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Machine Control

Speed, Accuracy, Safety and Economy

Guidance systems do the job with greater speed, accuracy and therefore economy in time and materials. 

Over/under digging, material overconsumption, machine stops for inspection and possibly returning for corrections are avoided. 

Also, less labor is required and the security against work accidents.

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What is Machine Control?

Introduction to Project Machinery Guidance

1.Introduction to Machine Control

The rapid technological developments of recent years allow the study and construction of large technical projects (Projects) for road construction, ports, railways, airports, etc. These large projects have high demands on speed and precision and therefore on economy and quality of construction.

Project machines are a decisive factor in the construction of such a Project, as their proper management and operation saves money time and money, while at the same time ensuring the quality of construction. The advantages of proper machine management, combined with the lack of modern experienced and trained operators, have been the main causes of technological development worldwide in the subject called Machine Control – Automatic Control and Guidance of Machine Projects.

What is Machine Control?

Machine Control Technology turns project machinery into "Smart Machines", helping Engineering Companies and Subcontractors Increase Productivity, Project Speed and Site Safety.

How is it applied?

Laser & GPS equipment is placed on the Project Machinery so that the Project is executed within Budget, within Schedule and within Specifications.

Advantages:

The project Study is implemented with the required Accuracy, helping the Machine Operator to implement the work in the first pass.

  • Productivity
  • Speed
  • Saving materials & fuel
  • Laying accuracy
  • Construction site safety
  • Smart Machines
  • Modern Equipment
  • Innovation
  • Digital Workshop
  • Respect for the Environment

See here Caterpillar's study on how Machine Control Increases Machine Productivity:

0 %
Productivity Increase
0 %
Fewer hours of Machine operation
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Fuel economy
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Fewer Working Hours

2. The concept of Machine Control

By the term "Machine Control" we mean the automated control and guidance of machines for road construction projects, earthmoving-railway-port projects, drilling or agricultural machinery. More specifically, in all construction machinery, regardless of make or model or age, it is possible to install electronic or analogue systems, which guide it basic "Tool"of the machine under the supervision of the operator. By basic machine "Tool" we mean:

✔ The Knife for Grader and Dozer

✔ The Finisher Plate

✔ The Excavator and Wheel-loader Bucket

✔ The Rotor for Milling (Milling Machine)

✔ Boom for Drilling Machine

and so on for the rest of the machines.

3. Mode of operation of Systems 
Machine Control

They are installed on the machine high precision measuring instruments (altitude sensors, inclinometers, Laser receivers, Geodetic Station prisms, GPS receivers, etc.). Instrument measurements are "translated" into Tool operating commands through the machine's electrical and hydraulic systems. This procedure automates the operation of the main tool of the machine, based on the precise measurements of the instruments.

With the automation of the machine, the role of the operator is differentiated, who now leads and controls instead of guiding based on his experience, knowledge, abilities and sometimes his arbitrary judgement. It is obvious that the result of the automated method of Machine Control gives more accurate results, without negating the role of the operator.

4. Categorization of Systems Machine Control

Automatic Guidance Systems are applied to all project machinery:

  • Finishers
  • Milling machines
  • Graders
  • Pavers
  • Excavators
  • Drilling machines
  • Dozers
  • Slipform pavers
  • Floating machines
  • Farm machinery
  • Weighing systems for loaders, excavators, etc.
  • Lifting machinery control systems

These systems are divided into two main categories, two dimensional (2D) and three-dimensional (3D),based on their operating principle. The categorization of Systems is independent of the machine, as both two-dimensional (2D) and three-dimensional (3D) systems can be installed on most machines.

The main difference between the two categories of Systems is that while two-dimensional (2D) systems require a reference plane based on which the tool of each machine is guided, three-dimensional (3D) systems apply the study data entered into the machine in digital form .

5. Two-dimensional Guidance Systems (2d)

Two-Dimensional (2D) Guidance Systems copy the surface of a reference plane and form a final surface in a plane parallel to it. The reference level can be:

✔ Stitch with pegs

✔ Existing layer (asphalt, earthwork)

✔ Milled surface

✔ Kennel or pavement of an existing road

✔ Virtual level from Laser spacewalker

More specifically, the measuring instruments (mechanical/electronic height sensor, inclinometer, laser receiver, ultrasonic sensor, etc.) accurately "read" the reference level. The measurements are processed by its unit Systemic, which gives commands to the Tool through the hydraulic/electrical systems of the machine. The final plane formed by the Machine Tool is parallel to the reference plane, i.e. the desired surface.

6. 3D Guidance Systems (3d)

The operation of a Three-Dimensional (3D) Guidance System is based on the existence of the study in digital form. The study results from the topographic mapping of the workplace and the subsequent processing by creation software 3D Models (DTM – Digital Terrain model).

This study is entered (loaded) into the system computer installed on the machine. Therefore, we know at every point of the workspace the final desired position of our surface.

Our measuring instruments give the exact position of the Tool at every point of the working area of the machine in real time. The system therefore compares the actual position of the tool with the desired position of the study and gives the command to the Tool to carry it out.

The main measuring instruments used to find the actual position of the machine tool are GNSS geodetic receivers (also known as GPS receivers) and robotic geodetic stations (RTS), while height sensors, inclinometers, tachometers, Laser receivers, etc.

Advantages of 3D Systems

Three-dimensional systems have the following advantages over two-dimensional systems:

✔ Apply with millimeter accuracy the digital study

✔ They provide the possibility of automatic recording as-built

✔ Less manpower required

✔ There is the possibility of it real-monitoring time of machine operations from the site office

✔ There is no need to install a seam with pegs

However, 3D systems have significant higher cost in relation to two-dimensional systems and therefore is not indicated as the best solution for small projects.

7. Additional systems

Systems, in addition to the above, for specialized applications can be installed on project machines. The evolution of technology, combined with the high demands of technical projects, make applications such as measurement necessary  temperature pavement during paving, its control condensation of the paver, the weighing systems in loaders-excavators-trucks, the security systems for cranes-clark-trucks, the telematics fleet control vehicles etc.

8. Its usefulness Machine Control in Technical Projects

Large projects are becoming more and more complex. Data management, lead times, construction costs and high specifications are putting more and more pressure on the project manager.

Guidance systems do the job with greater speed, accuracy and therefore economy in time and materials. Over/under digging, material overconsumption, machine stops for inspection and possibly returning for corrections are avoided. Also, less labor is required and the security against work accidents.

Also, the monitoring of project execution is immediate. Three-dimensional systems (3D) have the ability to create it automatically as built, but also her real-monitoring time of machine work from the site office

9. Applications of Machine Control

System MOBA-Matic installed on a Paver (finisher)

The system consists of an ultrasonic probe (Sonic-Ski) and a central unit (Controller). The sensor "reads" a reference plane, which can be either the kennel (Fig.1a) or the suture (Fig.1b). The operator determines the offset in the central unit, i.e. the distance that the laying plane must have from the reference plane (kennel or seam). The central unit processes the sensor readings, averages them and automatically commands the platen to raise/lower so that the laying plane is perfectly parallel to the reference plane. The machine, using the system, creates an absolutely smooth surface by removing all the irregularities of the ground.

System MOBA Big-Sonic-Ski installed on a Paver (finisher)

The system consists of three ultrasonic sensors (Sonic–Ski) fitted to metal "arms" that are bolted to the machine, a central processing unit and a junction box. The sensors take continuous height measurements by "reading" the previous layer or other reference layer. The central unit averages the measurements and automatically commands the machine plate to raise/lower to achieve the desired material laying height with millimeter accuracy. The Big–Sonic–Ski is a system upgrade MOBA–Matic.

 

Excavator with XSite Pro 3 System installedD GPS

The excavator has three-dimensional sensors (X,Y,Z) installed on the three joints (boom, stick, bucket) and chassis. Two receivers are also installed GPSin the chassis and a touch screen in the cabin. The operator enters the study into the system computer in digital form (DTM), which is displayed on the screen. In this way, the system guides the operator where and how much to dig, following the study precisely.

XSite Pro 3D GPS System installed on Promoter (dozer)

The system uses a receiver GPS to pinpoint the position of the knife. Study data are entered in digital form into the system's computer. The operator simply drives the machine to the job site and the system automatically raises/lowers/rotates the knife so that the finished surface is exactly the same as the study.

Frequent questions

Machine Control

Automation (Machine Automation) means that the hydraulics of the Machine are automatically controlled by the System (Grader, Dozer, Finisher, Mill, Pile Driver).
Guidance (Machine Guidance) means that the Operator has an indication with an audible and visual signal, so that he can control the Machine (Excavator, Drills).

The Laser System is suitable for applications of fixed slopes: Excavations, Ditches, Drains, Field Leveling, Stadiums, Parking, Industrial Buildings.
The GPS System assumes that the Survey is available in Digital format. The Study is entered on the Machine Screen and applied with centimeter accuracy by the Machine.

YES, the Laser/GPS equipment offered by MOBACT is Compatible with all Models and Brands of Earthmoving and Road Construction Machinery.
Caterpillar, Liebherr, JCB, Bobcat, Volvo, Komatsu, Wirtgen, Vogele, Dynapac, Case, HBM, Doosan, Hitachi, Hyundai, etc.

YES, Laser & GPS equipment is Simple and Easy to use by any Machine Operator, regardless of age and experience.

YES, MOBACT has specialized technical staff that undertakes the training of Operators, Foremen and Surveyors.

Typically, a Machine Control System that operates on a daily basis pays for itself within a few months or even weeks.

YES, it is possible to test install Laser & GPS Equipment on your Machine. Contact us for details

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THE MOBACT Provides automation, control and guidance solutions for road construction and earthmoving machinery with a key feature of increasing productivity and quality in the construction sectors.

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