Machine Guidance and Control System Pays Dividends
By Ryan Johnson
Utility contractors are leveraging cutting-edge technology, such as machine guidance and grade control systems for dozers, to enhance their efficiency and productivity.
Grade control systems for earthmoving equipment have increased in popularity in the last 30 years. Significant advancements in global positioning system (GPS) and global navigation satellite system (GNSS) technology and computerized control systems have allowed manufacturers to integrate precise guidance systems in construction equipment such as dozers.
Grade control systems for dozers play a crucial role today, especially in light of the widespread shortage of skilled equipment operators. With features such as automation and real-time guidance, these systems offer a user-friendly interface that allows less-experienced operators to quickly master dozer operations. This not only addresses the industry’s workforce challenges but also ensures that grading projects are executed with precision and efficiency. The integration of grade control systems is a practical solution, bridging the gap caused by the shortage of skilled personnel and contributing to the successful completion of construction projects.
Rasch Construction Adds Grade Control
Founded in 1947 by Ken Rasch, Rasch Construction originated as a vision to provide exceptional services in land clearing and lagoon-type projects. In the company’s early years, Ken personally operated a dozer to complete these projects. Over the decades, Rasch Construction has evolved into a successful construction firm based in Fort Dodge, Iowa.
Today, Dalton Rasch, a third-generation family member, continues the legacy of excellence established by his grandfather. Although the equipment has changed dramatically, the family-owned business is still pushing and digging in the dirt. Using a variety of heavy and compact construction equipment, Rasch Construction performs excavation, grading and underground utility work in Iowa and has a branch in Arizona.
The company purchased a new 115-horsepower DEVELON DD100 dozer from RTL Equipment in Grimes, Iowa, in summer 2023 and paired it with a Trimble® Earthworks 3D grade control system. This advanced technology is designed for heavy equipment like dozers, and the Earthworks system is tailored for bulk earthmoving, grading and fine grading applications.
“The technology that we use most is the GPS on our dozers,” he says. “To be able to put a full job site in a machine, so you know where you’re at on the site, and your cut fills and what’s the best way to attack a dirt job that way. It definitely pays for itself in time with efficiency of getting projects done.”
A significant difference from previous dozers and grade control systems is that the new setup gives the operator better visibility to the blade and the area in front of the machine.
“It’s a newer grade control system that doesn’t need masts on it, so the visibility is really nice,” he says. “The GPS monitor is right below the LCD monitor in the dozer cab. It’s conveniently located. Also, the shape of the dozer with the hood and the glass means our operators can see really well out of it. It does well for smaller applications like trail jobs.”
Dozer operators appreciate the 3D view accessible from the second monitor within the grade control system. This feature offers operators a comprehensive perspective of their work, providing not only a real-time view of the dozer blade but also a preview or aerial view of the entire job site once the relevant information is programmed into the machine. The 3D visualization is instrumental in enhancing precision and efficiency during grading operations.
The following grade control system information is available on the second LCD screen.
- Actual grade
- Alarms and warnings
- Cut/fill information
- Cross-section views
- Design data
- Data logging
- Guidance lines
- Machine parameters
- Machine position
- Status indicators
Increased Efficiency
Maintaining a level ground when grading is critical to ensure the structural integrity and stability of buildings, roads, bridges and other structures. The 3D machine guidance and machine control system, like the one installed in the Rasch Construction dozer, reduces the need for operator inputs by up to 80%. This not only improves efficiency but also lessens operator fatigue, because operating the dozer is less physically demanding than it has been in the past.
The machine control system uses real-time monitoring, such as GPS and sensors. The system automatically adjusts the dozer blade movements to make sure the new surface precisely meets the design requirements. The Trimble Earthworks grade control system for Dalton’s dozer works off two globes that are mounted to the dozer cab. They provide information to calculate measurements that tell the dozer where the blade is positioned, based on the sensors and the hydraulics.
With the advanced 3D machine guidance and control system, operators can work efficiently without the need for frequent manual grade checks. This not only streamlines the grading process but also allows laborers, who may have been dedicated to manual grade checks in the past, to be reassigned to other tasks, maximizing overall job site productivity.
Reduced Rework
When contractors like Rasch Construction implement a grade control system for their dozers, it helps them make fewer mistakes when grading. This system continuously monitors the blade, makes small changes to the position of the dozer blade during grading and reduces rework.
If the dozer doesn’t grade the ground exactly as planned, the operator can realign the dozer blade to correct the minor mistakes and make precise adjustments to reach the desired grade. This minimizes the rework and the impact on the project schedule.
Training Guidelines
When considering the purchase of a grade control system for a dozer, keep in mind that your operators will need training on how to use the system. Both new operators and seasoned veterans need to be familiar with the various components of the 3D grade control system, including the hardware (e.g., sensors, receivers) and software components. Speaking of software, operators should learn how to navigate and operate the software interface on the system’s display monitor.
Once the operator is comfortable with these items, the next step is training on the process of loading project-specific data into the system (e.g., design plans). Operators should also be trained on the calibration process to ensure the high accuracy of the system. And they need to learn how to interpret real-time feedback from the system. This includes grade information, elevation data and other relevant metrics displayed on the LCD screen inside the dozer cab.
Last but not least, operator training should cover how to effectively control the dozer blade using the 3D grade control system. This helps them understand how the system adjusts the blade in response to grade variations.
Expected Costs
Dalton Rasch says although the 3D grade control system for a dozer can be an expensive system to get into, it pays for itself over time when projects get done more efficiently.
Before buying a system, it’s a good idea to consider the following key factors.
- Initial investment: This includes the costs associated with purchasing and installing the grade control system hardware and software.
- Operating costs: Consider training expenses related to training dozer operators on how to use the grade control system effectively. Include ongoing expenses for system maintenance, software updates and technical support.
- Fuel efficiency: Track improved fuel efficiency from optimizing your grading operations and minimizing unnecessary movements.
- Material savings: If your grade is more precise, you may need less material for your job site. You may also reduce the need for rework and improve cost savings due to labor and materials.
This article was written by Ryan Johnson, APR, of Two Rivers Marketing on behalf of DEVELON North America, based in Suwanee, Georgia
Tags: DEVELON
