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

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

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

4. 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

5. 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

6. 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

7. 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.”

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

9. 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

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

11. 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

12. 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!

13. 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

14. 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

15. 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

16. 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

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

18. 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

19. 3D Paving Training AutoAdjust
March 2010
by Phil Jackson

20. 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

21. 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

22. 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.

23. 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

24. 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

25. 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

26. 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

27. 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

28. 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

29. 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

30. 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

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

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

33. AutoAdjust – Paving Change
Screed lowers
2D =
3D =
AutoAdjust = 0.000
Target Value
= 3.000
Measured Value
= 2.980
2D =
Design

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

35. 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

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

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

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

39. 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

40. 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

41. 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

42. 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

43. 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

44. 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

45. 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

46. 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

47. 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

48. 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

49. 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

50. 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

51. 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

52. 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

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

54. 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

55. 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

56. 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

57. 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

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

59. UTS Set-Up
Setup Total Station

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

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

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

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

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

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

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

67. 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

68. 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

69. 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

70. 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

71. 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

72. 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

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

74. UTS Line of Sight
What is wrong here?

75. UTS Line of Sight
What is wrong here?

76. UTS Line of Sight
What is wrong here?

77. 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

78. 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

79. 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

80. 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

81. 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

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

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

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

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

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

87. 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

88. 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.

89. 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 (~ 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.

90. 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.

91. Questions? ?