Professional Documents
Culture Documents
to automated
straddle carrier
terminal
Converting a manual straddle carrier
terminal to automation
Authors
Timo Alho
Michael Hickson
Tero Kokko
Tommi Pettersson
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Automation is the next
step towards improving
straddle carrier terminal
Conversion to automated
performance
Increasing the automation level of a terminal with products that automate a
single part of the operation or the whole process is recognised as the next
step towards improving performance at todays container terminals. The
benefits of automation include lower operational costs as well as improved
terminal productivity, capacity, safety and security.
In this paper, we examine several of these areas, ranging from the financial
impact of automation to terminal and infrastructure design as well as
technology options. Finally, we will look at proven results in the field.
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Sustainable terminal
automation
Automated equipment offers automated straddle carrier terminal in the future, one or more ASC
significant fuel savings through blocks can be added to increase the stacking density.
optimal driving patterns.
1.2 benefits of automated operation
An automated straddle carrier terminal offers several clear advantages
over a traditional manual straddle carrier terminal. The most immediate
and most easily quantified gain is significant savings in terminal
operating expenses such as labour and maintenance costs. Other
direct benefits include increased efficiency, more predictable operations,
higher availability, significantly improved occupational safety, better site
security and longer equipment life spans.
2. Terminal implications
2.1 Timeframes for conversion
The time required for the conversion of a manual straddle carrier
terminal to automated operation depends greatly on the specific design,
needs, operational environment and business goals of the terminal.
However, a typical timeframe for an automation conversion project
can be 12 to 18 months.
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When planning the conversion timeframe, a key consideration is
whether to optimise for maximum testing of new systems or for the swift
adoption of the new processes and organisational culture required by
automated operations. A slower transition will enable more thorough
straddle carrier terminal
Conversion to automated
The transition will also likely require changes to the terminal layout
and operating procedures. The procedures for ship-to-shore (STS)
Key priority is operation, landside interface and reefer operation will be changing
completely. Alternative processes may need to be introduced also to
carrying out handle non-standard cargo that cannot be taken into the automated
with minimal Change management of the workforce needs to be taken into account
disruption to from the very beginning. The professional profile of the people operating
and managing automated equipment will be markedly different from the
the existing staff running a manual terminal. Completely new skill sets are needed,
the terminal.
3. Infrastructure
3.1 The big picture
An automation conversion will require changes to the entire
infrastructure of the terminal. These changes need to be planned from
a wide perspective, not just focusing on the horizontal transportation
equipment. Areas to consider include:
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When handling exceptions, for example, strict safety protocols must be
developed for all activities that involve people moving in the same area
as the horizontal transport equipment. Particular attention needs to be
straddle carrier terminal
Conversion to automated
good as the An efficient automated terminal requires that business processes are
software mapped carefully. Software integration needs to take place at all levels,
from yard equipment to process automation. The complete system
controlling it. design, including all subsystems, has to be implemented according to
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a single set of business processes and exception scenarios, where the
roles and interfaces between the subsystems are clearly specified.
project requires deployments can include a number of different software versions and
releases from multiple vendors, which can all be tested beforehand with
thorough testing actual terminal data.
and simulation.
4. Navigation
4.1 Navigation technology options
Automated straddle carriers will require a navigation system that can
reliably and accurately determine the position and orientation of the
automated vehicle in the operating area. The two practical options that
are currently available are magnet and radar navigation. Both options
offer location accuracy of under a few centimetres with high reliability,
and have been proven in actual terminal operations.
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However, an important question is how future refurbishing of the
pavement will affect the magnet installation. The lifespan of the
pavement can be maximised by automatic incremental shifting of the
straddle carrier travel paths (stack shuffle).
straddle carrier terminal
Conversion to automated
Automated
5 IMU: the Inertial Measurement Unit provides three 6 Communication: vehicle communication
dimensional acceleration as well as vehicle roll, pitch and is backed by an all-weather, high-
yaw to improve the positioning accuracy and reliability. availability, secure WiFi network for
The unit is mounted either on the top (radar navigation) robust real-time navigational reporting,
straddle carrier
or on the side frame while a long-distance radio link is used
(magnet navigation). for remote Tele-Op.
1a
1a
5 6
1b
3
1a Radar: through triangulation relative to beacons
absolute vehicle positioning is obtained
(note that the alternative is the magnet ruler).
2 3
2 Hoisting Speed: 30m/min (empty) to 20m/min
and 15m/min for a 40 and 50 tonne load
3
respectively. 7
5
4 8 Encoders: measure steering
LIFTING CAPACITY angle and wheel rotation to
calculate the vehicle position.
40,000 kg 50,000 kg 4
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4.4 Other solutions
Radio-frequency identification (RFID) is occasionally used as the
navigation technology for automated horizontal transport equipment.
However, compared to magnet and radar navigation, RFID offers no
straddle carrier terminal
Conversion to automated
For the above reasons, magnet and radar navigation are currently the
best options for automated straddle carrier terminals, with the optimum
choice to be determined on a case-by-case basis.
John Mullen, MD & CEO Asciano Ltd, This LTIFR number is calculated per 1,000,000 man-hours whereas other
22/8/2012 parts of the world use per 200,000 man-hours
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Furthermore, automatic driving eliminates collisions and accidents in
the container yard, which will decrease the insurance premiums of
the terminal. The Patrick container terminal in Brisbane has reported
straddle carrier terminal
Conversion to automated
Automated
6. Maintenance
equipment Manual horizontal transportation systems will work even if the
equipment is not in perfect condition, since human operators can
always needs usually compensate for the quirks and deficiencies of each individual
to be in 100% piece of equipment. By contrast, automated equipment always needs
to be in 100% working condition to deliver its full potential.
working
condition to This requires a major change in attitude for maintenance operations.
With automated operations, the emphasis shifts to more frequent
deliver its full preventive maintenance. However, as this maintenance is usually done
potential. at planned intervals, the caused impact to the operation is minimal.
As collisions and other accidents due to human error are eliminated,
the need for ad hoc repairs is also reduced dramatically, bringing cost
savings in the long term.
7. Automating existing
equipment
The actual automation of most straddle carriers of recent models is
relatively straightforward. Electric or hydraulic steering is controlled
by onboard automation systems instead of from the cabin, while
sensors and data links are added for control, monitoring and system
diagnostics.
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Kalmar straddle carriers are available with various automation readiness
levels to meet the plans of terminals that are considering converting to
automation at some time in the future.
straddle carrier terminal
Conversion to automated
Kalmars automation solution is also suitable for use with any brand
of straddle carrier. However, there are limits due to the age and type
of straddle carriers that may not be practical and/or economical to
automate.
8. Human resources
The most significant and immediate cost savings from automation are
due to the drastically smaller number of operators required. Fleets of
dozens of straddle carriers can be handled by only a few highly skilled
operators.
IT meets contact with each other. With an automation rollout, they need to start
cooperating and form a joint team in which the skills and responsibilities
engineering. of the people match each other and mutual responsibilities are clearly
defined.
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New jobs that will need to be outsourced or insourced include
automation system specialists; system optimisation engineers; IT
system service and maintenance professionals; and instructors for
internal staff and external parties. On the other hand, significantly fewer
straddle carrier terminal
Conversion to automated
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straddle carrier terminal
Conversion to automated
10.2 integration
A key consideration in an automation project is implementation time. On
one hand, terminals seek to minimise the cost of conversion, often by
combining components from multiple vendors. On the other hand, every
interface between two systems needs to be integrated.
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completely integrated turnkey solution will be able to provide a system
that is not only deployed faster, but is also more cost-effective as a
whole, while providing lower lifetime maintenance and support costs.
straddle carrier terminal
Conversion to automated
The simpler the overall system and the fewer interfaces that need to be
integrated and tested, the faster the implementation.
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AutoStrads, and plans to implement 44 AutoStrads and real time control
systems automation at the companys Port Botany redevelopment
project in Sydney this year.
Fully
straddle carrier terminal
Conversion to automated
The fully automated container handling system was the first of its kind
automated to be built for unmanned operations. The unmanned Kalmar AutoStrads
straddle can operate 24/7 in almost any weather conditions, ensuring smooth
flow of cargo and significant cost savings. The transition to automation
carriers can can be done quickly and at low cost.
operate all
Unmanned operation cuts labour costs in the terminal. Machine hours
day, every day are minimised by employing automatic shutdown, which reduces idle
and cut labour time costs to zero. Additionally, as automated operation does not
require night-time lighting, energy savings in a 40-hectare terminal
costs. can be significant.
Fully automated straddle carriers can operate all day, every day and cut
labour costs. At Patrick a team of only four people is needed to operate
a ship-to-shore crane and the yard and stacking area.
Contact
www.kalmarglobal.com
kalmar@kalmarglobal.com
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Authors
straddle carrier terminal
Conversion to automated
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