Kalmar Crane Technology

Forum 2016

RTG Automation

Petteri Karjala – Sales Support Manager, Intelligent Crane Solutions

  Number of automated terminals
 Kalmar automation references
 Time for RTG automation
 Value for terminal operator
 RTG automation deployment paths
 The biggest must have pre-requisites
 Available automation levels
 Remote controlled RTG
 Example on where to start
 Reference case
 Automated RTG proven technology
 AutoRTG layout concepts
 Summary
Agenda
 Over 70 automation projects on radar screen by 2020

Exponential growth would more than double

the number of automated terminals by 2020
Numbers of terminals
140
120
100
80
Number 60
of brownfield
conversions expected
to grow faster than
40
completely new
terminals
20
0
Greenfields Brownfields Extensions Not known 1990 - 2000 - 2010 - E 2016 -
Source: Kalmar Business Intelligence 1999 2009 2015 2020

20 October 2016 4
 Kalmar Automation References

Kalmar automation projects

Navis only automation projects
Other automated terminals

1990- 2000- 2010- 2015- 2020-

1999 2009 2014 2019 2029
Automated terminals 4 16 17 30

Kalmar involved 1 2 5 9
?
Navis involved 0 4 7

20 October 2016 5
 Right time for RTG automation

 High-capacity stacking, low infrastructure and

flexible operation
 Fits transshipment, import/export and
intermodal terminals
 Can be applied to existing brownfield sites
using RTG:s without major infrastructure
changes or reconsideration of HT
transportation solution
 Implementation with the incremental steps
possible – risk mitigation
 Automation project can be combined with
electrification of RTG:s – implementation of
data communications to the crane

20 October 2016 6
 RTG automation - Value to terminal operator

 Containers are placed in the exact position consistently, safely, and

without lost containers
 Low initial investment cost decreases threshold towards automation
 Labor costs decrease significantly because one operator controls multiple
RTG´s (depending on automation level).
 RTG driver idle time is eliminated; human capacity and energy is
consumed only for actual moves
 Safety is increased as the operators can be placed in a separate office
building, and there is less personnel in the yard
 Ability to move cranes from block to block ensures flexibility in terminal
layout

20 October 2016 7
 RTG automation deployment paths

 Greenfield fully optimised for automation

 Crane built for automation
 Brownfield conversion from manual operations
to automated
 Step by step conversion gradually
increasing automation level
 Block by block conversion
 Possibility to choose from remote controlled to
semi-automatic or fully automatic

20 October 2016 8
 The biggest must have pre-requisites

 Safety in operations; detailed protocol planning and agreeing on

acceptable practices
 Change management of the workforce
 Data communication between RTG crane and essential Remote Control
software elements; speed of min 30Mbit/s per crane consistently and
reliably per ProfiSafe protocol
 Anti-sway being compatible for automation; in RC mode anti-sway is
largely a matter of operator convenience and work cycle time, Block
Automation mode requires highly effective anti-sway system to be
installed

20 October 2016 9
 Available automation levels
Step 3 Fully Automated
RTG

 (Future
Step-by-step approach development)
Step 2 Automated RTG  Automatic truck
is minimizing safety and
technical risks lane handling
2.1 2.2
 RC operation
Automated RTG Automated RTG
only for
 Gantry &  Gantry & Trolley
exception
Trolley moves moves automated
handling
automated  Automated pick
Step 1 Remote Controlled RTG  RC operated and ground in
pick and stack
1.1 1.2 ground  RC operated truck
Remote Remote lane and exception
Controlled RTG Controlled RTG handling
 Driver moved  Supervised gantry
to the office & Trolley moves to
Manual RTG  No interface the target location
 Auto between  TOS interface
Gantry automation  TLS
Steering system and
 Electrified TOS

20 October 2016 10
 Remote controlled RTG (Step 1.2)

Implementing Remote control and TOS – TLS (Terminal Logistic System)

interface to the RTG great benefits will be gained, such as
 Container inventory is shown in the Fleetview screen (part of TLS
architecture)
 Status of the crane visualized in Fleetview
 Detailed job description from the TOS
 Possibility to have supervised gantry & trolley moves to target location
 Driver moved to the office and does not have to be connected to
idle crane
 RC operators can focus on the jobs as they are dispatched from TOS (or
TLS Scheduler functionality)

20 October 2016 11
 Example of where to start easily
Proposal for high-level scope of work for Remote Control; - One block with two RTG´s

 Electrification of RTG´s with cable reel solution including optical fibre

connection
 Two Remote Control desks with Remote Control Center (software)
 Fleetview
 Liveview
 Central Safety PLC
 RTG crane hardware; safety PLC, cameras, crane networking
 Automatic gantry steering, data communication between cranes
and RC desks
 Installation and integration
 Software licenses
 Maintenance agreement for the entire system

20 October 2016 12
PSA Sines, Portugal
Terminal setup
 Brownfield
 RTGs and TTs
 1,100,000 TEU, planned 1,700,000 TEU
Equipment & software
 11 Kalmar remote controlled AutoRTGs
 8 Kalmar remote control consoles
 DGPS based automatic gantry steering
 Remote operator executes RTG movements
 Onboard camera system
 Kalmar TLS for fleet management
Comment
Customer faces shortage of labour due to remote location
of the port. By coverting RTG operation to remote control
one operator can control many RTGs. The target is to
have one operator per three RTGs. Long term plan is to
go gradually for full automation.
 Automated RTG proven technology

 Proven technology from other Kalmar products

 TLS is crucial part of Kalmar ASC deliveries, the exactly same platform
will be used
 Measuring systems are based on same technology as in ASC´s by
Kalmar
 TPMS (Target Positioning Measurement System)
 LPMS (Load Positioning Measurement System)
 Remote control desk and the functionalities are based on proven
technology from Kalmar ASC deliveries

20 October 2016 14
 Fully fenced AutoRTG concept

 Double truck lanes under RTG

 Possibility for trucks to pass by
each other under RTG
 Risk of RTG-truck collision
eliminated
 Reduced stacking capacity
compared to single lane setup

20 October 2016 15
 Open truck lane AutoRTG concept

 Single lane under RTG,

passing lane shared between
two blocks
 Only the container block is
fenced but truck lane is open
 less fencing
 Safe, flexible solution with anti-
collision system and additional
measures for gantry path
safety.
 Adaptable to existing RTG
layouts without lost capacity
in the RTG stacks

20 October 2016 16
 Summary

By 2020 number of automated terminals is expected to double

Feasible solution for Must have pre-requisites
 Greenfield  Detailed protocol planning and agreed
 Brownfield acceptable practices

 import/export  Change management of the workforce

 transshipment terminals  Data communication to the cranes

Different implementation strategies  Anti-sway

 Implement automation block by block Remote operation step in one block is easy
and simple way of proofing the concept in your
 Gradually increase automation level step terminal
by step
Automated and remote operated RTG´s are
based on proven technology from the ASC´s

20 October 2016 17
 Welcome to our own test site for AutoRTG located
in Tampere, Finland

20 October 2016 18