Remote Control Excavators
ROC (Remote Operated Control) System for Legacy Excavators
Safer Work, From a Distance
We worked with Stanley Black & Decker’s Infrastructure Innovation team to develop a retrofit kit that can be mounted to existing excavators for remote control operation. While new heavy machinery often comes with automation and remote control features, that’s not the case the for millions of otherwise perfectly good legacy models.
The Stanley Black & Decker team came to Harbor Designs and Manufacturing to support in ideating numerous technical solutions that fit the mission of the Infrastructure Innovation Unit. When proposed product solutions showed promise and garnered interest internally, Harbor was contracted to support in a deeper dive to prove out the viability of those technologies, like the ROC (Remote Operated Control) retrofit kits which could be quickly installed on legacy equipment to enhance them with modern capabilities. The system includes six core components that allow operators to control excavators from a safe distance.
Adding this capability not only enhances safety but also gives operators a better view of their work, improving both efficiency and accuracy. With out the need for a spotter it also requiring less people on site, and breaths new life into millions of legacy excavators - an ultimate game-changer for the construction and heavy equipment industries!
Harbor Designs & Manufacturing’s Role: Support in research, ideation, system architecture, industrial design, mechanical engineering, electrical engineering, embedded system development, prototyping, and refinement of the ROC System.
Modernizing The Construction Industry with Remote Control Retrofit Kits
Remote control technology is an innovative solution that enhances safety and efficiency for workers operating in hazardous or complex environments, especially for those in the construction industry.
Harbor Designs & Manufacturing helped define the product from a system architecture, human factors, and practical application prospective, surveying dozens of legacy excavators to establish a common feature set that would work on all of them. Working as an extension of their team, we worked together to develop designs that were safe, functional, ergonomic, and consistent with Stanley's brand identity.
Render demonstrating the Retrofit’s intended function.
Remotely Operated Control demonstration video.
Design Inputs for the ROC retrofit system.
Off-the-shelf controller branded for Stanley Black & Decker.
A Seamless Design Solution
In line with Stanley Black & Decker’s design language, the ROC retrofit system showcases a rugged appearance with a bold yellow and black color scheme. The design features sharp lines and accents of rubber over-mold, which highlights Stanley’s focus on durability and practicality in its products.
The retrofit kit includes six components installed inside the excavator's cab: a Control Box, Mode Switch Box, Joysticks, Blade Control, Beacon Light, and Floor Pedals. These components were made to be integrated into the cabin without damaging the original structure, and able to be powered down for the operator to quickly switch between in cab, and remote control operation.
Components of Stanley Black & Decker’s Remote Operated Control (ROC) system in an excavator’s cab interior.
The Control Box—the core of the retrofit system
The Control Box functions as the central hub for the retrofit system, housing PCBs and receivers that oversee all mechanical operations. For ease of control, it has a top-mounted key safety feature that allows the operator to switch between manual and remote modes.
The Mode Switch Box
Once remote mode is switched on, operators can turn the dial on the mode switch box to turn the excavator to remote mode. The magnets allow it to be mounted within the cabin and repositioned in almost any excavator brand.
Joysticks
For better control of the excavator's arm, the left and right joysticks were upgraded with omnidirectional servos for remote operation. To accommodate these new components, we also created new boots since the original rubber covers were not designed to work with the ROC kit and needed to be removed.
Blade Control
This component houses the servos that remotely control the joystick. Underneath the rubber over-mold that consequently provides protection from impact, lies the piston responsible for moving the joysticks. This design seamlessly aligns with Stanley's rugged aesthetic.
Beacon Light
Following Harbor Designs' human factors assessment, the Beacon Light was created to enhance safety and visibility on the job site. It flashes when controlled remotely to indicate whether the excavator is in manual or remote mode. It can be magnetically mounted inside the cabin for quick access and clear visibility.
Floor Pedals
The foot pedals and levers, located at the front of the cabin, control the excavator's movement. The servos that remotely control these pedals and levers are enclosed in two brackets strategically positioned on either side to prevent movement from being limited.
“It is definitely interesting technology and definitely has its uses. The environmental division of the company I work for does a lot of superfund cleanup of sites and are often in nasty material that requires the operators to were Tyvek suits and cartridge respirators so anything to get the human out of the cab and away from that stuff could prove worthwhile.”
Enhancing Safety and the Workplace Through Remote Solutions
Stanley Black & Decker's products are designed to support their mission to empower people to do better, safer, and more significant work. Retrofitting legacy heavy equipment with remote controls is an innovation with this commitment in mind.
This innovation doesn't just bring a lot of benefits—it also cuts down on risks and accidents for human operators. Now, operators can handle machines from better and safer angles. Remote control systems are naturally familiar and easy to learn, so operators can get up to speed quickly, which opens up more job opportunities in the construction market.
To learn more about the ROC Kits, click HERE and HERE to read a few of the articles published on their project.
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