Along with the environment as the BIG issue for not just the construction industry, but the entire world, operator health and safety remains a critical consideration for both employers and equipment manufacturers – as Mark Cherrington and Mary Searle report.

A number of technologies and developments are converging to bring ever-higher operator comfort levels to construction equipment. As reported in previous editions of Road Technology Live, maximum daily vibration limits are now in place in the EU – and look to become part of the regulatory landscape in the USA within a few years.

In 2007, the EU introduced maximum daily vibration limits for operators of new off-road vehicles, with existing vehicles to achieve similar ceilings by 2011 (since extended to 2013 in some countries). That's driving the development of seats that virtually eliminate vibration to the operator – backed up by control technology that allows cabs to be far better isolated from the machine chassis.

The major seat manufacturers have now introduced "active suspension" type seats that effectively counteract vibrations from the machine.  According to Webke Froehner, Grammer's vice president, marketing, the USA Occupational Health and Safety Authority (OSHA) is currently looking at introducing similar legislation to that applying in the EU.

"OHSA is doing a lot of work with the insurance industry on full-body vibration and soft-tissue injuries, which are in the top four causes of workplace injuries.  "Many corporations are becoming very very sensitive to lower back injuries, and the long-term problems they can cause," she said.

At the same time, a key benefit of good suspension is it allows a vehicle to travel across the ground – farm, quarry, jobsite – faster, thereby improving productivity, said Anthony Glick of seating manufacturer Sears Manufacturing, which works closely with John Deere in seat development.

Glick said there were four levels of suspension: mechanical, which allows vibration through the metal; air, which loses effectiveness with operators weighing over 90kg; semi-active, which uses a vibration reduction system; active, which uses an independent energy source to actively counter the vibration.

"More than 65% of John Deere customers in the US pay the extra cost to have our active seats installed as the cost benefit is readily realised," he said. "Key benefits, aside from increased productivity, are a reduction in harmful vibrations and improved comfort." Adding to the effectiveness of the latest seat designs is the move towards electro-hydraulic control systems, which eliminate the need to have hydraulic lines in the cab.

Eliminating hydraulic lines from within the cab gives significant operator comfort advantages, said Dave Wohlsdorf, director, product management, with Sauer Danfoss. These include reduced noise (hydraulic units generate noise), less heat (hydraulic oil generates heat), and improved visibility, because you can get a smaller operator station.

They also allow the cab to be much better isolated from the rest of the machine, so that the only direct connections to the machine are through vibration damping isolation mounts. Electro-hydraulic controls also make it much easier for maintenance, as they allow tiltup type cabs, which are easier to achieve with just wires, than with wires and hydraulic lines.

There are other areas also in the process of evolution, Wohlsdorf said. One example is the "steer-by-wire" concept that's already been adopted by some OEMs, including Komatsu, Cat and Case, to name just a few, which offers some clear advantages.

Examples include dozers, joystick control wheel loaders and the new M-series Cat graders, which have also replaced the steering wheel with joystick controls.Steering can be dealt with using variable speed controls, so that as the machine goes faster, the response times change to ensure the operator stays in control.

Steer-by-wire also allows OEMs to option of using a steering wheel or joystick controls – which may be a better option for dry hire machines, or where a machine is used by a number of operators.

SIDEBAR: Grammer's "dosimeter" lets operators know their limits

German specialist seat manufacturer Grammer has launched its VibroControl vibration "dosimeter" device on to the North American market, ahead of what it believes is the likely US introduction of regulations limiting whole-of-body vibration.

Grammer's VibroControl attaches to the operator's seat, and continuously monitors for up to 12 hours – warning when acceptable limits are exceeded. It was developed to meet the requirements of the EU directive, where employers are required to monitor daily vibration levels for each employee – and retain the records for up to 30 years.

The data capture by the VibroControl can be exported via a USB port to a PC, documented in an Excel spreadsheet, then saved and archived. Exposure limits are measured both horizontally and vertically with the VibroControl attached to the side of the seat.

In addition, while working, operators can tell by glancing at the integrated trend LEDs whether their accumulated vibrations are nearing potentially health-endangering levels. Visual and audible signals alert them if acceptable limits are exceeded. Currently the VibroControl use daily vibration limits based on the European regulations, with Grammer recommending that US employers use the European limits as a guide.

If OSHA introduces daily vibration limits in the US, it is a simple matter to upgrade the limits to meet any US requirements. A number of technologies and developments are converging to bring ever-higher operator comfort levels to construction equipment.

A number of technologies and developments are converging to bring ever-higher operator comfort levels to construction equipment. As reported in previous editions of Road Technology Live, maximum daily vibration limits are now in place in the EU – and look to become part of the regulatory landscape in the USA within a few years.

In 2007, the EU introduced maximum daily vibration limits for operators of new off-road vehicles, with existing vehicles to achieve similar ceilings by 2011 (since extended to 2013 in some countries). That's driving the development of seats that virtually eliminate vibration to the operator – backed up by control technology that allows cabs to be far better isolated from the machine chassis.

The major seat manufacturers have now introduced "active suspension" type seats that effectively counteract vibrations from the machine.  According to Webke Froehner, Grammer's vice president, marketing, the USA Occupational Health and Safety Authority (OSHA) is currently looking at introducing similar legislation to that applying in the EU.

"OHSA is doing a lot of work with the insurance industry on full-body vibration and soft-tissue injuries, which are in the top four causes of workplace injuries.  "Many corporations are becoming very very sensitive to lower back injuries, and the long-term problems they can cause," she said.

At the same time, a key benefit of good suspension is it allows a vehicle to travel across the ground – farm, quarry, jobsite – faster, thereby improving productivity, said Anthony Glick of seating manufacturer Sears Manufacturing, which works closely with John Deere in seat development.

Glick said there were four levels of suspension: mechanical, which allows vibration through the metal; air, which loses effectiveness with operators weighing over 90kg; semi-active, which uses a vibration reduction system; active, which uses an independent energy source to actively counter the vibration.

"More than 65% of John Deere customers in the US pay the extra cost to have our active seats installed as the cost benefit is readily realised," he said. "Key benefits, aside from increased productivity, are a reduction in harmful vibrations and improved comfort." Adding to the effectiveness of the latest seat designs is the move towards electro-hydraulic control systems, which eliminate the need to have hydraulic lines in the cab.

Eliminating hydraulic lines from within the cab gives significant operator comfort advantages, said Dave Wohlsdorf, director, product management, with Sauer Danfoss. These include reduced noise (hydraulic units generate noise), less heat (hydraulic oil generates heat), and improved visibility, because you can get a smaller operator station.

They also allow the cab to be much better isolated from the rest of the machine, so that the only direct connections to the machine are through vibration damping isolation mounts. Electro-hydraulic controls also make it much easier for maintenance, as they allow tiltup type cabs, which are easier to achieve with just wires, than with wires and hydraulic lines.

There are other areas also in the process of evolution, Wohlsdorf said. One example is the "steer-by-wire" concept that's already been adopted by some OEMs, including Komatsu, Cat and Case, to name just a few, which offers some clear advantages.

Examples include dozers, joystick control wheel loaders and the new M-series Cat graders, which have also replaced the steering wheel with joystick controls.Steering can be dealt with using variable speed controls, so that as the machine goes faster, the response times change to ensure the operator stays in control.

Steer-by-wire also allows OEMs to option of using a steering wheel or joystick controls – which may be a better option for dry hire machines, or where a machine is used by a number of operators.

SIDEBAR: Grammer's "dosimeter" lets operators know their limits

German specialist seat manufacturer Grammer has launched its VibroControl vibration "dosimeter" device on to the North American market, ahead of what it believes is the likely US introduction of regulations limiting whole-of-body vibration.

Grammer's VibroControl attaches to the operator's seat, and continuously monitors for up to 12 hours – warning when acceptable limits are exceeded. It was developed to meet the requirements of the EU directive, where employers are required to monitor daily vibration levels for each employee – and retain the records for up to 30 years.

The data capture by the VibroControl can be exported via a USB port to a PC, documented in an Excel spreadsheet, then saved and archived. Exposure limits are measured both horizontally and vertically with the VibroControl attached to the side of the seat.

In addition, while working, operators can tell by glancing at the integrated trend LEDs whether their accumulated vibrations are nearing potentially health-endangering levels. Visual and audible signals alert them if acceptable limits are exceeded. Currently the VibroControl use daily vibration limits based on the European regulations, with Grammer recommending that US employers use the European limits as a guide.

If OSHA introduces daily vibration limits in the US, it is a simple matter to upgrade the limits to meet any US requirements. A number of technologies and developments are converging to bring ever-higher operator comfort levels to construction equipment.

As reported in previous editions of Road Technology Live, maximum daily vibration limits are now in place in the EU – and look to become part of the regulatory landscape in the USA within a few years. In 2007, the EU introduced maximum daily vibration limits for operators of new off-road vehicles, with existing vehicles to achieve similar ceilings by 2011 (since extended to 2013 in some countries).

That's driving the development of seats that virtually eliminate vibration to the operator – backed up by control technology that allows cabs to be far better isolated from the machine chassis. The major seat manufacturers have now introduced "active suspension" type seats that effectively counteract vibrations from the machine.

According to Webke Froehner, Grammer's vice president, marketing, the USA Occupational Health and Safety Authority (OSHA) is currently looking at introducing similar legislation to that applying in the EU. "OHSA is doing a lot of work with the insurance industry on full-body vibration and soft-tissue injuries, which are in the top four causes of workplace injuries.

"Many corporations are becoming very very sensitive to lower back injuries, and the long-term problems they can cause," she said. At the same time, a key benefit of good suspension is it allows a vehicle to travel across the ground – farm, quarry, jobsite – faster, thereby improving productivity, said Anthony Glick of seating manufacturer Sears Manufacturing, which works closely with John Deere in seat development.

Glick said there were four levels of suspension: mechanical, which allows vibration through the metal; air, which loses effectiveness with operators weighing over 90kg; semi-active, which uses a vibration reduction system; active, which uses an independent energy source to actively counter the vibration.

"More than 65% of John Deere customers in the US pay the extra cost to have our active seats installed as the cost benefit is readily realised," he said. "Key benefits, aside from increased productivity, are a reduction in harmful vibrations and improved comfort." Adding to the effectiveness of the latest seat designs is the move towards electro-hydraulic control systems, which eliminate the need to have hydraulic lines in the cab.

Eliminating hydraulic lines from within the cab gives significant operator comfort advantages, said Dave Wohlsdorf, director, product management, with Sauer Danfoss. These include reduced noise (hydraulic units generate noise), less heat (hydraulic oil generates heat), and improved visibility, because you can get a smaller operator station.

They also allow the cab to be much better isolated from the rest of the machine, so that the only direct connections to the machine are through vibration damping isolation mounts. Electro-hydraulic controls also make it much easier for maintenance, as they allow tiltup type cabs, which are easier to achieve with just wires, than with wires and hydraulic lines.

There are other areas also in the process of evolution, Wohlsdorf said. One example is the "steer-by-wire" concept that's already been adopted by some OEMs, including Komatsu, Cat and Case, to name just a few, which offers some clear advantages. Examples include dozers, joystick control wheel loaders and the new M-series Cat graders, which have also replaced the steering wheel with joystick controls.

Steering can be dealt with using variable speed controls, so that as the machine goes faster, the response times change to ensure the operator stays in control. Steer-by-wire also allows OEMs to option of using a steering wheel or joystick controls – which may be a better option for dry hire machines, or where a machine is used by a number of operators.

SIDEBAR: Grammer's "dosimeter" lets operators know their limits

German specialist seat manufacturer Grammer has launched its VibroControl vibration "dosimeter" device on to the North American market, ahead of what it believes is the likely US introduction of regulations limiting whole-of-body vibration. Grammer's VibroControl attaches to the operator's seat, and continuously monitors for up to 12 hours – warning when acceptable limits are exceeded.

It was developed to meet the requirements of the EU directive, where employers are required to monitor daily vibration levels for each employee – and retain the records for up to 30 years. The data capture by the VibroControl can be exported via a USB port to a PC, documented in an Excel spreadsheet, then saved and archived. Exposure limits are measured both horizontally and vertically with the VibroControl attached to the side of the seat.

In addition, while working, operators can tell by glancing at the integrated trend LEDs whether their accumulated vibrations are nearing potentially health-endangering levels. Visual and audible signals alert them if acceptable limits are exceeded. Currently the VibroControl use daily vibration limits based on the European regulations, with Grammer recommending that US employers use the European limits as a guide.

If OSHA introduces daily vibration limits in the US, it is a simple matter to upgrade the limits to meet any US requirements.