New tech drives improved loading performance

Cutting-edge technologies are helping quarry operators to increase the productivity, fuel efficiency and safety of their loading equipment.
May 10, 2021 4 mins Read
By Liam McLoughlin
A Hyundai HX520L excavator working at the Colonnata marble quarry in Tuscany
A Hyundai HX520L excavator working at the Colonnata marble quarry in Tuscany

Marble quarrying company Alba Ventura has bought a Hyundai Construction Equipment (HCE) HX520L excavator from Toscomeccanica, the HCE dealer for the Italian region of Tuscany.

The 52-tonne excavator replaces a model of the same capacity and is working flat out at Colonnata quarry in the iconic marble quarrying area of Carrara, where high-quality marble such as White Cattani Marble is extracted.

The HX520L excavator is powered by the Scania DC13 084A 6-cylinder, 12.7-litre, Stage IV engine, which delivers an output of 316 kW, providing energy efficiency combined with high-level performance.

Alba Ventura owner Roberto Vernazza said the HX520L excavator has demonstrated standout attributes such as high power, a high degree of stability and maximum efficiency.

The Hitachi ZW220-7 has a camera system giving operators a bird’s-eye view of jobsites
The Hitachi ZW220-7 has a camera system giving operators a bird’s-eye view of jobsites

“From the first days of operation in our marble quarry, the Hyundai excavator showed what it was made of – a powerful machine, but also sensitive and precise in its movements; a true champion born to dominate the terrain, whatever the type,” he added.

To optimise performance in the toughest operating conditions, HCE has equipped the excavator with cutting-edge technologies: the Eco Indicator, a system that can give immediate feedback on fuel efficiency while the machine is operating; IPC (Intelligent Power Control), a function that regulates the hydraulic pumps based on the work environment and selects speed mode, balance mode or higher efficiency to adapt machine performance. In addition, the new variable power control is designed to increase performance, whatever the operating environment.

“In our quarry, we needed a new machine to replace an old model of the same capacity,” said Vernazza. “So, we contacted the dealer in Massarosa, Toscomeccanica, who has provided us with assistance service for years in a professional and timely manner. In this case, too, they supported us by immediately identifying a model which would meet our expectations.”

The HX520L excavator is designed to provide durability and strength. HCE says the solid structure of the model’s upper and lower frame, able to withstand external impact and work with large loads and the performance accessories verified by rigorous testing, are standout advantages of the HX Series.

The manufacturer adds that this is evident in challenging operating environments such as quarries, guaranteeing better productivity. Reduced noise, low vibration and an ergonomic design are intended to make the cabin space more comfortable and pleasant.

The HX520L’s comfort features include a spacious cabin, clear controls, excellent visibility, and high-performance air conditioning. The standard suspension seat, adjustable for height and weight, has a headrest and an armrest, also adjustable. There is an emergency engine stop at the base of the seat. With its focus on operator safety and comfort, the HX520L excavator is designed to allow quick, safe inspection of the instruments, providing its operators with an optimal work environment.

“In addition to being a robust, powerful machine, the Hyundai HX520L excavator offers longer maintenance intervals and greater ease of maintenance, reducing workshop time to a minimum,” said Toscomeccanica owner Claudio Bacci. “Also, the maintenance areas are easy to access, and the grease points are centralised. Not to mention that the high-performance oil filter extends the change interval to 500 hours. These are surely the key aspects for our customers, who need to keep machine downtime to an absolute minimum.”

Japanese original equipment manufacturer (OEM) Hitachi has introduced the ZW220-7, which the company says is its first Stage V-compliant wheeled loader and the first model from its next generation.

Doosan Infracore Europe’s ‘transparent bucket’ system aims to eliminate loader driver blind spots
Doosan Infracore Europe’s ‘transparent bucket’ system aims to eliminate loader driver blind spots

The OEM adds that the ZW220-7 has been designed to put operators in control of their workspace, with new safety features and increased comfort in the cab.

The loader features the Aerial Angle camera system, giving operators a 270-degree bird’s-eye view of the jobsite, while the rear obstacle detection and warning system alerts them immediately if anything is close to the rear of the machine.

Hitachi says the ZW220-7 is especially easy to use due to features such as the improved seat with mounted electric pilot control leavers, new monitor controller and convenient side switch panel.

The company adds that owners will be able to increase their profits due to the fuel economy and efficiency of the ZW220-7, in addition to faster and more efficient short loading operations due to the approach speed control feature.

The new ZW-7 model is also designed to load trucks more accurately using the payload monitoring system. In addition, operators can monitor the fuel consumption with the new ECO gauge and performance can be improved with several adjustable functions.

To support owners and operators throughout the life cycle of the new ZW-7 wheeled loaders, Hitachi provides a wide range of after-sales services, and access to vital data and tools so they can manage their machine effectively. These include remote monitoring systems, Owner’s Site and ConSite (part of Global e-Service), and the ConSite Pocket app, which help to monitor performance, track location and plan maintenance.

“Many years of extensive research have contributed to the development of the ZW-7 range to ensure that it meets the specific demands of European customers, from small business owners to large fleet contractors,” said Bill Drougkas, wheeled loader product manager of Hitachi Construction Machinery (Europe).

“As a result, we believe it offers a superior experience in the cab and exceeds expectations in terms of efficiency and performance.”

Doosan Infracore Europe has launched a ‘transparent bucket’ system for wheeled loaders that is designed to allow the loader driver to see blind spots in front of the bucket on the machine via the cab monitor.

The system records images in front of the wheeled loader with top and bottom front-loaded cameras and shows combined images on the monitor in real time using a curved projection method.

Owing to blind spots caused by the buckets on wheeled loaders, the area in front of the machines has been considered an area of major concern in terms of safety. Doosan says that with its new transparent bucket function the driver can now easily check the blind spots in front of the bucket via the cab monitor, to increase safety and prevent accidents.

Another claimed advantage of the transparent bucket system is that it can significantly improve work efficiency by providing a forward-view perspective for the driver during loading/unloading or when carrying materials such as aggregates, sand and soil.

The new Volvo CE EC300E heavy-duty excavator
The new Volvo CE EC300E heavy-duty excavator

Doosan Infracore says it is the first company in the world to develop and apply a front projection function with the transparent bucket for construction machines and has applied for patents in Korea, North America, Europe and China.

The manufacturer has also developed further sophisticated safety systems for its machinery range, such as the around view monitor (AVM) system, that can observe the machines’ surroundings, and a rear warning system using ultrasonic sensors, which it says have both received very favourable responses from customers.

A Doosan Infracore spokesperson commented: “As machinery and site safety standards continue to be significantly raised around the world, advanced safety systems have become a key factor in selecting equipment. We plan to continue developing safety features that can protect drivers and other workers on site, and we aim to be at the forefront in creating construction sites that are safer and accident-free.”

Volvo Construction Equipment (CE) has launched updated versions of its EC250E and EC300E excavators, which are claimed to offer improved fuel efficiency of up to 10%.

The updated heavy-duty machines weigh 26-31.5 tonnes and 30.2-36.8 tonnes for the EC250E and EC300E respectively. They can also come with purpose-built attachments - including buckets and breakers - which Volvo CE says will help operators move more, for less.

The manufacturer says the updated models deliver up to 10% improvements in fuel efficiency, due to a combination of features that includes more intelligent electro-hydraulics, the classic ECO mode and selectable work modes, and finally the new D8M Volvo engine.

This upgraded engine reduces rpm from 1,800 down to 1,600, while delivering a 5% increase in power. The EC300E also has a 700kg heavier counterweight – providing greater stability and a 5% increase in across lifting capacity.

Volvo CE says that operators will benefit from improved response times – thanks to the electric control joystick and full electric travel pedals – and are helped in their task by the optional Dig Assist apps which are powered by the 10-inch (25.4cm) Volvo Co-Pilot in-cab tablet. These include 2D, In-Field Design, 3D software packages and On-Board Weighing. In addition, the Volvo Active Control feature boosts digging accuracy and allows jobs to be completed up to 45% faster, thanks to automated boom and bucket movements. Operators can also set swing fence, height limit, and depth limit to avoid contact with side obstacles, overhead obstacles such as power lines, and underground hazards such as pipes and cables.

For operator comfort, Volvo CE says the excavators include new boom and arm bounce reduction technology – which reduces machine shock – and Comfort Drive Control to help reduce fatigue by enabling operators to steer the machine using the joystick rollers instead of the pedals.

The new Liebherr incident map lets loader operators implement measures to avoid on-site accidents
The new Liebherr incident map lets loader operators implement measures to avoid on-site accidents

Aggregates-processing solutions company DUO Operations has supplied a fleet of Doosan machines, including two wheeled loaders and a pair of excavators, that is proving central to the smooth running of Carnsew Quarry in Cornwall, south-west England. Carnsew Quarry is one of two locations in the Colas Cornwall Quarries division, along with the West of England Quarry. Both are hard rock quarries, providing a wide range of quarry products and asphalt to the local market by road, and further afield by road and sea.

Carnsew Quarry is the largest inland quarry in Cornwall and is located in the centre of the developing area lying between the county towns of Redruth, Falmouth and Truro. The quarry produces quality coarse-grained silver-grey granite, meeting demands in different sectors of the construction industry.

The Doosan products at Carnsew Quarry have been supplied to Colas under a long-term hire agreement with DUO Operations to assist in the operation of Carnsew Quarry and to ensure the quarry runs smoothly.

The Doosan equipment supplied by DUO Operations includes two DA40-5 articulated dump trucks (ADTs), which support the haulage between the primary and secondary crushing operations. Working alongside are Doosan DL450-5 and DL550-5 wheeled loaders used to stockpile quarry products, plus load the ADTs and road trucks delivering to sites around the area. The Doosan fleet from DUO is completed by a pair of Doosan DX380LC-5 crawler excavators that load the secondary crusher and assist with breaking.

All the Doosan equipment supplied by DUO Operations comes standard with DoosanCONNECT advanced telematics. Using the data provided by DoosanCONNECT, DUO Operations reports directly to Colas on a monthly basis.

This supplies Colas with information on fuel efficiencies, fuel levels, fault codes, warnings and for the ADTs, it shows load counts. This information enables Colas to plan and maximise the profitability at Carnsew Quarry, and also provides the company with a good indication of the cost per tonne. DUO Operations also provides Colas with details on any operator faults and offers advice and feedback to prevent any future maintenance issues.

Liebherr has added two new functions to its active personnel detection assistance system for wheeled loaders. The brake assistant and incident map functions have been added to active personnel detection in the system which is used in the Liebherr L 526 to L 586 XPower range of wheeled loaders. The brake assistant automatically slows the speed of the loader to a standstill the moment the active personnel detection issues a warning signal. The incident map displays potential risk zones on the site using GPS data in LiDAT - Liebherr’s in-house transfer and location system.

The manufacturer says that, statistically, accidents with wheeled loaders occur most frequently when the machine operator reverses after a loading process. This reverse travel is particularly risky if people are located in the wheeled loader’s operating area. In these situations, Liebherr says there is a huge responsibility on the machine operator, adding that this is why it is continuing to develop its assistance systems.

Active personnel detection visually alerts the machine operator via the display screen and sounds acoustic signals if there is danger in the wheeled loader’s rear area.

Besides the brake assistant, a second new function for the active personnel detection at the rear is the incident map. Each time the assistance system detects a danger and a warning signal is issued, the system transmits a GPS signal to LiDAT, Liebherr’s in-house transfer and location system. On the basis of this signal, and for each operator of a wheeled loader with active personnel detection, Liebherr provides a Google map in LiDAT showing these GPS points.

The result is an incident map displaying the risk zones and potential sources of danger on the site. The operator can use this to take measures to prevent accidents and therefore increase safety. For example, the operator might reroute footpaths, cordon off areas and alter dangerous work sequences. The head of operations can use the incident map to train employees and make them aware of risky situations.

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