Topcon

Topcon LS-B100 sets new standards for high-value, machine control sensors

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A new series of high-quality, affordable machine control sensors – the LS-B100 series – was recently announced by Topcon Positioning Systems (TPS).

Topcon LS-B100
Topcon LS-B100

 

The LS-B100 series, including the LS-B100, LS-B110 and LS-B110W (wireless), offers a modern new design and increased functionality.

Replacing the LS-B2 and B4 models, the new series provides the tightest accuracy and largest working range of machine control receivers in the market today, according to Neil Other, Topcon Positioning Systems Australia and New Zealand sales manager.

“The LS-B100 series is ideal for dozers, box blades, excavators and backhoes,” he said.

"Its unique features, such as on-grade matching and wireless capability, offer unmatched performance on any job site."

Features of the LS-B100 family include:

  • Large working range
  • Most accurate receiving resolution
  • Wireless display capability
  • On-grade matching function
  • Plumb indication
  • CAN compatible
  • Four selectable dead bands
  • Universal pole clamp.

The units use rechargeable or alkaline batteries.

Topcon A7 prism series and mounts provide multiple configuration options

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A new series of lightweight, compact, robotic prisms and mounts have been announced by Topcon Positioning Systems (TPS).

 

Topcon A7 prism

 

The A7 prism series supports the ability to mount a GPS receiver on top of the A7 prism for an integrated robotic and GPS rover solution. Additional accessories, including a regular top mount and a side-mounting option for the RC-3R, are also now available.

Multiple configurations are now available with the A7 series including:

  • The integrated GPS mount and A7 prism pole can be used in a GPS network for real-time GPS coordinates that a robotic instrument then uses for resection
  • With a full-size canister prism and RC-3R side-mount, the unit can take difficult prism shots through vegetation, wetland flag markers, and other obstructed views
  • The A7 can also be mounted inverted on a prism pole, and by having the ability to mount the prism closer to the ground, construction stakeout can be done with greater precision
  • The RC-3R side-mount can be connected at several angles, allowing very high or very low vertical angles of transmission.

Topcon LPS-900 provides millimetre-accurate local solution for Brisbane contractor

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The first LPS-900 3D local positioning machine control system is providing millimetre-accurate machine control for a Cat 12G grader engaged in small-scale paving applications around Brisbane.

The LPS-900 combines a robotic total station with precision machine control to provide what is said to be the world’s most advanced, high-accuracy local positioning 3D control system.

Topcon’s LPS-900 system features its X-TRAC® tracking technology and integrated radio communication for higher-speed operation under all conditions.

It is designed for users requiring millimetre-accurate final trim capability in applications where the multi-machine capabilities of Topcon’s Millimetre GPS™ are not required, or in built-up or heavily treed areas where satellite availability may be an issue.

It also offers a simple, cost-effective transfer path to GPS-based 3D machine control, including Millimetre GPS.
In addition, it can also be used as a survey total station.

On the LPS-900’s first Australian application, the 12G grader, owned by Universal Civil Contracting, has been achieving accuracies to within 5 mm on a small commercial development in North Lakes, to the north of Brisbane, according to operator Grant Thiele.

As of late March, Thiele had been using the LPS-900 system on the project for about two months, from final trim of the earthworks, to putting down the basecourses prior to asphalting.

“We’re easily getting to within 5 mm accuracies with this system; it works really well, and is much easier for putting the gravels in,” he said.

“It’s particularly critical to get that sort of accuracy for the top-course before you put the asphalt on; when you’re putting on 35 mm of asphalt, you don’t want to put any more down than you have to.

“We went for the LPS-900 system rather than standard GPS-based machine control because we really needed the accuracy here. We found it much easier with the Topcon LPS System because it got to within the mill we wanted, while the GPS only got you between 20 and 10 mm,” said Thiele.

Topcon’s mmGPS system would also have met or exceeded the high-accuracy spec, but given the relatively small job size, Universal Civil opted for the added engineering versatility of the LPS system.

“It takes me about 30 minutes to set it up each morning, or about half that if there’s someone here to help me – and after that, it’s right for the day,” he said.

Although this was his first application with machine control, Thiele said he had no trouble picking up the system.

“I’m finding it very good, much easier on me. It means I’ve got more hands to work the other levers.

“This Topcon system is perfect for this application; it’s easy to operate and gives us the precision accuracy we need,” he said.

Topcon automates Australia’s first Cat M-series and T-series machines

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The first Caterpillar M-series graders and T-series dozers sold in Australia have been fitted with Topcon Positioning Systems’ GPS-based 3D machine control systems, with dealer technicians and end users reporting that fitting of the Topcon systems is even easier and quicker than on previous-generation Cat machines.

In May 2006, Caterpillar announced its innovative M-series motor graders – including joystick control system in place of a steering wheel, designed to make them easier to learn and less fatiguing to operate – with the first machines delivered to Australian owners in late 2007.

The first three M-series graders in Australia – two in NSW and one in Victoria – were fitted with Topcon’s millimetre-accurate Millimetre GPS™ system and are being used in final trim applications on road projects and residential/recreational developments.

In the US, TPS worked closely with Caterpillar – even borrowing an M-series grader – to ensure that fitting of Topcon machine control systems was seamless and easy.

Most recently Topcon Positioning Systems (TPS) has developed a valve-switching unit (VSU) which bypasses the CAN-BUS on the M-series grader, and plugs directly into the hydraulics – eliminating the need for Cat dealer technicians to key in a code to allow the Topcon system to “talk” to the machines’ electro-hydraulics.

 Typically, fitting of a Topcon system to a Cat G or H series grader took around a day, but the new hydraulics systems on the Cat M-series graders (and the T-series dozers) means they are essentially “Topcon-ready”, said Garry Fleming, of Topcon’s national Australian distributor Position Partners NSW branch.

Fleming carried out Australia’s first installations of Topcon Millimetre GPS systems on M-series graders – both 140M machines – for Sydney contractor JK Williams, and immediately after for Illawarra-based Coastwide Civil.

“The process was actually surprisingly straightforward,” he said.

“Mounting points on the grader are already designed into the system and the Topcon components can just bolt straight onto those, integrating into the computer, hydraulics and electronic systems.

“There’s no special hydraulics package anymore, so it’s all very seamless. In fact, it’s easier than it was with the previous generation of graders,” Fleming said.

“That’s because we can integrate into existing wiring harnesses, we take advantage of the computer system that runs the grader, and we don’t have to put external hydraulics on any more.

“Traditionally it would take a full day to install either a G or an H series grader – but we probably took about two thirds of that time to do the M-series grader.”

Fleming’s comments were backed by Matt Brown, of Position Partners Victorian dealer, who installed Millimetre GPS on a Cat 140M for Akron Roads

“The install was carried out at William Adams on the M-series grader and it was very simple to do,” he said. “The electrics and so on that went into the machine all plugged in to the existing CAN-BUS cabling for the M-series.

“The cabling was neatly run, just like a factory install – and in fact, there is a cost-saving involved using the machine’s existing valving.

“It was a very neat install and it was actually done it in a fraction of the time, due to not requiring the fitting of hydraulic valves and so on.

“The kit we use was developed by Topcon in California and it is fully sanctioned by Caterpillar, so it was beautifully designed and meant to be fitted to that machine,” Brown said,

Chris Forrest, senior service technician with Position Partners’ Queensland branch, said there were three options for owners of M-series graders.

“With the hydraulics, we have three ways we can go: we have the traditional manifold that we put on G-series machines; the other way is we can use the Cat CAN-BUS system, but, we’ve got to activate a code for that; the other is the new Topcon valve switching unit, which by-passes the CAN-BUS – and means no additional cost.”

And fitting Topcon systems to Cat’s new T-series dozer is equally simple, said Forrest – who installed the first Topcon GPS+ system to a D8T dozer owned by Brisbane’s Bachmann Plant Hire.

“This is a very simple and quick process; we just put an interface in, and we don’t have to worry about activating codes or anything like that,” he said.

“We put the interface in between the joystick and the dozer’s computer, we put a new interface in and the control box talks straight to the Cat system, and then it all works well.”

Owners of Cat M-series and T-series machines have also found the Topcon/Cat combination working very well for them.

Scott Rogers, a director of Wollongong’s Coastwide Civil in Wollongong, said the Topcon fit up for the M-Series grader was very easy.

“It was done in less than a day, and then we were under way,” he said. “The setup was straight-away perfect the first go.”

Andrew Kuraj, an operator with JK Williams, said he found the Topcon/Cat combination ideal.

“It makes final trimming a lot quicker and accurate; it’s all computerised and you can just put in your pavement sets and away you go,” he said.

It’s also very versatile, as it can go on from this machine to the 825 compactor or dozers as well,” he said. “The same system can be programmed on to different machines.

Scott Rafferty, GPS technical manager with Bachmann Plant Hire – which had the first T-series dozer in Brisbane fitted with Topcon 3D machine control – said the installation went “faultlessly”.

“Instead of the older type systems, where they had to run an external valve, it’s now all electronic,” he said.

“Basically, they just plugged in a control box, which is in line with the blade lever and, it’s that simple. It was a lot easier.

“With the D8s we normally use them for pushing 621 scrapers, and you’ve normally got to have a D6 following up behind you, trimming, but now with the Topcon system on the D8T, we’re now able to trim the bulk earthworks as we go,” said Rafferty.

Topcon develops customised machine control kits for Komatsu dozers

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Topcon Positioning Systems (TPS) has developed customised machine control add-on kits for Komatsu’s recently released D51EX/PX-22 dozer.

Komatsu D51EX/PX-22 dozer

  Customised machine control add-on kits for Komatsu D51EX/PX-22 dozer.

The new kits offer a “glove-fit package for mounting brackets, cables, hydraulics and MC components,” according to Neil Other, Topcon’s Australia and New Zealand sales manager. 

“These kits simplify the installation, saving valuable time in the field,” he said.

Features of the kits include:

  • Access holes throughout the machine for easy cable routing
  • Low-profile control box bracket for better viewing
  • Preset locations for mounting Topcon’s machine receiver
  • Bolt-on mounts for pilot valve bracket
  • Cable protection through a recessed J-box
  • Bolt-on slope sensor bracket and anti-vibration mount.

To minimise cable routing, a new junction box has been designed for Millimetre GPS cable connection, single and dual GPS connectors, slope and laser/sonic connectors.

Automating your World: An introduction to machine control

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Welcome to the first Automating your World column, a series of advice articles by Position Partners' technical experts. In this series of articles, we will be exploring the various aspects of machine control solutions – from a simple stick-on laser receiver on a backhoe to full blown 3D machine control systems using satellite positioning technology to automatically control motor graders, dozers, excavators, pavers and profilers.

mmGPS

 

Sometimes referred to as grade control systems, machine control systems are now an everyday sight on construction sites around the world. If you do not already use such systems, chances are that you soon will.

Just a few years ago, contractors bought machine control systems to get a ‘leg up’ on their competition. The increase in productivity achieved with these systems allowed them to greatly reduce their bids and still maintain a healthy profit.

The ability to maintain tight tolerances lead to great material savings, thus reducing the cost of earthmoving operations and adding to the contractor’s bottom line.

Today, however, this technology is quickly becoming standard and contractors are realising that they need to implement this technology simply to stay competitive. Bidding a job now without factoring in the productivity gains from machine control is becoming increasingly difficult.

Everyone working in the construction industry nowadays has at least heard about machine control and hardly a month goes by without a magazine having a special feature article detailing the use of these systems on some high-profile project.

What is not always clear, however, is what differentiates the various types of systems. Exactly how do they work? How does the site plans get into the machine? Which system is most suitable for a special application? How can I get started with this technology and how should it be maintained?

In these columns, we will examine these questions and try to provide you an answer that is simple and easy to understand.

We hope this information will serve to educate the reader and assist those who are contemplating investing in machine control in making an informed decision.

For those who are already using this technology, we will explore ways to maximise the utilisation and productivity of existing systems. We plan to look at some unique machines and specialty applications as well.

While machine control systems have been around for a long time, they were previously limited to grading in a plane or following a physical reference such as a stringline or curb and gutter.

Today, the biggest excitement in the industry comes from the use of 3D machine control systems.

These systems are capable of grading complex surfaces such as super-elevated curves without the use of any pegs or stringlines. This 3D technology was introduced commercially less than 10 years ago, but it has already become a necessity on large earthmoving projects.

Head contractors and project managers are increasingly specifying that subcontractors use this technology as well. That the requirement to use machine control is trickling down to the subcontractor is no surprise.

The project owner wants to ensure that the job stays on schedule and that all work is done to specification. For this to happen, every stage in the construction process must stay on schedule, rework must be kept to a minimum and change orders must be executed ‘yesterday’.

Machine control systems can assist with all of the above and help keep cost down as well.

While the project owner gets his road built well, on time and to specification, other parties in the construction process also benefits from this technology.

Reducing rework (which often comes out of the contractor’s own pocket) is in itself a great thing, but this technology also helps the contactor to better utilise his fleet.

Reducing the number of passes to get to grade reduces both fuel and labour cost and reduces the wear on the machine. Increasing the productivity of each machine allows the contractors to use fewer machines on the job and keeping the grade as close to tolerance as possible generates great material savings.

The machine operator in turn also benefits by having a system that makes it easy for him to maintain grade, regardless of the conditions. Automated machine control manages the blade elevation for the operators and also gives steering indication.

This lets the operator focus on managing the material instead of the blade elevation, leading to less operator fatigue.

Lately, another issue has helped accelerate the implementation of machine control: The construction industry skill-shortage (something which even the current industry downturn is likely to only affect in the short term).

As most of you are painfully aware of; a whole generation of master operators have either retired or are close to retirement and it has been difficult both to recruit and retain new machine operators.

Contractors world-wide have discovered that implementing machine control on their sites not only lets their good operators do more, it also allows fine grading to be done with lesser-skilled operators.

With an automated machine, the time it takes for an operator to become proficient is greatly reduced — and a shorter learning curve means less training cost.

Interestingly, Australia and New Zealand have been pioneers in developing machine control solutions.

In fact, all the major manufacturers of these systems have research and development operations right here in Australasia.

The mining industry here has helped develop much of the underlying technology and the systems we use in construction today have a lot of things in common with the ones used in the mining sector. No doubt, our region will continue to play a very important role in the field of construction automation for a long time to come.

We hope you will enjoy this column and that you will find it helpful in making decisions about construction automation. Next time we will take a closer look at the inner workings of a 3D machine control system.

Grade well, grade quickly.

How GPS-based machine control means a new lease of life for small dozers

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GPS-based machine control is rapidly revolutionising the civil construction business, through the cost savings and productivity improvements it’s allowing. And almost as a side effect, it’s revitalising the small to mid-size dozer market.

Harry Katsanevas, machine control manager with Topcon’s Queensland dealer ABC Lasers, maintains that the combination of the latest precision GPS-based machine control, and power-angle-tilt (PAT) blades makes smaller dozers (D4-D7 size) highly productive and versatile machines.

“We are finding with small sized dozers – the small Komatsu, John Deere, Case, Liebherr and Caterpillar machines – that GPS-based machine control plus a PAT blade is becoming a tool that they’re using on subdivisional work, on road jobs and so forth,” he said.

“It allows them to easily push material around, with speeds and precision similar to that of a motor grader. 

“As everyone knows, the industry is experiencing trouble now getting operators for motor graders, but with dozers being easier to operate, plus the increased productivity with 3D machine control, contractors are using dozers to finish off batters and windrow material out.

“Because of these factors, the dozer market is really taking off, with more and more operators utilising automation; that’s increasing productivity because operators are able to get across the ground a lot quicker, and it reduces the amount of rework that has to be done.”

Katsanevas said that Topcon’s introduction of its forthcoming 3D-MC2 dozer system at Conexpo – which will allow dozers to carry out trim at speeds comparable to graders – would add to the versatility of dozers.

“With previous systems, dozers have had to trim in first gear, but when 3D-MC2 becomes available, they will be able to trim at double the speed and twice the accuracy.

“The end result is you will have a really versatile machine- and one that’s much easier to operate than a grader,” he said.

“Already with our existing systems, we’re finding that a lot of the batters done by machine control dozers are really not having to be touched now – so the graders are just coming through at the very end and cleaning up the formations and so forth as they should be doing – which is keeping everything a hell of a lot cleaner.”

His comments were backed by Scott Rafferty, GPS technical manager with Brisbane’s Bachmann Plant Hire, which recently fitted Topcon’s GPS-based 3D machine control system to a new D6R with PAT blade.

“With the D6R with the PAT blade, we’re using it for a number of applications, such as subdivisional work, where you’ve got rock retaining walls with cuts of up to 2 to 3 m high on 800 square metre pads.

“It works really well for pushing our trimmings out, plus the scraper has a much easier job picking up a long windrow instead of a short heap – so it’s actually working really well,” he said.

For use on dozer PAT blades, Topcon has introduced a dual GPS mast, running two GPS receivers on the one mast, looking after elevation, blade roll and blade angle.

 “This ability to roll the blade – on both dozers and graders – and still maintain the correct elevation, is a major advantage,” said Katsanevas.

“This means that operators can be sure that the cutting edge is cutting to design level even with the blade rolled, giving a nice clean edge to the precise elevations,” he said.

“All this means that very quickly I think we’ll see dozers utilised from bulk earthworks right through to the final trim – and only then will the motor graders will come through and finish off.

“This will give contractors tighter control on the job site; as the motor graders will be coming through and utilising their Millimetre GPS technology.

“This will take them away from doing all that bulk work, so the contractors can give that back to the dozers – and the graders will just do the trimming and cleaning up, which is what they’re designed to do,” said Katsanevas.

Topcon Valve Switch Unit simplifies Caterpillar M series automation

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Automating Caterpillar M series motor graders with Topcon’s 3D machine control systems – including Millimetre GPSTM – has become even easier for owners with the introduction of a special Valve Switch Unit from Topcon Positioning Systems (TPS).

TPS’s Valve Switch Unit (VSU) eliminates the need to add a hydraulic valve or connection to M Series grader’s hydraulic system through the CAN field bus, resulting in an integrated, real-time distributed control.

In addition, the VSU eliminates the need for an activation fee to be paid to Caterpillar to enable the interface between the machine control system and the grader’s operating system.

According to Brian Juroff, TPS director of construction sales, the VSU acts as an interface between the OEM controller and the Topcon controller to run a machine’s hydraulic solenoid valves.

“It’s a simple procedure to mount the new box, plug the cable into the Cat valve connectors – and that quickly, the machine is fully automated,” he said.

Juroff said that benefits of the Topcon VSU for Cat M-series graders include:

  • Minimal time for simple install
  • Low cost for high benefit
  • No Cat activation fee required
  • Works on all M series graders – Accugrade-Ready Option (ARO)  and non-ARO
  • Controls both 2D and 3D machines
  • Weather-resistant, rugged housing
  • Built-in LED indicators for visual operation and easy troubleshooting
  • Operator able to manually override the VSU at any time.

Topcon mmGPS makes debut on major profiling job in Adelaide

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Contractor Blacktop Profiling has been using one of the world’s first applications of Topcon’s Millimetre GPS™ fitted to a profiler on a major road upgrade project in Adelaide.

 

Blacktop loader
Contractor Blacktop Profiling using Topcon’s Millimetre GPS

 

Melbourne-based Blacktop, which has recently opened a branch in Adelaide, fitted the Topcon system to its Wirtgen W2000 profiler in mid-March, to carry out deep lift excavation profiling on the Port Wakefield Road upgrade.

According to Drew Cotter – one of two partners in Blacktop along with Greg Ellis of Ellis Profiling in Sydney – tolerances for the profiling work on this project are 0-20 mm, profiling to depths of 200-400 mm.

“If we under-cut, we are required to rework, while penalties apply if we over-cut,” said Cotter.

“Since we’ve had the Millimetre GPS system on the profiler, we haven’t had any problems and we’ve been spot on. We’ve been achieving all the desired outcomes.”

Topcon offers “best of both worlds” for final trim

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Topcon Positioning Systems (TPS) has released a significant upgrade to its 3D local positioning system (LPS), which combines a robotic total station with precision machine control to provide the world’s most advanced, high-accuracy local positioning 3D control system – and an alternative solution to Topcon’s GNSS-based precision Millimetre GPSTM system.

Topcon’s new LPS-900 features its exclusive X-TRAC® tracking technology and integrated radio communication for higher-speed operation under all conditions.

The LPS-900 is designed for contractors requiring millimetre-accurate final trim capability in smaller projects, as well as in built-up work areas or tree-covered worksites, where the capabilities of Topcon’s Millimetre GPS are not required or where satellite reception may be limited.

In addition, many common elements between the LPS-900 system and Millimetre GPS, as well as other Topcon 3D-MC systems, mean that switching between systems is quick and economical.

“The introduction of our LPS-900, complementing Topcon’s Millimetre GPS, means we can truly offer the best of both worlds for precision final trim and other grading and dozing applications,” said Neil Other, TPS’s Australasian sales manager.

“The LPS-900 is ideal for small jobs where just a single machine has to be controlled, or in applications where there may be limited satellite reception. In larger-scale projects, or where multiple machine control is required, it’s then a very simple matter to switch to Topcon’s GPS+ machine control systems.”

A combination of Topcon’s advanced robotic total station technology and its proven 3D automation technology, features of the LPS-900 include:

  • providing dual use as a base for high-accuracy machine automation or traditional robotic surveying operation
  • supplying grade information in a continuous stream via high-speed radio
  • allowing easy switching between Topcon’s GPS+ and LPS whenever the specs or job demands.

The LPS-900 uses electronic site plans to control the grade of individual machines, such as graders, dozers and excavators – with millimetre-precision, said Other.

“Site plan information is constantly referenced, with measurement differences transmitted to the machine via radio link.

“The LPS-900 uses Topcon’s patented technology to simplify work with uncompromising accuracy, allowing users to save time on even the most demanding job, thus increasing profitability,” he said.

“This system seamlessly integrates traditional survey technology with the latest in local positioning and digital site plan-based grade control.

 “Less initial pegging is required, while re-pegging and conventional string-lining become obsolete, saving time and money. The result is fast, fully automatic grade control with industry-leading accuracy,” he said.

“It also means that Topcon customers have the choice of millimetre-accurate final trim systems depending on their needs, the application, and their budgets – with an easy transfer path from LPS to Millimetre GPS whenever they require it,” said Other.