Wirtgen has been developing smart 3D-machine control systems for the road construction sector for the past 30 years, and continues to set benchmark standards when it comes to precision and automation.
From Pioneering Idea to Integrated Machine Control
With Wirtgen AutoPilot 2.0, Wirtgen supports and assists construction contractors around the globe in the successful realization of demanding infrastructure projects. The track was to be laid entirely without conventional pre-stressed concrete sleepers and ballast. For the construction of the required slab track, concrete surfaces had to be paved with precision.
Leica Geosystems and Wirtgen collaborated on the development of a new measurement and control system for this purpose, which integrated measurement technology and machine control via a 3D interface.
"At the time, there was no measurement and control system that could truly satisfy the extremely high precision requirements of slab track construction," said Matthias Fritz, application manager 3D controlsSystems at Wirtgen GmbH. "The development of the 3D interface between the measurement system and the machine was the decisive breakthrough, and formed the basis for all subsequent developments."
The technology was used for the first time in the construction of the ICE high-speed rail link in 1999. On that project, multiple slipform pavers worked simultaneously without physical stringlines and were guided entirely by a 3D control system. A short time later, Wirtgen cold milling machines were equipped with the technology, which has since been continuously revised and upgraded.
Smart Machines Enable More Automation
With the introduction of satellite-based GNSS technologies and the increasing integration of machine control into vehicle control systems at the time, ongoing developments raised the system to an entirely new level. The goal was to further simplify working procedures, reduce setup times and increase process reliability on the construction site.
"The decisive step in the further development was the replacement of the conventional physical stringline with a virtual stringline and the integration of the control system in the machine," said Fritz. "This enabled us to increase precision, productivity, and operator comfort in equal measure."
Wirtgen presented the Wirtgen AutoPilot at Bauma 2013 as the world's first hybrid control system for slipform pavers — and went on to win the prestigious Bauma Innovation Award at the event. The current generation, AutoPilot 2.0, enables high-precision paving of offset and inset profiles such as curbs, concrete safety barriers or road surface slabs — without laborious surveying or having to setup and break down physical stringlines.
"The purpose of technology is to make things easier for its users, not more complicated," said Fritz. "That is why we develop solutions that are aligned with our customers' needs and create real added value on the construction site."
Standardized CAN bus interfaces support the flexible use of a wide range of different measurement solutions. Depending on their requirements, customers can use systems from other providers and simultaneously enjoy the benefits of deep integration in their Wirtgen machines.
Driving Digitalization
Wirtgen has Autopilot 2.0 for practice-relevant control of offset slipform pavers without a physical stringline. With the future integration of further systems via the Work Planner in the John Deere Operations Center, other areas of Wirtgen will also benefit from these developments.
Focus on Practical Solutions
After 30 years, the precise control of height, grade and slope, milling depth and steering remains one of the core competencies of Wirtgen. Building on its many years of expertise and experience, the company is actively engaged in the continuous development of its automation solutions, and thus contributes to the increasing digitalization of construction sites.
