A comparison of approaches to the automation of container terminals. Perpendicular [Euro Design] based on HHLA implementation vs Horizontal ATS design using large robust RMGs and industrial automation techniques.
ATS larger more automated machines = fewer machines in the design and consequently lower CAPEX and OPEX.
All machines in the ATS design are built to Severe Duty standards [CMAA or ASIE] for 25 year minimum life at or near max load capacity in continuous operation.
2. Automated Container Terminals
What Works + Why
or
Why Not
Port & Terminal Technology
International Conference & Exhibition
Houston, TX 12-13 April0 2011
Dr. Joseph H. Discenza, Automated Terminal Systems (ATS)
SmartCrane, LLC
3. Container Terminal Design
State of the Art
• Too Fragile
• Too Complex
• Too Expensive
• Too Slow
• Decreasing Cost - Benefit Ratios
• New Facility Designs Repeat the Errors of the
Past
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6. Why?
• Terminal Operations were Sub-Optimal in the First Instance
• Accretion of Methods and Subsystems
• Lack of Integration
• Piecemeal Solutions
• Keeping those Practices in Place only Embeds them Even
Further
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7. Examples
• Response to Larger Ships
• Add Ship-to-Shore Cranes
• Continue to Use High Maintenance Equipment Not
Suited to Automation; e.g., Strads + RTGs
• Add GPS, MDTs, DGPS and Associated Support
Infrastructure
• Further Elaboration of Existing Expert Systems
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8. Expert Systems
• Work WellOn Discrete Problems in a Simple Ordered
Environment [Heuristic]
• Not
so Good On Complex Large Problems in a Highly
Randomized Environment [Stochastic]
• Container Terminal Management is:
• Complex
• Stochastic
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9. What Does Work
• The
Industry has Recognized the Need to Employ Larger
More Robust Equipment - Rail Mounted Gantry Cranes
[RMGs]
• Simplify Facility Layouts
• Adopta more "Factory-Like" Approach to Processing
Containers
• All - Electric Designs
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10. Two Emerging Models
• CY Stacks Arranged Perpendicular to the Quay "End-Loaded"
• HHLA - CTA - Altenwerder
• APMT - Portsmouth
• EuroMax - Rotterdam
• ZPMC - Shanghai Prototype
• CY Stacks Arranged Horizontally to the Quay "Side-Loaded"
• Automated Terminal Systems - the Integrated Automated
Container Terminal [IACT]
• Pusan, Korea
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22. ZPMC Prototype
• Reduces
CO2 by Replacing Diesel Electric Shuttles or
AGVs with a Steel Infrastructure + More Cranes
• Attempts to Resolve the Congestion Issue But:
• Adds Machines
• Adds Complexity
• Increases Dynamic + Static Loads on the Quay
Structure
• Increases Capital Expenditure
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31. IACT
• RMG:
• Cantilever; Steel Mill Standards; SmartCrane Precision
Anti-sway Control
• STS:
• Industry Standard; High Speed; Anti-sway Control
• Truck Station:
• Short Hang; Remote or Local Operator Control
• Conveyor:
• Dual or Single Level; Fully Automated
• Shuttle Car
• Rail Car; Single or double Stack; Fully Automated
• System:
• IACT Continuous Optimization
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32. Current Methods
Euro IACT
Dual Hoist Standard Design
STS CRANE STS CRANE
Tandem Pick Dual Hoist Capable
Semi Automated
TRANSFER TO
TRANSFER TO Indexed Conveyor
STACK
STACK Automated over Land
AGVs
Fully Automated
Small RMGs
Stack Stack
Large RMGs
Transfer Strads
Operations Operations
Perpendicular
Fully Automated
Truck + Rail Operator In the Loop Truck + Rail
Manual Transfers
Semi-Automated
Industrial Design
Transfers
Computational Intelligence
Operating Operating
Expert
System System
Real-Time Process Control
Complexity High
Complexity Low
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37. The IACT Solver
• Long-Horizon Solution
• Genetic Algorithm
• Minimizes Weighted Sum of Multiple Criteria
• Produces Work Order Database
• Short-Cycle Re-plan
• When Simulation/Real Life Out of Sync
• Replaces Only Future Work Orders
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38. Genetic Algorithm
Random Solution Key n1, n2, n3....nm
Produces One Schedule w1, w2, w3....wN
“Parent” Solution Keys
Two “Child” Keys
& Two New Solutions
Save Key from “Best” Solution
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