Topcon

IP-S2 – Topcon’s magic wand of survey mapping

US-based specialist construction writer Richard Ries looks at the science and technology behind Topcon’s latest survey mapping solutions. Note that this was written for a general consumer audience, rather than specialised industry people.

With the map features found on many Internet sites today, you can zoom into your country cousins’ property and see if they planted corn or soybeans this year. If it’s corn, you can almost see the silk drooping from the ends of the ears. If it’s beans, you can almost see the fuzz on the pods.

How on Earth can these sites provide this level of visual information about any place on Earth to you wherever you are on Earth? Is it magic?

Well of course, it isn’t magic, it’s technology – although the line separating the two almost grows less distinct every day.

Truth is, the base technology in this case isn’t all that magical.

According to Charles Rihner, vice president of planning for emerging business units at Topcon, it is a collection of familiar, proven components that form the foundation of the system.

Those components are satellite navigation systems, cameras, lasers, a vehicle’s onboard computer (CANbus), and a laptop computer.

But tying together the data from all these sources is as close to magic as you can get.

The unifying force comes in the form of Topcon Positioning Systems’ IPS-2 parallel program measurement integrated positioning system (see the separate section at the end of this article).

Data collection

“Before data can be integrated, individual data points must be gathered,” said Rihner. “This is done in real time by driving a research vehicle along the desired route.”

As the vehicle proceeds, the IPS-2’s GNSS antenna gathers position data from the two satellite constellations currently in operation, GPS and GLONASS (again, please see separate section below).

Six cameras, which are ganged together, provide 360-degree digital imaging at 30 frames per second. Each frame is time-stamped and geo-referenced.

A light detection and ranging (LiDAR) system integrated in the IPS-2 delivers 3D information about structures, tree cover, and other roadside features.

“LiDAR is like radar,” Rihner said, “but it uses lasers instead of radio waves and therefore employs shorter wavelengths.
“LiDAR also has excellent beam density and coherence. These traits provide backscatter, a highly detailed reflected image that, unlike radar, picks up small items and non-metallic objects.

“Radar is great for finding airplanes and ships, but LiDAR finds such features as leaves, fiber optic lines, and even smoke and dust,” he said.

A typical IP-S2 setup would use three laser scanners, one on the left side of the vehicle, one on the right, and one more aimed straight up or to the rear. The system will support as many as six lasers.

Running at 75 Hz, each scanner delivers 45,000 data points per second. As with the digital images, each data point is time-stamped and geo-referenced. Scanners from SICK AG of Germany are well suited to the IP-S2 application.
Information on pitch, roll, and yaw is delivered in the form of an inertial measurement unit, or IMU.

Pitch describes whether the vehicle’s nose is pointed up or down or remaining level.

Roll describes whether the vehicle is level from side-to-side.

While both pitch and roll relate to horizontal planes, yaw is the amount of rotation around a vertical axis, as when the vehicle is turning.

The vehicle’s CANbus gathers odometer and tracking information from wheel sensors, which are part of a vehicle’s anti-lock brake system.

The IMU extrapolates velocity information, which includes both speed and direction, from the data provided by these sensors. Vehicles lacking ABS can use aftermarket, add-on wheel sensors.

The IPS-2 and the laptop computer work together to co-ordinate all the information gathered as the vehicle moves about.
Information is available in real-time in the field.

Further refinement of the information takes place during post-processing, when the resulting data-rich file is combined with an analog map to create a digital map with extremely high accuracy and which includes 3D elevation views and time stamps.

The last step is to remove “noise”, such as out-of-range data points, and put the final polish on the file. Post-processing is especially adept at restoring the accuracy of data gathered using the IMU only, which occurs when satellite signals are unavailable.

Who needs it?

Okay, it’s cool to see corn tassels shimmering in the country sunshine on your computer screen, but it’s unlikely anyone would commit the necessary resources for such precise mapping just to amuse ’net surfers.

But as Eduardo Falcon, senior vice president for emerging business units at Topcon, points out, there is a broad assortment of mapping applications that justifies the investment. They include:
• Cartographers, who make up the biggest market for IP-S2, whether they’re creating maps for print publications, online customers, or on-board vehicle navigation systems.
• Surveyors, who rely on IP-S2 because the information it provides is complete, accurate, and up to date.
• Road maintenance crews, who use IP-S2 to locate and identify areas where work is needed. It not only gives the location but also pictures of problems such as blocked drains, potholes, rutting, and edge crumbling. Snow removal operators can’t see the roadway under a foot of snow and use IP-S2 for edge detection.
• Telephone, electric, and cable providers, who can see where trees need to be trimmed back from transmission lines. IP-S2 will be a key enabling technology for intelligent transport systems and the automated vehicles that run on them.

While every aspect of IP-S2 is impressive, three features truly stand out.

1. IP-S2 can use IMU data to interpolate position information when satellite signals are blocked. Signal blockage can occur when the research vehicle is in a canyon, either natural or man-made (think high-rise), or under a dense canopy of trees. This makes IP-S2 the tool of choice when gathering information in urban settings. Using an IMU, IP-S2 can continue to collect data even in tunnels and under bridges.

2. IP-S2 is scalable. Not every application needs every feature. Cameras, lasers, and other components can be added or removed as needed for the task at hand. Because the whole raison d’être of IP-S2 is to integrate data from parallel sources, custom configuration of the system really is a plug-and-play operation. As new components are developed in the future, these, too, can be added to the IP-S2 repertoire.

3. While the point cloud acquired by LiDAR is adequate for identifying objects and features, the integration of the visual images provided by the cameras adds even more value. A tree is identifiable in the point cloud, but from the camera image a technician can tell if the tree is healthy or diseased and whether it’s an elm or an oak. By clicking on that tree’s image in the point cloud the technician can access all the geospatial information stored by IP-S2.
This level of detail makes IP-S2 the preferred tool for mapping and for asset management because it saves so much time and money, said Falcon.

“With traditional survey mapping, it’s hard to gather the right amount of information.

“The surveyor may spend excessive time in the field gathering too much information for fear of overlooking something. Or the surveyor may indeed overlook something and then have to make another trip to the field to gather the missing data.

“With IP-S2, neither situation will occur. A single pass gathers all the information the technician needs, and that information is then available at the technician’s computer,” he said.

What’s next?

Although IP-S2 is a new development, mobile mapping began in the late 1980s.

Early challenges included limitations in both data storage and scanning technology. Those challenges have long been met, but new ones have taken their place.

The biggest problem, said Falcon, is that “the information is dumb. It still takes a human to extract and interpret and edit the data.” The next step, then, is to automate the interpretation.

It would be fairly easy to program IP-S2 to recognise stop signs, for example, except that computers don’t recognise things in the same manner that humans do.

When approaching a red, octagonal sign with the letters “STOP” on it, both the computer and the human will recognise the object as a stop sign.

But what about when the approach is from an angle?

What if the stop sign has baffles to make its message unidirectional, as is done when one road intersects another at an acute angle?

What if the stop sign is part of an ad on the side of a city bus (“STOP wasting time and money. Let ACME Corporation help with your investments”) and what if the bus is moving? The human will assess each of these situations with unfailing accuracy.

The computer’s accuracy will likely be much lower.

“Software engineers can set parameters to help interpret the data,” said Falcon. “At the extreme it’s artificial intelligence.”

Even if the algorithm can’t identify every feature with 100% accuracy, the autoprocessing of just the easily identified objects would greatly reduce the need for data interpretation by humans.

It’s no exaggeration to say that IP-S2 will revolutionise survey mapping and asset management.
IP-S2 gathers information quickly and accurately and it doesn’t miss a thing. It reveals the location and condition of every single feature it encounters.

From the tassels in your country cousin’s cornfield to the parking meters outside your city cousin’s office complex, IP-S2 sees everything and stores everything it sees.

It isn’t magic, but it’s close. Really close.

Footnote 1: IPS-2 is the second generation of a parallel program measurement system used to monitor multiple programs that are running simultaneously.

Essentially, IPS-2 is a “traffic cop”. It makes sure the data tributaries from the various components of a research vehicle flow smoothly into one wide data stream.

It allows programmers to easily identify data conflicts and bottlenecks so they can be resolved.
IPS is built on the Charlotte Distributed Operating System. This second iteration extends the original IPS system with new instrumentation techniques, an interactive and graphical user interface, and new automatic guidance analysis techniques.
Footnote 2: GNSS (Global Navigation Satellite System) is the preferred term when discussing satellite positioning systems.

GPS, the 24-satellite constellation deployed by the US government, is part of the GNSS, as is Russia’s GLONASS system of 17 satellites. The European Union’s Galileo system is to be operational by 2013 and China plans to expand its regional Beidou system to a global system, named COMPASS, by 2015. GNSS is the collective term that includes all of these systems.

Topcon buys leading Italian technology company

Topcon Positioning Systems (TPS) has purchased a significant ownership interest of Destura, srl, a software and hardware technology company located in Concordia Sulla Secchia, Modena, Italy.  TPS has committed to buying the remaining ownership interest by 2014.

In conjunction with the purchase, TPS will purchase a large tract of land and several industrial buildings to be used as a training facility and field test site for Europe.

Destura designs and manufactures software and hardware electronic and mechanical products for the electronics, automotive, agriculture and telematics industries.

Destura products include data management boards, system diagnostic wireless interfaces, wireless transducers, transmitters/receivers and related systems, vehicle (automobiles and tractors) engine control unit devices and portable mobile navigation system devices, telemetry systems and high-frequency antennas and transducers, among others. 

Prior to the purchase agreement, Topcon was one of Destura’s largest customers. The company is best known for its Telepass toll-road payment system, and its work with Ferrari and Maserati in manufacturing engine test computers.

Ray O’Connor, TPS president and CEO, said Topcon’s business relationship with Destura proved the company was an excellent provider of services and products to the telematics, vehicle and electronics industries.

“This agreement to purchase the company shows our commitment to help grow the business, and strengthen our position in the telematics and controls market.”

Topcon’s IP-S2 allows fast and accurate precision mapping and surveying

Topcon Positioning Systems (TPS) recently launched its IP-S2 vehicle-mounted, mobile 3D precision mapping and survey system. The IP-S2 combines dual-frequency GNSS signal tracking and positioning and inertial measurement to integrate laser scanning and digital imaging.

Using 3D laser scanners, LIDAR, and/or cameras, the data collected is integrated, time-stamped and geo-referenced. The customer can then quickly and accurately combine LIDAR “point cloud” and digital imaging data to build 3D models of the areas driven. 

Industry-leading sensor integration creates unlimited applications for the technology in GIS, construction, agriculture, mapping, and machine control — all areas where Topcon has market leadership.

Ray O’Connor, TPS president and CEO, said Topcon’s Inertial Positioning System (IPS) “makes it possible to track motion through 3D space, creating an instant solution to myriad asset management and data collection applications.”

With its high accuracy scanning and inertial measurement capabilities, its ability to support a variety of sensors and its 360-degree hemispherical digital video camera system, he said,

“The IP-S2 can gather accurate measurement data in extremely difficult conditions, such as tunnels, under bridges, in heavily wooded areas or urban canyons.

“The applications for the IP-S2 are limitless,” he said.

“Whatever you can conceive of in the areas of asset management, data collection on precise location of virtually any subject, using digital photography capabilities, as well as laser scanning options, with its onboard tools the IP-S2 can do the job.”

Collecting field data for GIS applications has always been a time-consuming task, usually taking several years to fully accomplish.

As a result, many databases are incomplete, preventing managers from utilising their full potential. Safety has also been an issue, requiring personnel to stand in highly travelled road corridors where most assets are located.

Eduardo Falcon, senior vice president and general manager of Topcon’s Emerging Business Unit, said the IP-S2 would revolutionise the way in which GIS field data can be collected.

“One pass of an area at normal vehicular travel speeds provides a complete dataset of highly accurate position information and high resolution imagery.

“Using new software tools, GIS operators can easily identify features, assign attributes, and then export them to geospatial applications. The reduction in cost and improvement in safety are exponential compared to traditional ground survey methods.”

The IP-S2 standard system includes three high-resolution LiDAR scanners which cover the vehicle path at ground level and sweep the adjacent areas to a distance of 30 m.

Integration of LIDAR point cloud data with digital imaging allows users to obtain co-ordinate measurement of objects and surfaces.

The technology can provide location and geo-referencing with survey accuracy of visible utilities, traffic signals and roadways, modeling GIS maps, examining tunnels, taking inventory of and collecting 360° digital images (at a rate of 15 frames per second) to catalog surroundings in real time.

The IP-S2 software and hardware have been designed and constructed in a modular format so that an array of present and future sensors can be easily integrated to the existing scanner ports. 

The IP-S2 also works in coordination with an online data post-processing service to provide data sets with the highest possible accuracy. Users can obtain the information, store the information safely and retrieve it effortlessly.

Falcon said the IP-S2 was designed “from the beginning with the goal to be easier to install, learn and use than any other existing mobile positioning solution.”

There are more than 400 of the units currently in use worldwide.

In Australia, the first installation will be commissioned very shortly, according to Bob Bent, executive director with Topcon’s Australian distributor, Position Partners.

“We are very excited about this new technology, and the fact that one of our customers will shortly be putting the IP-S2 to work on a major infrastructure project,” said Bent.

“It represents a major step forward for asset data capture across a wide range of industries – and once again is an example of Topcon’s industry leading technology.

“We can see huge benefits for this system and this technology around Australia,” he said.
Additional IP-S2 information is available at www.topconpositioning.com/products/mapping-and-gis/mobile-mapping/ip-s2.html

An overview of the technology behind IP-S2 is availble here http://www.positionpartners.com.au/news/topcon/ip-s2-topcons-magic-wand-of-survey-mapping/

 

Topcon picks up major government contracts in Japan and China

Over the past few months, Topcon Positioning Systems has picked up some significant government contracts for the supply of precision positioning equipment for critical public infrastructure.

They include:
• 450 NET-G3 receivers to Japan’s Geographical Survey Institute as part of a major upgrade to its GPS Earth Observation Network System (GEONET)
• The supply of GNSS CORS receivers and GNSS choke ring antennas for an earthquake prediction system in China
• Supplying 14 sets of Net-G3 CORS receivers and CR-G3 GNSS choke ring antennas to the Beijing Meteorological Bureau (BJMB), for use in the Beijing ground-based GPS-PWV (Precipitable Water Vapor) detection system project.

According to Bob Bent, Executive Director with Australian Topcon distributor Position Partners, these contracts indicate public sector confidence in Topcon products, technology and innovation for critical projects.

“Whether it’s earthquake prediction, weather forecasting or providing key elements for a major CORS network upgrade, major government agencies in Japan and China have opted for Topcon product excellent and engineering expertise,” said Bob.

“Likewise in Australia, we are finding increasing numbers of government agencies and departments choosing Topcon products — not only for their technological excellence and reliability, but also because they offer a ‘future-proof’ way forward to forthcoming new technology.”

More details of these recent contracts are as follows.

Japanese GSI reference stations contract

Topcon’s selection by the Geographical Survey Institute (GSI), an affiliate of the Japanese Ministry of Land, Infrastructure, Transport and Tourism (MLIT), to supply 450 GPS reference stations, as well as new software and a database system for the GPS Earth Observation Network System (GEONET) operated by GSI.

In 1992, GSI initiated the introduction of a GPS Continuously Operating Reference Station (CORS) known as GEONET. As of March 2009, nationwide 1236 stations are in place throughout Japan, providing precise positioning data to the public.

Today the GEONET is a vital infrastructure of the country, providing GPS data for diverse applications such as surveying, construction, GIS, weather forecasting, among others. It also provides the real-time observation data of earth’s crustal movement for the purpose of researches in earthquake and volcanic activities.

In this project, GSI is replacing 450 old receivers with Topcon’s NET-G3 series incorporating the latest tracking technology for currently planned L2C and L5 GPS signals. Topcon will also develop GPS observation/control software as well as a database management system exclusively designed for the GEONET.

It is expected the new systems will be in operation by the end of March 2010.

With the recent ordering of an additional 90 new Topcon receivers, more than 35% of the GEONET network will implement Topcon NET-G3 series receivers.

Earthquake prediction system in China

Topcon Positioning Systems (TPS) has been selected to supply GNSS (Global Navigation Satellite Systems) receivers for the Crustal Movement Observation Network of China (CMONOC).

Topcon will supply 132 campaign-mode (portable) GNSS CORS receivers and GNSS choke ring antennas for CMONOC. 
The CMONOC project was established by the China Earthquake Administration (CEA) of the People’s Republic of China, to monitor crustal deformation and to predict earthquakes using GNSS technology.

In the context of the devastating Wenchuan Earthquake (8.0 on Richter scale) in 2008, the Chinese government hopes to use state-of-the-art technologies to enhance disaster-relief capability. CEA used the equipment to re-measure more than 2000 ground monuments throughout China in 2009.

Crustal deformation is measured by tracking the movement of points on the Earth's surface, ground tilt and strain, as well as fault slip. The Topcon Net-G3 family of receivers will be used to record geodetic data for the CMONOC in campaign mode, also known as portable, episodic or survey mode.

The Topcon Net-G3 family of receivers being used by CMONOC incorporate Topcon G3 technology, which allows for universal signal tracking compatible with all existing and planned satellite navigation systems. 

Weather forecasting project for Beijing

Topcon has supplied 14 sets of Net-G3 CORS receivers and CR-G3 GNSS choke ring antennas to the Beijing Meteorological Bureau (BJMB), for use in the Beijing ground-based GPS-PWV (Precipitable Water Vapor) detection system project.

The Net-G3 family of receivers incorporate Topcon G3 technology which allows for universal signal tracking compatible with all existing and planned satellite navigation systems.

Topcon’s relationship with BJMB goes back to 2006, when the Bureau established its first 14 GPS CORS as a pilot project in Fangshan District and Huairou District of Beijing City, using Topcon CORS receivers.

This pilot system was used to provide weather forecasts during the 2008 Beijing Olympics.
The 14 receivers are being deployed in Yanqing District and Miyun District of Beijing, where two major water reservoirs are located, to detect precipitable water vapor in the atmosphere above the area and improve the weather forecast service to the public.

Automating your World: Getting the last millimetre with machine control

Welcome to the fourth Automating your World column, a series of advice articles by Position Partners technical experts. In this series of articles, we look at the various aspects of machine control solutions.


A high-accuracy 3D grade control system showing the combined
GNSS antenna and laser receiver.

In the previous column, we looked at how single-antenna, twin-antenna and dual-mast GNSS (Global Navigation Satellite System – a generic term for all satellite positioning systems, including GPS)) grade control systems compared to each other and which application each was best suited for.

GNSS-based 3D grade control systems have made a major impact on how heavy construction is done, but they still have limitations when it comes to achieving very tight vertical accuracies.

This is true regardless of which brand you use.

And, while triple-constellation (GPS, GLONASS and Galileo) grade control systems will be able to work in more places and under more adverse conditions, they are still subject to the various orbital errors and environmental factors, which degrade the vertical accuracy somewhat.

Now, there are many examples of contractors who use GNSS exclusively for all their earthmoving tasks and even finishing. However, the manufacturers of these systems will tell you that they cannot guarantee the vertical accuracy will be good enough for finishing.

So, what to do?

GNSS and Lasers

The various GNSS systems will give you a horizontal accuracy that is pretty much good for any earthmoving and grading task. The challenge is to find a way to improve the vertical portion of your position.

It is possible to combine the GNSS position with a terrestrial vertical reference such as a rotating laser. Such a system will use the GNSS signal to position the grader horizontally and the laser signal to get a very accurate vertical position – to within a few millimetres.

There are two ways this can be done:
1.    By using a conventional, construction-grade laser
2.    By using a purpose-designed, “fanned-beam” laser.

With a conventional laser, you have the benefit of being able to use the laser you already own, but you will be limited to working within a vertical range that cannot be wider than the physical length of the laser receiver you put on the grader.

What this means is that, if you have a laser receiver on the grader which is physically 1 m long, then you must keep your grader working within ±50 cm from the height at which the laser is set up.

If your grader travels further than 50cm vertically, you will lose the laser signal.

The other way to solve this is to use a fanned-beam laser


A fanned-beam laser set up on a job site.

Instead of sending out a single plane of light like a standard grade laser, this laser sends out a “fanned” beam that lets the operator work to high vertical precision within a 10 m elevation range.

A fanned-beam laser will also let you use a “normal” sized laser receiver on your grader, which is far less susceptible to failure from mechanical shock and vibration.

No matter which solution you choose, a combined GNSS/laser 3D grade control system is incredibly versatile.

For most of your earthmoving tasks GNSS alone will be good enough, but when you need to tighten up your vertical, you simply pull out your laser and finish the job with that.

A strong selling point for these systems is that an unlimited number of machines can run off of a single laser. This not only lowers the cost of achieving high vertical accuracy, it also reduces the potential for set-up errors, because all machines are working from the same laser.

If you have five graders with GNSS systems already on them, you may well only have to purchase two additional laser add-ons, since they can easily be shared between all the graders.

One thing to be aware of with such a combined GNSS/laser system is that you are now faced with maintaining two lines of sight to your grader: One from the GNSS antenna to the satellites and one from the laser receiver on the grader to the rotating laser on the job site.

However, the benefits of the combined GNSS/laser system far outweighs this detail and you will find that with proper site planning and management, disruption stemming from people, other equipment, vehicles or trucks breaking the line of sight will be kept to a minimum.

Robotic Total Stations

Another way that 3D grade control systems achieve high vertical accuracy is to use a robotic total station as the positioning device. In fact, this is older technology than the above-mentioned GNSS/laser systems.


Robotic total station and grader with the robot target mounted on the mast

This system does not make use of satellite signals for positioning at all and can therefore also work indoors or in places where there is a severe obstruction of the sky, such as directly underneath an overpass or underground.

A robotic total station automatically tracks a target mounted on a mast on the blade of your grader, placed where you would otherwise mount the GNSS antenna.

Because the total station always knows where it is in the local co-ordinate system, it will also know where the target (that is, your grader) is at all times – simply by locking onto the target and following it.

The robotic total station feeds the 3D position of the target to the control box in your grader many times per second via a radio link.

These positions are then used by the onboard computer to determine cut/fill for where the blade is at a given moment, in exactly the same manner as a 3D position derived from GNSS would be used.

These systems are highly accurate and have been field-proven for more than a decade.

Although outnumbered by GNSS systems in the field, the ability to work underground and indoors will ensure that these systems will be around for a long time to come.

However, as with a combined GNSS/laser system, you must maintain clear line of sight between your grader and the robotic total station tracking it.

But, in contrast to the combined GNSS/laser system, the total station can only track a single target at a time, so this set up requires a dedicated robotic total station for each machine.

Choosing your system

The various positioning technologies available for 3D grade control systems today have all come about because they each solve a particular problem and are particularly well suited for a specific application.

It is unlikely that a single positioning technology will solve all the earthmoving and grading tasks faced by your company, so it is important that you stay educated about the various solutions currently available.

For many contractors, the ease with which various sensor technologies can be switched around is paramount  – so ensure you speak to your positioning system sales representatives to ensure you have the maximum flexibility from whatever solution you choose.

Something else to look for is a consistent operator interface between different positioning technology, so the operator screen remains unchanged and familiar no matter which type of positioning is currently being used.

That means shorter learning curves, and the ability for operators to very quickly switch from one type of system to another.

Speak to your sales representative not only about which system is right for your particular job, but which systems are right for your company across your full range of work and projects.

Advanced technology is great, but it is essential it be combined with competent and timely local support in order to be of most value to you, and to help you sort out problems and issues.

Grade well, grade quickly.

 

 

Victoria’s Matt Brown inducted into Topcon’s President’s Club

Matt Brown, Machine Control Manager with Position Partners’ Victorian branch, has been inducted into Topcon Positioning Systems’ President’s Club. 

Matt Brown award winner

  From left, Jamie Williamson, Topcon Positioning Systems Senior Vice President
for Sales and Marketing; Matt Brown, Position Partners; and Ray O’Connor, president
of TPS with Matt following his induction into Topcon’s President’s Club.

This is a prestigious award made by TPS for high achievers and future industry leaders and is awarded on merit and performance.

As a member of the exclusive Topcon President’s Club, Matt joins a small but elite group of people from TPS and its global distribution organisations in shaping and directing the future of Topcon products, customer service and marketing direction.

Our warmest congratulations to Matt on this outstanding achievement.

Topcon increases productivity, cuts costs on complex highway project

NSW contractor Coastwide Civil is using a range of Topcon machine control and rover systems to increase productivity and reduce costs for itself and its client on a complex highway project just north of Wollongong.

Coastwide M series grader

Coastwide M series grader

Wollongong-based Coastwide is carrying out the earthworks and pavement works on the 3.5 km Northern Distributor extension project, as a subcontractor to Reed Constructions.

The project, due for completion in mid-2009, will result in a four-lane highway from just north of Wollongong, to Bulli.

It traverses a highly built-up area, with numerous road and services crossings, and is in a fairly low-lying area subject to heavy rainfall.

Topcon equipment on the project includes Millimetre GPS on a Cat 140M grader and Cat 12H, X63 indicate systems on Cat 330D excavators, 3D MC systems on Cat D8L and D10R dozers, plus rover systems running Millimetre GPS.

 

Coastwide M series grader

 

Coastwide M series grader

 

“We’re using our Millimetre GPS rovers to do all our set out and the site’s basically pegless; it's a big advantage for our company not to have to put a peg in the ground,” said Scott Rogers, a director of Coastwide Civil.

“We find that it is giving us a huge advantage, especially with our speed. We get the levels right first time and there's no guesswork.

“And our clients are very happy with it; it's saving them a lot of work as they’re not doing any surveys for us – basically we are doing all of our own.

“There are no problems for them, and we are saving the client money by using Topcon gear,” Rogers said.

 

Scott Rogers Coastwide Civil

 

Scott Rogers, Coastwide Civil

Automating your World: Configuring your machine for successful 3D machine control

Welcome to the third Automating your World column, a series of advice articles by Position Partners’ technical experts. In this series of articles, we look at the various aspects of machine control solutions.

A single-antenna 3D grade control system on a Komatsu GD655 motor 
grader

 

Look at any job site and you can immediately tell whether or not the contractor is taking advantage of 3D grade control:

The ubiquitous masts sticking up from the blades of the machines give them away instantly.

They are on graders, dozers, scrapers and excavators and are now a common sight on Australian job sites.

But why is it that some machines have a single mast and others have two? Is there a difference between the systems? Is one better than the other? How do I choose which set-up is right for me?

Before looking closer at the various options, let’s recap what a 3D grade control system does: A data model of the job site resides in the on-machine computer. A GNSS (Global Navigation Satellite System) antenna determines the position of the cutting edge of the blade several times per second and feeds this information to the computer.

The difference between where your edge is (as measured by the GNSS antenna) and where it should be (as determined by the data model in the on-machine computer) is your cut/fill for the particular position where the blade is currently located.

The cut/fill information can be fed to the hydraulic system in order to drive the blade to design elevation in real time.

We must know the 3D position of the entire cutting edge of the blade, not just a point along the edge. Most graders are therefore set up with a rotation sensor, blade slope sensor and a mainfall slope sensor.

When all the dimensions of the machine is known to the computer, these sensors combine with the position from a single GNSS antenna to give us the exact 3D position of the entire cutting edge.

For many applications, a single-antenna system is a good solution. The drawback with this configuration is that the machine doesn’t instantaneously know the direction in which it travels.

A single 3D point is not capable of giving the system an orientation. The on-board computer therefore makes certain assumptions (such as the machine must be going forward when it is grading; no back dragging) in its algorithms.

An example of where a single-antenna system falls short would be when a dozer is used for finishing a steep slope.
If the slope and conditions are such that the tracks are slipping, the machine will be ‘crabbing’, meaning the direction in which its nose is pointing is different to the direction the machine is actually travelling. This could lead the system to query the data model in a spot that is slightly off horizontally, resulting in an elevation error.

Enter the twin-antenna system.


A dual-mast system is a must for an excavator, as seen here on a 
Caterpillar 325B

In the above example, we could query the data model in the correct spot if we just knew where the machine was pointing. By putting two GNSS antennas on the same mast we get two 3D positions and therefore know the heading of the machine in real time.

If the machine is fitted with a PAT (power-angle-tilt) blade, we can add a rotation sensor and the system will know both the heading of the machine and the orientation of the blade, ensuring correct cut/fill calculations.

The twin-antenna system also excels when installed on a motor grader. In addition to the system always knowing the direction of travel, a twin-antenna lets the operator roll the blade to suit the material and current conditions.
Other systems either require the operator to keep the blade fixed (so that the mast and antenna are always perpendicular to the mainfall of the machine) or must have a slope sensor installed to measure the roll. A twin-antenna system overcomes both these problems.

It is also possible to dispense with the rotation, blade slope and mainfall sensors on a motor grader and replace them with an additional GNSS mast and antenna.

Such a system is referred to as a dual-mast system and consists of two masts, each with a single GNSS antenna on top. The masts are mounted close to each blade corner.

Because the system gets a 3D point for each corner, it will instantly know the 3D position of the whole cutting edge and its direction of travel.

Note that I said direction of travel of the blade, not the machine. With a dual-mast system there is no way to measure the relationship between the blade and the machine.

The system must make assumptions as to the direction of the machine by having the software use empirical data to chart the path of the machine. For most grading applications on near-level surfaces this is usually not a problem.

A dual-mast system can let an operator articulate the machine and side-shift the whole A-frame to work very steep slopes.

However, one must be careful of how much the blade is sloped.

Because we deal with satellite signals, a very steep blade slope means the GNSS antennas will be pointing towards the horizon and not straight up. This can affect their ability to receive the satellite signals.

A drawback of the dual-mast system is that it is difficult to switch from using the GNSS antennas to using other positioning sensors.

Laser grade control, sonic grade control and 3D systems using robotic total stations all rely on the mainfall, blade slope and rotation sensors ‘normally’ found on a motor grader.

A dual-mast system cannot easily switch over to other poisoning methods unless the above sensors are already installed on the machine.

On dual-mast machines, they are normally not. If they were, there would no need to install two masts and have two antennas, since a single mast and antenna would be sufficient.

On excavators, though, a dual-mast system is the most practical solution.

This machine is fundamentally different from other earthmoving equipment in that it doesn’t work when it is travelling. It works only when the tracks are still.

It does, however, rotate. Because of this, two separate masts with one antenna on top of each are mounted on the back of the machine body. When the tail swings, the system knows it instantly because it works with two 3D positions at all times.

Be sure to ask your sales representative which antenna configuration is right for your application.

A twin-antenna 3D grade control system installed on the yet-to-be-
released John Deere 764HSD (High Speed Dozer)

 

And because some manufacturers only supply one or two of the above configurations be sure to ask why the sales representative is offering you a particular configuration over another.

Getting the right system for you application will ensure you the most return on your investment.

Grade well, grade quickly.

Automating your World: Unlocking the data model mystery – or how does a 3D system know how much to cut?

Welcome to the second Automating your World column, a series of advice articles by Position Partners' technical experts. In this series of articles, we look at the various aspects of machine control solutions.

Figure 1

One of the questions I am asked most often is: “How does the 3D system know how much to cut?”

Many prospective 3D grade control buyers quickly grasp the concept that a GNSS (Global Navigation Satellite System) receiver mounted on the blade of a motor grader can give you the position of the cutting edge of the blade in real time.

However, how the computer in the cab knows where grade is and how it gets that information deserves an explanation.

Before we proceed, though, let’s review what the 3D grade control system actually does.

In short, an on-board computer in the cab has a digital copy of the site plans stored in its memory and a GNSS receiver combined with various on-board sensors tell the computer the position of the cutting edge of the blade.

The computer then makes a determination of how far the cutting edge is from grade and sends a signal to the hydraulics to drive the blade to grade. This comparison is done several times per second, creating a real-time 3D grade control system.

When we use a 3D grade control system we are essentially bypassing the traditional process of grade staking.
Instead of giving site plans to the surveyor, who uses these to set stakes and then having the machine operator visually read those stakes, we are now putting the site plans on a screen directly in front of the machine operator.

In order for the system to have useful information to work with, the site plans have to be prepared in a format that the on-machine computer can understand.

A site model, or DTM (Digital Terrain Model) needs to be created – either from paper plans or from the engineer’s CAD (Computer Aided Design) file.

When starting with 2D printed plans (Fig 1), information on the paper will have to be manually transferred to a computer in an office environment.

 

Figure 3

 

Co-ordinates, along with templates and alignments must then be turned into digitised linework (Fig 2). There are a number of software packages on the market that can do this, so check with your machine control system sales representative for what he recommends.

Once in the office computer, this linework can be further transformed into a DTM (Digital Terrain Model) through a process often referred to as “tinning”. TIN stands for Triangular Irregular Network and is the description of a mathematical method of creating surfaces from a set of point

Figure 3

 

Lines are drawn between three close points to create a surface between them. This process is then repeated using adjacent points until the whole site has been turned into a 3D surface, comprised in turn of tiny, triangular surfaces (Fig 3).
On some projects the engineer can make a CAD file of the site available. If this can be obtained, a DTM can sometimes be generated more easily.

However, it is important to remember that the engineer’s CAD file shouldn’t go directly in the machine; rather it needs to be “stripped down” to only the relevant grade information.

Manufacturers of 3D grade control solutions often use proprietary formats (types of DTMs) in their on-machine computers.
This is because DTMs created for purposes other than grade control often are large and difficult to use in a real-time application.

So, in order for the system to run well, the on-machine computer will often require a specific format and one that differs from those of other manufacturers.

This is normally not an issue, as most manufacturers supply conversion software with their 3D grade control system, which will convert an industry-standard DTM to the specific format required in their on-machine computer.

Additionally, these software packages also contain a data model viewer that is very helpful in controlling the quality of the data you put into your 3D system.

A viewer allows you to look at the completed model from all angles, spin it around and zoom in and out. If there is an error in the data, it is usually easy to spot as it will show up as a “wild” grade break.

While a machine operator can learn the basics of a 3D grade control system in about a day, learning how to prepare the data models can take a bit longer.

If you are doing it in-house, you’d want to give the task to someone with CAD experience. The trick in learning how to make a good data model is knowing which pieces of information the machine wants.

When considering the purchase of a 3D system, be sure to ask your supplier about the data preparation. Your supplier should be able to give you a good understanding of the data flow as it relates to that particular system and let you know which options are available for training on how to prepare the data models.

They should also tell you if the conversion software comes with the system or if it has to be purchased separately.

The data is a very important part of your 3D grade control system. It need not be difficult, but it helps to be educated about the process so you can better implement the technology in your company.

Grade well, grade quickly.

New Topcon FC-120 field controller is compact, powerful and affordable

A powerful, compact and affordable field controller  – the FC-120 – has been unveiled by Topcon Positioning Systems (TPS).

 

Topcon FC-120

 

 

The FC-120 is available with TopSURV, Pocket Layout or Pocket 3D — Topcon's survey, layout and 3D site management software packages.

According to Neil Other, Topcon Positioning Systems’ Australia and New Zealand sales manager, the FC-120 incorporates an innovative design that packs the power of the previous model FC-200 into a smaller data collector with a large array of capabilities.

Its operating system, Windows® CE.NET 5.0, provides a field-proven operating environment that is well known and accepted in the surveying and construction industries.

Fitted with a 520MHz processor, the FC-120 provides the best balance of performance and power consumption.

“With the FC-120, Topcon has designed a compact instrument with advanced software functions that are easy to use such as a large key pop-up keyboard for data entry,” Other said. 

The FC-120 provides Compact Flash (CF) and Secure Digital (SD) card slots. 

“We can’t know what might be available in five years for a CF or SD card slot but the FC-120 is ready for it.  The card access is a superior design element.  It’s a simple, yet reliable access door allowing a user to quickly add or change memory cards,” he said.

“The FC-120 is a valuable job site tool available at an affordable price.

“It’s a rugged controller and with its advanced features, and the fact that it’s easy to learn to use and operate, the FC-120 fits the project needs for any operation,” said Other.

Features of the FC-120 include:

  • 520 MHz XScale processor
  • Windows® CE.NET 5.0 operating system
  • Compact Flash (CF) and Secure Digital (SD) media card slots for memory expansion and connectivity options