Beyond the cab: Making the case for remote controls

03 October, 2024

While adoption of wireless remote controls is widespread in some applications, there are pockets of the offhighway industry that have not yet taken the leap. Original equipment manufacturers considering the addition of remote controls may question the benefits and worry about machine redesign implications. This article offers a guide to remote control integration, addressing common concerns as well as the basics of remote control selection.

Optimising operations, comfort, and safety

From cranes and concrete pump trucks to machinery used in firefighting, mining, and demolition, remote controls are common in applications where visibility or safety are challenges for operators working in the cabin. Remote controls are also increasingly common in industries such as construction, agriculture, and forestry, where moving the operator away from the machine can increase productivity. In each of these applications, remote controls are optimizing operations, increasing operator comfort, and improving safety. These are the primary reasons OEMs should consider remote controls for non-traditional applications.

Remote controls enable operational optimization as they allow users to exit the cabin and operate the machine from a location that provides a better view of the task or the machine’s surroundings. The elimination of blind spots leads to greater site safety and may also allow one person to perform a task that previously required two or more people.

A better view can also prevent an operator from holding their head in an uncomfortable position, reducing the risk of muscular strains. Performing work from a more natural position increases operator comfort. In addition, providing operators with the option to work while standing — especially those who typically sit for the duration of their shift — can improve health and wellbeing.

Another considerable benefit of remote controls is their ability to increase operator safety. In many industries, machines operate in challenging areas: steep slopes or unstable ground; within or close to buildings lacking structural integrity; and in environments that are flammable, explosive, or have poor air quality. Remote controls allow operators to work in these areas, but from a safer position, mitigating or eliminating safety hazards.

While remote controls are suitable for many applications, they may not be right for every situation. Device range varies, but typically reaches up to 500 meters (1,640 feet). For applications requiring remote operation over longer distances, teleoperations may be a better, safer choice. Autonomous operation may also be an option. Environments requiring radio silence or areas with high interference will need a tethered backup.

Overcoming remote control resistance

OEMs considering the addition of remote controls often have questions or concerns. Cost is sometimes a factor, particularly for base-level machines or those destined for the rental industry. A cost-benefit analysis or voice-of-customer study can help determine if the added value remote controls provide justifies the higher machine price. Another concern may be whether the devices will work in every country the machine is exported to, but many remote controls today operate on a universal 2.4 gigahertz radio frequency. Among the more frequent concerns, however, are safety and security, operator acceptance, and machine redesign.

From a safety perspective, machines need to be protected from unintended movement and access. Movement is covered by emergency stop functionality, which is standard on all remote-control transmitters. Look for performance level E certification, the highest possible safety rating for this function. The ability to integrate deadman switches, free-fall detection, tilt detection, two-handed/interlocking operation, and range limiters provide additional measures of protection. As for access, look for remote control suppliers with proven secure solutions and the inclusion of cybersecurity in product development and testing processes.

Operator familiarity and acceptance can be a challenge, as operators used to controls within the machine’s cabin may be reluctant to learn and use a remote control. To increase operator comfort and acceptance, it’s important to configure the transmitter in a way that mimics the controls look and layout within the cabin. This includes mechanism type and placement plus overall look and feel, such as icons and display design. Remote control configuration and programmable display capabilities are key to enabling this replication.

A key question in considering the addition of remote control capabilities is whether and to what extent the machine needs other design modifications. Fortunately, many machines today are ready for remote control integration as the basic requirements are minimal. The remote control receiver requires either digital control such as CAN bus, or it can be wired directly to the machine’s proportional valves and sensors. The receiver is capable of handling machine logic and direct control of valves. The solution depends on the machine, so look for a supplier with a flexible portfolio that can adapt to different types of machines and functions. This will minimize machine redesign needs.

Selecting the right solution

Remote controls are a combination of transmitter and receiver, with receivers typically being straightforward to specify. The primary choices are its connection to the machine – discrete outputs vs. CAN – and its voltage output control. Compact machines need compact receivers, and if the device will be inside a metallic enclosure, it may require an external antenna.

Transmitters can be a bit more involved to specify, but understanding a few key points will help determine the correct type for the application. For off-highway machinery, there are three common types of transmitters: handheld, pistol grip, and console box (also known as belly pack).

A handheld transmitter is a small device held in the palm of a hand. These devices are narrower in width but thicker in depth than a mobile phone. Handheld transmitters are on the basic end of the spectrum with limited mechanism types, which makes them ideal for machines with fewer and simpler functions. They have between two and 14 buttons, which can be on/off or proportional.

Pistol grip remote controls are held, as the name suggests, in one hand like a pistol. There is a trigger used for proportional control of a valve or as a deadman switch in conjunction with thumbsticks on the main body. The face plate can include a variety of functions, such as buttons, switches, joysticks/thumbsticks, and graphical display screens. The sides of the device can also house functions, typically auxiliary. The pistol grip has more functionality than a handheld transmitter, but not as much as a belly pack.

The most flexible transmitter is the console box, which the operator straps on around their neck, shoulders, and/or waist, depending on the harness, with the transmitter resting against the operator’s stomach. A console box can have multiple different functions through buttons, switches, and joysticks/thumbsticks. They can also incorporate high-resolution, sunlight-viewable display screens. Console box transmitters are ideal for machines with more – and more complex – functions.

The number of inputs/outputs needed can narrow transmitter selection to one type, but some applications can be covered by more than one option. In this case, operator familiarity or preference is typically the decision-making factor. For example, both a handheld and a console box transmitter are suitable for some applications, but if the cabin has levers rather than buttons, the belly pack is the better choice. Keep in mind, operator preferences can vary by country and device operation time.

In choosing between models from different suppliers, look at size, weight, ergonomics, customization and branding capabilities, local supply and service, and ruggedness as the differentiators. Ruggedness refers to the device’s ingress protection ratings and ability to withstand drops and vibration.

Many OEMs looking to optimize operations and improve operator comfort and safety have already implemented remote controls. Usage is widespread and operator acceptance is high. OEMs weighing whether it’s time to move controls beyond the cab would be wise to consider the low barriers to entry and abundant benefits of radio remote controls.

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