Staying on Track: Cat Track Wear Sensor Technology

In selecting a dozer, operators naturally look at specifications including horsepower and operating weight, as well as special features. However, a powerful dozer equipped with the latest wizardry is only as good as its undercarriage. Afterall, you’re not pushing dirt if you’re stuck in the mud.

To help customers get the most out of their undercarriage – and in turn maximum efficiency and productivity – Caterpillar offers its new Cat Track Wear Sensor (CTWS) technology.

Cat Track Wear Sensor technology is a proprietary innovation for Cat machines and undercarriages that remotely monitors wear to better predict wear-out for easier planning and minimization of downtime.
As an enhancement to its tried-and-true Cat Track Service Program and Cat Wear Management System, CTWS provides automated alerts to the customer and dealer at key wear percentages (40, 70 and 100 percent), allowing the operator to schedule maintenance and replacement when it is convenient.

“With the Cat Track Wear Sensor, customers are now able to get key alerts about the life of their track at critical times, which enables them to better plan better for maintenance, machine downtime and expenses,” said Tim Nenne, Caterpillar’s Senior Undercarriage Market Professional. “We believe that the new CTWS adds significant value to the customer. By properly managing an undercarriage, the customer can achieve the lowest ownership and operating cost.”

CTWS is being released as a standard feature on the D6 and D8 dozers, with other models available in the coming months, and it is available as an aftermarket add-on for existing equipment.

How it Works

The CTWS is installed in a customized pocket in each track link. As the track link wears down, the track wear sensor wears at the same rate, allowing it to calculate the amount of remaining track wear.

The sensor communicates the critical wear information about the track link from the machine via Bluetooth. It sends information wirelessly to the Cat equipment management software, where the status can be monitored by the customer and the Cat dealer. When the wear reaches the 40, 70 and 100 percent trigger levels, the customer is notified via an email from the Cat Dealer.

The development of the CTWS was years in the making as Cat experts had to ensure the reliability of the system, which is exposed to the harshest of operating conditions. “We have hundreds of thousands of test hours on this equipment,” Nenne said. “The sensors must be able to withstand the most severe conditions you can think of including vibrations, impacts, moisture, and extreme temperatures.”

A key element of the reliability of the CTWS is battery life. Recognizing that not all machines have a high utilization rate, Caterpillar designed sensor batteries with a life of up to seven years. And, the batteries are designed to withstand that same tough operating conditions as the sensors themselves.

Benefits

With the CTWS system, customers can keep their undercarriages performing at peak efficiency by better predicting wear-out. The key alert intervals allow customers to better plan for maintenance and replacement. Additionally, by having accurate wear information, customers have improved reliability and uptime with less frequent interruptions.As a side benefit, CTWS enhances the Cat dealers’ ability to service their customers. “Not only does CTWS benefit the customer, but it also helps our dealers manage their time more efficiently,” Nenne said. “They are better able to schedule maintenance orders, and ensure that any parts are available.”

Maximining Performance

While the CTWS system is designed to help increase efficiency for customers, there are other to-dos to bear in mind, according to Nenne.

By using the CTWS in conjunction with good operating and maintenance procedures, operators can get the most out of the equipment purchases. For more information on CTWS and other features, contact Caterpillar or your local Cat dealer.