Machine Control – Working Smarter

Machine Control – Working Smarter
1
Global Survey Update
Recently employed full-time tech support specialist
Martin Drabble
B. Surv
Surveyor with extensive experience in NZ and overseas
Recently awarded NZ’s largest ever 3D machine control
order.
35 machines to be fitted.
DrillRigs, Dozers, Excavators, Trucks, Site vehicles ….
Full real-time fleet management and material tracking
Chosen after 6-12 month evaluation.
Features
Local Service and Support
Overview
What is Machine Control?
Machine Control vs. Machine Guidance
Why use Machine Control?
Machine Control Solutions
Positioning Technology
2D versus 3D
New Zealand Examples
Productivity Analysis
What is Machine Control?
Machine Control is:
The use of GPS, Total Stations or Lasers technology to guide or
control agricultural, construction and mining machinery.
Accurately guiding, positioning or controlling the machine can
significantly improve accuracy, and productivity as well as
reducing operational costs.
Machine Control vs. Machine Guidance
Machine Guidance
Machine Control
Visual Indication for the operator
Full Hydraulic Control
Operator
machine.
Machine Types
fully
Machine Types:
Dozers,
Excavators,
Scrapers ….
controls
the
Graders,
Dozers,
Pavers ,
Scrapers
Scoops / BoxBlades
Milling machines….
Why Machine Control? - Market Drivers
Higher productivity and performance –
profitability.
Reduced Costs
Significant time savings
Savings in Fuel and Emissions,
Lower machine hours with less idle time,
Reduction in labour content
Minimise re-work.
Higher accuracy with less material
wastage. Closer adherence to
specifications.
Operator retention – ease of use,
flexibility
“Positioning Systems” used in machine control.
Grade Control Lasers and Sensors
Rugged rotating laser systems used to
determine height or depth.
Options for single and dual grades
Total Stations (TPS)
Combination of angle and distance measuring system used to
accurately measure position in 3 dimensions.
Robotic instruments will automatically follow the prism /
reflector. Accurate to 2-3mm at 300m.
Global Positioning Systems (GPS/GNSS)
Using the GPS satellite system for high precision
measurements in 3 dimensions. Accurate to approx 1cm.
On Machine Sensors and Systems
Combination of angle, rotation and slope
sensors used to measure the geometry
of the machine.
Sonic and laser sensors can be used to
measure to a physical reference (kerb,
stringline) or laser beam.
Can be used to control slope (grader /
dozer)
Hydraulic
control
or
electric
over
hydraulic
Basic Solutions – 2D Machine Control and Guidance
Guidance or control provided in a
single plane
Can be used with positioning systems
Cross-Slope control
Usually use a rotating laser to establish
the reference plane
Slopes can be handled by setting the
laser into the plane of the slope
Stringlines are used for Horizontal
Alignment
No Slope
Single
Slope
Dual
Slope
Indicator
Rotating
Laser
Reference
Required
Depth
Excavating using laser positioning
2D System Examples
Excavator
Set a depth below a peg to dig
from.
Enter X and Y slopes and dig to
grade.
Avoid over-cuts etc.
E.g. Trenching, Siteworks, Batters
….
Grader
Control Cross-slope
Control Height - work relative to a
laser, stringline, kerbline
E.g. Road Construction, Siteworks
and general grading.
Cut to grade quickly and
accurately.
Depth and Cable Avoidance
The operator establishes a known
reference point, sets the desired
depth and slope, then starts
digging. The display panel and
lightbar guide the operator to
grade.
2D System Examples
Dozer
Guidance or Control
Typically laser control
Accuracy 5-10mm
Dragscoop / Boxblade
Single or dual laser control
Typical accuracy 5-10mm
Used for floor slab preparation, siteworks …
Bodley Bros.
Before
Typically 3 Staff
One Dozer operator, one roller operator, one
grade checker
Finish 200 m2 per day
Accuracy 10-20mm
Fitted dual laser hydraulic control
After
Typically one operator
Finishing 1000 – 1300 m2 per day
Accuracy 5mm
500% Productivity improvement with less staff, less
fuel and machine time and higher accuracy.
Summary - 2D System Capability
What can I do with a 2D system ?
Control Cross-slope, height ….
Work relative to a reference e.g. laser, kerbline
(sonic), peg or stake.
Works well with simple designs.
What can’t I do ?
Work with complex designs containing changing
super-elevation, vertical curves …..
What do I need?
2D control or guidance system fitted to your
machine
Optional Laser / Sonic sensors
Paper plans of the design
3D Solutions
Guidance or control against a design shape
Compares Position of the blade or bucket to the 3D design.
Uses GPS or Total Station (TPS) positioning, depending on location and
required finish accuracy
GPS
Vertical accuracy
TPS
(robotics) Vertical accuracy
+/- 10-20 mm
+/- 5mm
Removes the need for stakeout and grade checking – lower survey costs.
Usually requires a Digital Terrain Model (DTM) or design lines loaded on the
machine.
Handles very complex designs and shapes.
What do you need ?
3 parts required
2D hydraulic control or guidance
Positioning system (TPS/GPS)
3D computer and software.
3D systems are scaleable
Can start out with entry level 2D system and upgrade.
Transferable between machines.
Each of the 3 parts is useful on its own.
Electronic Data Exchange
3D Electronic Data is uploaded into the machine.
Advantages of Electronic Interchange
Avoid errors
Allows better utilisation of technology for the benefit of all
parties (consultant, contractor and client)
Need to work with design consultants to get datasets
electronically.
3D Machine Control
Types of 3D Machine Control Systems
Machine Guidance
Operator is guided to grade
Typically
using
GNSS
earthworking machinery
for
Dozers, Excavators, Scrapers, Rollers
…..
Machine Control
Full Hydraulic Control
Typically used
machines
for
finer
finishing
Graders, Pavers, Trimmers, Dozers
……
Typical Accuracy
TPS Grader (total station) = approx
+/- 5mm
GNSS Grader = +/- 10-20mm
3D Machine control
Advantages:
No need for pegging and staking
Better adherence to design and shape – not
just right at pegs
Higher ride quality
Pavement can be constructed in even layers
avoiding any differential compaction.
Significant savings in time, materials and costs
Fewer passes when
aggregate segregation
grading
minimises
Case Studies – Stringfellows (Palmerston North)
Small – Medium sized civil contractor
Roading and subdivisional work
Ap[prox 20 staff
3D Machine Control system on CAT 130G motorgrader
Robotic Total station controlled
Purchased second robotic for Survey work
Purchased GPS system for bulk earthworks
Purchased 2D Excavator (x2) for trenching, batters and
general excavator level control
The Results
Getting about 5mm height accuracy with grader.
Don’t have additional staff grade-checking
More time on machinery
Lower fuel and machine hours
I’ve been grading for over 20 years. The 3km of road we did recently with the Leica
system is the best road I’ve ever built and took about half the time.
- Kim (Grader operator)
Case Studies – Goodman Contractors (Wellington)
Project:
8km re-alignment at Kaitoke (between
Masterton) over Rimutaka ranges
Subcontractor to Higgins
Client – Transit NZ
Wellington
and
GPS 3D Machine Control system on CAT 16G motorgrader
The Result
Getting about 10mm accuracy on a steep job.
Significant issues with poor weather on the job
Using the system allowed Goodmans to achieve
significantly higher production rates when the weather was
good.
“Normally to do a 1m cut for 1km of subgrade takes us
about 15 days. With the Leica system we did it in 4.5 days
with less people and less gear.” - Stan Goodman
3D Machine Control Video