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Excavators are now almost a century-old, as an equipment category. It has evolved over the years from a mechanical device to electrically-operated machines and then hydraulically-operated, much faster, production equipment. The evolution is ongoing with the induction of newer technologies to improve various operating parameters like fuel efficiency, versatility, faster or safer operations etc.

While the basic operation of the excavator has remained consistent over the years, advancements in technology have improved technology, controls, performance, versatility, efficiency, and more. With the advancements in technology as well as the evolution of design, today's new generation excavators provide more purposes than what it is intended to do.

New excavators coming to market offer a combination of increased performance and smart technology. Key manufacturers are offering new excavators that benefit from the advanced electronic technologies and sophisticated tools to deliver smart performance. These machines also have new hydraulics and the latest in engine systems, boosting output. Every manufacturer is updating its excavator models and trying to come up with a more intelligent automation system than the previous model of the same.

More Versatile than before

Hydraulic excavator capabilities have expanded far beyond excavation tasks with buckets. With the advent of hydraulic-powered attachments such as a breaker, a grapple, or an auger, the excavator is frequently used in many applications other than excavation. Many excavators feature a quick coupler for simplified attachment mounting, increasing the machine's utilization on the jobsite.

Attachments are the key element in an excavator's arsenal of versatility. A greater variety of attachment offerings and improved coupling systems have been key to increased excavator versatility. Today's customer considers excavators to be less of a bucket machine and more of a hydraulic tool carrier. In the last few years there has been an explosion in the number of attachments people are putting on excavators. As a result of customers demand manufacturers are providing auxiliary circuits for various attachments.

Latest Engine System

Excavator manufacturers are continually trying to improve their machines to reduce operating costs and improve fuel efficiency. New generation excavators are powered by latest engines delivering high torque at low rpm and comes fitted with auto-idle and shutdown features to help reduce fuel use.

Machines are now using the auto engine shutdown feature. It operates much in the same way as the auto-idle feature. Instead of switching to idle mode, the machine's engine will shut down after say five minutes of inactivity. This feature helps to cut down on emissions when the machine is idle. A machine can be left idle 40-60% of operating time which contributes significantly to fuel consumption.

In-cab Controls

Onboard monitors on current new generation excavators provide a wealth of information and capability that can increase productivity, reduce fuel consumption and enhance safety on the jobsite. The monitors often interface with modern electrohydraulic systems to provide semi-autonomous functions and customized capabilities that make novice operators more efficient while reducing fatigue in more experienced operators.

There is a wealth of information at available on fingertips. For instance, the monitors on excavators allow operator to monitor the machine's hydraulic work mode, attachment flow and pressure settings, diesel exhaust fluid (DEF) level, real-time fuel consumption, fuel efficiency and machine surroundings. Approximately 200+ items of machine performance, parameters, read-outs, historical issues, engine functions and more can be accessed by sitting in the operator's cab.

Improved Hydraulics

Excavator hydraulics has improved dramatically over the past years. Flow and pressure have increased and the ability to modulate both while providing quick access to the machine's hydraulic power have turned excavators into prime movers for a host of attachments. By integrating electronic control and hydraulic performance, manufacturers provide work modes where excavator performance is tailored to general types of tasks.

Manufacturers are also incorporating more sophisticated hydraulic functions that allow the operator to adjust hydraulic flow to the application. Hydraulic upgrades on the latest models include selectable modes to optimize available hydraulic speed and power, plus a manual throttle dial to adjust engine speed and power as needed. Hydraulic efficiency has been a big concentration point for manufacturers. Efficiency is a result of improved system designs that are capable of higher pressure, increased cooling and optimized use of the available oil flow. The lower engine horsepower found in some machines has also created a need to do more with less, making more efficient hydraulics requirement.

Smart hydraulic system in many new generation excavators also features bucket regeneration, boom priority and reduced internal losses in the hydraulic circuit for increased efficiency and productivity, as well as lower fuel consumption.

Advanced Electronics

Electronics also are important in improving the capability of the machine, and this is one area where excavator advances are taking place. Most advances taking place involve the electronic control of machine systems. Electronics allow the machine to be tailored to the specific job at hand by adjusting the engine rpm and the flow of the hydraulic system.

Electronics are making the machine easier to operate and are responsible for improved productivity and operating costs. The use of electronics and electronic controls allows operators the benefit of selecting machine performance perimeters through the selection of a few well placed buttons on an instrument panel. Operators can select and influence engine and hydraulic power, hydraulic flow priorities, engine speed and travel speed. The result is better performance and productivity while maximizing fuel efficiency,

Advanced electronic systems provide superior fuel economy and faster, more accurate diagnostics. Improved fuel economy is achieved through the help of a computer, which controls engine rpm and hydraulic pump flow. This allows the engine to operate at the most efficient rpm range without sacrificing performance. Electronics also improves troubleshooting by providing on-board diagnostics and major systems overrides. The result is maximum up-time and improved productivity.

Machine Control System

Similar to advancements in computers and smartphones, the advancement of machine control interfaces is making the excavators more powerful. Machine control system has significantly increased efficiency and productivity of excavators by reducing the operator's workload. Machine control enables excavator operators to execute everything from a simple job to those based on complex 3D designs. The machine control system shows operators in real-time how to level sites, dig trenches, grade slopes, and take quick measurements or even create complex multidimensional site profiles.

Machine control systems use a combination of GNSS, inertial and laser, or total station technology to accurately position the excavator's bucket in real time. Using an in-cab display, the operator can then see the 2D or 3D design surface, grade or alignment inside the excavator. Following the design, the operator can cut to grade or dig to desired depths quickly.

Zero and Reduced Tail-Swing

Full-sized excavators offer zero tail-swing, reduced tail-swing and conventional tail-swing configurations. On a zero tail-swing design, the excavator housing doesn't extend beyond the tracks as the housing rotates. With a reduced tail-swing machine, the housing typically extends only a few inches beyond the track.

Reduced and zero tail-swing models have become popular due to their easy maneuverability in urban and residential areas where space is limited. With a minimized counterweight radius, the excavator has a decreased chance of damaging property when working close to buildings and other obstructions. They are also ideal when working within a single lane of traffic or a busy metropolitan area when it's important to swing within your tracks.