Volvo Construction Equipment has introduced a major software update for its EC480E large excavator series, dubbed "Active Load Assist" (ALA). In large-scale mining and quarry operations, the primary goal is to maximize the amount of material moved per hour. However, operators often face a dilemma: filling the bucket to maximum capacity risks tipping the machine backward (reducing undercarriage life and stressing the boom), while under-filling reduces efficiency.
The ALA system solves this by integrating real-time data from the machine's inertial measurement unit (IMU) and the engine control module (ECM). As the operator crowds the bucket into the pile, the system monitors the angle of the chassis relative to the horizontal plane. If the rear of the track frame begins to lift-a sign of excessive vertical load on the boom-the system instantly calculates the exact weight in the bucket based on hydraulic pressure in the lift cylinder.
Instead of simply sounding an alarm, the ALA system actively intervenes. It sends a signal to the main hydraulic control valve, slightly restricting the flow to the boom lift circuit to prevent further lifting, and simultaneously increases the flow to the arm crowding circuit. This encourages the operator to crowd the bucket horizontally rather than lifting vertically, optimizing the cut into the material. Furthermore, the system features a "Smart Dump" function. When swinging to the haul truck, the system detects the height of the truck bed via the angle sensors on the boom. It automatically limits the boom height to prevent dumping material over the truck's cab, a common cause of heavy equipment damage.
