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Edition 41 26-1

CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . .26-1Product vs. Application chart . . . . . . . . . . . . . .26-3Product Link . . . . . . . . . . . . . . . . . . . . . . . . . . .26-6AccuGrade™ Grade

Control System (GCS) . . . . . . . . . . . . . . . . . .26-8AccuGrade™ Paving

Control System (PCS) . . . . . . . . . . . . . . . . .26-11AccuGrade™ Compaction

Control System (CCS) . . . . . . . . . . . . . . . . .26-12Computer Aided Earthmoving

System (CAES) . . . . . . . . . . . . . . . . . . . . . .26-13AQUILA™ Drill System . . . . . . . . . . . . . . . . .26-15AQUILA™ Dragline System . . . . . . . . . . . . .26-16MineStar™ FleetCommander . . . . . . . . . . . .26-17MineStar™ Health . . . . . . . . . . . . . . . . . . . . .26-18VIMS™ System . . . . . . . . . . . . . . . . . . . . . . . .26-19Cat® Integrated Object Detection System™ . .26-20Cat® Integrated Remote Control . . . . . . . . . .26-21MINEGEM™ Underground Mining

Automation System . . . . . . . . . . . . . . . . . . .26-22Work Area Vision System (WAVS) . . . . . . . . .26-23

INTRODUCTIONIn Cat machines you’ll discover a unique combina -

tion of iron and electronics. Powerful, produc tive —equipped with the latest in proven informa tion tech-nology. A full line of systems that will work harder,last longer, and help you move more material at alower cost.

At Caterpillar, we’ve applied technologies selectively— incorporating only those that deliver intelligent solu-tions. So if it doesn’t improve performance, increaseproductivity, extend component life, help the operator,reduce service time, lower operating costs, enhanceresale value, address an environmental challenge,or make your time more efficient, you won’t find iton our machines. Utilizing these technologies pro-vides the most advanced systems available to keepyour site running at peak efficiency and productivity,at the lowest possible owning and operating costs.

Grade, paving and compaction control systemsare centered around robust position awareness tech -nologies and rugged on-board systems, revolution-iz ing the move ment of material. Guidance productsprovide real-time job progress with centimeter-levelaccuracy to the operator, eliminating guesswork thatleads to rework or constant surveying, slowing prog -ress and driving up costs. Control products take thistechnology a step further by integrating positionawareness to automatically adjust the work tool.This results in accurately meeting the design planwhile reducing the number of passes needed.● AccuGrade™ Grade Control System (GCS)● AccuGrade Paving Control System (PCS)● AccuGrade Compaction Control System (CCS)● Computer Aided Earthmoving System (CAES) for

Landfill

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TECHNOLOGY PRODUCTS

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Sustainability:● Reduce electronic component waste — For all

displays and GPS receivers utilized in Caterpillar’smining technology products, Caterpillar offersrepair services and remanufactured components.This reduces the number of electronic componentsin landfills and ensures any unrepairable compo-nents are disposed of properly.

● Productivity gains — Each mining technologysolution improves mine productivity ranging from10–25%. By increasing productivity, mines canachieve higher productivity without increasingthe number of machines which translates to moretons with fewer overall emissions.

● Increased utilization of natural resourceswhile lowering processing costs — Cat miningtechnology products help mines ensure ore andwaste materials are properly identified and routed.This means that less ore is wasted by misdirectedloads. Cat products also minimize processing costsand chemicals by reducing the amount of wastematerial sent to the processing plant.Mining Technology Products continue to have

a positive impact on mining operations around theworld. Caterpillar offers a complete suite of tech-nology products purpose built for the harsh miningenvironment. Our products combine the latest GNSSpositioning technology with sophisticated electroniccontrol modules and software to help miners increaseproductivity, monitor fleet health and lower operat -ing costs.● MineStar™ FleetCommander● MineStar™ Health● AQUILA™ Drill System● AQUILA™ Dragline System● CAESultra for Mining● Cat® Integrated Object Detection System™● Cat® Integrated Remote Control● MINEGEM™ Underground Mining Automation

System● Work Area Vision System (WAVS)● VIMS™ System

Fleet Management products and services pro-vide data and information about multiple aspectsof equipment, such as machine location, hours andhealth, to help custom ers more effectively managedown-time and plan mainte nance. Offerings in thiscategory are:● Product Link

For more information on these and other Cat tech -nology products, visit www.cat.com/pl.

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Technology Products Introduction


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Technology ProductsProduct vs. Application chart

PRODUCT APPLICATIONS MACHINES

Asphalt Compactors Used to improve process control. Documents the number of passesa roller made over a section of the site along with the temperatureof the asphalt mat during each pass.

Soil Compactors Measures Cat Compaction Value and when combined with a basestation, provides finished grade information. Used to determine whencompaction is complete and document results over entire job site.

AccuGrade CCS 900

Asphalt PaversSystem to remove irregularities from paved surfaces and control matthickness. Features text based display with dual mode which can con-trol both sides of the screed.

AccuGrade PCS 400

Asphalt PaversThe 3D system is an extension to the 2D AccuGrade Grade andSlope for Asphalt Paver system. It allows paving without a referencesurface or string line. Contractors can switch from 2D to 3D depend-ing on job requirements.

AccuGrade PCS 900

Asphalt PaversIntegrated grade and slope system to remove irregularities frompaved surfaces and control mat thickness. Features text based dis-play with dual mode which can control both sides of the screed.

Cold PlanersIntegrated system automatically controls cutting rotor depth and crossslope to a preset cutting depth. Contacting or non-contacting sensorsplus a cross slope sensor can be used to meet job specifications.

Cat Grade and Slope

Hydraulic Excavators Wheel Tractor-Scrapers

Indicate only machine control system with positioning informationvia the Global Navigation Satellite System (GNSS) [or for the exca-vators, Universal Tracking Sensor (UTS)] for complex contours, bulkearthworks and design files.

Skid Steer Loaders/Multi Terrain Loaders

For use with endorsed third party boxblade. For finish grading, automatic laser elevation control can be added to reference lasertransmitter.

Hydraulic Excavators Indicate only site and laser reference systems. Provides depth andslope guidance for trenches and excavations. Additionally, this sys-tem can be upgraded to AccuGrade GCS 900.

Track-Type TractorsFor finish grading, automatic laser elevation control can be added toreference laser transmitter. Additionally, this system can be upgradedto AccuGrade GCS 900.

Motor GradersTrack-Type Tractors

Automatic machine control system with positioning information via theGlobal Navigation Satellite System (GNSS) or Universal TrackingSensor (UTS) for complex contours, bulk earthworks and design files.

AccuGrade GCS 900

Motor GradersAutomatic cross slope system to control one end of the Motor Graderblade to correlate manually controlled slope of the other end. Forfinish grading, automatic elevation control (Sonic or Laser) can beadded to reference string line/curb or laser transmitter. Additionally,this system can be upgraded to AccuGrade GCS 900.

AccuGrade™ GCS 600

Product Link Product Link comes standardon many Cat machines, and isavailable for retrofit on Cat andother brands of equipment.

Product Link enables remote monitoring of your equipment to helpkeep your jobs on schedule, maintain machine health and reducethe costs of owning and operating your fleet. The system providesinformation via satellite or cellular connection to simplify fleet man-agement, track equipment, maximize uptime, monitor machineusage and link your entire fleet.


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Technology Products Product vs. Application chart


Mining machines equippedwith VIMS™

Provides machine health data and reports.MineStar Health

Entire mining fleet(Cat and other brands)

A modern decision-support tool based on industry standard opensystems allowing mines to understand, test, and capture events intheir mine. Features an advanced truck assignment system, alarmdefinition, charting and reporting, field machine communication,machine control, productivity, and machine and materials tracking.

MineStar™ FleetCommander

DraglinesMonitor performance and improve machine productivity. Uses a pair ofhigh precision GNSS receivers for accurate bucket positioning.

AQUILA Dragline System

Blast hole drillsFor mining customers that value machine and operator performancereports, precise placement and depth of blast holes, and detailed stratainformation on each drill hole. Requires radio network and ability toreceive GNSS signals.

AQUILA™ Drill System

Landfill Compactors, Track-TypeTractors, Wheel Tractor-Scrapers,and Motor Graders

Uses high precision GNSS plus on- and off-board software to maximizelandfill airspace and machine productivity. Ideal for landfill planning,engineering, surveying, grade control, and production monitoring appli-cations in dump areas.

Computer Aided EarthmovingSystem (CAES) for Landfill

Track-Type Tractors, Wheel Dozers,Wheel Tractor-Scrapers, WheelLoaders, Shovels and Excavators

Surface Control, Machine Guidance and Ore Control. Uses high pre-cision GNSS plus on- and off-board software to minimize machine pro-ductivity and ore extraction.

Computer Aided EarthmovingSystem (CAES) for Mining


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Technology ProductsProduct vs. Application chart


Optional on: 773, 775, 777FStandard on: 784, 785, 789, 793,and 797 Off Highway Trucks;854 Wheel Dozer; and 992, 993and 994 Wheel LoadersRetrofit on: 777D and 776DOff Highway TrucksVIMS Guardian is available forD9T, D10T, D10R, D11R andD11T Track-Type Tractors;R1600G, R1700G, R2900G,AD30, AD45B and AD55BUnderground Mining Machines;24H Motor Graders

Cat Integrated Remote Control

785, 789, 793, and 797Off Highway Trucks

Entire fleet (Cat and other brands)One, two, or three camera system providing operator in machinewith optimal viewing angles all around equipment.

Work Area Vision System(WAVS)

Combines cameras, radar, and alarms to notify the operator whensomething is close to the machine but not within an immediate view-ing range. The system is configured with zones around the equip-ment and objects in those zones trigger various levels of alarms.

Cat® Integrated ObjectDetection System™

Available as an attachment to allUnderground Loaders: R1300G,R1600G, R1700G, R2900G,R2900G XTRA

This automation system removes the operator from the dangeroussit uations and allows them to work in a more comfortable, ergonomicenvironment. Using technology to automate and enhance opera-tions, the system provides safety and productivity benefits for under-ground mines.

MINEGEM™ UndergroundAutomation System

Provides operators, maintenance, and engineering with vital machinehealth and production information. VIMS Guardian, a retrofit product,excludes operator display and payload information.

VIMS™ System


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Technology Products Product Link

PRODUCT LINKFor more information see www.cat.com/pl

Product Link is a fleet management system thatallows remote monitoring of equipment with featuresand capabilities that will improve overall fleet-man-age ment effectiveness. Product Link is available forall Cat machines, and included as standard equip-ment on approximately 75 Cat models delivered tocustomers in over 50 countries around the world.

Product Link is deeply integrated into the machineinteracting with engine, transmission and implementcontrol systems. Events and diag nostic codes as wellas hours, fuel, idle time and other detailed informa -tion is transmitted and displayed in a secure webbased application, known as VisionLink™.

The VisionLink application includes powerfultools and features used to process and convey infor-mation to users and dealers. The application alsoincludes essential tools to manage your entire fleetof equipment include mapping, working and idletime, fuel level and more.

Hardware options provide the ability to transmitinformation from (and to) your equipment via cel-lular network (GSM) or Low-Earth-Orbit satellites.The family of enabling hardware provides you theability to select the right fit option for the locationfor which your fleet operates.


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Technology ProductsCat® Product Link

Supporting Hardware

Features PL522 PL321 PL121

*Special features are enabled by integration into Cat equipment electronic systems and related applications. Similar features are available for other makes of equipmentor Cat machines with mechanical systems.

For more information about Product Link, customers cancontact their local Cat dealer or visit www.cat.com/pl.

One minute updatesService Meter HoursLocation

Rapid ReportingTrack and trace equipment movement with one minutelocation updates. Display movement history in multiplemap views including street, satellite or terrain.

Cat HealthCat Health features provide insight to the condition ofyour equipment as well as timely notification of issuesas they occur. Temperature and pressure warnings,operator driven events like overspeed or abuse warn-ings, fluid analysis reports and more.

4 Switch Inputs4 Switch InputsDigital InputsEnables notification from a switch as events occur. Forexample, connect to a lubrication system to know whenthe reservoir needs to be refilled or to an evacuationpump so you know when oil is drained.

Fuel Used While Working*Fuel Used While Idling*Fuel Burn*Daily updates4 Switch Inputs

Fuel Used While Working*Fuel Used While Idling*Fuel Burn*One hour updates4 Switch Inputs

Cat UtilizationIdentify when your equipment is working compared toexpected runtime hours. Monitor efficiency with work-ing vs. idle utilization details for both hours and fuel.Easy graphical views allow comparison between equip-ment, job sites or other groupings of equipment.

Scheduled Reporting*Event Codes*Diagnostic Codes*Single Sign on to SIS*Links to Troubleshooting*

Continuous Reporting*Event Codes*Diagnostic Codes*Single Sign on to SIS*Links to Troubleshooting*

Cat MaintenanceApply an effective and efficient planned maintenanceprogram with this service plan. Know when your machineis due for service and what parts are required with detailedchecklists and on-line parts ordering. Manage and doc-ument other maintenance events such as inspections,backlogs and planned component services.

PM Service intervals*Service Meter HoursChecklists*Parts lists*Partstore Integration*

PM Service Intervals*Service Meter HoursChecklists*Parts lists*Partstore Integration*

PM Service intervals*Service Meter HoursChecklists*Parts listsPartstore Integration*

RuntimeLocationGeo Zones (radius)S•O•S™ Notification*

Runtime with Idle*Expected RuntimeStart/Stop TimesLocationGeo Zones (radius)Fuel Level*S•O•S™ Notifications*

Runtime with Idle*Expected RuntimeAsset On/Off NotificationLocationGeo Sites (polygon)Fuel Level*S•O•S™ Notifications*

EssentialsBasic asset management features allow for locationmonitoring, working vs. idle time and fuel level. Machine,job site or fleet views make it easy to manage all equip-ment, at all sites, all the time.


26-8 Edition 41

Technology Products AccuGrade™ Grade Control System (GCS)

ACCUGRADE™GRADE CONTROL SYSTEM (GCS)

The GCS systems reduce guesswork and costlyrework by moving material right the first time, reducessurvey costs and increases material utilization. Thesystems improve operator skills, which reduce laborrequirements, aids operators in maintaining a con-sistent depth, grade and slope across the work siteand reduce material cost. GCS Systems compute thelocation of the machine implement and compare theposition to the desired design location and give theoperator real-time cut/fill information to achieve grade(indicate-only) or signal the machine hydraulics tomove the implement to the desired design automat -i cally (on applicable systems). GCS systems offerthese advantages and cost-savings:● Fuel savings of up to 40%● Increase productivity by up to 50%● Reduce guesswork and costly rework by moving

material right the first time● Reduce survey costs up to 90%● Increase material utilization● Reduce operator costs● Reduce labor requirements and costs● Reduce the need for staking, string lines and grade-

checkers● Extend the work day● Finish jobs faster

AccuGrade GCS 600Cross slope

Cross slope systems are the foundation systemfor motor graders and control one blade tip withoutany off-board infrastructure. It can be combinedwith sonic, laser, GNSS or UTS technologies to makefine grading more efficient and productive. Crossslope systems are indicate-only or automatic gradecontrol systems designed to control surface crossslope. Machine mounted sensors are used to calcu-late necessary blade slope positioning to achievedesired cross slope of the surface. The system makesautomatic adjustments to the left or right lift cylin-der, typically performed by the operator. The in-cabdisplay delivers all of the cross slope informationthe operator needs to quickly and easily spread orcut material at the correct cross slope. The opera-tor can select which side of the blade to control auto-matically and swap direction on the return passwithout readjusting the settings. Elevation is con-trolled manually by matching grade or automaticallyby adding an elevation control device (sonic or laser).

The cross slope systems are ideal for maintainingaccurate cross slope over long distances without theneed for infrastructure.


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Technology ProductsAccuGrade™ Grade Control System (GCS)

Site/laser referenceSite reference systems are the foundation system

for excavators and can be combined with laser, GNSSor UTS technologies to make excavating more effi-cient and productive. The site reference system isan indicate-only system that provides the operatorwith precise real-time bucket positioning relative tothe desired grade. Using a combination of front link -age (stick, boom and bucket) sensors, the system cal-culates bucket tip position relative to a grade/surveystake or benchmark. When combined with the sitereference system, the optional laser receiver allowsthe machine to move after obtaining a reference bench -mark. The laser receiver attachment references arotating laser to calculate the desired grade for ele-vation changes over large work sites, significantlyincreasing productivity.

The site/laser reference systems are ideal for build -ing pads, trenches, and general utility applications.

LaserLaser systems are elevation control systems

designed for precise grade control with tight toler-ances using a laser transmitter and receiver(s). Alaser transmitter is set up on the work site and cre-ates a constant grade reference over the work area.A digital laser receiver is mounted on the machineand senses the laser signal as the machine movesacross the work site.

When combined with cross slope on a motor grader,the single laser system provides automatic bladeadjustments to one side of the blade for automaticcontrol of elevation and cross slope.

When combined with a Level Best boxblade onC Series Skid-Steer Loaders, Multi-Terrain Loadersand Compact Track Loaders, the machine electro-hydraulic controls create an automated grading sys-tem capable of extreme accuracy. Unlike conven tionallaser grading systems for SSL-type machines, the lasersystem requires no additional externally mountedhydraulic valves or displays, nor any additional in-cablevers, switches, control boxes or cables. The inte gratedsystem allows use of the loaders existing controls,keeping the operator securely in the seat and pro-tected by built-in safety features.

The laser systems are ideal for the elevation con-trol on fine grading applications and sites with flat,single or dual slope surfaces, such as industrial, com -mercial or residential building sites.

SonicSonic systems are elevation control systems designed

to control surface elevation. The sonic system usesan ultrasonic sensor to maintain the blade at thesame relative vertical distance to an external ref-erence such as a string line or a curb and gutter.The system makes automatic elevation adjust-ments, typically performed by the operator. Theoperator simply steers the machine to maintain thesensor over the external reference. When combinedwith cross slope, the single sonic system providesautomatic blade adjustments to one side of the bladefor automatic control of elevation and cross slope.

The sonic systems are ideal for the elevation con-trol on fine grading applications on sites using exist-ing curb and gutter or string line references.


AccuGrade™ GCS 900GCS 900 systems use 3D design files that are

stored on the in-cab display and are ideal for all appli -cations including finishing slopes, excavating andtruck loading, complex trenches, site with 3D designssuch as super elevations, retention ponds, and golfcourses.

GNSSGlobal Navigation Satellite Systems (GNSS) use

satellite technology to deliver precise blade posi-tioning information to the operator in the cab. Usingmachine-mounted components, an off-board GNSSbase station and Real Time Kinematic (RTK) posi-tioning, GNSS provides the information necessaryfor the system to accurately determine blade position -ing with centimeter level accuracy. GNSS systemscompute the positioning information on the machinecompares the position of the blade relative to thedesign plane and delivers the information to theoperator via an in-cab display. Information such as:● Blade elevation● Level of cut/fill necessary to achieve grade● Visual indication of blade position on design surface● Graphical view of design plane with machine location

GNSS systems put all the information the oper-ator needs to complete a job in the cab, resulting ina greater level of control. Vertical and horizontal guid -ance tools visually guide the operator to the desiredgrade. Automated features allow the hydraulics sys-tem to automatically control blade adjustments tomove the blade to grade. The operator simply usesthe light bars to steer the machine for consistent,accurate grades and slopes resulting in higher pro-ductivity with less fatigue.

UTSUTS systems are high-accuracy, dynamic track-

ing systems that utilize Universal Total Station(UTS) technology on the work site to track a target,which is mounted on the blade of the machine todetermine precise 3D positioning. Active target tech-nology allows the system to reliably lock onto andtrack the intended target. This ensures the correctmachine is being tracked and eliminates false lock-ons to other active machine targets, survey crewsor reflective surfaces. The UTS instrument contin-uously measures the targets position and transmitsreal-time positioning data to the operator via thein-cab display, which shows the exact position of theblade in relation to the design. The system combinesthe position of the target with the known position ofthe instrument, machine measurements and sen-sor outputs to calculate precise positioning of theblade tips. The system uses the positioning data tocalculate desired elevation and cross slope. Cut andfill values are computed by comparing the position-ing of the blade with the design file. The systemmakes automatic blade adjustments typically per-formed by the operator and provides automaticblade control to one or both cutting edge types.

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Technology Products AccuGrade™ Grade Control System (GCS)


ACCUGRADE™PAVING CONTROL SYSTEM (PCS)AccuGrade PCS 400Cat Grade and Slope

The two dimensional (2D) Grade and Slope sys-tem allows contractors to place precise amounts ofasphalt mix on the surface being paved by control-ling the screed. The system accepts input from sonicsensors, contacting sensors or grade sensors.

The LSD display can provide control for both sidesof the screed. Sealed to withstand both moisture anddust contamination, it alerts the operator with anaudible alarm whenever a diagnostic message occursor when a sensor measures an off-grade condition.

AccuGrade PCS 900The AccuGrade PCS 900 system utilizes Uni versal

Total Station (UTS) technology and is an extensionof the PCS 400 system. It allows paving without areference surface or string line. Contractors canswitch from 2D to 3D depending on requirements.The system accepts input from contacting sensors,sonic sensors, a slope sensor, sonic averaging beam,3D slope or 3D elevation controls. An SPS Series UTSis required to use the 3D controls.

The AutoAdjust Feature monitors the trailing edgeof the screed and automatically corrects for errors toachieve higher accuracy and mat smoothness.

The 3D system will allow contractors to better pavemore complex designs such as transitions, highlyelevated curves and frequently changing cross slopes.

Cat Grade and Slope for Cold PlanersThe two dimensional (2D) Grade and Slope sys-

tem controls rotor depth and cross slope to a presetcutting depth. The system accepts input from con-tacting wire rope sensors, non-contacting sonic sen-sors, a sonic averaging ski or a cross slope sensor.

The display can provide control for both sides ofthe cutting drum. Sealed to withstand both mois-ture and dust contamination, it alerts the operatorwith an audible alarm whenever a diagnostic mes-sage occurs or when a sensor measures an off-gradecondition.

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Technology ProductsAccuGrade™ Paving Control System (PCS)


26-12 Edition 41

Technology Products AccuGrade™ Compaction Control System (CCS)

ACCUGRADE™ COMPACTIONCONTROL SYSTEM (CCS)AccuGrade CCS 900

AccuGrade™ Compaction and Temperature Map -ping for asphalt compactors helps contractorsincrease efficiency and productivity while recordingdata for quality control documentation and futureplanning. The system provides a real-time visualreference of the pass-count and asphalt mat tem-perature. Utilizing AccuGrade Compaction can leadto better mat quality and higher bonus payments.

Pass-count mapping helps achieve target densityand increase roller efficiency. With proper pre-pro-ject planning, including machine selection, vibratoryselection, and speed control, the operator can exe-cute the rolling pattern in the most efficient mannerpossible. Incomplete pass coverage can result in lowermat densities, premature road failure, as well as penal-ties for failure to meet specification requirements.

Temperature mapping helps operators determinewhen the asphalt is acceptable to compaction.

The display provides real-time pass-count map-ping and temperature readings. This enables theoperator to visualize where the machine is on themat and how many passes have been made.

Better process control during construction willresult in longer periods without required mainte-nance on asphalt roads. This reduces material needsand minimizes traffic delays for construction.

AccuGrade CCS 900AccuGrade Compaction on a soil compactor senses

compaction as the machine works and correlates thedata with machine position. These capabilitiesimprove work quality while lowering owning andoperating costs. Reducing the amount of manpowerrequired enhances sustainability and the numberof compaction passes used to finish the job.

The level of compaction is determined based ondrum movement measured by an accelerometer(used to predict soil stiffness). The system providesproject owners with complete project documenta-tion of the number of passes and stiffness values ofthe soil.

Elevation mapping is also provided which alertsan operator to inaccuracies in grade elevation.

The display provides the operator with compactionlevels compared to target and site coverage information.


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Technology ProductsComputer Aided Earthmoving System (CAES)

COMPUTER AIDED EARTHMOVINGSYSTEM (CAES)The Right Material in the Right Place forMaximum Machine Productivity

CAESultra uses high precision GNSS technologyto help customers maximize machine productivityand job efficiency. Traditionally, an engineer workingin the office creates a site plan on a computer. Thisinforma tion is then transferred to paper, and thesurveyor goes out and stakes the area to identifyelevation, grade, slope, or material type. Once themachine operator has completed the job, the surveyorresurveys the area and updates the office plan. Thisprocess is labor intensive and is prone to a check,rework, recheck approach. CAES revolutionizes thisprocess. Its high pre cision GNSS system allows themachines to act as surveyors. Changes to a digital ter -rain model (the engi neering design file) are recordedas it occurs. The engineer can work with the updateddesign and modify it further without stopping themachine. It also provides machine operators andsite managers information to eliminate rework, reducefield survey ing and more accurately complete theearthmoving plan. CAES combines centimeter-levelaccuracy with Real Time Kinematic (RTK) initial-ization times for fast and accurate positioning.

Figure 1. Overview of the System

GPS satellites

GNSS base stationand data radio

Machine equippedwith CAES

Repeater radio


26-14 Edition 41

Technology Products CAES

High Precision Positioning using GlobalNavigation Satellite System (GNSS)Site Requirements● Line of site to multiple satellites that are part of

the GPS or GLONASS constellations. These trans -mit signals that are used to determine position.

● Base Station with a GNSS receiver and radio. Thebase station compares its known (or surveyed)position to the position calculated from the GNSSsignals. The difference is used to produce aCompact Measuring Record (CMR).

● A radio network to relay the CMRs to machinesequipped with CAESultra system.

On-board Requirements● Antenna to receive low-precision signals from the

GNSS constellation.● Radio to receive the CMR corrections from the

base station.● Receiver that combines the GNSS signals and

CMR corrections to calculate the vehicle positionwith centimeter accuracy.

● Display running software that provides real-timefeedback on job progress and design plan to theoperator.

CAESultra On-boardCAESultra on-board components keep the opera-

tor informed with real-time information, which pro-vides greater control and empowerment. Caterpillarhas designed the on-board components to meetharsh environmental demands of equipment in min-ing applications. Easy-to-use software provides theoperator with critical information required to getthe job done quickly and safely. The on-board systemalso monitors and logs specific parameters that canbe used to determine site productivity as well asindividual operator and machine performance.

CAESultra for LandfillCAESultra helps the landfill industry conserve air -

space. For a landfill compactor, each time the wheeltravels over a surface, the CAESultra screen changescolor to acknowledge the compaction pass. CAESultraindicates finished areas. The operator achieves max-imum effective compaction, by making only the nec-essary number of passes. Track-type tractors inlandfills benefit from CAESultra because it indi-cates lift thickness of cover material and trash.

Additionally, CAES permits the recording of site-specific storage areas such as hazardous waste,medical, industrial, organic, and other materials whichrequire special handling or a record of placement. Allof this information is monitored and managed in thelandfill office with CAESultra Office Software.

CAESultra for MiningCAESultra moves the material identification file

and survey system into the machine, eliminatingthe need for survey stakes or pin flags. A touchscreen monitor displays the location of pit bound-aries, material type, bench height, and design grade,eliminating operator guesswork. With materialtypes and locations displayed, ore identification andrecovery are optimized.

The CAESultra for Mining system is an ideal toolfor mine planning, engineering, surveying, gradecontrol and production monitoring applications. Forexample, the CAES system can be used for:● Haul road and bench construction and maintenance● Production dozing● Leach pad construction and maintenance● Reclamation● Task List Management● Ore grade control and material identification● Coal load out terminals

The system can be used on scrapers, loaders, doz-ers, shovels, motor graders, hydraulic excavatorsand track-type tractors.


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Technology ProductsAQUILA™ Drill System

AQUILA™ DRILL SYSTEMProduction, Strata Recognition and Guidance

AQUILA Drill Systems are designed for installationon electric and hydraulic rotary blasthole drills. Itprovides production and performance monitoring,strata recognition and GNSS guidance. Pro vided asa field retrofit to machines already operating at minesites, the AQUILA Drill System uses on-board com-puting integrated with sensors to monitor criticalmachine performance characteristics. System mod-ules help the operator and site managers enhancedrill performance and improve the drilling and blast -ing operation.

The Production module offers a graphical userinterface to provide the operator with immediatefeedback on drilling productivity and performance.The product minimizes operator input by an arrayof sensing hardware to detect:● hole depth● reaching target depth● steel changes

The Strata Recognition module analyzes themonitored drilling variables in real-time, determin -ing variability in the hole geology. The different stratahorizons are presented on the display. The systemprovides useful and concise information from thestart of drilling — not large amounts of raw data thattypify traditional drill monitoring systems. A Blast -ability Index is determined by the Strata Module andapproximates the hardness of the ground. The hole-loading requirements and ore grindability predic-tions are then based on measured rock hardnessenabling improved blending and optimized millthrough put rates.

Combining the Production module with the StrataRecognition module logs:● bit rotary speed● penetration rate● depth● rotary torque or pressure● pulldown pressure● bailing air pressure

Drilling practice, efficiency and productivity canthen be analyzed and assessed.

The GNSS Guidance module adds high precisionGPS to help precisely position a drill on a blast pat-tern without the need for surveying or staking. TheGuidance module uses a moving map display thatshows the 3D (Northing, Easting and Elevation) ofthe drill and drill bit relative to the designed positionof the blastholes. Once the drill is positioned and lev-eled over a hole, the system automatically determinescollar elevation and then calculates the designedtarget depth. Guidance improves the drill’s produc-tion and utilization, and the operator’s ability todrill to the plan. This leads to better rock fragmen-tation for easier loading. Since holes are drilled tothe correct elevation leading to a flatter post-blastsurface, the result is smoother pit floors. This helpseliminate rework, enhances the mobile equipment’sperformance and reduces its wear and tear.

AQUILA™ Drill Office SoftwareAQUILA™ Office Software integrates planning and

design operations. Engineers can transmit designsto the machine’s on-board computer, which show themachine location relative to the design area, currentsurface, final design surface, and material map (forloading machines). The software package allows youto create customized reports on productivity data,cycle times, volume and material type.


AQUILA™ DRAGLINE SYSTEMThe AQUILA Dragline System provides real-time

monitoring and reporting of dragline operations. Bycombining Global Navigation Satellite System (GNSS)and production monitoring data, the system empow-ers the mining office to plan and control operations.It records the complete, detailed data associatedwith each load cycle.

The AQUILA Dragline System gives the operatorthe design plan and real-time position of thedragline relative to the plan in 3D. It also monitors,displays, and logs various parameters from themachine and site.

The dragline system is packaged with Cat OfficeSoftware, providing access to the data collected by theon-board components. This enables office personnelto track production and monitor operator performance.

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Technology Products AQUILA™ Dragline System


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Technology ProductsMineStar™ FleetCommander

MINESTAR™ FLEETCOMMANDERMineStar FleetCommander is the Cat fleet man-

agement system developed to maximize miningprocess productivity while simultaneously maxi-mizing equipment and fleet productivity.

FleetCommander is a modern decision-support toolenabling mines to manage and administer installa-tion, user interface, configuration, security, systemadministration, database administration, disasterrecovery, logging and diagnostics, software updates,calendars, charting and reporting, alarming and sched -uled jobs.

The MineStar platform communicates to the mineand integrated process entities with PitLink, the com-ponent which manages field communications withmachines and fixed plant as well as operators. It alsoensures the delivery of the latest on-board softwarefiles to all MineStar equipment.

The key office components that are built into theMineStar office to suit the host mine’s complexityand needs are:● Machine Tracking provides position analysis of

MineStar equipment as it is moved around thetravel network.

● Material Tracking uses the mine’s mining blockmodel for equipment assignment and for loadingmaterial according to local blending and produc-tion requirements.

● Operator Management manages and monitorssite personnel for machine licenses, pre-startchecklists, scheduled breaks and shift changeoptimization.

● Production monitors site activities, delays, cycles,payload monitoring, Key Performance Indicator(KPI) summaries, fluids and tire management aswell as Service Meter Unit (SMU) interpolation.

● Assignment applies FleetCommander’s assign-ment engine to provide the best allocation solutionwhen all trucks are considered so that every assign -ment provided to each truck is always computedconsidering the most relevant, current information.

FleetCommander provides a proven solution suitebased on a single trusted set of data for real-timeKPI and for standard and ad-hoc reports. It providesthe mine with information to:● Identify and quantify performance improvement

opportunities (within and post shift)● Develop strategies to capture performance improve -

ment initiatives● Support engineer and operator performance● Assign equipment and fleets for maximized fleet

production or achievement of material managementgoals. Capability scales from simple assignmentto full truck assignment with linear programmingto ensure maximal flexible loader, truck and mate -rial capacity utilization

● Blend materials in order to meet preparation plantquality, tonnage and timing requirements

● Track machines and materials to ensure correctdelivery of materials from sources to planned sinksand to monitor equipment routing

● Manage operators (licensing, shift allocation androstering)

● Manage equipment fluids and tires● Track equipment productivity capability, consump -

tion and variance● Monitor equipment health including alarms and

sensor channel monitoring, pre-start checklists● Determine “what if” impacts of mak ing specific

changes to the product planCost reduction of 10% and greater can be achieved

and sustained using MineStar FleetCommander.Cost reductions are typically realized through reducedequipment, manning, lower fuel and service require -ments, while achieving the same levels of productivity.


MINESTAR™ HEALTHEquipment failures, excessive wear rates, over-

temperatures, overloading and degrading operatingconditions are all examples of machine health infor-mation that when correctly acquired, managed andanalyzed can improve a mine’s efficiency and loweroperating costs.

Caterpillar’s MineStar Health system constantlyrecords information on critical machine parametersfleet-wide. Linked with on-board monitoring sys-tems like VIMS, MineStar Health provides wirelessor wired transfer of this critical data to the servicecenter for processing and review. It uses VIMS datato remotely monitor events and alarms, allowingfocused channel polling to log condition-based eventtracking and Application Severity Analysis calcula-tions. It allows service personnel and maintenanceplanners to track health changes on a large arrayof on-board components while completing mine dutycycles. Some of the data collected by MineStar Healthincludes: system voltages, component performanceoverloading and load/dump/travel/delay times.

MineStar Health is designed to work seamlesslywith MineStar FleetCommander or is available asa stand alone health reporting system from yourCat dealer. It can also be integrated into a produc-tion database for expanded analysis.

Key benefits of MineStar Health include:● Saved component failures● Extended component life● Reduced phantom breakdowns● Full fleet health monitoring● Efficient data analysis● Improved maintenance practices

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Technology Products MineStar™ Health


VIMS™ SystemVIMS™ is an advanced diagnostic and equipment

management tool. By continuously monitoring awide range of vital machine functions, this high-tech electronic monitoring system improves machineavailability, component life, and productivity whilereducing both repair costs and risk of catastrophicfailure.

By integrating numerous machine sensors intoeach machine design, VIMS monitors over 250machine functions and health statistics. Essentialmachine functions are displayed for the operator viathe message center. If a parameter falls outside ofthe specification, VIMS sends a warning messageto the operator and depending on the severity of theevent recommends an appropriate course of action.VIMS not only provides important machine and sys-tem information to the operator, it also stores a largeof amount of data about the machine for proactivehealth and production management.

The third generation of the VIMS System —VIMS 3G — is now available for select Cat Miningequipment, offering enhanced convenience and func-tionality, along with updated communications capa-bilities.

Analysis tools help turn data into decisions.The software applications of the VIMS Off-Board

System include a number of data analysis file types.Each file type analyzes different kinds of informa-tion and is used to produce specific results.● Event List records, categorizes and stamps up

to 500 system “events” that occur during machineoperation.

● Event Recorder (Snapshot) helps technicianstroubleshoot a specific event by capturing detaileddata before and after the event occurs.

● Data Logger enables the operator to trigger record -ing of real-time machine data that can show ser-vice personnel exactly what is happening whenan event occurs.

● Payload helps enhance truck and loading tooleffectiveness and improve total fleet productionby collecting payload, cycle-time and haul-dis-tance data.

● Trends, Cumulatives and Histograms providea variety of reporting and analysis tools for mon-itoring specific machine parameters.

Value of VIMS System● For the machine operator VIMS establishes two-

way communication between the operator and themachine. Real-time machine information allows theoperator to make informed decisions that directlyaffect safety, machine availability, and ultimatelythe productivity of the mine.

● For maintenance VIMS provides an in-depth viewof operator and machine performance. This allowsmaintenance managers and technicians to maxi-mize component life, reduce catastrophic failures,minimize unscheduled down time and improve assetmanagement.

● For production VIMS collects the informationneeded to monitor equipment usage, personnelperformance, and productivity levels. Payload infor -mation can be used as an accounting tool, an indi-cator of cycle time efficiency and truck overloadingor under loading.

VIMS Wireless InterfacesVIMS information can be transmitted wirelessly

using VIMS Communicator or Health InterfaceModule. These units download VIMS data at userprogrammable intervals and send it back to theoffice via various telemetry systems.

VIMS Analysis ToolsVIMS information can be downloaded and viewed

by VIMS pc, VIMS 3G Connect and VIMS Supervisorusing a laptop at the machine or wirelessly. VIMSinformation is also available with MineStar HealthSystem.

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Technology ProductsVIMS™ System


CAT® INTEGRATED OBJECTDETECTION SYSTEM™

The Cat® Integrated Object Detection System™is designed for machines ranging from large min-ing and quarry trucks to machines such as wheelloaders and motorgraders. It is meant to reduceblind spots and increase perimeter awareness. Thisrobust system includes both radars and a vision sys-tem providing optimal awareness around themachine. With both audible and visual indicationsof a detected object, the Object Detec tion Systemhelps prevent work area injuries caused by limitedawareness. Using a combination of short-range radars,medium-range radars, cameras, and a high-resolutiontouch screen display, operators can view the areasimmediately surrounding their machine, helping toprevent collisions and accidents.

The Object Detection System is highly integratedwith the specific machine configuration to optimizeradar and camera coverage. The system has beencalibrated to provide appropriate fields of view andrange. Unlike basic camera systems, the Object Detec -tion System provides operators with audible andvisual types of warnings that enable the operatorto make informed decisions when moving or oper-ating the machine. When a camera system is run-ning at all times, it’s easy for the operator to overlookthe screen when performing job tasks. This systemalerts the operator when an object is in close prox-imity so they can decide if action needs to be takento avoid it.

Features● Provides coverage on up to four sides of machine.● Robust components designed and tested to work

in heavy-duty off-road applications.● Radar detects both moving and non-moving objects.● System uses visual and audible means to alert

operator to objects.● Cameras allow operator to identify objects detected

by radar.● On-board diagnostics monitor system health and

alert operator to any issues.● Configurations allow operator to adapt system to

local conditions.

Benefits● Improves site safety by enhancing operator’s sit-

uational awareness.● Reduces cost and machine downtime due to accidents.● Does not require any off-board infrastructure.● Easy to learn display interface.● Minimizes nuisance audible alarms.● Scalable solution allows user to start with camera

system and later add radars.

26-20 Edition 41

Technology Products Cat® Integrated Object Detection System™


CAT® INTEGRATED REMOTE CONTROL™The Cat® Integrated Remote Control™ system

enables machine operation from a safe location withthe operator removed from the cab. This systemenhances operator safety by limiting exposure tofull body vibration, dust and sound, and slips, tripsand falls from machine ingress/egress. The machineis controlled remotely through use of an OperatorConsole which is an over the shoulder, line of sightunit. Integrated Remote Control is ideal for use inhazardous situations such as stockpile operations,cleaning up high wall and bench failures, or work-ing with hazardous materials. This system is inte-grated with engine, implement, and power traincontrols. Safety controls are built in which stop themachine in case of the loss of radio, transceiver, orECM communications. The machine will also stop inthe event the Operator Console is tipped. Additionalprotection features include the use of auto-brakeswhen in neutral and engine over-speed protection.Perhaps the most unique feature is the integrationwith the Computer Aided Earthmoving System(CAES) avoidance zone functionality which preventsthe machine from entering predefined avoidancezones.

Advantages of Integrated Remote Control include:● Improved system response (more direct control of

electro hydraulic system)● Improved reliability/serviceability (fewer parts/

hardened components)● Enhanced performance features (AutoCarry, ABA)● Faster installation times (fewer parts)

Engine controls include:● Engine Start● Engine Shutdown● Engine Speed/Throttle● Engine Deceleration

Implement controls include:● Blade Control (raise/lower, tilt left/right, pitch for-

ward/back, float)● Single/Dual Tilt Blade Mode (assuming dual tilt

is installed on machine)● Auto Blade Assist Mode● AutoCarry● Ripper Control (raise/lower, in/out, auto stow)● Implement Lockout

Power train controls include:● (FNR) Direction● Gear (1 or 2)● Steering● Bi-directional AutoShift● AutoKickdown● Service Brake● Parking Brake

Auxiliary controls include:● Machine Power● Lights● Horn

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Technology ProductsCat® Integrated Remote Control™


MINEGEM™ UNDERGROUND MININGAUTOMATION SYSTEM

Developed out of the need to reduce human expo-sure to injury, the system removes the operator fromdangerous situations and allows them to work in amore comfortable, ergonomic environment. Usingtechnology to automate and enhance operations, theCat MINEGEM system will increase productivityand make a measurable impact on your mine’s bot-tom line.

MINEGEM offers 2 levels of control:● Co-pilot: operator-assisted automatic steering● Auto-pilot: machine is operated under its own

self-guidance systemMINEGEM consists of four major sub-systems

that support the functionality of the system.

Operator StationThe Operator Station allows machines to be oper-

ated from an ergonomically designed seat in a vari-ety of locations. The operator can safely operate themachine from a mine control room or mobile office,either above or underground. This removes the oper-ator from potentially dangerous environments inthe mine drives underground. The Operator Stationconsists of a computer, three monitors, a seat andtwo joysticks; one controlling the movement of themachine, the other controlling the bucket.

Machine Automation SystemThe Machine Automation System consists of the

on-board hardware components that make theMINEGEM system function. LADAR, cameras,lights, sensors, antennas, and control modules com-bine to create a system that provides safety and pro-ductivity for your underground mining operation.

Area Isolation SystemEnsures that personnel cannot enter or equip-

ment cannot leave the Operations Area while themachine is in autonomous mode. The operator hasthe ability to arm and disarm the system to com-pensate for changing business needs. A barrier con-trol panel is located at each entry to the OperationsArea. These are connected to barriers to ensure thearea is secure. The status of each barrier controlpanel is reported to the programmable logic con-troller via the Local Area Radio Network (LARN).The programmable logic controller then determineswhether the Operations Area should be armed.

Local Area Radio Network (LARN)The LARN is a wireless Ethernet data network

that enables communication between the machineand the operator station. The network uses the802.11 b/g protocols and requires exclusive use ofthe 2.4 GHz RF spectrum.

Signals from the Machine Automation Systemroam between LARN antennas as the machinemoves within the operations area. The signals workprimarily over line-of-sight, but can reach a shortdistance around corners. Video images and data aresent via the LARN.

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Technology Products MINEGEM™ Underground Mining Automation System


WORK AREA VISION SYSTEM (WAVS)Cat WAVS is offered in one, two or three camera con -

figurations for Cat machines and your entire fleet.WAVS meets Caterpillar’s rugged testing to func-tion in tough environments and to withstand harshclimates.

Operators are finding that the use of a reliablecamera system allows them to efficiently accomplishthe job with minimal risk of machine incidents. Lessrisk on the job reduces liability and maximizes profit.

Site AssurancePosition the cameras to view blind spot locations;

this reduces machine incidents due to poor visibil-ity. Cameras will reduce the guessing of machinesurroundings.

Work EfficiencyEnhanced visibility around machines increases

up-time, operator efficiency and productivity.

Ergonomics/ComfortOperator maintains forward direction as display

shows machine surrounding and reduces operator’spositional motion.

WAVS improves productivity by increasing theoperator’s field of visibility. The closed circuit cam-era system can be integrated into the machine sothe camera view will be automatically promptedbased on camera set-up preference. For example,when the machine is placed in reverse the rear cam-era is automatically displayed.

7" Color LCD Display● Auto-sensing illumination for changes in light

conditions● 2 Camera views available

– Panoramic 115°– Narrow 78°

● Splash-proof● Adjustable mounting

Camera● Robust design withstands 15G’s of vibration and

protection from high-pressure washing● Includes internal heater for removal of conden-

sation, snow, and ice● Chemically hardened glass, which prevents break-

age, scratches and damage

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Technology ProductsWork Area Vision System (WAVS)


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