data is collected, use SSI’s Profile Design module to enter configurable parameters (target cross-slope, min/max cut-fill thresholds) and generate a surface design optimized for smoothness.  The design data can then be exported to formats compatible with third party machine control solutions for variable depth milling, paving or diamond grinding.  Fine grain 3D surface topographies can be output in conventional survey formats (PNEZD, PLLHD, GPGGA) at a user specified interval down to 1 inch.  Control data can be added to tighten survey elevation accuracy on longer data collections.   The exported survey data can be used in third party CAD applications for 3D site preparation and machine control.  Repeat surveys can be quickly undertaken with the Survey-Profile systems to monitor progress of the project surface throughout construction to completion.  

Use SSI CAD software’s Profile Design module to generate surface designs optimized for IRI smoothness with configurable parameters for cuts, fills and slopes.  The surface data also exports to CAD software for surface design and machine control.  The SSI design data supports variable depth milling, paving and diamond grinding.

 

SSI Profile Design Module 

 

Create Open Area 3D Topos with Multiple Run Stitching 

The CS9500 system is capable of stitching multiple, separately collected passes into a single open area topography.  SSI’’s CAD software utilizes proprietary post-processing algorithms to build an accurate unified topography stitched together from several separate data collections. The figures below show an open area surface in third party CAD software generated after stitching together several separate CS9500 data collections.

 

 

Example of Multiple Lane Surface Stitched from Individual CS9500 Data Collections

 

Lidar Formats Supported for Use of Laser Intensities for Reflectivity Visualization 

The CS9500 instrumentation collects surface intensity data. Once the surface is built in SSI’s post-processing engine, the data can be converted to the .LAS LIDAR format for working with surface reflectivity attributes in third party CAD software. The Figures below are examples.

 

 

 

Sample Multi-lane Outputs

 

 

 

Hardware & Software

 

Hardware

The CS9500 hardware attributes include the following:

  • DOT certified inertial profiler for IRI smoothness testing (compliant with AASHTO M328, R054, R056-057 ASTM E-950, and state/provincial agency specifications).
  • Scalable: Add transverse profile system for rut depth and other measurements under AASHTO PP69-10 & 70-10.  Transverse profile measured with ultra-wide beam lasers (1280 points each across 2.3ft / 0.7m).  
  • Scalable: Add IMU for cross-slope and 2D profile design, corrected GPS and control data for 3D survey.
  • Quickly generate dense, open area 2D or 3D surfaces.
  • Highest resolution scanning outputs transverse profiles at 0.5” spacing and longitudinal spacing at 1-3“(speed dependent).  Surfaces generated by patented process combining inertial profiler, IMU and corrected GPS data sets.  
  • Add occasional control points for tighter, more accurate elevation data—near total stations accuracy!
  • Multiple configurations available; examples:
    • 2 laser track profiles, IMU and GPS for 2D relative profile.
    • 3 laser track profiles, IMU and corrected GPS/control data for 3D Topo.
    • 6 laser full lane width profile, IMU and corrected GPS/control data for highest resolution 3D Topo.
  • Choice of vehicle platforms:
  • High speed system attaches to front or rear of host vehicle.
  • One setup for multiple passes, slopes, and lanes.
  • Corrected GPS with RTK post processing (3D system).
  • Supports use of customer GPS base units.  
  • Works with third party machine control systems for variable depth milling, paving or grinding.
  • Detachable core components minimizes risk of damage or theft.  
  • Panasonic Toughbook rugged operator interface computer with solid state hard drive.
  • Software license for desktop computer or workstation sue.

 

Software

The CS9500 software attributes include the following:

  • Ride quality, rut depth, and cross-slope reporting in accordance with agency specifications 
  • Data compatible with ProVal.
  • User configurable data collection and analysis parameters.
  • Easy software for calibration, collection and analysis of data on in-vehicle Toughbook; software license for use on desktop PCs.
  • Patented process combines Inertial profiler data with IMU and corrected GPS/Control for 2D/3D surfaces.   
  • Dense surface data for better designs.
  • Create a design file with 2D or 3D survey data in conventional survey formats, but with higher resolution.
  • Use surface data in SSI Profile Design module to analyze existing surface and optimize design for best smoothness values.  
  • Configurable design parameters for slope, cut/fill and smoothness.  
  • Data compatible with third-party CAD design software.
  • Design flexibility—resurvey surface to assess changes as project build progresses. Build based on the true surface profile. 
  • Surface designs work with both milling and paving machines.
  • Separate or combined data formats: profile only, slope only, GPS only, or integrated 2D/3D survey data.
  • Multiple export formats:  PNEZD, PLLHD, LAS, Excel, CSV, ERD/PPF, Custom TXT & PDF.
  • Precisely calculate areas of localized roughness for corrections or bonus/penalty results. 
  • On-screen GPS navigation along profile data.
  • Surface data complies with all DOT & Industry specifications.
  • Web based issue reporting and automatic software updating.

 

 

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At a Glance

The CS9500 Survey Profiler combines the point-to-point precision of a high-speed inertial profiling system, data from a tactical grade IMU sensor to eliminate the impact of vehicle dynamics), and corrected GPS positions. The resulting outputs feature open area or roadbed topographies with accurate cross-slopes and elevations approaching total stations accuracy (with control point merger).  Use the data for road design (optimized for smoothness) and variable depth machine control. 

The CS9500 Survey-Profile system is both a DOT certified inertial profiler and high resolution mobile surveying system.  The CS9500 can simultaneously measure IRI (longitudinal profile), transverse profile and 2D/3D surface scans for land surveying and machine control applications.  The survey side of CS9500 system has been end-user validated as more accurate than any commercial scanning system.  This device does full 3D scanning and can be simultaneously (or separately) used for IRI testing and full lane transverse profiles (for rutting, lane edge change and more under AASHTO PP69-10 & 70-10).  The surface survey data can be adjusted with a merge in of control points for very accurate 3D elevation content. 

The CS9500 system can also be used for 2D scanning for pavement rehabilitation work that does not involve paving to grade.  SSI’s software includes a Profile Design module for configuring slope and cut/fill parameters for a design output optimized for best IRI results.  The data can be exported to machine control systems, including 2D grade control systems such as Paveset/Pavesmart devices.

The CS9500 system has these core features: