Cold milling machines

MILLING CUTS TO THE CHASE WIRTGEN’S NEWEST GENERATION OF TWO-METRE COLD MILLING MACHINES HAVE LANDED IN AUSTRALIA, FEATURING TECHNOLOGIES TO INCREASE PRODUCTIVITY AND OPERABILITY WHILE DECREASING DOWNTIME AND LOWERING OPERATING COSTS.

New technology on Wirtgen’s latest cold milling machines is designed to simplify the operator experience and improve efficiency on a range of road works.

The F-Series cold milling machines by Wirtgen are brand new to Australia and represent a further leap ahead in milling performance and capability over previous generations.

The W200F and W210Fi models present a range of advances in machine technology and features aimed at setting a new benchmark in milling performance.

The benefits of these technologies can broadly be broken into three classes: operator assistance, improving machine availability and operational efficiency.

OPERATOR ASSISTANCE Every new feature is aimed at easing the load on operators and equally enabling

them to produce a quality job at the highest level of efficiency.

In these machines, Wirtgen has created a balance between operator and machine that aims to hit the sweet spot for results that benefits owners, operators and clients.

Wirtgen Product Support Manager Brett Ferris explains that he found that operators were getting secondhand information when they were learning to operate the machines.

“Often, operators would have the machine at full revolutions per minutes (RPM) all the time because they thought power was key, so we created the Mill Assist feature to optimise the process and make it easier for them to get the best results,” Mr. Ferris says.

The new generation of Wirtgen milling machine comes standard with Mill Assist. Mill Assist is an automated feature that offers the operator a simple choice of three modes: power, economy and pattern.

“Operators can choose which element of the job they would like to focus on by simply pressing the corresponding button,” Mr. Ferris says.

“The machine will then automatically adjust operating parameters to optimise performance and deliver that chosen element.”

“Mill assist will do everything for you. It changes the drum speed, travel speed, engine RPM and water levels on the go.”

Mill Assist can also be optioned with Wirtgen Performance Tracker.

This feature measures the width of each cut and automatically adjusts the amount of water and power needed to cut to the selected quality.

In addition, Wirtgen’s Level Pro Active levelling system has undergone upgrades to simplify the levelling process for operators.

“The upgraded system shows operators icons for each of the levelling components which are easy to understand and adjust,” Mr. Ferris says. “All of the sensors are connected and shown on the Level Pro Active display and it will highlight the sections that need be levelled out.”

Level Pro Active is “active” all the time, so when the machine is traversing between cuts or manoeuvring on and off a trailer, it keeps the machine in a level and stable condition.

All of these features are fully machine integrated and work together to eliminate inaccurate milling results.

“Any discrepancies in the accuracy of your job will end up costing the business because you may have to rip the road up and start again or you may face delays because more asphalt is needed,” Mr. Ferris says.

“If the machine doesn’t give accurate results, when the asphalt pavers come through, the asphalt will be uneven and the result is a bumpy road.”

To combine all of these systems and make the milling machine simple to operate, Wirtgen has also upgraded the Man-Machine

Wirtgen has created a balance between operator and machine that aims to provide results for all parties.

Interface on its new series.

“The interface is now customisable everywhere in the display. I have talked to customers that change the interface for each operator using the machine,” Mr. Ferris says.

The adaptable interface allows operators to make the most of the new and upgraded technologies such as Mill Assist, Dual Shift and Level Pro Active. Each operator can customise the dashboard displays to prioritise different functions.

“For example, one operator might like to keep an eye on the sensors right through a job, but another might like to constantly adjust the water levels, so these can be displayed on the interface wherever they might want,” Mr. Ferris says.

IMPROVING MACHINE AVAILABILITY There are a number of features on the machine that assist owners in improving machine availability and uptime.

One example is a new diagnostic concept which, in the event of an issue, guides the machine operator through troubleshooting in a few simple and intuitive steps.

Similar to the systems employed on photocopying machines, a combination of easy-to-understand coloured graphics and text guidance help to pinpoint the issue and start the rectification process.

In addition, there are also redundant machine control systems that enable the quick continuity of operations in the event of a computer fault.

They duplicate CAN networks in critical machine areas to minimise downtime during a failure.

Looking at machine availability from a different perspective, there is also a new drum change technology that materially reduces the amount of time taken to change a milling drum required when changing to, or from, a fine milling job.

With the new F-Series, the W200F and W210Fi, the team at Wirtgen have developed and implemented a multiple cutting system.

On Wirtgen’s previous “FCS” drum system, a drum change could take a few hours depending on experience and with even older technology, it could take over a day to make the change.

The latest multiple cutting system enables that same drum change to be undertaken in less than 15 minutes.

Importantly, the advancement could help contractors bid and deliver a range of jobs with different drum patterns or sizes in the space of a week, as machine downtime is significantly reduced.

Mr. Ferris says costly machine movements and swaps involved in the drum change process can now be avoided.

OPERATIONAL EFFICENCY Specific elements have been included on the new generation machines to improve them further.

The Dual Shift application is one such feature that works hand in hand with the Mill Assist technology on the W210Fi milling machine.

“We have replaced our standard splitter gearbox with a dual shift gearbox which enables the drum to produce different cutting patterns depending on the speed of the drum,” Mr. Ferris says.

“To achieve a finer pattern, the drum speed needs to be fast.

“Rather than have the machine on the fastest engine speed, if necessary, the machine will automatically put it into gearbox speed two which speeds the drum up, but brings the engine RPM down. This results in a more precise pattern and lower fuel consumption.”

Mr. Ferris worked on this machine in the US where the team was cutting 80 feet a minute and running the machine at only 1300-1400 RPM.

“On that project, the fuel costs were down and the overall production was improved,” he says.

In addition to the Dual Shift powershift transmission on the W210Fi, there is an automated start/stop feature on the milling drum and an intelligent dual fan concept which reduces wear, fuel consumption and noise.

While the W200F and W210Fi are of similar size, quality and are customisable, there are some differences.

Mr. Ferris says the W200F is the more costeffective machine in the range and features a Tier 3455-kilowatt and 610-horsepower engine. It is also available in Tier four form. The W210Fi is the premium model and uses a different motor and gearbox combination with a 563-kilowatt and 755-horsepower engine Tier four final engine.

Both machines offer an array of options that enables each owner to tailor a machine to their specific business needs.

“It really depends on what the customer’s overall work is going to be when deciding between models and options so they can ensure they have the right machine that will work best for them,” Mr. Ferris says.

He says regardless of the work being undertaken, Wirtgen will not only have a solution to suit, but also a suite of technologies to benefit every stakeholder.