Motor graders have
traditionally been one of the most difficult pieces of equipment to master, but
incorporating advanced technology like machine control makes it operation
easier and increase its productivity and efficiency.
Used by the construction
industry on earthworks equipment since the late 1990s, the machine control
technology allows decisions to be made based on data, rather than relying on
fallible traditional methods or the skill and experience of the operator. As a
result, machine control effectively increases operators’ productivity and
accuracy. Prior to its adoption, however, operators had to manually check grade
and position machinery themselves – a process that was less accurate,
time-consuming and held higher safety risks due to the grade checkers’ or
banksman’s proximity to the machines.
What
is Machine Control?
Machine control is an
intelligent technology that is integrated into construction and earthmoving
equipment to optimise job efficiency. In the most absolute layman’s way of
putting it, machine control is the use of positioning tools and a display to
provide an equipment operator with a reference between the position of the
bucket or blade and the target cut/fill and grade.
A myriad of hardware and
software solutions exist with the sole purpose of determining an equipment's
current position on the earth and then comparing that position with a desired
design surface. The difference is then displayed inside the operator cabin
allowing the operator to easily and efficiently determine what is required to
create the intended design on the ground.
Machine control system uses
various components, such as onboard sensors, geospatial beacons, lasers and
digital data, to control the functions of the equipment. There are two ways
that machine control can get onto an equipment: it can either be installed onto
the equipment as it is being assembled or retrofitted afterwards.
How
Machine Control Works on Motor Grader Machine
Advanced machine control
systems use GPS satellite signals to provide accurate, real-time information
about a job site. This data is then used to create a digital topo, or survey,
that records the measurements of the location and maps out changes to elevation
or gradient across the site, quickly and efficiently.
Once the job site has been
surveyed, a 2-D or 3-D design blueprint is created to establish the overall
layout of the project, and the materials and work required. This digitally
“stakes out” the different elements.
The site plan is then
uploaded onto the machine’s computer, which uses the information to direct
sensors fitted on the blade to cut or fill a profile that corresponds with the
exact co-ordinates on the plan.
Depending on the type of
mode in use, the operator can manually adjust the elevation or slope of the
blade to match the contours in the plan or – in the case of automatic mode –
the blade is directed by the grader’s hydraulics to make these adjustments.
Machine
Control Options for Motor Graders
Motor graders rely on
sophisticated grade control systems to deliver fine grading work. These systems
are either built-in at the factory or available as aftermarket kits. As this
type of technology is highly scalable, contractors can easily upgrade from entry-level
options to more advanced systems if and when the need arises.
The condition of the
jobsite and the required accuracy and complexity of the work largely determine
what type of grade control system is the best fit. There are currently three
available options; 1D, 2D and 3D systems.
1D grade control systems
The 1D grade control system
is an affordable entry level option that uses lasers to achieve optimal output.
As an ‘indicate only’ system, the operator is alerted when a predetermined
grading contour has been achieved or exceeded. The 1D system is the ideal grade
control option for rough grading work with simple slopes.
2D
grade control systems
With the 2D grade control
system, the grader can operate in two dimensions; slope and plane. It uses lasers,
sensors and jobsite reference points to rapidly and accurately regulate
elevation and cross-slope. This type of system is available in ‘indicate only’
or ‘automatic’ modes and is more expensive than the 1D system. The 2D grade
control option is designed to carry out precise drainage work with a fine
finish.
3D
grade control systems
A 3D grade control system
is a high-tech option that uses a series of laser-guided sensors, GPS or GNSS
satellite signals and worksite topography to carry out complex grading work
with absolute accuracy. This level of
control is suitable for large, complex development and infrastructure projects.
Machine
Control Enhances Motor Grader Performance
Machine control provides an
extensive list of benefits and ways that contractors can streamline their
jobsite, reduce operating costs and become more competitive, whether working on
a mass grading project, building a road, digging utilities or completing trim
work on a commercial site.
Using machine control on
construction sites offers numerous benefits, including increased accuracy,
reduced rework, and improved efficiency. It enables operators to complete tasks
more quickly and with greater precision, ultimately saving time and resources.
Additionally, machine control enhances safety by providing operators with clear
guidance and reducing the need for manual grade checking.
Machine control systems
transform construction precision. They take complex designs and turn them into
exact instructions for machinery. Every dig, grade, and level matches the plan
perfectly. As a result errors drop, rework disappears, time and labour saved.
Motor graders are difficult
machines to operate, even for the most experienced operator. Integrating
machine control technology simplifies machine operation, regardless of operator
skill level. The complex adjustments are taken care of by the technology,
allowing the operator to focus on blade rotation and blade pitch as required
for the particular grading task and steering the machine. With machine control
technology automating more of the blade operation tasks, operator fatigue is
minimized and operator turnover is reduced.
Machine control reduces
rework and thus increases productivity. Rework is always a pain for the
contractors as it involves extra cost, time and effort. The need for rework
arises when the work is not considered up to the mark. Earlier, often motor
grader operators had to rework since the machine did not deliver accurate
results. With machine control technology, the task of rework reduces and allows
the motors graders to reach the final grade much faster with more accuracy,
thus, saving time and cost associated with rework tasks and allowing
contractors to move forward easily without looking back.
Machine control reduces
grader maintenance and wear and tear. Equipment experiences more wear and tear
the more often it is used, especially the ground-engaging moldboard, while also
piling up more hours on the engine and the machine’s filters and fluids. Machine
control will generally allow a task to be completed in fewer passes with a
grader, helping to minimize each of these factors while completing the same
amount of work.
Being able to work more
efficiently with machine control allows contractors to more intelligently
sequence and plan their equipment. If the contractor knows that a grader will
get the grade to where it needs to be after a specific number of passes, they
can better plan for the compactor to be there and ready to go as soon as the
final pass is completed.
It also eliminates the re-staking task and thus cost involved for it. With machine control, data points don’t change and the plan remains constant within the system, unless the plan changes – at which point a new plan is uploaded rather than staking the whole site again.
