Applications
Excavators are crucial operating machines on construction sites and are used for excavation activities and material handling. The integration of advanced sensors allows operators to accurately monitor and control boom movements, vehicle tilt, command pedal rotation and hydraulic systems, ensuring stability, safety and maximum operational efficiency.
Requirements:
Throttle lever angular position control
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Boom and bucket position monitoring
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Steering angle control
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Hydraulic circuit pressure monitoring
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Stabilizer positioning adjustment
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Vehicle tilt monitoring
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Requirement:
Throttle lever angular position control
The control of the angular position of the excavator’s throttle lever plays a crucial role in the optimal management of vehicle performance. A precise detection system allows the operator to continuously modulate the speed and available power, ensuring smooth and safe manoeuvres in all working conditions. This helps to optimise operational efficiency, fuel consumption and the durability of the vehicle’s mechanical and electronic components.
Solution:
Gefran offers the GRA rotary sensor, a robust and versatile solution, which can guarantee stable performance even in the most challenging environments.
- Non-contact Hall technology guarantees measurement stability and long life, eliminating mechanical wear
- It is available with redundant output and with different electrical interfaces, both analogue and digital, to adapt to multiple application needs
- With strong connections and resistant to shocks, vibrations and high temperatures, it is ideal for use in harsh environments
Requirement:
Boom and bucket position monitoring
The control of the position of the boom and bucket is essential to ensure maximum precision in excavation and when handling materials. An accurate detection system allows the operator to manage movements smoothly and safely, preventing positioning errors and reducing the risks linked to vehicle stability. In addition, optimal adjustment promotes the efficient use of available power, increasing productivity and reducing wear-and-tear on mechanical components.
Gefran offers a complete range of solutions for controlling the position of the excavator boom, combining linear and rotary sensors to cover all measurement needs.
RK5 linear position transducer
- Direct installation inside the hydraulic cylinder, without external encumbrances
- Non-contact magnetostrictive technology that eliminates wear and guarantees long life
- High resistance to shock, vibration and contaminants
GRA rotary sensor with shaft
- Available in single or redundant output version for high safety requirements
- Supports analogue and digital interfaces (CANopen, SAE J1939) for versatile integration
- Robust design, resistant to shocks and vibrations
Requirement:
Steering angle control
The control of the steering angle is an essential requirement to ensure the precise and safe manoeuvrability of the excavator. A reliable detection system allows the operator to more accurately manage vehicle movements, even in confined spaces or during complex operations. This helps reduce the risks of instability and wear of the components, improving the machine’s operational efficiency and safety.
Solution:
To ensure precise and reliable steering control, the GRN rotary sensor without shaft is particularly suitable because:
- It uses non-contact Hall-effect magnetic technology, ideal for repetitive movements and long operating life
- It is compact and simple to install
- It is highly resistant to shocks and vibrations, ensuring solid performance over time
Requirement:
Hydraulic circuit pressure monitoring
Monitoring the pressure in the hydraulic circuit is a crucial element to ensure the efficiency and operational reliability of an excavator. The continuous and accurate control of the pressure values allows the prompt identification of any anomalies, preventing faults and reducing machine downtime. This function optimises the performance of the hydraulic system, ensuring the correct use of the available power and helping increase the safety, productivity and overall life of the components.
Solution:
For the precise and safe control of pressure in the hydraulic circuit, Gefran recommends the pressure transducers of the KM series because:
- They are small in size, which makes them easy to install, even in limited spaces
- They guarantee high resistance to shocks, vibrations and high temperatures
- They are SIL2/PLd certified, ensuring high standards of functional safety
Requirement:
Stabilizer positioning adjustment
Controlling the position of the stabilisers is a fundamental requirement to ensure stability and safety when using the excavator on uneven terrain or poorly compacted soil. A precise monitoring system allows operators to verify the correct ground support and to ensure the optimal balance of the machine in the different operating phases. This helps to reduce rollover risks, improve productivity and preserve the structural integrity of the machine over time.
Gefran offers two alternative solutions for adjusting the position of the stabilisers: rotary sensors or multi-variable position sensors. Both solutions allow safe control of the extraction angle, improving vehicle stability, efficiency and reliability.
GRA rotary sensor with shaft
- Available in single or redundant output version for high safety requirements
- Supports analogue and digital interfaces (CANopen, SAE J1939) for versatile integration
- Robust design, resistant to shocks and vibrations
TWIIST LM-C multi-variable position sensor
- Multi-variable sensor, which can simultaneously measure both angular and linear position
- Contactless technology ensures long life and reduced maintenance
- High resistance to shocks and vibrations
Requirement:
Vehicle tilt monitoring
Monitoring the inclination of the machine base is a crucial aspect to ensure the overall stability and operational safety of the excavator. An accurate detection system allows the prompt detection of any variations from the ideal position, reducing the risks of rollover and loss of control during operations. This function increases the protection of the operator and the equipment, improves the efficiency of manoeuvres and the durability of the vehicle’s structural components.
Solution:
To accurately monitor the inclination of the base of an excavator, Gefran offers the GIG inclinometer, which has the features listed below:
- Single or redundant output, to meet different safety requirements
- Resin-sealed structure, which offers protection against dust, water and external agents
- High resistance to shocks and vibrations, to ensure measurement stability over time
Operating principle:
To carry out excavation and handling activities efficiently, it is necessary to continuously know the position and extension of the hydraulic cylinders, in order to precisely coordinate the movements of the boom and bucket. In the same way, the accurate control of rotation angles and the movements of the slewing ring is fundamental for operational speed and safe manoeuvres.
Since excavators often operate on uneven ground, it is essential to maintain stability and ensure the safety of the machine and the operator. In addition, the constant management of pressures in the hydraulic circuits is crucial to modulate applied forces, prevent overloads and ensure reliability, even in the most challenging working conditions.
Requirements and Technology:
The intensive use of the excavator requires robust and precise control systems, capable of withstanding shocks, vibrations, dust, mud and extreme weather conditions.
These applications require the use of advanced sensors, essential to ensure accurate control of the machine in all operating conditions.
Key technology requirements include:
- Throttle lever angular position control
- Boom and bucket position monitoring
- Steering angle control
- Hydraulic circuit pressure monitoring
- Stabilizer positioning adjustment
- Vehicle tilt monitoring
Gefran supports excavator builders with rotary, linear position, tilt and pressure sensors, designed to withstand the harshest environments and ensure reliable performance over time.