Most of the energy that heavy commercial vehicles use is not consumed moving around sites but rather in lifting, carrying or digging. The hydraulic equipment used to perform these functions can often be old-fashioned and inefficient.

In 2018, the Advanced Propulsion Centre (APC) awarded a £10.9m grant to the DDisplace project, to address these challenges by redesigning hydraulic systems. It is led by Edinburgh-based technology developer Artemis Intelligent Power, working in collaboration with Danish-American multinational Danfoss Power Solutions and hydraulic system specialist Robbie Fluid Engineering.

Alasdair Robertson, marketing director at Danfoss Power Solutions, said: “Hydraulic systems in a machine like an excavator have been shown to waste up to 70% of the energy that goes into them as heat. This inefficiency is a barrier to widespread electrification of off-highway machines and needs to be tackled urgently as part of the global road to net zero.”

Radial design
The DDisplace concept uses a radial configuration on its DDP096 Digital Displacement pump rather than a mechanically governed axial pump, with its pistons actuated by computer-controlled valves.

“By replacing a conventional pump with a DD one you can expect to save 10-20% of the input energy,” said Robertson: “For more complex implementations where we start to use the ability of the DD pump to have multiple independent outputs we will leverage that to develop more advanced system architectures.”

Robertson believes that, once the technology is fully developed, it could improve system efficiency by up to 50%, considerably reducing emissions and energy consumption. Furthermore, it could play a key role in the electrification of heavy commercial vehicles. Danfoss has also developed an electric powertrain as part of a second APC-backed project, and the company estimates that the two technologies combined could reduce the lifetime CO2 emissions of the global excavator fleet by 80 megatonnes by 2030.

Zoe Hall, head of competitions and projects for the APC, said: “Off-highway vehicles, due to the duty cycles and power requirements, are notoriously difficult to decarbonise, so the impact of the work of the DDisplace project shouldn’t be underestimated. Danfoss’s investment in UK hydraulics manufacturing in the past year alone has been significant, and I’m sure we’ll see the learnings from the APC project applied to future products.”

Read more: Hydraulic systems redesigned to boost efficiency of heavy commercial vehicles

Boasting more standard features and more power, Kobelco has introduced the SK260LC-11 conventional hydraulic excavator.

With a 23-percent increase in torque compared to the previous model, the 194-horsepower Tier 4 Final Yanmar engine on the SK260LC-11 delivers 577 pound-feet of torque at 1,500 rpm.

The machine weighs in at 60,200 pounds and has a bucket digging force of 42,000 pounds, 63,300 pound-feet of swing torque, and 55,600 pounds of drawbar pulling force.

An ‘Independent Travel’ function, which dedicates one hydraulic pump to travel and one to the attachment, enables smooth and steady operation while moving heavy objects, Kobelco says.

The SK260LC-11 has three work modes – Eco, S and H – for balancing between high performance, economy and low fuel consumption. The heavy-lift and power-boost (with unlimited time use) features can be activated when more muscle is needed.

Durability and performance have been improved through thicker side panels and a larger bucket cylinder pin.

Read more: Kobelco’s New SK260LC-11 Excavator Brings the Torque

Taking the next step to battery power for its machine lineup, Volvo Construction Equipment has electrified its first large crawler excavator as a customer pilot.

Designed and built at the Volvo facilities in Changwon, South Korea, the 22-metric-ton EC230 electric excavator, which is not yet commercially available, has been tested by customers in South Korea and China. Now the EC230 E machines are due to come to North America for demos.

Remi Teysseire, excavator product manager, discussed some of the high points of the EC230 at the recent Volvo Days event.

During his presentation, he said it offers the same features as the EC220, the diesel-powered conventional excavator in the same size class.

“We can bring the same tool size. We have the same digging forces, the same lifting capacities with the added value to have less noise and zero emissions,” Teysseire said.

With its battery power, the excavator is expected to achieve 60-70% reduction of energy running costs compared to the EC220. Teysseire said the EC230 E is equipped with four 66-kilowatt lithium-ion battery packs that enable the operator to work four to five hours in general purpose applications. With a high-power fast charge on a lunch hour, the machine should last through a full eight-hour shift.

Read more: Volvo Testing its First Large Electric Excavator, the EC230 E

Technology has enabled many features that save costs when running an excavator, by reducing fuel consumption and machine wear-and-tear. But there are so many variations among brands, the choices can be confusing.

So for this report, we spoke with manufacturers to help sift through the many offerings. They offer tips to help you find the right features on your new excavator, as well as make the most of your existing machines. We also highlight the latest excavators on the market.

So many work modes
Kobelco SK210LC-11 excavator arm stretched horizontally with bucketful of dirtThe -11 Series of Kobelco excavators are designed for efficiency and productivity. The SK210LC-11 has a Yanmar engine with 594 pound-feet of torque providing digging force of 35,300 pounds and lifting capacity of 16,660 pounds. Operating weight is 50,000 pounds. The three-camera system displays on a 10-inch monitor.

There are several work modes, auto-idle and auto-shutdown settings on the market, but there is little standardization.

Delay intervals on auto-idle and auto-shutdown may be user-settable or may be factory set; some machines have auto-idle but no auto-shutdown.

Read more: New Excavators Decked with Cost-Saving Tech

No matter how much recycling you do, there is always a certain amount of stuff you have to just throw away. While most of us never really give a second thought to what happens to our garbage once we put it on the street, this stuff has to be picked up and taken away by someone and something.

That’s where garbage trucks are an essential piece of kit for many municipalities around the world. Let’s watch some being made.

Step 1: Prepare the truck base
The first step, once a suitable truck base has been selected and sourced, is to begin to prepare the chassis for the garbage truck’s main rear dumpster. Mounting bars and other parts are welded to the main chassis, as well as, the main hydraulic lifting arm.

Angle grinders are used to clean up any welds. Other parts are also added like access ladders, etc, that will be used by the garbage truck operatives once the garbage truck is put into service.

Step 2: Make the main garbage dumpster
With that body ready, sheets of metal are then used and prepared to make the main dumpster for the garbage truck. Tubular steel bars are also cut down to size for incorporation into the dumpster as needed.

This is done using special cutting machines that can cut through steel with ease.

Industrial-sized lathes are also employed to cut and shape metal rods. To ensure consistency, the lathes are computer-controlled to make sure that the parts turned are the same every time.

For other parts of the garbage truck, a special computer-controlled plasma torch is used to cut out shapes from large sheets of steel. This is completely automated, by a human worker is often present to ensure the process is running as it should.

Read more: This is how garbage trucks are actually made

At a Glance:

Mitch Eichler, business development manager at Parker Hannifin, is a mechanical engineer with a passion for commercializing hydraulic valve applications designs. He shares insights from his field.
With the advantages of a high power density, large force output and easiness to actualize linear motions, hydraulic transmission systems are widely used in industrial hydraulics and for mobile hydraulic machinery.
Along with the trade up from purely mechanical to electrohydraulic components comes the expectation of higher levels of performance, accuracy and scalability.

The current surge and expected growth in the integration of electronics with hydraulics reveals a shift in focus. It compels industrial manufacturers to review their competitive stance so they can identify the simplest, safest, most economical systems that are both scalable and easy to maintain. But does it also mean that traditional hydraulics are on a steady path to being permanently displaced?

With the investments shifting toward renewable energy and as time goes on, newer technologies related to high-pressure hydraulic systems become more applicable. Electrohydraulic pumps, for instance, are touted for being up to 80% more efficient than their traditional counterparts.

Mitch Eicher, a business development manager at Parker Hannifin, contends that traditional hydraulic components will remain critical to systems where the flow rate, pressure or actuators need to be controlled. Based solely on the force, speed required and the energy consumed, he argued, it would be size- and cost-burdensome to drive all components directly using electromechanical solutions.

“Those really high-force, high-demand applications still are largely done by hydraulic valves,” said Eicher. “You can get a lot of bang for your buck—it’s a very dense solution.”

Across the board, hydraulic experts tend to agree that the combination of high power density, large force output and the ease with which one can actualize motion makes hydraulic transmission stand head above shoulders in industrial and mobile hydraulic machinery.

“The way that fluid power works, you can get a lot of bang for your buck—it’s a very dense solution in a small space,” emphasized Eichler, a mechanical engineer who specializes in hydraulic valve applications.

Read more: Are Hydraulic Components on a Steady Path to Being Displaced?

Link-Belt Cranes designed the new 120 US-ton base rated, 120|HT hydraulic truck crane — loaded with features and a new look to match. The new hydraulic truck crane’s production models are set to begin shipment in the fourth quarter of 2021.

Ride quality
The four-axle 120|HT features a new, wider single occupant cab that reflects design elements of the 175|AT all-terrain crane. The 120|HT also comes with an all-new air ride suspension design, the first-of-its-kind for truck crane buyers. Its suspension and braking system is a result of a two-year collaborative design process with suspension manufacturer Hendrickson International. Air disc brakes, another first for the hydraulic truck crane market, will improve brake performance and reduce maintenance time.

Transportability
Counterweight payload increases from 16,000 pounds on the HTC-86110 to 20,500 pounds on the new 120|HT without a boom dolly. Full counterweight for the 120|HT is 49,100 pounds. Increased counterweight payload is a result of a strategic design approach to reduce the 120|HT’s gross vehicle weight coupled with an increased rating on the front steering axles to 26,000 pounds each.

Fuel efficiency has increased with the introduction of Cummins X12 single overhead cam engine that is EPA 2021 compliant. Top speed on the 120|HT is 62 miles per hour. Link-Belt has improved upon access for daily service checks like fill points, filters and grease points.

Upper
The 120|RT delivers outstanding reach with a six-section 38.3 – 164.1 feet pin and latch formed boom, built to Link-Belt’s specific boom profile and tolerances. An available two-piece on-board off-settable fly provides greater flexibility and range, and manually offsets at 0, 15, 30 and 45 degrees. Two 16 feet lattice insert extensions provide a maximum tip height of 261.7 feet.

Features like Link-Belt SmartFly, Link-Belt’s patented one-person fly erection technology, and a wireless rigging remote to control your outriggers, outrigger beams and jacks, boom hoist, and winches make setup quicker and easier with increased efficiency.

The new operator cab features wide-entry access and egress, USB and 12-volt power supply, and increased storage with interior lighting. The view from the seat is uninhibited in all kinds of weather with large sweeping wipers in the front and top, and strategically-placed vents for fast-acting defrost.

Read more: Link-Belt Cranes 120|HT Hydraulic Truck Crane

The world’s first digger powered by a hydrogen combustion engine was given a royal outing at the weekend in a parade marking the Queen’s 70-year reign.

The JCB backhoe loader – in distinctive green and white livery – was cheered loudly as it made its way along The Mall in London towards Buckingham Palace driven by JCB Test Site Operator Georgina Williams, 30.

The machine has been developed in top secret by Staffordshire-based JCB and the Platinum Jubilee Pageant was its first it first major public outing on a world stage. JCB Chairman Lord Bamford is leading the project to develop JCB machines powered by hydrogen.

“I was immensely proud to see JCB’s first hydrogen powered product take centre stage at the Platinum Jubilee Pageant to mark Her Majesty the Queen’s 70-year reign,” said Bamford. “So much has happened over the past seven decades and the jubilee has now focused minds on the need to take greater care of the environment in the future. I was so pleased to share at the Pageant how we are focusing on the development of JCB machines powered by hydrogen, which will help drive us towards a zero-carbon future.”

Read more: JCB’s world-first hydrogen digger joins Queen’s jubilee pageant

Offering long-term durability in a wide range of applications, the new Cat 966 GC wheel loader is designed for high performance and efficient operation. Its Caterpillar-designed components, on-demand fan, load-sensing hydraulics and intuitive controls keep fuel consumption and operating costs low, making it a versatile machine that also fits the needs of the rental and municipal markets.

The Cat C9.3B engine meets U.S. EPA Tier 4 Final, EU Stage V, Korea Tier 4 Final, China Nonroad Stage IV and Japan 2014 emission standards with a gross power rating of 239 kW (321 hp). The engine’s automatic Cat Clean Emissions Module (CEM), including SCR catalyst and diesel particulate filter (DPF), works in the background without impacting the production schedule.

RELATED: Cat launches three new compact wheel loader models
The Cat Engine Idle Management System (EIMS), Auto Engine Idle Shutdown (EIS), variable speed fan and load sensing hydraulics help result in low fuel consumption and reduced sound levels on the machine. Also, an optional automatic reversing fan assists in cleaning cooling cores to improve performance in high-debris environments.

Furthermore, the new loader features a 4-speed electronically-controlled, automatic planetary powershift transmission with shift protection and single clutch gear shifting. According to Cat, the loader’s optional ride control improves operating smoothness over rough terrain while optional limited slip differential axle configurations increase traction in poor underfoot conditions.

Front linkage
Caterpillar’s Z-bar loader linkage with cast crossmember and tilt-lever looks to provide both strong digging capabilities and high breakout forces when the loader is equipped with Cat Performance Series buckets. The load-sensing implement hydraulic system continuously controls flow and pressure to precisely match requirements of the operating situation, reducing both the load on the pump and overall fuel burn.

Using a system-based approach to balance bucket shape with the machine’s lift and tilt capacity, weight and linkage, Cat’s Performance Series Buckets are available for a range of applications including general purpose, flat floor, heavy duty rock and light material. The company claims that design features enable operators of all experience levels to routinely attain 10% higher bucket-fill factors, compared with legacy designs, to improve production and reduce fuel consumption.

Also, the 966 GC can be equipped with the Cat Fusion™ quick coupler and controls, and combined with optional third-function auxiliary hydraulics, the coupler allows use of a wide selection of Cat work tools.

An optional Cat Payload kit provides on-the-go weighing for more precise of load targets with flexible and simple installation and easier calibration. Cat Payload weighs the material while moving to the truck and lifting, limiting interruptions in the load cycle. Also, it allows the operator to load to exact specifications and load more trucks and move more material faster.

Read more: New Cat 966 GC wheel loader boasts high performance and low costs

New wheel loader delivers high performance, easy operation, and low owning and operating costs

OFFERING long-term durability in a wide range of applications, the new 22-tonne Cat 966 GC wheel loader is designed for reliable performance and efficient operation, with its Caterpillar-designed components, on-demand fan, load-sensing hydraulics, and intuitive controls keeping fuel consumption and operating costs low.

The Cat C9.3B engine meets US. EPA Tier 4 Final, EU Stage V, Korea Tier 4 Final, China Nonroad Stage IV, and Japan 2014 emission standards with a gross power rating of 239kW (321hp).

The engine’s automatic Cat Clean Emissions Module (CEM), including SCR catalyst and diesel particulate filter (DPF) works in the background without impacting the production schedule, whilst the Cat Engine Idle Management System (EIMS), Auto Engine Idle Shutdown (EIS), variable-speed fan and load-sensing hydraulics help deliver low fuel consumption and reduced sound levels. An optional automatic reversing fan assists in cleaning cooling cores to improve performance in high-debris environments.

The new loader features a four-speed forward/reverse electronically controlled, automatic planetary powershift transmission with shift protection and single clutch gear shifting for efficiency, durability, and smooth gear changes. Ensuring excellent material retention and increasing efficiency, the loader’s optional ride control improves operating smoothness over rough terrain, whilst optional limited-slip differential axle configurations increase traction in poor underfoot conditions.

Caterpillar’s field-proven Z-bar loader linkage with cast cross-member and tilt-lever provides both strong digging capabilities and high breakout forces when the new loader is equipped with Cat Performance Series buckets. The load-sensing implement hydraulic system continuously controls flow and pressure to precisely match requirements of the operating situation, reducing both the load on the pump and overall fuel burn.

Using a system-based approach to balance bucket shape with the machine’s lift and tilt capacity, weight, and linkage, the Performance Series Buckets are available for a range of applications including general purpose, flat floor, heavy-duty rock, and light material. Design features allow operators of all experience levels to routinely attain 10% higher bucket-fill factors, compared with legacy designs, to improve production and reduce fuel consumption.

The 966 GC can also be equipped with the Cat Fusion quick-coupler and controls, and combined with optional third-function auxiliary hydraulics, the coupler allows use of a wide selection of Cat work tools.

An optional Cat Payload kit provides on-the-go weighing* for precise load targets with proven accuracy, flexible and simple installation, and easy calibration. Bringing payload weighing to the cab, Cat Payload weighs the material while moving to the truck and lifting, so there are no interruptions in the load cycle. It allows the operator to load to exact specification and load more trucks and move more material faster.

The new 966 GC loader features a simple, intuitive, and ergonomic control system with an operator interface display that includes six analogue-like gauges, colour indicator lights, and an LCD screen all within easy view, so operators can quickly monitor machine systems. Low-effort, pilot-operated implement controls feature a remote transmission kick-down switch for operating comfort.

With safety in mind, inclined ladders and integrated handholds are located on both sides of the machine to provide access to the cab and to the engine air filter. A large roof-to-floor, distortion-free, flat-glass front windshield; standard rear-view camera; and exterior mirrors with integrated spot mirrors provide all-around visibility. The standard heating and air-conditioning system with 10 louvered vents helps to keep the operator comfortable in all climates.

Ground-level access to service points reduces maintenance time and improves safety, whilst large gull-wing engine hood side panels and a tilt-up rear grill provide unrestricted access to daily service points, fuel and DEF filling points, greasing points, filters, and fluid-sampling ports. Further reducing maintenance, an optional Cat Autolube greasing system is available.

Read more: Caterpillar introduce new 966 GC loader