Capital Equipment News October 2017

For informed decision-making OCTOBER 2017

SCREENING: Ushering in a new screening era LOAD WEIGHING SYTEMS: Taking guesswork out of your loadout process EXCAVATORS: More than a dirt mover

TRANSPORT: HIGHLIGHTING COMMITMENT TO TRUCK SAFETY PAGE 10

MAJOR PARTS SUPPORT BOOST FOR CAT ® EQUIPMENT OWNERS

TRANSPORT & LOGISTICS NEWS 35 FAW trucks tip beyond expectations 36 Iveco buses for Glenwood Boys High School 36 Truck market gains more ground 37 Telematics data set to reinforce positive driver behaviour CONSTRUCTION NEWS 38 New Bobcat T870 loads in Mozambique and Malawi 38 New Cat 426F2 offers choice of value- added configurations MINING NEWS 39 Flexibility in maintenance package should be infinite 39 Shaw Controls supplies switchgear solution to DRC mine 40 Booyco demonstrates PDS compliance to SACEA COVER 4 Major parts support boost for Cat equipment owners EXCAVATORS 6 More than a dirt mover TRANSPORT 10 Highlighting commitment to truck safety PROFILE 14 Time is money LOAD WEIGHING SYSTEMS 16 Taking guesswork out of your loadout processes BUSINESS 20 Enabling Zambian growth SCREENING 24 Ushering in a new screening era SCREENING 28 Restating the significance of integrated processing solutions WASHING 32 Water constraints down the drain CONTENTS Capital Equipment News is published monthly by Crown Publications Editor: Munesu Shoko capnews@crown.co.za Advertising manager: Elmarie Stonell elmaries@crown.co.za Design: Anoonashe Shumba Publisher: Karen Grant Deputy publisher: Wilhelm du Plessis Circulation: Karen Smith PO Box 140 Bedfordview 2008 Tel: (011) 622-4770 Fax: (011) 615-6108 www.crown.co.za Printed by Tandym Print The views expressed in this publication are not necessarily those of the editor or the publisher. FEATURES REGULARS Total circulation Q2 2017: 3687

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EDITOR'S COMMENT

TECHNOLOGY MAKES IT POSSIBLE; PEOPLE MAKE IT HAPPEN

M odern machines and vehicles operating across a number of sectors, including construction, mining, transport and logistics, to mention a few, contain countless processors, SIM cards and other high-tech components. In a nutshell, they are complex tools with which operators have to solve more challenging tasks on sites and different workplaces. Despite well-known benefits, there continues to be some trepidation regarding modern technologies and their impact on the role of people in the workplace. Automated systems sound improbable in an African

environment where we are still grappling with huge social issues like closing the unemployment gap. There are fears that technology will take away the few jobs available; but I believe newer technologies will further empower people, as humans will become supervisors, rather than the direct means of control. But, this calls for critical training regimes to align the workforce with the core competencies of being able to operate high-tech machines which are fast becoming the competitive edge for many businesses. One of the sectors already at the forefront of the tech revolution is the logistics industry. In a recent conversation with Detlev Duve, MD of DACHSER South Africa, he alluded to the fact that competitive logistics providers know that it is all about speed, agility, reliability and even versatility. He is of the view that delivering all of this requires intelligent logistics – a growing concept the world over. But, he further reiterated that this not only refers to leveraging digital technology, people still remain at the core. According to Duve, smart logistics means having to do many things at the same time. But you only have intelligent logistics if you have the right people to bring it all together. Intelligent logistics operates across several dimensions but if these systems are not accurately and timeously brought together, the process could collapse. It is not just about having the best technology and systems in place. Of course, there is no denying the importance of the latest technology for logistics service providers. Having the ability to track and trace, respond in real time, deliver speedily and offer choice and visibility along the way requires an ongoing and significant investment in technology. But Duve reiterates that just as important as the tools are the staff operating these systems.

It is worthwhile to remember that automatic processes and digital movements of cargo are made possible via a network of well- trained and skilled people who understand the complexities of the logistics supply chain and are able to adapt the systems accordingly. To leverage the growing impact of tech on businesses, forward-thinking companies are investing in skills. For example, DACHSER South Africa trains up to 15 learners each year, and since the inception of the programme in 2012, has been able to employ 70% of its graduate learners. Caterpillar has over 35 000 active machines and engines operating throughout southern Africa, and to keep all those machines running smoothly, there is need to provide replacement parts as quickly as possible, but skills are as vital. To help people in Africa develop their technical skills, two years ago, Caterpillar launched an e-learning website called Technicians for Africa to support local skills development in South Africa and in 14 other African countries. Technicians for Africa is a completely free online training programme that provides future technicians a base level of technical knowledge to make them viable candidates for careers as heavy equipment technicians and several other related fields. To date, Caterpillar has over 700 registered users in South Africa and 3 500 in southern Africa. These are great initiatives by companies that understand that their future successes will hinge on both new tech and smart people. Skills in today’s workplace are rapidly diversifying and all employees need to pursue broader areas of learning to remain competitive. Companies need to upskill their workforces to leverage the tech revolution. Technology will only make it possible; people will make it happen! b

Munesu Shoko – Editor

capnews@crown.co.za

@CapEquipNews

CAPITAL EQUIPMENT NEWS OCTOBER 2017 2

COVER STORY

MAJOR PARTS SUPPORT BOOST FOR CAT ® EQUIPMENT OWNERS

Parts support for Cat machines working in southern Africa has taken a quantum leap following a one-of-a-kind collaboration between Caterpillar and southern African Cat dealer, Barloworld Equipment.

F ittingly coinciding with the 90 th anniversary of their partnership, Caterpillar and Barloworld have officially opened a new, state-of-the-art parts distribution centre in Kempton Park, Johannesburg, that will dramatically reduce the time it takes for customers to order and receive Cat parts and consumables. Customer value Barloworld Equipment’s customer partner- ships are built around aftersales service, which includes repair options and compo- nent rebuilds that keep machines healthy and productive through first and subse- quent lives to save costs for customers. The new parts facility will reinforce this strategy. The collaboration, in the interests of adding customer value, testifies to the sustainability of the 90-year partnership between Barloworld Equipment and Caterpillar. The new parts facility also underscores Caterpillar’s belief in growth in southern Africa and its commitment to continued development across the continent. Barloworld Equipment’s retail operation at the distribution centre will occupy 3 500 m², including a parts counter and sales office. “This arrangement is the first of its kind in the Caterpillar network and further improves our industry-leading aftermarket parts distribution network across the region.

Customer friendly “Our Linbro Park parts facility, serving mainly major mining customers with parts for EMPR (formerly Bucyrus) machines, has moved to Isando,” says Fourie. The new Johannesburg facility holds traditional Cat machine parts and eliminates double handling and stocking of parts by Caterpillar and Barloworld. Tania van Peer, Barloworld Equipment operations manager: Parts, says lead times have been halved and the new retail facility is much more customer friendly with dedicated customer liaison staff and integrated systems enabling full sight of every order at any point in time. Van Peer adds that customers are very positive about the facilities offered and ease of doing business at the new centre. The facility is easily accessible, located just off the R21 at the R25 offramp in Kempton Park and about 20 km from Barloworld Equipment’s Isando campus. It is close to OR Tambo International Airport and freight distribution facilities for ease of shipping into Africa. “This not only improves the parts pro- curement experience for local customers, but also increases capacity to provide fast and seamless parts availability to our cus- tomers in Mozambique, Angola, Botswana, Malawi, Namibia, Zambia, Zimbabwe, Le- sotho and Swaziland, as well as our joint

The initiative is another example of our close collaboration and partnership with Barloworld Equipment by leveraging our parts inventory data to significantly improve the Caterpillar customer experience,” says Chris Monge, manager of Caterpillar’s southern African regional office in Johannesburg. “The increased collaboration between Barloworld Equipment and Caterpillar gets replacement parts to our customers as quickly as possible,” adds Bonnie Fetch, Cat Parts distribution director. “This is extremely important as it allows our customers to reduce idle time and save money. When our customers win, we all win.” Anton Fourie, senior general manager: Parts at Barloworld Equipment, explains that Caterpillar’s decision to build the new distribution centre was based on limited capacity at its existing Isando facility, as well as inefficiency due to the need for supplementary warehouses in the area. Fourie adds that Barloworld Equipment had a similar problem, with parts facilities in three locations within a 30-km radius. “Our Isando parts facility has recently completed its move to the new site, now known as Barloworld Equipment Johannesburg. For both Caterpillar and Barloworld Equipment, this immediately reduces multiple transport collection points to a single source.”

CAPITAL EQUIPMENT NEWS OCTOBER 2017 4

Caterpillar and Barloworld have officially opened a new, state-of- the-art parts distribution centre in Kempton Park, Johannesburg.

The retail parts operation at the Barloworld Equipment warehouse in Kempton Park.

venture business in the DRC,” says Fourie. “Reducing parts turnaround times is critical to cutting downtime and improving productivity, which is central to Barloworld Equipment’s customer value proposition.” Parts management Caterpillar has developed a parts man- agement system together with SAP which is now used in all its modern parts facili- ties worldwide. The common platform has created global consistency of service with centralised support. The Johannesburg Distribution Centre is the only Cat parts warehouse in Africa. Through the global network, parts can be quickly and effortlessly exchanged between the facility and other Caterpillar parts facilities anywhere in the world. “We have automated and integrated our own SAP based parts management system more effectively with the Caterpillar system to avoid duplication of tasks,” says Fourie. “We will soon be launching an electronic tracking system that records a customer’s progress through the system from the moment of arrival on site. This will enable us to reduce queues, keep customers informed, and make constant improvements based on our customers’ experiences.“ Walk-in customers are also encouraged to call in their orders in advance to avoid delays on collection. Self-help terminals

At the Barloworld Equipment retail facility in Kempton Park (from left): Sonja Cox, parts manager; Msebenzi Nkosi, owner of Msebenzi Transport, the first customer to visit the new facility; parts sales person Nelson Seloana; and Vanessa Potgieter, customer liaison officer at the new parts counter. Msebenzi Nkosi was the first black customer to buy a backhoe loader from Barloworld Equipment in the early 1990s and owns six Cat machines today.

new facility in August 2017. “Our people take great pride in this shared drive for ex- cellence, innovation, continuous improve- ment, an intense focus on customer needs and a dedication to meet those needs with a sense of urgency.” Visit the new parts centre at 7b Lindsay Street, Witfontein, Kempton Park, or call at (011) 929 0407. For an even quicker turnaround try Parts.cat.com

are also available at Barloworld Equipment Johannesburg to help customers familiarise themselves with online ordering of Cat Parts. The online Cat Parts Store, Parts.cat. com, can be accessed via the Barloworld Equipment website as well. “The product quality and superior af- ter-sales support that Caterpillar and Bar- loworld Equipment deliver is second to none in the industry,” said Barloworld CEO Dominic Sewela at the official launch of the

CAPITAL EQUIPMENT NEWS OCTOBER 2017 5

EXCAVATORS

KEY TALKING POINTS

Electronic control of the engine and hydraulics are now fundamental in the designing of Volvo excavators.

Flexibility to easily accept a wide range of hydraulic attachments increases excavator versatility

MORE THAN A DIRT MOVER

Hydraulics, electronics, telematics, op- erator comfort and versatility are all at the centre of major feature upgrades on today’s excavators, making the prominent piece of equipment on many sites more than just a dirt mover. Increased versatility The basic nature of an excavator makes it versatile, thus increasing its productivity. But, attachments have become the key element in an excavator’s versatility. Key to this is the continued focus on improving coupling systems by OEMs to allow better handling of an array of attachments. “Most hydraulic operated attachments can now be fitted to our range of excavators without any need for modifications as the machines come factory fitted with two- way piping with foot-operated controls,” says Corne Coetzer, Product Manager: Kobelco Excavators at Bell Equipment. “Hydraulic flow can also be adjusted from inside the cab at the flick of a button. This alleviates the need for flow gauges and mechanical adjustments on the pump itself. This is now a standard feature on all of our machines up to, and including,

The hydraulic excavator continues to be one of the most prominent pieces of equipment on any earthmoving site. Continued innovations in hydraulics, electronics, telematics, operator comfort and increased flexibility to easily accept a wide range of hydraulic attachments, have combined to make the excavator more than just a dirt mover, writes Munesu Shoko

V alue is very significant to a consumer and getting the most for their buck is a key factor in influencing people’s buying habits. The same goes for construction equipment – getting the most out of machines is a key factor in today’s buying decisions. Based on this notion, the modern-day hydraulic excavator continues to evolve to meet the ever-changing needs of a market that is seeking increased productivity at the lowest cost per tonne of material moved.

CAPITAL EQUIPMENT NEWS OCTOBER 2017 6

Continued improvements in coupling systems allow for easy handling of attachments

Electronics are becoming important in improving machine productivity

Provision of optimum operator comfort is proving to be another key focus area for excavator manufacturers

Telemetry solutions have become the gold standard of the equipment industry

Most hydraulic operated attachments can now be fitted to the Kobelco range of excavators without the need for any modifications as machines come factory- fitted with two-way piping with foot- operated controls.

the SK500. Kobelco machines also allow for the switching between single and bi- directional hydraulic flow within the cab.” DISA Equipment, operating as Doosan South Africa, recently introduced its 51 t Doosan DX520LCA and one of the key features is the machine’s improved heavy duty boom and stick for better handling of attachments. Overall reinforcement of steel on the boom and arm was achieved through a 20% increased thickness on the side plate and 15% on the bottom. Its 7,1 m boom and a shorter 2,9 m stick translate into better breakout force, especially in taxing working conditions. This makes it a perfect fit for running heavy duty attachments such as hammers and crusher buckets. The Doosan DX520LCA excavator also comes with standard hydraulic piping for work tool applications. In many of the competition’s offerings, this is said to come as an extra. This feature alone can cost in excess of R150 000 to install where it comes as an extra. What is more is that the main high-pressure lines from the main control valve to the pump have been changed from a combination of pipes and hoses to entirely hoses to minimise

DISA Equipment recently introduced its 51 t Doosan DX520LCA in the local market and a key highlight of the machine is its improved heavy duty boom and stick for better handling of attachments.

the risk of leakages. Instead of the resin (synflex), the hoses are now made from full rubber (Acryl nitrile butadiene). The new material, combined with a new fitting, reduces bending and therefore ensures sound hydraulic flow, while reducing internal pressures. Roger Teece, Product Manager for Volvo CE, Sales Region EMEA, says apart

from hydraulic improvements, to optimise attachment usage on its machines, Volvo CE offers a range of quick couplers, allowing the operator to quickly and efficiently change between attachments. “In certain markets and certain models, we have a Tiltrotator system available as factory fit, which provides ultimate versatility for our excavators,” says Teece.

CAPITAL EQUIPMENT NEWS OCTOBER 2017 7

EXCAVATORS

CareTrack, Volvo Construction Equipment’s telematics system, allows access to a wide range of machine information designed to save customers time and money.

Kobelco has invested a lot of time and resources to achieve the best fuel consumption figures across its excavator range without compromising performance.

The electronic age Apart from hydraulics, electronics are playing a very significant role in improving the overall productivity of construction gear, and this is one area where design advances are taking centre stage in hydraulic excavators. For example, the Doosan DX520LCA is 5% more fuel efficient than the previous model. Several new features make this possible. Typically, the fuel pump tends to supply flow even when the maximum pressure on the system has been reached due to severe working environments and large workloads. Doosan’s Relief Cutoff technology prevents transfer of unnecessary fuel flow, but keeps a desired working level at the maximum value while reducing consumption of fuel. Relief Cutoff technology is said to save between 20-30% of fuel in heavy workload applications. Kobelco has invested a lot of time and resources to achieve the best fuel consumption figures across its excavator range without compromising performance. “For this reason, all Kobelco excavators have two digging modes – H mode for heavy duty and higher performance, and S mode for normal operations with lower fuel consumption. Real life situations show that the S mode can deliver around 20% reduction in fuel when performing the same tasks as same-sized machines, while engagement of the H mode delivers 8% more productivity at the same fuel burn as competitor machines,” says Coetzer.

for excavator manufacturers. The Doosan DX520LCA has several features focused at the operator. The Electronic Power Optimising System (e-POS), said to be the brains of the machine, has been improved compared with its predecessor. It now comes with a Controller Area Network (CAN) communication link, which enables continuous exchange of information between the engine and the hydraulic system, perfectly synchronising the two crucial components. Through its various features, the new e-POS system guarantees ease of operation and user-friendliness. For example, an operational memory provides a graphic display of the status of the machine, while its automatic deceleration mode also means better fuel saving. A new user-friendly LCD monitor panel gives the operator full access to machine settings and maintenance-related data. The control panel is very clear, simple to read and positioned for ease of use. The PC monitoring function enables connection to the e-POS system. Thus, various parameters, including pump pressures, engine rotation and engine speed, can be checked during maintenance. Teece says operator comfort is extremely crucial. “This is why Volvo invests so much in the operator cab – an operator spends a large part of the day in the cab and it is essential that they are comfortable and able to focus on the job at hand, which in turn should result in higher output,” he reasons. With the operator in mind, Volvo CE offers a large, spacious cab, with high visibility by employing thin pillars in the cab structure, as well as multi-adjustable suspension seats, which can be adjusted independently to the joystick consoles, ensuring operators of all sizes can find a comfortable operating position. “Low in-cab sound levels, ergonomic layout of switches and controls

According to Teece, electronic control of the engine and hydraulics are now fundamental in the designing of Volvo excavators, as this ensures the machine is operating at optimum performance and providing the best productivity and fuel efficiency. “Volvo engineers have also done a fantastic job by designing a unique and patented electronic control of certain machine functions, which reduces losses in the hydraulic system – again ensuring optimum performance and even better class- leading fuel efficiency,” he says. Teece further reiterates that electronics are very essential in today’s operating environment. “Not only for the optimum control of the machine’s performance, but also for machine monitoring, fault warnings and diagnosis, as well as remote monitoring, for example, using the Volvo Caretrack system,” he says. Coetzer says electronics significantly affect the versatility of the machine when it comes to switching between different functions and from a diagnostics point of view. The Kobelco range uses an Intelligent Total Control System (ITCS) – an electronic system which responds quickly to sudden changes in hydraulic load to ensure that the engine runs as efficiently as possible with minimum wasted output. Operator comfort A machine’s productivity revolves around its operator, and provision of optimum operator comfort is proving to be another area of focus

“All Kobelco excavators have two digging modes – H mode for heavy duty and higher performance, and S mode for normal operations with lower fuel consumption.”

CAPITAL EQUIPMENT NEWS OCTOBER 2017 8

“CareTrack presents infinite opportunities to help you get the most out of your machine, from fuel consumption data to machine location and usage reports.”

also larger for greater operator comfort. The wide access cab allows for smooth entry and exit and the operator seat has a double slide enabling it to recline to a horizontal position. A quieter working environment is achieved through strategic component positioning and superior sealing of the cab, while the rigid cab construction and liquid-filled viscous cab mounts minimise cab vibration for fatigue- free operation. Telemetry solutions Telemetry solutions have become the gold standard of the equipment industry and OEMs have made significant headway in developing their own solutions in this regard. For example, the Kobelco range of excavators can be integrated with the Bell Fleetm@tic fleet monitoring system to enable fleet owners to monitor their whole fleet with one, user-friendly telematics system. CareTrack, Volvo Construction Equipment’s telematics system, allows access to a wide range of machine information designed to save customers time and money. It reduces fuel costs, optimises machine and operator performance and proactively manages service and maintenance. “CareTrack also allows our customers to optimise productivity, manage their

machines and increase uptime. Planning service and maintenance requirements in advance reduces risks and downtime. Through CareTrack, it’s possible for the local Volvo dealer to troubleshoot faults remotely – minimising service time,” says Teece. Teece adds that through operational reports you can identify excessive idle time that, in turn, can reduce fuel consumption, non-productive machine hours and service costs. The system can highlight potential problems before they happen to save on costly maintenance bills. “CareTrack presents infinite opportunities to help you get the most out of your machine. From fuel consumption data to machine location and usage reports, the system provides access to a wealth of information that will have a noticeable impact on a business,” concludes Teece. b

are just a few examples of the time and care taken by designers to ensure the best operator comfort,” says Teece. Coetzer is of the view that operator comfort reduces operator fatigue, which positively influences productivity. “The key to operator comfort is operator-friendly controls, and the Kobelco range has a comfortable and spacious cab with excellent visibility, a powerful automatic air-conditioner, easy to understand displays and smooth controls,” he says. The travel pedal in the Kobelco range is

CAPITAL EQUIPMENT NEWS OCTOBER 2017 9

TRANSPORT

HIGHLIGHTING COMMITMENT TO TRUCK SAFETY

The Adaptive Cruise Control automatically adapts the vehicle’s speed to the actual flow of traffic and informs the driver when the distance to the vehicle in front represents a risk.

WHAT CAUSES ACCIDENTS?

30% environment

10% vehicle

90% human factor

W hile commercial trucking is integral to any economy, crashes, and the resultant injuries and deaths involving commercial vehicles have been increasing over the past several years. Torbjörn Christensson, president of the Volvo Group Southern Africa, says all stakeholders in the transport value chain should play their role in increasing safety on roads, reiterating that every original equipment manufacturer (OEM) in the trucking industry has a responsibility to provide the safest transport solutions to their customers – as this has a trickle- down effect to all road users. Christensson says truck accidents have a snowball effect; when a truck is involved in an accident, it’s not only the metal that crashes, it’s the business and people behind it who suffer the most. “The impact that a truck has when involved in a collision

In a move that underscores its commitment to truck safety, Volvo Truck South Africa has invested R6,5 million in a new calibration centre at its Durban SKD assembly plant that allows the OEM to install and calibrate selected unique active safety features previously not available to the local market, writes Munesu Shoko .

is often very serious and to this end Volvo Trucks is constantly increasing the safety of its vehicles in a bid to decrease the overall impact to all road users in the event of a collision,” he says. One such initiative is the recent R6,5 million investment in a new calibration facility at Volvo Trucks South Africa’s Durban manufacturing facility. The new facility and related equipment allow the truck maker to install and calibrate features that form part of the Volvo Active Safety

Package recently made available to the local market. Available as options on most Volvo truck models fitted with Electronic Brake System, Electronic Stability Control and DiscBrakes, the active safety features can now be installed locally. Malcolm Gush, sales director at Volvo Trucks South Africa, says previously the company had to import trucks specified with active safety features. Local installa- tions started in April this year after com- missioning the new calibration centre.

CAPITAL EQUIPMENT NEWS OCTOBER 2017 10

Emergency brake assist

HMI

Scenario

Speed retardation

“The reason we have introduced local in- stallation is to reduce the cost of import- ing the trucks with active safety features, especially considering the duty implica- tions,” says Gush. Gush has seen an increased interest in active safety features by local truck owners. He reasons that early adopters of these in- novations are forward thinking companies that embrace safety technologies because of their experience with the cost of a collision to their businesses. He adds that the R45 000 upfront cost of the Volvo Active Safety Pack- age is insignificant compared to the cost of accidents. Volvo Active Safety Package in detail The Volvo Active Safety Package comprises the Adaptive Cruise Control, Emergency Brake Assist, Lane Keeping Support, Lane Changing Support and Driver Alert Support. The Adaptive Cruise Control automatically adapts the vehicle’s speed to the actual flow of traffic and informs the driver when the distance to the vehicle in front represents a risk. “The system has a radar fitted to the front of the truck, which interacts with I-Shift and the vehicle’s brakes. If the distance becomes unsafe, the wheel brakes are activated,” explains Gush. Emergency Braking Assist allows for a warning system first, in the form of a red light on the windscreen that is activated when the system detects a vehicle that the truck may likely collide with at its current speed. “Should the driver not react, the warning signal is upgraded to a flashing red light and beeping; if this is ignored then the system mildly applies the braking

through the use of a camera sensor that tracks the position of the truck in its respective lane as well as monitoring the steering wheel movements of the truck; this detects if the driver is inattentive or drowsy. If any symptoms of fatigue or tiredness are detected, the audio- visual alert is activated. “The system continuously monitors driving behaviour and the position of the truck in relation to the lane and road edges,” says Gush. “It is aimed at preventing accidents through the detection of drowsy and inattentive driving habits and encourages the driver to take a break in such circumstances.” Meanwhile, Acloclock is a factory- mounted electronic breath alcohol analyser designed to reduce alcohol- related accidents. “It requires the driver to take a breathalyser before the engine of the truck can be started. It is made of a stationary unit inside the instrument panel of the truck and a hand-held unit with a cable,” says Gush. Alcolock is not part of the Active Safety Package, however, it is available as an optional extra. Towards active safety Quoting Volvo Trucks’ Accident Research into truck safety, which indicates that 90% of all truck safety incidents are due entirely

system of the truck,” says Gush. In the event of this also failing, the emergency braking system activates to ensure that the truck is prevented from colliding with the vehicle. Emergency braking is only available on the FH model range. Lane Keeping Support drastically reduc- es risk factors in traffic such as tiredness and distraction. The system is designed for long haul operations and monitors the truck’s position on the road when ex- ceeding speeds of 60 km/h. If the driver unintentionally crosses a road marking, the system alerts the driver by means of a buzzer. “Lane Keeping Support alerts the driver with an audible signal during unin- tentional deviation from the driving lane. A digital video camera system constantly monitors the truck’s position relative to the road markings,” explains Gush. Lane Changing Support uses a radar sys- tem that checks the blind spot area when the driver activates the turn signal. If the blind spot area is not clear, it notifies the driver by a means of a loud hooter sound and a flashing icon on the passenger side’s A-pillar. “Changing lanes can be a chall- enge for drivers due to blind spots, espe- cially on the passenger side. This feature helps drivers in that regard,” says Gush. Driver Alert Support monitors the driver

“Lane Keeping Support alerts the driver with an audible signal during unintentional deviation from the driving lane. A digital video camera system constantly monitors the truck’s position relative to the road markings.”

CAPITAL EQUIPMENT NEWS OCTOBER 2017 11

TRANSPORT

In the event that the driver ignores initial warnings, the emergency braking system activates to ensure that the truck is prevented from colliding with another vehicle.

Volvo Trucks has invested R6,5 million in a new calibration facility at its Durban assembly facility.

or partly to human error, Christensson says a lot needs to be done to get rid of the carnage on our roads, and through the introduction of active safety systems, Volvo Trucks is playing its part. This initiative comes on the back of some damning figures which show that 16 000 people die in traffic accidents in South Africa every year. “More than 1,2 million people perish in road accidents per year globally – equating to 10 air crashes per day,” says Christensson. “90% of all accidents are caused by human error, 30% by the environment and 10% by the vehicle. It’s a combination of factors but the majority of accidents are caused by the driver,” says Christensson. The Volvo Active Safety Package is an initiative designed to help drivers avoid accidents. Previous truck designs have had greater focus on passive safety systems such as the three-point safety belt, which was invented by Volvo in 1979, as well as cabs with high-strength steel to absorb much of the crash’s energy to reduce its severity. Volvo also designs cabs in a way that in the event of a crash, the engine and transmission drop down and away from the driver, while the steering column collapses. While these passive safety systems remain the pillars of truck safety, Christensson believes more focus is now on active safety systems that help drivers avoid accidents in the first place. Gush says there has been increased demand for active safety systems locally, and believes that these technologies will become a norm in the near future. “We have a fleet operator who has installed active safety features to his whole fleet. Since then, he has had no accidents,” says Gush. Volvo Trucks SA has sold about 300 trucks installed with active safety systems to date, while some 60 trucks installed with Acloclock are also operational in the

Emergency Braking Assist allows for a warning system first, in the form of a red light on the windscreen that is activated when the system detects a vehicle that the truck may likely collide with at its current speed.

Lane Keeping Support is designed for long haul operations and monitors the truck’s position on the road when exceeding speeds of 60 km/h.

field. Gush says on the back of peaking demand, the company will probably have 500+ trucks with active safety systems

within the next year. “Local fleet owners are starting to see the benefits,” concludes Gush. b

CAPITAL EQUIPMENT NEWS OCTOBER 2017 12

PROFILE

KEY TALKING POINTS

WearCheck flag flies over 15 laboratories on the African continent

transformer health through regular assess- ment of insulating fluid and diagnosis of results. This includes a range of fluid and non-fluid tests, such as insulation paper quality testing. MS: How big is your footprint on the continent to be able to service your customers across these portfolios ? NR: The WearCheck flag flies over 15 laboratories on the African continent, all of which are strategically placed to service industry clusters such as large mining zones. The laboratories are spread out as follows: Johannesburg (2), Cape Town, Durban (2), Middelburg and across South Africa’s borders in Zambia (Lumwana and Kitwe), Zimbabwe, DRC, Namibia, Mozambique and Ghana, as well as additional laboratories further afield in Dubai and India. MS: Which industries represent your key customer base at present? NR: The mining/earthmoving sector is our largest customer base, followed closely by electrical/power generation, as well as industrial, transport, shipping and aviation. MS: Just how crucial is condition monitoring? NR: We continuously have cases where potential machinery failure is detected early through condition monitoring, and corrective action is taken to remove the faulty part and either repair or replace it. The importance of forewarning about potential mechanical failure cannot be stressed enough. The old adage “forewarned is fore-armed” springs to mind – if you know that a component is about to fail, you can then avoid the extremely costly unplanned downtime when it would have actually failed. In this way, condition

Neil Robinson, MD of Wearcheck, reiterates that forewarning about potential mechanical failures is very important.

TIME IS MONEY

In today’s operating environment, any unnecessary equipment downtime is money down the drain, but condition monitoring can actually save the day as it allows service personnel to anticipate a potential failure and take action accordingly. Neil Robinson, MD of Wearcheck Africa, believes ‘time is money’, and the importance of forewarning about potential mechanical failure cannot be stressed enough, reiterating that it is better to be down for a short time to replace a worn part than to have a failure that requires an unknown amount of downtime. By Munesu Shoko

an oil analysis laboratory. Today we offer analysis of all fuel/ industrial fluid samples, including oils, diesel, coolants, greases and lubricants. In addition, our reliability ser- vices division offers monitoring techniques which include vibration analysis, thermal imaging, balancing and laser alignment. Our transformer services division promotes

Munesu Shoko (MS): WearCheck is a leading name in the oil condition monitoring space in Africa. Just give me a brief rundown of your service portfolio. Neil Robinson (NR): WearCheck has evolved into a “one-stop-shop” for all con- dition monitoring needs across a range of industries, after beginning 40 years ago as

CAPITAL EQUIPMENT NEWS OCTOBER 2017 14

Recently invested in excess of R1,7 million in new high-tech equipment

WearCheck recently bought out Transformer Chemistry Services

WearCheck is listed as the preferred supplier to some major OEMs

monitoring saves our customers money every single day. In many cases, the component that is about to fail could have then damaged other components, causing even more repair costs. By planning downtime, an operation can then pre-order the necessary components so that the parts are ready when the faulty machine is taken out of service for maintenance and there is no waiting period. Another way in which oil analysis saves our customers money – if the oil is found to be of good enough quality to continue using it – we advise that the oil replacement pe- riod be extended based on scientific facts. In this way, the oil, which can be very expensive to replace, can be reliably used for longer. MS: How is the uptake of your services by local fleet owners, especially in earthmoving and transport sectors? NR: We do provide monitoring services for many large fleets of vehicles, and we are able to maintain these vehicles operating at their optimum performance and to avoid unscheduled mechanical breakdowns, which would cause untold havoc for load deliveries. In South Africa, our service is well-used by transport companies as well as those with vehicles operating in mining and quarrying. MS: I understand WearCheck has some strategic partnerships with several OEMs as a preferred supplier, in line with global trends of outsourcing specialist services. Tell me more about these strategic partnerships and how significant are they to your business? NR: Yes. WearCheck is listed as the preferred supplier to OEMs such as Bell Equipment, Volvo and Gamesa, to mention a few. The partnerships are very significant to our business on several levels – firstly the

actual number of samples that we process as a result of the alliance, but more importantly, it is the vote of confidence from the OEMs, that our service quality is sufficiently outstanding that they trust us to maintain their products. That is very significant. The vote of confidence from recognised industry leaders in their own fields lends assurance to other potential (and existing) customers of ours, knowing that our service excellence and high standards are recognised. MS: WearCheck recently invested in excess of R1,7 million in new high-tech equipment in both the transformer and fuel sections of its Johannesburg-based Speciality Laboratory. What is driving these investments? NR: We are very much a technology-based business, and we are constantly looking to maintain our position as an industry leader in terms of our service level, turnaround time, accuracy and customer satisfaction. Therefore, the technology which helps us to achieve and maintain these goals is a very worthwhile investment for us. Also, we are members of a global network, the International WearCheck Group (IWCG), which has representation in many countries. The group is committed to ongoing investment in new technology that makes sound economic sense, and we are proud to subscribe to this ethos for the benefit of our customers. MS: You recently bought out Transformer Chemistry Services (TCS), adding an already-established transformer analysis and maintenance division to the company’s condition monitoring portfolio. How crucial is the acquisition to your service capacity? NR: Through the acquisition, we added two additional laboratories to our portfolio, as

well as some extra transformer maintenance tests being added to our range. So, through the acquisition, we were able to boost our capacity in terms of quantity of samples processed, as well as increasing our test offering and eliminating the need to outsource those specialised transformer tests. MS: What is the state of your business at this stage, especially considering that many fleet owners understand the importance of preventative maintenance in the quest to prolong the lifecycles of their equipment? NR: Over the last decade, WearCheck has enjoyed steady growth in terms of the number of samples processed. This can be attributed partly to organic growth within the company, as well as an increased demand from a growing customer base as our clients realise the value of condition monitoring, and how it can save them time and money. Added to this, our portfolio of tests has increased substantially during this period through the addition of the reliability services division and the accompanying battery tests, as well as the additional transformer tests. In some cases, where we acquired new laboratories, such as those of TCS and that of WearCheck Zimbabwe, we also took over their customer base, which boosted our customer numbers. We attribute our growth to increased de- mand from our customers as they seek to ensure that their machinery is operating at optimum capacity with reduced maintenance costs. We all know that “time is money”, and our goal is to predict and prevent unscheduled downtime, thereby saving our customers mon- ey. We have found that more industrial opera- tions, mines, fleet owners, electrical and other industries are becoming aware of this over time, hence our positive growth rate. b

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LOAD WEIGHING SYSTEMS

The LOADRITE L2180 can be easily configured to suit a wide range of industries, including sand, stone and gravel, public works, as well as waste and recycling.

TAKING GUESSWORK OUT OF YOUR LOADOUT PROCESSES Regardless of application, the challenge for site and fleet managers is the same: achieving maximum value from existing equipment by utilising it in the most efficient manner. The key to making effective decisions is having the right information available and on-board weighing systems have become the gold standard internationally. In line with international trends, leading supplier, LoadTech Load Cells, reports increased uptake of its LOADRITE on-board weighing technology in the African market, writes Munesu Shoko .

O n-board weighing systems are among the very best technologies used to de- termine payload weights today. These technologies make it easy for site managers to assess and record those very important metrics which may raise the operation’s profits. Keeping this in mind, several African

aggregate and mining customers are follow- ing the global trend by adopting these tech- nologies to optimise their loadout processes tremendously. Christiaan Luttig, LOADRITE brand execu- tive at Loadtech Load Cells, the authorised Trimble dealer i n Africa, tells Capital Equip-

CAPITAL EQUIPMENT NEWS OCTOBER 2017 16

ment News that there has been a significant change in the African market in recent years, and the adoption rate of this type of technol- ogy has increased substantially in all market sectors, largest of which are mining and ag- gregate industries. “Aggregate and mining have benefited the most from the LOADRITE weighing systems, and conclusive return on investments have proved this fact through studies done on sites prior to installation and measuring changes after installation,” says Luttig. LOADRITE, a Trimble company, is a renowned manufacturer of on-board weighing systems designed for wheel loaders, excavators and conveyor belts, from entry-level through to ad- vanced functionality options. Within the three product types, the company provides two prod- uct offerings in each category to suit different customers’ unique requirements. Wheel loader and excavator range LOADRITE wheel loader scales comprise

KEY TALKING POINTS

+/-3%

The L2180 is the most popular scale in the LOADRITE product range, accounting for 70% of all installations globally

The LOADRITE X2350 excavator scale achieves accurate weighing to +/-3% margin of error with no disruption to the operation of the excavator

InsightHQ is a quarry management portal that shows near real time productivity

The LOADRITE C2850 is best suited to mobile conveyor belt applications

CAPITAL EQUIPMENT NEWS OCTOBER 2017 17

LOAD WEIGHING SYSTEMS

processing engine that converts signals from the load cells and speed wheel into weighing data. The speed sensor provides data to cal- culate belt speed, flow rate and total weight, while the scale assembly measures vertical forces for an accurate weight signal to the integrator. “Communications can send conveyor infor- mation to a remote display, a PLC, local com- puter or web-based reporting via Ethernet, or wireless communication (optional),” says Luttig. Remote display is designed for the office or control room to monitor and control all LOADRITE belt scale integrators. It also allows data entry of downtime reasons (op- tional). LOADRITE belt scales can measure the fuel or energy consumption of a motor or electric engine via a fuel gauge or energy meter connected to the motor (optional). Tracking productivity Having a weighing system installed is one thing, and being able to keep track of production is quite another. Luttig argues that fixed and mobile equipment is a major investment, and Trimble’s InsightHQ, a web- based software, helps optimise assets by tracking productivity. “Efficient use of fixed and mobile equip- ment is key to maximising profits. InsightHQ (web-based) and Materials Management System (for PC) reporting platforms are spe- cifically designed for loading and quarrying operations. LOADRITE can track the stock- pile inventory levels and loader tasks, for example, stockpiling vs. loadout, when using data fields,” says Luttig. “LOADRITE reports on key metrics of the quarry operation – pit processing and loadout – empowering quar- ry managers to optimise their production, not just a scale on a loader.” InsightHQ is a quarry management portal that shows near real time productivity, avail- ability and performance dashboards and re- ports for extraction, processing and loadout. To view changes over time, the site manager can adjust reports to suit either the shift, day, week, month or year. Snapshot connects with LOADRITE scales to present near real time data so the site manager can react during the shift. In terms of equipment management, the InsightHQ loading performance summary helps staff understand product throughput by weight and by truckloads, while simple and accurate visibility of conveyor TPH and performance help production teams meet daily targets. “InsightHQ presents information in simple, easy-to-consume chunks, or drill down into raw data to identify specific issues or bottle- necks,” says Luttig, adding that InsightHQ is a fraction of the cost of similar PLC or SCA- DA-based reporting systems, but offers addi- tional functionality. b

The LOADRITE X2350 excavator scale ensures bucket-by-bucket optimisation of load-out process.

the L2180 and L2150. The LOADRITE L2180 can be easily configured to suit a wide range of industries, including sand, stone and gravel, public works, as well as waste and recycling. It is said to be the most pop- ular scale in the LOADRITE product range, accounting for 70% of all installations globally. The L2150 is a user-friendly weighing system designed for ease of use with fast access to menus and data. By using multi- ple-point triggering, speed compensation and dual pressure measurement, the L2150 is said to offer high-level weighing accuracy regardless of lift speed and loader move- ment. The screen display is uncluttered and only relays pertinent information to the op- erator when required. This enables the op- erator to concentrate on the loading process without unnecessary distractions. The Active Tip Off feature allows the loader operator to adjust the last bucket load at any height. This is possible due to the rotary posi- tion sensor which allows the scales to com- pensate for boom position. “LOADRITE uses a rotary position sensor to continuously monitor boom position over the entire lift, allowing multiple measurement points. Multi-point weighing allows variations in weights calcu- lated to be averaged out or even discarded if outside tolerance levels. The variances can be caused by inexperienced operators or weigh- ing on rough ground,” says Luttig. Meanwhile, the LOADRITE X2350 exca- vator scale uses proprietary technology to achieve accurate weighing to +/-3% margin of error with no disruption to the operation of the excavator. The dynamic payload weigh- ing system is said to ensure bucket-by-buck- et optimisation of the load-out processes. The bucket sensor is installed on the bucket or quick-hitch. It measures the angle of the bucket to provide increasing weighing per-

formance and a larger operating area for the operator. The LOADRITE trigger units are mounted on the boom and stick pivot point. They sense the position of the excavator boom and stick arm to ensure measurement accuracy. The X2350 indicator is mounted in the cab, and it receives data from the sensors and calcu- lates weight. Meanwhile, the LOADRITE angle sensors, mounted on the excavator chassis frame, provide machine angle and movement information used to compensate for variable ground slope conditions and pro- vide greater accuracy of measured weights. Speaking of key benefits of LOADRITE’s loader and excavator scale solutions, Luttig explains that hydraulic weighing is effected by temperature, but LOADRITE wheel load- ers and excavator weighing systems with friction and ambient compression technology (FACT) compensate for hydraulic tempera- ture, bearing, machine friction and lubrica- tion levels without the additional expense of extra sensors. He also adds that when weighing on un- even ground, centre of gravity greatly affects the weighing accuracy. LOADRITE’s exclusive ground-slope compensation allows for accu- rate weighing on any surface angle or ramp. Conveyor belt scales LOADRITE belt scales are said to give plant operators and managers a range of powerful tools to measure the actual production from screens and crushers, track final product stockpiles, analyse plant and machine downtime, as well as monitoring loadout of trucks. The LOADRITE C2850 is best suited to mobile conveyor belt applications, while the C2880 for fixed plant brings multiple convey- ors onto one display. Explaining how these scales work, Luttig says the integrator is the

CAPITAL EQUIPMENT NEWS OCTOBER 2017 18