Caterpillar Product Specialist Darren Hodge introduces the latest mastless construction technology from Cat® designed to increase performance and accuracy.
Caterpillar revolutionised the operation of motor graders with the introduction of joystick controls and a suite of advanced machine control solutions delivering enhanced operability and boosting productivity.
More than a decade ago, Cat® introduced three-axis joystick control for steering, implement and transmission control on the all- new M Series.
The new technology machine with joysticks included electro over hydraulic (EH) valve control systems and has proven exceptional in reducing operator fatigue and allowing easier multi-function work compared to traditional lever controlled hydraulic systems.
“Construction technology has evolved rapidly, and the industry has embraced new innovations that simplify work and finish grade with greater accuracy and higher productivity,” Darren said.
“The EH valves and joystick controls are the catalyst for Caterpillar designers to continuously develop automated grade control features solutions to keep the construction industry moving ahead,” Darren said.
“Caterpillar’s innovation in leading technology has long been a foundation in design and development for new products and in fact for Motor Graders this started back in the 1960s when they developed a basic grade control feature. ABC (Automatic Blade Control) was designed to automatically raise and lower blade to follow intended road design.”
“Where possible, technology integration in the original machine design is most beneficial for positive aesthetics, seamless fit and finish, reliability and end-to-end service and support Cat dealers.”
For basic 2D slope control, the integrated Cat Grade Control Cross Slope System was developed as a factory-installed option over 10 years ago, replacing aftermarket installs.
“This feature, although an option, was quickly accepted by over 90 per cent of our customers as a minimum requirement,” Darren said.
“Operators appreciated the autonomous benefit of maintaining the desired cross slope in a road without the need of external grade slope checks. Using the basic 2D guidance and automatic control of one side of the blade for road maintenance results in greater accuracy, and more timely completion of the job.”
For road and infrastructure designs with complex curves, slopes and contours, customers install aftermarket 3D Grade control technology that utilised much of the hardware. EH valves and electronics are already integrated into the machine.
“This higher technology provides vertical height and horizontal positioning guidance or by controlling the blade relative to an electronic design,” Darren said.
“Whilst these systems are highly accurate to achieve design elevation parameters, they do have some limitations when using typical machine operations such as Articulation and Circle rotation and remaining accurate to design.
“The hardware associated with masted technology is cumbersome. Tall, heavy GNSS antenna masts are installed at one or both ends of the blade for 3D control. In some jobs these masts restrict operation in steep slope applications, and if caution is not used damage from masts impacting the cab can occur.
“The mast mounted antennas are costly and prone to theft, so for security at the end of the workday operators remove them and securely store them, a heavy burden on the operator.
“For greatest accuracy using masted 3D technology, best practice is to keep the machine in a straight heading and restrict drawbar positioning, blade tip changes and articulation movements.
“These operations usually limit the machines operation and productivity, so with limitations in movement some applications can’t be completed effectively using masted 3D GNSS technology.”
More than four years ago, the Cat 3D GNSS Mastless option was introduced to the market on the T4f emissions-built Motor Grader product to overcome issues associated with blade mast antenna systems.
“The take-up of this option has significantly exceeded our expectations,” Darren said.
“To provide greater customer reach with this technology, Caterpillar has introduced Grade 3D Mastless on our T3 emission platform now.”
“The new Mastless GRADE 3D system on Cat motor graders integrates the receivers and IMU grade sensors that work to compensate for the machine’s acceleration and position changes to deliver a superior finish.
“The operator can position the grader and blade in the most productive position with no compromise to grade accuracy and with no masts to interfere with visibility or performance.
“Wheel lean, drawbar offsets and frame articulation can be re-positioned to process the material effectively for greater productivity and performance.
“This expands the use of the grader in other applications such as side slopes and drains where guidance was not previously possible due to the mast restrictions in drawbar positioning.”
Automatic blade control reduces operator inputs and the number of passes to finish the job – saving time and money. The operator also benefits from the updated 10-inch touch screen display, which has been improved for faster performance.
The Grade display puts the design plan clearly in front of the operator. Grade control buttons are integrated into the advanced control joysticks for seamless operation.
“Mastless GRADE 3D assists the operator to get to the design plan faster and with more accuracy and increased efficiency,” Darren said.
“This also reduces rework costs, fuel, labour and material costs and of course, boosts productivity.”
“Importantly it can be used on all phases of the job and in more applications, including bank slope, mixing materials, cutting passes, ditch building, back slope and high bank.”
The mastless integrated system allows for closer proximity work such as alongside buildings while maintaining accurate grade. Having the technology factory integrated eliminates messy, expensive retrofits of aftermarket systems that do not necessarily integrate well with existing machine systems.
“When factory fitted, Cat technology solutions are fully calibrated for optimal performance and, most importantly, all supported with factory warranty and backing of the dealer network,” Darren said.
“The latest receivers are integrated into the cab roof and front frame for better line of sight and nothing needs to be removed at the end of the shift or for transport.”
“The latest receiver technology has improved performance near tree canopies and enables faster signal tracking.”
“The new Cat Mastless GRADE 3D option is an example of Caterpillar innovation and technology leading the way; setting a course for our customers to be more successful.”