Kalmar has designed and built a state-of-the-art automation test facility to better aid the integration of its intelligent applications with its customers’ container handling equipment and terminal operating systems. The ability to test the control system prior to delivery will enable Kalmar to troubleshoot possible technical problems before field tests are conducted, thus helping to streamline the process of automating a customer’s operations.
The facility – located in Kalmar’s Tampere, Finland factory – will first test the automation and control systems developed for HHLA’s conversion of Container Terminal Burchardkai (CTB) from straddle carriers to automatic stacking cranes (ASC). In phase one of the terminal conversion, Kalmar will equip the first five yard stacking blocks with 15 ASCs, along with their automation and control systems, during 2007 and 2008. The Port of Hamburg’s biggest container terminal operator plans to increase its handling capacity from 2.7 million TEU in 2005 to 5.2 million TEU by 2015.
To test the automation applications developed for the CTB project, a computer simulation of a block stacking area with three ASC cranes was created to represent the terminal layout as it has been designed in Hamburg. Using this simulator, Kalmar can test the operation of the machine controls and the supervisory control system, which is responsible for commanding the cranes.
The crane block simulator can also be used to train operators on the remote control systems for loading and unloading trucks at the landside operation. At CTB, the crane operators will be located at the terminal’s central control tower where they will utilise the spreader and overhead camera systems to monitor tasks.
For the first time in the container handling industry, Kalmar will use a supervisory control system – a typical solution for the process industries – to manage CTB’s crane blocks. The control system will distribute and implement the job orders from the terminal operating system safely, effectively and economically. It will also send back real-time information about the cranes, container stacks and ongoing events. Sophisticated measurement systems will feed information to the supervisory control system, which with high computing power makes decisions for job selection, routing and collision avoidance.
Although in its early phase, automation has already proven its worth when resolving a number of terminal operating dilemmas – from increasing productivity needs and addressing labour shortages to controlling costs and fulfilling environmental responsibilities.
Projects for fully-automated terminals began in the 1990s, but in December 2005, automation showcased its full potential when, in association with Kalmar, Patrick Stevedores accomplished its long-term goal of opening the world’s first large-scale fully automated straddle carrier (AutoStrad®) terminal in Brisbane, Australia.
Employing 18 unmanned electric straddle carriers, the facility operates 24 hours a day, 365 days a year in nearly all weather conditions. Each machine has the capacity equal to that of a conventional straddle carrier and the ability to achieve a duty cycle exceeding that of a manned vehicle. Because the machines are controlled with precision and follow a set work schedule, Patrick has achieved a smoother overall operation, a reduction in fuel and maintenance costs, and a greatly improved safety record.
In 2005, Kalmar created a dedicated business unit, Kalmar Intelligence & Automation, to focus on the marketing and development of on-board smart features for container handling equipment, integrated systems and remote maintenance products in cooperation with customers and partners. Since its inception, the unit has tripled its resources due to the fact that more customers worldwide are seeking productive solutions like container verification and positioning systems and remote service monitoring software.
Kalmar’s range of innovative onboard products and automated systems today includes:
* Fleetview: a real-time monitoring system that optimises the deployment of container yard equipment.
* Smartrail®: an autosteering and container position verification system for RTGs.
* Smartpath®: a container position verification system for straddle carriers and RTGs.
* Remote Machine Interface (RMI): a tool for remote machine monitoring, maintenance tasking and reporting suitable for use with all Kalmar equipment.
* Automatic stacking cranes (ASC): an automated handling solution providing high productivity and stacking density for large terminals.
The facility – located in Kalmar’s Tampere, Finland factory – will first test the automation and control systems developed for HHLA’s conversion of Container Terminal Burchardkai (CTB) from straddle carriers to automatic stacking cranes (ASC). In phase one of the terminal conversion, Kalmar will equip the first five yard stacking blocks with 15 ASCs, along with their automation and control systems, during 2007 and 2008. The Port of Hamburg’s biggest container terminal operator plans to increase its handling capacity from 2.7 million TEU in 2005 to 5.2 million TEU by 2015.
To test the automation applications developed for the CTB project, a computer simulation of a block stacking area with three ASC cranes was created to represent the terminal layout as it has been designed in Hamburg. Using this simulator, Kalmar can test the operation of the machine controls and the supervisory control system, which is responsible for commanding the cranes.
The crane block simulator can also be used to train operators on the remote control systems for loading and unloading trucks at the landside operation. At CTB, the crane operators will be located at the terminal’s central control tower where they will utilise the spreader and overhead camera systems to monitor tasks.
For the first time in the container handling industry, Kalmar will use a supervisory control system – a typical solution for the process industries – to manage CTB’s crane blocks. The control system will distribute and implement the job orders from the terminal operating system safely, effectively and economically. It will also send back real-time information about the cranes, container stacks and ongoing events. Sophisticated measurement systems will feed information to the supervisory control system, which with high computing power makes decisions for job selection, routing and collision avoidance.
Although in its early phase, automation has already proven its worth when resolving a number of terminal operating dilemmas – from increasing productivity needs and addressing labour shortages to controlling costs and fulfilling environmental responsibilities.
Projects for fully-automated terminals began in the 1990s, but in December 2005, automation showcased its full potential when, in association with Kalmar, Patrick Stevedores accomplished its long-term goal of opening the world’s first large-scale fully automated straddle carrier (AutoStrad®) terminal in Brisbane, Australia.
Employing 18 unmanned electric straddle carriers, the facility operates 24 hours a day, 365 days a year in nearly all weather conditions. Each machine has the capacity equal to that of a conventional straddle carrier and the ability to achieve a duty cycle exceeding that of a manned vehicle. Because the machines are controlled with precision and follow a set work schedule, Patrick has achieved a smoother overall operation, a reduction in fuel and maintenance costs, and a greatly improved safety record.
In 2005, Kalmar created a dedicated business unit, Kalmar Intelligence & Automation, to focus on the marketing and development of on-board smart features for container handling equipment, integrated systems and remote maintenance products in cooperation with customers and partners. Since its inception, the unit has tripled its resources due to the fact that more customers worldwide are seeking productive solutions like container verification and positioning systems and remote service monitoring software.
Kalmar’s range of innovative onboard products and automated systems today includes:
* Fleetview: a real-time monitoring system that optimises the deployment of container yard equipment.
* Smartrail®: an autosteering and container position verification system for RTGs.
* Smartpath®: a container position verification system for straddle carriers and RTGs.
* Remote Machine Interface (RMI): a tool for remote machine monitoring, maintenance tasking and reporting suitable for use with all Kalmar equipment.
* Automatic stacking cranes (ASC): an automated handling solution providing high productivity and stacking density for large terminals.