We explore the current situation with grader machine control in Australia, the different options available and why there is still so much to be gained from the technology.

In Australia, the uptake of machine control for graders is high compared with other markets around the world, with between 15-20% of all machines fitted with some form of the technology. However, when compared with the 95% of new machines that now come fitted with basic machine control from the factory, there is still an enormous number of graders that are operating in this country without any form of machine control.

The fact that almost all new graders are fitted with machine control tells us that the benefits of the technology for fine grading applications are well established and widely acknowledged. Machine control technology saves time by reducing or eliminating reliance on pegs and stringlines, it increases productivity by assisting the operator to get to grade faster without rework and it improves safety by removing the need for regular grade checks near working machines.

If the benefits are well known, what are the risks of not having machine control technology for grading applications and why are 80-85% of machines still working without it?

It could be argued that the ultimate success and profitability of a job revolves around the grader. If fine tolerances are not achieved consistently across the site, it will result in rework and extra materials – both costly and inefficient alternatives to getting the grade right the first time. On road applications the costs will really soar if the grade isn’t consistently right, with additional ‘black gold’ required for laying asphalt to even out the surface and additional work for compactors to achieve the right results.

2D technology

A basic 2D machine control system, the likes of which are now factory-installed on a number of models from Caterpillar, Komatsu and John Deere, connects to the machine valves to automatically hold the blade to the whatever grade or cross slope set by the operator. They can also be used in manual or indicate mode, to inform the operator of the blade’s position in relation to grade, without automatically controlling it.

The standard slope sensors that come with a 2D machine control system can be augmented with either laser and/or sonic trackers to provide a height reference and/or grade reference. Height reference does not come as standard on most newly-purchased machines, so discuss this option with your supplier to see if it is something that you may need.

These basic 2D systems will increase productivity at the fine grading stage by 10-15% on standard road applications and they have a far wider impact on a range of other machines on site.

Haul trucks bringing in material, dozers and wheel loaders spreading material and the machines that follow the grader including compactors, pavers and asphalt compactors, will all be more efficient and get the work done faster as a result of the machine control system fitted to the grader. Because the grader is able to get to grade more accurately, consistently and quickly, all other machines are able to move just the right amount of material and only move it once.

Although 2D machine control now comes as standard on almost all graders sold in this country, it is still readily accessible and affordable as a retrofit option for all makes and models of machine. Retrofitting machine control is also beneficial because the system can be swapped between machines, giving the owner greater flexibility while reducing capital expense by extending the benefits of the system to more machines.

Upgrading to 3D machine control

3D machine control involves the use of GPS and/or laser levels and total stations to calculate a 3D position for the machine blade and its position on site. 3D technology is mandatory on graders for almost all large infrastructure projects as it involves numerous machines working alongside one another to the design.

3D technology delivers unparalleled accuracy and speed for fine tolerance applications, with results typically well within +/-5mm range. The development of GPS networks such as AllDayRTK enable RTK positioning accuracy without the need to setup and maintain a base station on site. This saves time and eliminates human errors associated with base station setup, while improving efficiency across the project.  

3D-MC² is the latest product offering from Topcon that involves the use of a super-speed sensor, which updates the blade position more than 100 times per second. This technology enables the operation to drive at much faster speeds, while maintaining the same high precision accuracy as the machine control system instantly detects and adjusts to any changes in the cutting edge position.

Currently, there are no graders sold in Australia that come fitted with 3D machine control from the factory.This technology requires a different level of expertise, operator training and support from a dedicated solution provider such as Position Partners to ensure its success.

3D systems are available to hire, to ensure you have the right system for any given application or project. Some systems, such as those available from Topcon, can be swapped easily between graders or other types of earthmoving equipment including dozers, excavators, scrapers, skid steers and compactors, giving greater flexibility to the plant owner.

Explore your options – now!

As I mentioned before, the benefits of machine control technology, for grading applications in particular, are well recognised throughout the earthmoving and construction industry. The reluctance to embrace it may be based on financial reasons, or a sense that the current setup has worked for many years without this technology and so can continue to do so for many more.

To those arguments, I would suggest the following responses: from a financial aspect, as with all technology, it gets more affordable the longer it has been around. Explore the different options available to you and you may be surprised at just how affordable machine control technology is these days, especially when it can be hired for a particular project and/or swapped between a number of machines across a fleet.

For the ‘why fix what isn’t broken’ argument, I would say that just because something works, it doesn’t mean it can’t be done better or more efficiently. I could send a letter by post to apply for a new job, or I could send an email. My application would get there either way and may be equally well received, however while waiting for the post to arrive the job could have gone to another applicant, someone who got there faster.

Optical Services, Trig Instruments and Position Partners form strategic alliance

Three companies align to better serve New Zealand’s surveying, mining, construction and local government industries.

From left to right: Roger Gibbs, Optical Services Sales Manager, Alex Felgate, Optical Services Director, Kevin Stevens, Trig Instruments Director, Heath Low, Position Partners Scanning Products Manager, Jason Hilton, Trig Instruments Manager and Jamie Nelson, Position Partners New Zealand Sales Manager.

Auckland-based Optical Services, Wellington-based Trig Instruments and Christchurch-based Position Partners have formed a strategic alliance to offer a broader range of solutions and local expertise to New Zealand industries.

The alliance will see the three companies combine their product lines to offer exclusive distribution of Sokkia surveying instruments, Carlson machine control for mining and landfill applications, MAVinci and Ascending Technologies Unmanned Aerial Systems (UAS) for aerial mapping, and US Radar Ground Penetrating Radar (GPR). Additional solutions include a range of construction lasers and C.Scope cable locators, plus software platforms including Autodesk, MAGNET and Carlson SurvCE.

All products are available for purchase or hire, with the exception of UAS which cannot be hired as they require specialist training for safe operation. Service, training and calibration across all product lines are provided locally by each branch.

“This alliance is great news for New Zealand industries,” said Bob Bent, New Zealand Manager for Position Partners. “A greater product range will mean easier access to the latest technology throughout the country, with the added peace of mind that comes with dealing with a local supplier who is on hand to help with support and training.”

Kevin Stevens, Managing Director for Trig Instruments, added: “What’s really exciting about our strategic alliance, is that it allows us to offer new technologies that each company specialises in. Our group buying power results in better pricing, faster delivery, and detailed product knowledge across a number of industries. This enables us to supply everything our customers need, with an unparalleled support network.”

“Supporting customers throughout the North and South Islands is a challenge for any business, no matter where you are based,” said Alex Felgate, Director of Optical Services. “This alliance enables us to provide comprehensive sales, hire, service and calibration support to customers anywhere in New Zealand.”

For more information contact Position Partners on 03 366 1726, Trig Instruments on 04 473 7935 or Optical Services on 09 479 3064.

###

About Position Partners

With more than 200 people in offices Australia-wide, in South East Asia and New Zealand, Position Partners is the largest Australian-owned company focussing entirely on the distribution and support of positioning and machine control solutions for surveying, civil works, mining and building projects. At Position Partners, we are committed to increasing productivity for our customers and building lasting business relationships around high calibre positioning activities.

Based in Christchurch, Position Partners’ New Zealand business offers a range of machine control, Unmanned Aerial System (UAS) and Ground Penetrating Radar (GPR) technologies for the mining, utilities, local government and surveying industries.

All systems are serviced and supported by manufacturer-trained technicians, with local training and flexible hire options also available.

About Optical Services

Optical Services was established in 1989 specifically for the distribution and maintenance of surveying equipment. As New Zealand’s exclusive distributor for Sokkia survey technology, Optical Services provides the latest in total station, GNSS, digital and automatic levels to the surveying and construction industries. A dedicated service facility is factory-equipped to deal with any technical problems, repairs or calibrations to return an instrument to as-new condition.

About Trig Instruments

Trig Instruments is the longest established survey instrument supply company in New Zealand.  Founded in 1973 by Peter Kinsella as the New Zealand agents for Wild Heerbrugg, Trig Instruments had one of the first survey service departments in the country, repairing and maintaining optical instruments for both government survey agencies and private land surveyors.  As technology advanced in to electronic instrumentation, Trig Instruments continued to grow and expand its product range, supplying and supporting new markets such as the construction industry.

The current managing director, Kevin Stevens, joined Trig Instruments in 1990 as a service technician, but soon took over the management of the company, purchasing the business outright from Peter Kinsella in 2000. This change of ownership was the catalyst needed to grow the business further, both increasing staff and expanding the product range.

Carlson Machine Control upgrades PDGrade Piling System which will reduce the amount of manual processes for piling applications. 

Carlson Machine Control has upgraded PDGrade™, a 3D GPS machine guidance system designed specifically for piling applications. PDGrade™, with its accuracy and ease-of-use, empowers piling contractors to work with higher efficiency, improving production while lowering cost and increasing safety.

The PDGrade™ Piling System v6.0 reduces manual processes for piling applications, notes Randy Noland, vice president for Carlson Machine Control.  “The traditional piling workflow is a manual process requiring staking, marking, and trial and error,” he says.

“With PDGrade™, piling contractors can benefit from high accuracy navigation, positioning and easy-to-use software that offers features such as navigation to pile, pile location, as-builts, and production reports. The system also increases safety, as it requires fewer people to be near the machines when erecting piles.”

 

Dieter von Mollendorf, Product Manager for Carlson machine guidance solutions at Position Partners, Carlson’s exclusive Australian distributor, said the time savings alone provide a very fast return on investment on the PDGrade system.

“Even a small time saving across every pile will result in huge time and money savings at the end of the project,” Mr von Mollendorf said. “Before PDGrade, piling contractors’ only option to measure the accuracy of the piles was via flat plane lasers, which have to be moved constantly as the job progresses.”

“With PDGrade, operators and managers can ensure accurate spacing and positioning of each pile,” he added. “There is also the flexibility to drive piles to a required depth, or to a required height above ground, or to the natural terrain.”

Key benefits of PDGrade version 6.0 include the ability to:

• Load pile design grid by supported file types (csv, dxf, dwg, and more) or enter patterns in the field;
• Navigate to hole (machine heading);
• Position piles more efficiently and with high accuracy;
• Store as-built points easily, showing previously driven piles including their positional accuracy and azimuth;
• Benefit from a user interface designed specifically for piling and the simplest, piling-centric software available;
• Work with much larger pile designs with no degradation of speed thanks to performance enhancements;
• Produce sophisticated reports via built-in software functionality, without the need for telematics or back office software. Display the accuracy of driven piles and flag those that fall outside required tolerance levels, report on average pile time, piles left to drive and more.
• Get real-time piling status with support from the new LDx6 laser distance sensor for driving piles to elevation, surface or depth, without an external, traditional laser setup.

New optional LDx6 Laser Distance option for piling to an elevation, contour or pile depth-No Laser Setup!

“In addition to navigation and high accuracy RTK positioning to the designed pile location, PDGrade™ facilitates piling to an elevation, surface or depth,” adds Randy Noland. “These new features are achieved by offering scalable support for the LDx6 laser distance sensor.” The LDx6 kit mounts near the top of the feeder, offering real-time indication of piling progress. Most importantly, this eliminates the need for a laser transmitter setup and the associated limitations such as range, line of sight and the need to continually calibrate and move the laser to new locations. The LDx6 laser distance sensor offers higher piling production.” 

Easy to calibrate, easy to install
The basic configuration of PDGrade™ uses only two components, the CBx6 Control Box Console and the MC Pro Vx6. Installation has one-quarter the footprint of other systems with fewer points of failure. The system is supported by an industry-exclusive, three-year warranty. The rugged IP69K MCPro Vx6 provides GPS/GLONASS/BEIDOU L1/L2 high precision positioning and heading – up to 20Hz, along with dual axis slope. The CBx6 Control Box Console has a bright, sunlight readable display, IP67 rugged with the same 3-year warranty and big 10.4” touch screen. Connects with just one cable.

For more information about PD Grade™ and machine guidance solutions, visit www.positionpartners.com.au, email info@positionpartners.com.au, or call 1300 867 266.