In the specialized world of pavement preservation, equipment reliability and operational efficiency directly impact project timelines, material quality, and ultimately, road longevity.

Pavement preservation requires precise control over material preparation and application. The hot-applied crack sealants and mastics must be maintained at specific temperatures and applied consistently to ensure proper adhesion and performance. The equipment responsible for heating, maintaining, and applying these materials traditionally relied on basic control systems with multiple independent gauges and limited diagnostic capabilities.

For over four decades, Crafco Inc. has established itself as a global leader in pavement preservation, pioneering innovative solutions for maintaining asphalt and concrete surfaces. Because Crafco’s sealant melters and applicators used independent control systems for different functions, it was challenging to diagnose issues when they arose. The company lacked a more integrated approach that could provide comprehensive monitoring while enhancing operational efficiency.

These limitations created several operational challenges. Without detailed diagnostic data, technicians struggled to pinpoint engine-related performance issues. Material temperature variations could affect application quality, while unexpected equipment shutdowns during operation resulted in wasted material and project delays. Additionally, the lack of historical performance data made preventive maintenance difficult to schedule effectively.

In pavement preservation, reliability isn’t just about avoiding downtime—it directly affects material quality and application consistency. Crafco needed a solution that could enhance control precision while providing actionable diagnostics.

TRANSFORMING EQUIPMENT CONTROL ARCHITECTURE

Crafco’s collaboration with Cattron began with a comprehensive assessment of operational requirements and control limitations. The solution centered on incorporating Cattron’s DynaGen TG410 engine controller, a sophisticated system designed for both mechanical and electronically governed engines.

Based on Crafco’s feedback, the transformation was significant. The company went from having a single dashboard light indicating general status to a fully equipped control center providing comprehensive engine diagnostics and operational management.

The implementation extended beyond basic engine control to encompass multiple equipment functions, creating an integrated system that enhanced operational efficiency. Key features included:

  • Real-time monitoring of critical parameters including oil pressure, engine temperature, and engine speed control of idle/rated speed, based on material temperature saving fuel operational expenses on both mechanical and electronic engines.
  • Control of burner management power on startup to avoid disturbances in the system and reliable burner management.
  • Control of air compressor on/off to prevent engine overload and ensure the compressor is enabled when engine is at full speed. The air compressor allows debris to be cleared in the pavement cracks.
  • Integration to Yanmar Stage 5 engine, Isuzu mechanical engine; one simple control solutions for all engine platforms.
  • Expandability to remote cellular connectivity as a field upgradeable option with GPS location, machine data feedback, operator alerts.
  • CAN data integration for enhanced diagnostic capabilities.
  • Material temperature-based engine speed control.
  • Automated burner system management tied to engine status.
  • Advanced fuel efficiency features including idle management.

The controller’s design, featuring conformally coated electronics and an IP-rated front enclosure, ensures uninterrupted performance in the harsh environments typical of pavement operations. Its input/output architecture, with four analog inputs and six switched outputs, provides the flexibility needed to monitor and control multiple equipment functions.

What made the TG410 particularly valuable to Crafco’s operations was its adaptability. The ability to configure the system for the application’s specific requirements allowed Crafco to address the unique operational challenges of pavement preservation equipment.

OPERATIONAL BENEFITS

The implementation of the DynaGen TG410 controller rapidly delivered significant operational benefits across Crafco’s equipment line. The most immediate impact was enhanced diagnostics, allowing operators to quickly identify potential issues before they result in equipment failures and the resulting scheduling delays.

Previously, operators had minimal insight into engine performance beyond basic warning indicators. With the DynaGen, they could access detailed diagnostic information, allowing them to address minor issues before they escalate into major problems.

This enhanced diagnostic capability has translated into reduced downtime and improved operational efficiency. When issues occur, maintenance personnel can quickly identify the root cause through detailed error codes and performance data. This targeted approach to troubleshooting has significantly reduced repair time and associated costs.

Fuel efficiency has seen notable improvements through the controller’s advanced speed management capabilities. By automatically adjusting engine speed based on material temperature and operational requirements, the system minimizes fuel consumption while maintaining optimal performance.

Crafco customers have seen approximately 15-20 percent fuel savings since implementing the TG410 controller. When considering the number of units in operation and their typical run time, this represents significant operational cost reduction.

The system has enhanced material application consistency by ensuring that  the engine is running at its full-rated speed when the material is being heated, and that the compressor is enabled to clear debris from cracks. The TG410 also makes certain that the burner control system is properly powered, avoiding possible disturbances during engine startup and initial running. 

SCALING IMPLEMENTATION SUCCESS

The scale of this implementation underscores its success. Crafco is now integrating more DynaGen controllers into its equipment line. This adoption reflects both the controller’s reliability and its tangible impact on operational efficiency.

Combined with the controller’s extensive diagnostic capabilities, the enhanced equipment reliability has transformed how Crafco approaches equipment maintenance. Rather than relying on reactive maintenance when failures occur, the system enables a more proactive approach based on performance data and early warning indicators.

Crafco’s maintenance professionals now have a much clearer picture of equipment health. This allows them to schedule maintenance based on actual operating conditions rather than arbitrary timeframes, reducing both maintenance costs and unexpected downtime.

AUTOMATION ENHANCEMENTS

The implementation has also enabled significant automation enhancements across Crafco’s equipment line. The controller manages the complex interaction between engine operation, hydraulic pumps, air compressors and burner systems, ensuring optimal coordination between these interdependent systems.

One critical automation feature prevents burner system activation until the engine has fully started, eliminating the power brownouts that previously occurred when these systems competed for electrical resources. This seemingly simple enhancement has significantly reduced electrical system issues while extending component lifespan.

The controller’s material temperature-based speed control automatically adjusts engine output to maintain optimal heating conditions. This precision not only improves material quality but also reduces the operator attention previously required to manage these parameters manually. 

about the author

Shane Samson is business development manager, engine & mobile equipment OEM for Cattron.