Enhancing devices for heavy construction equipment

Quick couplers are most common on heavy construction equipment such as excavators. About 90 % of all excavators in Europe are equipped with quick couplers. These devices require tools to be changed very frequently, leaving operators without the required level of experience needed to properly operate them. This damages the tools and compromises safety at construction sites.

To address this issue, the EU-funded PROSYMA (Process-optimized system functionality of mobile work machines) project is developing a novel modular guidance system that can be fitted onto a conventional hydraulic excavator with any quick coupler or tool. Overall, the aim is to provide excavator operators and construction workers with real-time data from a sensor on machine stability and on tasks such as digging, grabbing, lifting and loading.

During the first reporting period, work began on the sensor system for the quick coupler that will accurately measure loads by the excavator. With concept development complete, sensor design will follow.

To analyse the sorting grabber, bucket and ripper tools, a mathematical model was devised for the tool positioning and measurement systems and the tip-over stability subsystem. The model has been applied in the developed software.

A software specifications booklet for the modular guidance system was produced, and all required hardware components were delivered. Casings for the sensor components were designed.

A generic excavator model has been developed to accommodate the various motions of standard hydraulic excavators. This measurement system was then simulated. A demonstration excavator was also tested.

Ongoing work in PROSYMA will help introduce the construction industry to optimised, safe, cost-effective and clean technological solutions for their excavators.