There are increasing numbers of automation and assistance tools being made available for off-highway machines. As this technology proliferates, operator assistance systems are becoming more widely accepted, with full automation being used in some sectors.
Machine control systems can allow even inexperienced operators to deliver quality results, eliminating the need for costly reworking. And when used by experienced equipment operators, machine control tools can make significant gains in productivity.
There are several reasons for this drive towards higher levels of automation in the segment. One of the biggest comes from the shortage of machine operators. The construction industry has been facing an increasing problem with regard to personnel, with young people proving reluctant to enter the sector in sufficient numbers resulting in an ageing and shrinking workforce.
However, sophisticated technology is helping to deliver solutions.
It is now nearly 30 years since Caterpillar first demonstrated its prototype autonomous dump truck technology in public. Those invited to Caterpillar’s Tinaja Hills research facility watched in amazement as one of the firm’s 777 rigid dump trucks drew to a halt, the operator got out of the cab and climbed out of the machine, and it then drove off again with nobody behind the wheel.
The truck was equipped with GPS technology from Trimble so it could geolocate itself as well as being equipped with a forward scanning radar system able to detect obstacles in its path. The hardware was extremely advanced for the time, allowing the truck to travel on haul roads between loading points and dump areas, as required by the scheduling software. This innovation represented the future for the mining industry, the Caterpillar executives explained. With many surface mining sites in remote locations that are difficult to access and may also have harsh climates, it is easy to understand why taking operators out of the cabs of large machines would be advantageous.
Since that time, the technology has become far more refined. The sight of fleets of large mining trucks without operators in the cab has become more common, with Caterpillar and rival Komatsu both having proven their systems over the decades, with other suppliers having also introduced comparable systems. There are now many mines using these systems around the world and for operations in remote areas, this saves on the costs of getting personnel to each working site.
The use of autonomous dump trucks in the mining sector soon began to highlight other benefits of the technology also. Trucks running autonomously do not get tired towards the end of a shift, do not require rest breaks and cups of coffee to ensure efficient operation is maintained, with the risk of human error being taken out of the frame. Autonomous trucks can operate 24/7 and can also be used in conditions or areas that might be unsafe for humans to access.
Long time use of autonomous dump trucks soon revealed that the machines tend to use less fuel and have less wear and tear because operation is optimised. With large machines in particular, this technology can deliver considerable savings in maintenance costs over time.
Along with the automation technology, telematics systems fitted to heavy off-highway equipment has helped to further reduce fleet costs. These systems monitor performance and can highlight when service intervals are due or components will require replacing. Maintenance can then be scheduled so as to have a minimum effect on overall productivity, boosting utilisation and simultaneously reducing the costs inherent in machine downtime.
For the mining industry, the cost of installing the technology into large and expensive mining trucks was justifiable. The reduced wear on the equipment as well as the savings in terms of sending personnel to remote locations. With large capital investments required to buy and maintain large mining machines, the cost of the automation technology was not significant. Furthermore, the benefits these systems delivered in terms of reducing fuel burned and general running costs offset the price tag for the automation systems.
However, over time the cost of this highly sophisticated technology has also dropped as computing power has become ever cheaper. More and more surface mining operations use automated truck fleets, with other types of equipment also now being offered in remote control or automated form.
With the technology having become well proven over time and the cost and wider availability of systems on the market, automation technology has moved beyond being used just for large mining trucks. The quarrying sector, where machines are smaller and margins tighter, has also begun to see the introduction of automation systems.
But both Caterpillar and Trimble agree that fully autonomous machine fleet operation remains some way in the future for general construction operations though. Trials of autonomous machines have been carried out on some construction projects (such as a hydroelectric dam project in Canada). But these have been on large sites and in specific areas where access by personnel has been restricted for the duration of the trials.
Autonomous machines can be used on surface mining sites (or quarry operations) as working is confined to clearly defined areas where personnel access is restricted.
Part of the issue for the use of autonomous construction equipment is regulatory. In addition, the prospect of coordinating multiple autonomous machines on a construction site presents technical challenges.
What semi-autonomous assistance technology can do though is allow inexperienced operators to deliver high quality working. Similarly, the technology ensures that experienced operators can carry out work to even higher standards than without.
For example, semi-autonomous steering controls allow machines to carry out repetitive tasks accurately, while boosting productivity. New systems are available for use on soil compactors that will ensure optimum overlap between each pass while the operator supervises the working of the machine. Once in the work location, the machine will handle the steering and ensure optimum compaction density is achieved with the minimum number of passes. Both quality and productivity are boosted, while fuel use and emissions are reduced, with a benefit for project sustainability.
Semi-autonomous systems, remote controls or assistance technologies are becoming utilised widely. Machine assistance systems from the three key technology providers, Leica Geosystems, Topcon and Trimble, have become much more common across the various off highway equipment sectors. Once fitted to large machines such as heavy earthmoving equipment only, these tools are now used widely and even in much smaller compact equipment.
Telematics technology, once the preserve of large mining machines only, is now more or less standard across the quarrying and construction equipment sectors. Sophisticated telematics systems are now fitted to even small rental market machines such as mini excavators and compact tracked loaders. Equipment owners can track machine performance remotely, schedule servicing and can even set geofencing boundaries, so that units can only be operated in certain locations.
Customers can use telematics systems for monitoring machine condition, even if the contractor has equipment from another manufacturers. Similarly, operating data from the machine on how it is working can be downloaded, even if other technology solutions are being utilised.
Meanwhile, the well-established partnership between Caterpillar and Trimble has seen the machine manufacturer fit technology in the factory to customer order. The two partners recently refreshed their long running partnership. Scott Crozier of Trimble and Todd Farmer from Caterpillar explained some of the key points of the new agreement and how it will benefit both companies.
Crozier said, “Innovation has been key to the joint venture for a number of years.” He explained that the rate of innovation in the technology sector is now so fast that the two firms had to update their joint venture partnership to ensure they could continue maximising the benefit.
Farmer said that the construction industry is shifting and machine control systems are becoming more commonplace. However, a key part of the new agreement is that the technologies developed jointly will be able to operate with solutions from other technology suppliers. And these systems will also be able to operate on construction machines from other manufacturers, recognising that many contractors run mixed equipment fleets.
Around 20 years ago, Caterpillar carried out trials for construction works at its facility in Malaga, comparing the efficiency of machines equipped with grade control systems against those that were operated using conventional manual methods. Even then, the early generation grade controls were able to deliver fuel savings of around 15%, not to mention improved productivity. The technology has improved considerably since that time.
Both Crozier and Farmer commented on how the technology has become more refined over the years. Farmer said, “Twenty years ago you could be either fast or accurate.” But both agreed how the machine control systems now allow full speed operation, while delivering high quality finish exactly to grade. Both also agreed how machine control systems have progressed from indicate package to technology that takes over some operations.
The cost of the technology used to be prohibitive for all but the largest firms. But steady advances meant that advanced technologies such as 3D machine control packages are now affordable even for small contractors for use on compact equipment. He said, “The technology is not just for the large machines. You can get it on skid steer loaders and mini excavators now.”
In addition to machine control tools on machines that make them easier to operate, remote systems mean that operators can be in a comfortable and safe location, removed from the noise, dust and potential danger inherent in a working area. Several of the major manufacturers now offer remote control systems which can be used on a range of machines, including crawler excavators, crawler dozers and tower cranes.
A modern remote-control system will utilise a state-of-the-art teleoperation stand equipped with the latest control technology. Several cameras provide real-time images from different perspectives, while microphones transmit the machine sounds. This comprehensive sensor technology enables machine operators to precisely control the construction machinery from a safe distance.
The technology offers several major advantages for construction sites. Not only does it increase operator safety in high-risk environments, it increases machine efficiency through faster shift changes and reduces downtime and can be used to access areas that would be too dangerous for direct on-site operation.
These remote systems makes it possible to modernise the workplace for machine operators. Operators can work together in a comfortable office environment that is remote from the noise and vibration of a construction site. The real-time images from different perspectives also provides operators with more information, boosting efficiency. The new machine control system simplifies communication between the machine operator and the site supervisor, with regard to logistics.
The machine control tools, semi-automation and use of remote control all form part of a wider move towards digitalisation for the construction sector. With building information model (BIM) systems becoming used widely employed for large construction works, the technology used on the machines is being integrated with the software used to progress the projects. The technology providers have also allowed for a greater interoperability, so that machine control technologies from firms such as Leica Geosystems Topcon and Trimble can operate together and can also link with engineering software from firms such as Bentley Systems.
Chief executive of Topcon is Ivan di Federico and he commented, “Digitalisation is the engine we see transforming many industries. The reason we see that is that it is possible!”
He continued that there has been a rapid acceleration in recent years in the use of technologies. Previously, digital technology and the sensors used were comparatively expensive, limiting implementation. He explained, “What has made the change is the smartphone. The huge volume of units being sold has meant that industry was able to reduce the cost of technology.”
According to Di Federico, construction processes or projects that would have been impossible before the widespread adoption of digital technologies are also becoming feasible. “That’s the benefit you get from digital control of the project. You can anticipate trends. Now you can see if you will need extra machines while you will have early warnings if there are problems and you can also see options to fix them.
He said that using digitalisation will help address inefficiencies in construction. “There is 30% waste in construction because of unforeseen problems. Digitalisation is the best weapon we have against waste.”
Di Federico said that for the full benefits of digitalisation to be realised, there will have to be a change in perspective across industry as people do not typically see digitalisation in this respect. “We need to make sense of what we do in real life. We can add value to our customers. Digitalisation allows you to have a deeper control in space and time of these unknown values.”
Looking ahead, Di Federico believes that AI will have a profound effect on construction, as with other industries. “AI will change workflows. As we use AI, equipment will learn from us and correct our mistakes.”
He said that this will go beyond being predictive and will begin to understand the user and how the user works and will then be able to propose how work should be done. “Digitalisation becomes not just a technique but an interactive tool.”
Digitalisation will help deliver sustainability by reducing waste and increasing efficiency according to Di Federico. “We should be able to do much better determining sustainability and environmental assessments. The ability to calculate and measure things is the first stage of environmental compliance.”
Michael Gomes is vice president of Global Sustainability and CSR at Topcon Positioning and is convinced that digitalisation can also help firms meet environmental targets. He said, “Digital data layers prove the act of sustainability. They prove the value in a world where information is everywhere, the proof becomes more important.”
These systems can highlight the value of an operator too, not just showing productivity as in the past. It can reveal the quality of working, the time taken, fuel burned and provide a more comprehensive quality assessment.
