The off-highway industry is undergoing great change lately, in particular with autonomous technologies advancements. For hydraulic engineers developing systems for mobile construction machinery, this transformation represents both challenges and opportunities. While autonomy may not aim to replace human operators entirely, it is redefining their role, improving productivity, safety, and efficiency.
Modern off-highway machines incorporate features that reduce operator workload, enhance safety, and streamline processes. However, full autonomy remains rare outside controlled environments, leaving room for innovation, said Adam Khaw, Head of Autonomy, Senior Director of Danfoss, during the company’s annual distributor meeting last fall.
Sam Long, sales developement manager with Danfoss’ autonomy, said there are five levels of autonomy, with level 0 being fully manual machines with no automation.
- Level 1: Basic operator assistance, such as automatic braking
- Level 2: Partial automation, where some functions (like cruise control) are managed by the system
- Level 3: Conditional automation, allowing machines to handle all functions under specific conditions but requiring the operator to remain nearby
- Level 4: High automation, where the machine controls all functions but still requires on site supervision
- Level 5: Full automation, with no human supervision necessary
“We’re just beginning to see Level 5 systems in action,” he said. “But to make them viable, factors like reliable internet connections and safety protocols must be flawless.”
While Levels 4 and 5 offer the greatest potential, most development currently focuses on Levels 3 and 4. These systems provide significant benefits without the complexity and cost of full autonomy.
The goal of autonomy is not to replace operators but to assist them and augment their work. Machines equipped with operator-assistance systems use technologies like cameras, LiDAR, and GPS to simplify challenging tasks.
For example, Khaw detailed one application for ground-support at airports. The most high-stress job for cargo loaders occurs when docking machinery close to aircraft. Even a minor bump or misalignment can cause downtime and thus delay flights, not to mention financial loss. By automating the final docking steps, Khaw said, these systems improve accuracy and reduce anxiety, preventing costly errors.
“There’s an estimated $5 billion worth of damages just done by ground support vehicles every year. That’s estimated to grow to $10 billion over the next 10 years, and 40% of that is from cargo loaders, belt loaders and the airport stairs,” Khaw noted. “The reason for that is those vehicles get up right up close to the plane, and oftentimes they’ll contact the plane. And anytime the plane is contacted, even if there’s not damage, on average, it’s $250,000 per incident, because they have to pull that plane out, inspect it, refuel a new plane, get a new plane in, unload the cargo, and reload the cargo.”
For this cargo loader vehicle, Danfoss developed an operator assistance feature. Rather than making the full operation of driving throughout the tarmac automated, they focused on the high-stress part for the driver. What the autonomous operation does is identify the opening and automatically dock to that vehicle so the driver can reliably get to within an acceptable distance from the plane without ever touching it.
Additionally, construction machinery outfitted with sensors can establish “virtual fences” using cone markers or other inputs. These fences restrict equipment to operate within predefined zones, preventing collisions with buildings, traffic, or people. Systems can also detect human presence, stopping operations if someone enters the boundary.
“In construction, what we’re looking at is more around the safety of the operator. How can we make the the operator and the people around that operator safer,” Khaw said. “And we can do those things by giving them more precision, and giving them the skill of a 30 year operator, making them more productive and then increasing their safety.”
Some manufacturers are introducing fully autonomous machines designed to perform entire tasks without human intervention. For example, Khaw said a soil compactor with Danfoss technology can define its operating boundaries, generate an optimal path, detect obstacles, and adjust its behavior to avoid disruptions. Such innovations enhance productivity by minimizing rework and error and elevating safety.
“Autonomy is growing most in Level 3 systems. These allow machines to do much of the work while a human handles unexpected situations,” Khaw said. “For instance, if a cow unexpectedly crosses into the operating area, the operator can intervene to ensure safety.”
While autonomy brings electronic control systems into the spotlight, hydraulic systems remain fundamental to the operation of heavy machinery. The integration of autonomy and hydraulics presents opportunities for innovation for fluid power manufacturers.
Hydraulics provide force and precision. Autonomous technologies enhance this by introducing advanced control algorithms. For instance, with automated path generation and obstacle avoidance, machines can make instantaneous adjustments to hydraulic actuators, maintaining stability and accuracy while optimizing efficiency.
To support autonomy, hydraulic systems are increasingly tied to modular electronic architectures. Tools like Danfoss’ Plus+1 Guide software integrate perception, navigation, and control layers within hydraulic-powered machines. “Think of it as visual coding,” Long said. “You don’t need a computer science background, but you do need to understand the systems. Prewritten code blocks make it accessible to most engineers.”
By utilizing LiDAR, radar, GPS, and position sensors, these systems enable seamless coordination between the machine’s electronic and hydraulic components.
Telematics can add a data-driven layer to hydraulic systems. By monitoring parameters like pressure, flow rate, and actuator performance, telematics allows for predictive maintenance, reducing downtime and prolonging the lifespan of hydraulic components. In autonomous machines, this data also informs decision-making, enabling machines to adapt dynamically to changing conditions.
While these systems are changing the way they work, they are not without their challenges. Addressing challenges starts with the sensors, Long said. Sensors detect obstacles and gather data. However, sensors like LiDAR may not be as effective in adverse conditions, such as dust, fog, and heavy rains. To mitigate this, filters and advanced algorithms are being developed to refine data, ensuring machines operate effectively in all environments.
“Consider the machine stopping safely if geese suddenly land in its path. It’s all about safety first,” he said, emphasizing the importance of robust operational design domains.
Hydraulics will continue to provide unmatched power and flexibility for most mobile machines. Khaw noted that as autonomy becomes more widespread, engineers will need to rethink hydraulic systems’ design and integration, focusing on:
- Increased system intelligence: Adding more sophisticated sensors and controls to hydraulic systems will allow for real-time adjustments, improving precision and responsiveness.
- Improved safety mechanisms: Autonomous features must include fail-safe designs to prevent accidents. For hydraulic systems, this may involve redundant circuits or pressure-relief mechanisms that ensure operations stop safely if control systems fail.
- Energy efficiency: With sustainability becoming a priority, autonomous systems can optimize hydraulic energy use, reducing waste and improving overall efficiency. This includes incorporating hybrid systems that leverage electric actuators alongside hydraulics for lighter tasks.
- Seamless human-machine interaction: Even as machines become more autonomous, operators will still play a crucial role. Interfaces must simplify complex operations, providing intuitive controls and real-time feedback for tasks requiring manual intervention.
Danfoss
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