New Product Release Trimble PCS900 v1.1 & Cat AccuGrade v1.1 Update of new sales features October 2010

Recap: Trimble PCS900 3D Paving AS200 SNR2410 and CB430 and AS450 MT900 CB440 Single - or - Dual SPSx30 Total Station

Recap: Target Application - 3D Paving Airports, roads and commercial surfaces Variable depth and slope paving Base material and asphalt

PCS900 v1.1 – New UI Features AutoAdjust Typically, the mat behind is 3D paver is manually checked every 10 meters (30 feet) in traditional paving operations with competitive systems AutoAdjust automatically corrects the trailing edge of a screed to target grade The benefit is: Increased accuracy & Strongly reduced manual intervention

PCS900 v1.1 – New UI Features Distance to the UTS is now a text item Plan View Map shows an accurately positioned UTS icon Machine Radio Configuration can now be configured by the operator

PCS900 v1.1 – New UI Features Faster UTS/MT900 locking Initial UTS Quick Search is performed in the direction the UTS instrument is facing. If the total station is set up with the MT900 Machine Target in its field of view, the UTS will very quickly establish lock. Results in a fast relock when the line of sight is temporarily obstructed

Quote PCS900 v1.1 User Savko Ohio “The [Savko] supervisor, who is very proud of what they can do with RCC material, admitted that the side of the road that our system paved was the smoothest RCC he has ever driven on.”

Phil Jackson September 2010 3D Paving Points Phil Jackson September 2010

Welcome Why are we here? Because our Beta sites prefer to work with different work-flows We need to understand different methods of working So we can match our system to their practice We have also changed the way some functions work To better match our system to their practice

Discussion Today’s training is designed to be a discussion Please ask questions to clarify the topics being discussed

3D Paving 3D Paving is a complete package You must: Understand & check the 3D Design Understand & check the site control Set-up and check the SPS930s Install & Calibrate the PCS900 paver Know the operating procedures and best practice for PCS900 Know how to Grade Check correctly

3D Paving Don’t start! 3D Paving is a complete package You must: Understand & check the 3D Design Understand & check the site control Set-up and check the SPS930s Install & Calibrate the PCS900 paver Know the operating procedures and best practice for PCS900 Know how to Grade Check correctly If the team can’t do EVERY step above Don’t start!

Agenda Best Benching practice AutoAdjust 3D Offsets vs. 2D Offsets Paving Operation mm Accuracy UTS Set-Up & Calibartion Joint Match & Differential Compation Design Tolerance Documentation

Bench on Material Best Benching Material fully supports the screed As opposed to blocks Material fully supports the screed Stops flexing of the screed Angle of attack is correct If you have paved a short distance You can Bench on blocks But on material is better

Best Benching Once you have benched AND you are happy with the results You do not need to bench again for the next run – So long as NOTHING changes E.g. You can bench for run 1 and then come back for runs 2, 3, and 4 withOUT rebenching You can rebench any time you are unhappy with the accuracy

PCS900 Benching Warning We have also added a full screen warning on benching if the 2D system offset is nonzero You must remove any 2D system offsets and then bench PCS900

Terms Explained Actual Asphalt Surface “On Grade” Surface PCS400 Target Value (2D Offset) PCS900 Offset Surface PCS900 Vertical Offset PCS900 Design Surface

Terms Explained Measure Up Distances PCS900 “3D Grade Sensor” Elevation (not displayed) Elevation (Screed Tip) PCS900 Txt Item Actual Asphalt Surface AutoAdjust Offset Raise/Lower PCS900 Text Item PCS400 Grade Lights PCS400 Measured Value (3D Sensor Deviation) “On Grade” Surface PCS400 Target Value (2D Offset) PCS900 Offset Surface Design Elevation PCS900 Txt Item PCS900 Vertical Offset PCS900 Design Surface

3D Paving Training AutoAdjust March 2010 by Phil Jackson

What is AutoAdjust? AutoAdjust automates the previous manual nudging of the screed PCS900 v1.10 monitors the height of the trailing edge of the screed and automatically adjusts the system to keep this point on grade Manual nudging via the underlying 2D control system (PCS400, AccuGrade, Cat Grade & Slope or MOBA) is still supported

PCS900 v1.00 PCS900 v1.00 emulates a 2D grade sensor Think of the MT900 as a sonic tracer Control point is below the mast Move the target forward for smoother response Move the target backward for a more accurate response Screed trailing edge is not automatically controlled in v1.00 Manual adjustments were required

Why We Needed To ‘Nudge’ The height under the mast is controlled, but the height at the trailing edge “floats” During paving the Angle of attack changes to compensate for the other factors that control the trailing edge height Material head Mixture Speed Temperature Etc.

No Different To 2D System 2D systems test depth to check mat thickness Then adjust the operation to correct depth Assuming all other factors are OK then by incrementing or decrementing the 2D offset On US Screeds in 2D can also turn the crank handle After paving some distance Depth Checker confirms the correction

No Different To 2D System V1.00 3D system uses a Grade Checker to check mat surface height Then you adjust the operation to the correct height Assuming all other factors are OK then by incrementing or decrementing the 2D offset On US Screeds in 3D canNOT turn the crank handle After paving some distance Grade Checker confirms the correction

AutoAdjust V1.10 3D system automates this V1.00 3D system requires you to inc/dec the 2D system to correct height because we only control under the target V1.10 3D system automates this Design

V1.10 3D System AutoAdjust By monitoring the height of the trailing edge of the screed Like having a permanent Grade checker riding on the back Then adding or subtracting an adjustment Just like a manual inc/dec in v1.00 Slowly In very small steps

How Not to Break AutoAdjust Use a Non-US Screed With No Crank Handle Mount the 3D Target on the screed Not the tow arm Do NOT wind the Crank handle on US screeds If your target is mounted on the tow arm Do NOT let the tow arms drive to extent And the screed still be Off Grade by < 50 mm

Tow Arm Mounted Target on US Screeds Winding the Crank Handle alters the position of the back of the screed relative to the target Invalidates the measure-up IF you Wind the Crank Handle you MUST Re-Bench Step 14 of the Quick Start Guide

Details Always on by default Text item reports amount of Automatic Adjustment applied Can turn this off in Manager Mode But why would you? AutoAdjust learns Starts with value from Benching Remembers and updates constantly

Graphical Explanation The next slides step through time and explain each stage of AutoAdjust Time is given as T0, T1, T2, etc. The sample values are larger than you will see on a real job

AutoAdjust – Definitions 2D is height from Target to Design 3D is height from Screed to Design AutoAdjust is correction value Values are exaggerated Design

AutoAdjust – Steady State Everything is correct 2D = 0.000 3D = 0.000 AutoAdjust = 0.000 Target Value = 3.000 Measured Value 2D = 0.000 Design

AutoAdjust – Paving Change Screed lowers 2D = -0.020 3D = -0.030 AutoAdjust = 0.000 Target Value = 3.000 Measured Value = 2.980 2D = -0.020 Design

AutoAdjust – 2D Response 2D Drives tow point to correct Target Height 2D = 0.000 3D = -0.010 AutoAdjust = 0.000 Target Value = 3.000 Measured Value 2D = 0.000 Design

AutoAdjust – 2D Steady T3 2D on Zero for a period, 3D low 2D = 0.000 Target Value = 3.000 Measured Value 2D = 0.000 Design

AutoAdjust – AutoAdjust Starts AutoAdjust adds difference to Set Height 2D = -0.010 3D = -0.010 AutoAdjust = 0.010 Target Value = 3.010 Measured Value = 3.000 2D = -0.010 Actually AutoAdjust grows in much smaller steps over a long distance & 10 mm would never be applied all at once Design

AutoAdjust – 2D Corrects 2D Drives tow point to correct Target Height 2D = 0.000 3D = 0.000 AutoAdjust = 0.010 Target Value = 3.010 Measured Value 2D = 0.000 Design

AutoAdjust – Steady State Screed steady in new position, 3D correct 2D = 0.000 3D = 0.000 AutoAdjust = 0.010 Target Value = 3.010 Measured Value 2D = 0.000 Design

Benching & AutoAdjust Population of the AutoAdjust value when benching PCS900 Probably the biggest change Used to be set to zero When benching the 3D system PCS900 will pre-populate the AutoAdjust value with the deviation seen under the mast Minus any deviation to design

Benching & AutoAdjust This is the amount AutoAdjust would have learnt after you started paving This means, if the screed is setup on design, customers will see green grade lights on the 2D boxes It isn't a problem if they aren't on design as we back that deviation out of the calculation When they do get to grade they will see green grade lights

Benching & AutoAdjust If the customer has the screed at an incorrect angle of attack when they bench, the pre-populated AutoAdjust value will be incorrect to start with

AutoAdjust Limits The maximum positive AutoAdjust limit has been increased from 30 to 100 mm The negative limit remains at -200 mm These limits are now applied relative to the initial AutoAdjust offset value calculated at the time of benching previously centred around 0 mm

3D Offsets vs. 2D Offsets Which do you use when? 3D Offsets are for Site Wide offsets You have a final design but want to build in more than one lift E.g. offset -100 mm You are building to final design but need to allow for compaction E.g. offset = +35 mm

3D Offsets vs. 2D Offsets Which do you use when? 2D Offsets are for Temporary offsets You must allow extra thickness over a low area that is small E.g. offset = +15 mm until you pass over it You need to “feather” the design to match another surface E.g. Manually change offset from 0 mm to +25 mm over the transition distance

3D Offsets vs. 2D Offsets Which do you use when? 2D Offsets are for Temporary offsets If grade check is off by a few mm Can be used to nudge the screed until the Grade Check cut/fill number matches the 3D raise/lower value *Assumes* Grade Checker is correct Like a manual bench Useful when changing from one UTS to another

Design or Minimum Thickness? Are you building to Design or to Minimum Thickness? Sounds like a basic question? Yes it is! Building to Design Use 3D Building to Minimum Thickness Use 2D

Design or Minimum Thickness? One Beta site wanted both Real answer Survey the base surface and make a “correct” 3D design Then use 3D What they did Pave in 3D to original design Manually add 2D offsets to ensure minimum thickness over high spots

Paving Thickness Or Subgrade level IF the base level is too high PCS900 will try to grade it off Very Bad PCS900 (3D) gives you an absolute height When the base is higher than your paving design, the PCS tries to keep the screed on grade and tries to plough the screed through the base

Paving Thickness IF the base level is too high PCS900 will drive the Tow Arms to the limits Do NOT let the tow arms drive to limits And the screed still be Off Grade by < 50 mm Warning: AutoAdjust will keep learning But it will be wrong When you get back to “normal” AutoAdjust will have to unlearn the false correction

Paving Thickness Really Simple Don’t EVER let the rams hit the limits with AutoAdjust turned on If this happens: Change to Manual Pave until back on grade Bench Continue in Auto

Starting Surface Too High This happened also during Beta… In the morning found that yesterday they achieved less compaction then planned Start surface too high

Starting Surface Too High Answer: Set up screed per normal practice Bench Enter 2D offset – 2D is “on-grade” Place in Auto and start paving Slowly reduce 2D offset back to zero To get back to design Note: Grade check will not check in with 3D raise/lower text items until 2D offset is brought back to zero

Millimetre Accuracy What is a millimetre? 9 sheets of paper = 1 mm thick!

Millimetre Accuracy Just like a NASCAR racing car They spend a lot of time tuning it And it goes faster than the car you drive If you want the absolute best out of a UTS Then spend a lot of time looking after it Calibrate it regularly Don’t throw it in the back of the truck

Millimetre Accuracy Does the PCS give the same result as the Grade Checker? Are the 2 UTS in the same terms We are trying to squeeze the tightest tolerances possible out of large, heavy machines Everything must be perfect

Millimetre Accuracy Start with Site Control Or infrastructure The survey marks you use to set up the SPS930s You cannot be better than this Most important when your paving run requires multiple setups You can use best surveying practice to minimise errors

Millimetre Accuracy Always set the 2 UTS up near each other Use the same marks to resect in (free station) Does Not make it more accurate Does mean they will be in the same terms Same errors, so Grade Checker will agree with PCS900 Use extra marks for resection More than the minimum Extra redundancy = more accurate 3 marks are a LOT better than 2 marks

UTS Set-Up How to get the best UTS Set-Up And how to Check that your UTS is accurate enough Observe Two Faces

UTS Set-Up Setup Total Station

UTS Set-Up Pick a Point (right) Observe 2 faces (left) Tolerance screen (right)

UTS Set-Up Observe 2 faces (above) Point summary screen (left)

UTS Set-Up Select the next point to observe Observe 2 faces (left) Tolerance screen (right)

UTS Set-Up Observe 2 faces (above) Point summary screen (left) Set-up summary screen (right)

UTS Set-Up Take a third point (left) Select the next point to observe Observe 2 faces (left) Tolerance screen (right)

UTS Set-Up Observe 2 faces (above) Point summary screen (right) Set-up summary screen (right)

UTS Set-Up Complete Instrument setup Set up for use with machine control

UTS Set-Up Summary Always use at least 3 marks for Set-Up This gives you a more accurate set-up And checks that the set-up marks are correct Always use Averaging Mode – Two Faces This checks you point correctly at each mark And checks that the UTS calibration and collimation has not changed

Millimetre Accuracy Then when you are ready use both UTS to measure to the same stationary target Suggest MT900 Read coords in Diagnostics Do you get the same result? Trick question, there will always be an error What is the error you get Real question You should not expect to be more accurate then this error

UTS Collimation Carry out a collimation test in the following situations: When you can’t get measurements in tolerance Whenever the instrument may have been roughly handled during transport. When the ambient temperature differs by more than 10°C (18°F) from the previous collimation test When your height changes by more than 300 m

UTS Collimation This can be done by a competent user But if you get it wrong, all measurements will be wrong until it is corrected. Should do it once a week Must do it at least once a month

Shock Isolators for AS200 The AS200 is mounted on the Transverse Beam Usually on shock isolators Are the Shock Isolators in top condition? Or are they old and worn allowing the AS200 to vibrate and wiggle? Replace as required This was the source of one Beta Sites poor performance

UTS Line of Sight Sounds very basic, … and it is! Must have line of sight Consider where Asphalt trucks drive Consider where other machines drive Consider where second and subsequent paving runs are Preferably when paver moves over for the next run it gets closer to the UTS

UTS Line of Sight Maximum range for top accuracy 200 m (660 ft)

UTS Line of Sight What is wrong here?

UTS Line of Sight What is wrong here?

UTS Line of Sight What is wrong here?

UTS Quick Search Time Limit This has been reduced to 15 seconds Previous PCS900 release candidates had a 2 minute time limit on UTS quick searches This should greatly improve the user experience when the UTS loses lock on the MT900

UTS Quick Search Sequence The system will quick search for 15 seconds If no target is found it will then perform a full search in the configured search window If no target is found it will go back to the quick search window for 15 seconds, etc. The loop continues until the target is found

Joint Match & Differential Compaction Differential Compaction increases Mat thickness when sub grade drops so the final compacted surface is correct Joint Match with sonic matches that side to the existing surface

Joint Match & Differential Compaction Differential Compaction should be used as 3D Elevation and 3D Slope Entire width gets the benefit of the differential design 3D Elevation to a differential design on one side and 2D Elevation Joint Match on the other is DIFFERENT Cross Slope will vary But some customers do this successfully

Direction Softkey Gone Based on the feedback and severe negative performance with Western Rock we have removed the ability to toggle the direction the paver is facing The system is now back to like it is in v1.00 i.e. motion is always assumed to be forward

Design Look-up Tolerance As long as the MT900 is above the design MT900   Virtual MT900

Design Look-up Tolerance As long as the MT900 is above the design On Design On Design Off Design

Design Look-up Tolerance When screed is narrower than MT900 MT900   Virtual MT900

Design Look-up Tolerance When screed is narrower than MT900 200 mm Use points 200 mm in from screed gates

Design Look-up Tolerance When screed is narrower than MT900 On Design On Design Off Design

Documentation UTS measure-up documentation and Quick Start Guide tweaks We have made some corrections to the UTS measure-up instructions in chapter 7 of the installation manual We have also removed some wording from the Quick Start Guide

Quick Start Guide Step UTS inst. SCS 900 PCS 400 PCS 900 1. Ensure PCS900 has valid machine measure-up and AS450 calibration.   X 2. Ensure PCS400 is configured correctly. For example, 3D elevation and 3D slope control. 3. Ensure the 2D cross-slope sensor is calibrated. 4. Ensure the PCS900/UTS instrument and SCS900 grade check/UTS instrument set-ups have adequate range and line of sight for the desired paving run. 5. If using manual masts, ensure the correct mast extension is entered. 6. Load the design in PCS900 and optionally select a horizontal alignment. 7. Establish a connection between PCS900 and the UTS instrument that is responsible for paver control. 8. Establish a connection between the grade check SCS900 system and the UTS instrument responsible for grade checking. 9. Enter any horizontal or vertical offsets in PCS900.

Quick Start Guide Step UTS inst. SCS 900 PCS 400 PCS 900 10. Ensure the SCS900 setup used for grade checking uses the same design and vertical offset as PCS900.  X   11. Prepare screed for paving using normal techniques (for example, 'Pave-by-the-Numbers'). Try to get screed as close to grade height as possible. 12. With screed on starter blocks pull the machine forward until PCS900 obtains the screed orientation (~300-400 mm). Once the orientation is known, the 'Low Accuracy: Move' message stops. This procedure assumes that the starter blocks get the screed on grade relative to design. X 13. Bench PCS900 using an external reference such as a UTS rover pole. Do not use a GPS rover for benching. Bench point should be at screed point, as defined by machine measure-up.

Quick Start Guide Step UTS inst. SCS 900 PCS 400 PCS 900 This step only applies to US style pavers that have depth crank handles. 14. Do not adjust the depth crank handles again! If you re-adjust the depth crank handles, rebench PCS900. Note – If there is a large elevation change you may run out of cylinder. In this instance, buy back some cylinder by slowly adjusting the depth crank handle until PCS900 adjusts to grade. If you have to crank faster than PCS900 can adjust the screed back to grade, crank and wait until the system is on grade again. If the 2D system is back on grade and enough cylinder has been gained back, stop the paver and rebench as outlined in step 13. Then complete the steps from step 15. 15. Begin paving and place the 2D system into Auto.   X 16. Check the grade of the laid mat with an SCS900 grade check rover. 17. If required, increment or decrement the CB440 responsible for 3D elevation to get on-grade. Only very small adjustments may be required. Be careful not to overreact to grade height changes. The screed reacts very slowly to grade changes.

Questions? ?