SICK PORT AUTOMATION AND RISK REDUCTION AT PORTS AND TERMINALS ARE NOT AT ODDS User guide

INDUSTRY GUIDE

PORT

AUTOMATION AND RISK REDUCTION AT PORTS

AND TERMINALS ARE NOT AT ODDS

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TABLE OF CONTENTS

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Tasks

Challenges in ports 4

Applications in focus

The application graphics shown are not binding, they are no substitute

for the need to seek expert technical advice.

Quay area 8

Yard area 12

Ground transportation 16

Intermodal area 18

Collision awareness in ports 20

Products

Product overview 22

General information

Company 42

Industries 44

SICK LifeTime Services 46

Versatile product range for industrial automation 48

Industrial communication and device integration 52

Services 55

TABLE OF CONTENTS

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CHALLENGES IN PORTS

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Automation and risk reduction at ports

and terminals are not at odds

A high level of terminal automation across the board and risk reduction

are increasingly driving port operators worldwide. SICK offers support in

connection with the identication, detection, measurement, protection

and collision prevention of goods, cranes, crane booms, containers, and

essential port equipment. With its comprehensive and detailed industry

knowledge, SICK has become the number one partner for sensor solu-

tions in port processes. Innovative, fast development and implemen tation

of comprehensive customer-tailored solutions – this is where SICK‘s

strength resides.

Position detection

SICK’s sensors assist in correctly positioning and detecting

freight and other objects They determine data and transmit

it to the relevant controller to ensure that every item of cargo

reaches its destination in one piece.

Protection

Avoiding collisions involving containers, cranes, and other

objects is the highest priority when it comes to port logistics.

Specic demands are placed on sensors in order to guarantee

the level of outdoor safety and security required in ports, and

SICK is perfectly placed to respond with its many years of

experience and the innovative solutions it has to offer.

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CHALLENGES IN PORTS

Detection

SICK’s sensors provide assistance for controlling and

maneuvering cranes and other vehicles. They detect containers

and bulk materials that are to be picked up by transportation

equipment and can determine whether there are objects in the

vicinity of moving vehicles.

Measurement

Sensors and sensor systems measure the dimensions, con-

tours, speeds, and distances involved in freight positioning,

thereby optimizing transport routes and increasing handling

safety for crane operators.

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APPLICATIONS IN FOCUS

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APPLICATIONS IN FOCUS

Applications in focus

Focus 1 8

Quay area

Focus 2 12

Yard area

Focus 3 16

Ground transportation

Focus 4 18

Intermodal area

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Focus 1: Quay area

Quay area

It is essential that collision avoidance

and efciency are provided on quay

cranes, as larger vessels are launched

and avoiding damage are of paramount

importance – especially since the num-

ber of automated ship-to-shore cranes

continues to increase. SICK’s sensors

determine the contour and position to

enable them to operate economically

and without any damage being caused.

1

Collision avoidance on ship-to-shore crane booms

and between adjacent cranes

The AOS502 STS securely and reliably

detects ship superstructures on ship-to-

shore container cranes, such as radar

systems. By analyzing the various laser

scanner warning and stopping elds,

the AOS502 STS provides collision

avoidance from crane to crane as well

as boom to object. The safety controller

and integrated control software monitor

the system functions.

AOS Prime g p. 40

2

Distinctionofdierentcontainer

lengths

The TiM3xx laser scanner in the spread-

er can distinguish between one 40 foot

container and two 20 foot containers

because it can detect the gap between

two 20 foot containers without mak-

ing contact. The crane controller reads

the sensor outputs to check that the

spreader retention device is correctly

aligned for each container.

TiM3xx g p. 24

1

2

3

4

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Focus 1: Quay area

3

Collision avoidance on the path

of a ship-to-shore crane by means

of laser scanner

The LMS111 2D laser scanner can

be relied upon to help avoid collisions

between the crane and other objects.

The laser scanner has an innitely ex-

ible 2D scanning detection eld of up to

20 m and can monitor areas precisely

dened in terms of their length and

width.

LMS1xx g p. 26

4

Collision avoidance on the path

of a ship-to-shore crane by means

of radar

An economical solution, the RAS4xx

radar sensor has detection ranges that

extend to a length of up to 20 m. It

assists the crane operator in monitoring

the travel path and helps avoid collisions

between the crane and other objects.

RAS4xx g p. 33

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Focus 1: Quay area

5

Shipmentproledetermination

The LD-LRS 2D laser scanner is in-

stalled on the trolley to help position

the spreader as it moves over the cargo

hold. The trolley’s position and the laser

scanner’s distance measurements are

combined to create a dynamic 2D prole

of the vessel and its contents. This

data is then used together with control

software to assist the crane operator

in handling containers smoothly and

efciently.

LD-LRS g p. 32

6

Adjustment of the spreader for con-

tainersofdierentsizes

The spreader needs to be adjusted for

containers of different sizes. A rotary

encoder system determines the posi-

tion of the retention devices in order to

prevent damage that may be caused by

falling containers.

A3M60 PROFIBUS g p. 37

6

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Focus 1: Quay area

7

Access protection at lashing platforms

It is becoming increasingly common

to see ship-to-shore cranes tted with

platforms for handling twist locks.

Suspended containers pose a danger

to stevedores and others, so danger-

ous crane movement needs to be

stopped when anybody they access a

lashing platform accidentally. Multiple

light beam safety devices, such as the

M4000 Standard with heated device

columns, provide reliable access protec-

tion.

M4000 Standard g p. 38

5

7

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Focus 2: Yard area

Yard area

Different vehicles are used to handle

containers depending on the volume

of freight. For example, manned forklift

trucks are sufcient for smaller volumes,

while manned gantry cranes and then

unmanned automated stacking cranes

are required as container volume

increases. The level of automation and

requirements for protection increase

as the number of handled containers

increases.

1

Collision avoidance on a rubber

tired gantry crane

A reliable solution for preventing gantry

crane collisions is the AOS104 RTG

object detection system consisting of a

2D laser scanner and a safety control-

ler. The 2D laser scanner helps prevent

collisions between the crane and other

objects along the crane’s path as well as

assists the crane operator in monitoring

the route to be traveled and during cross

travel.

AOS Prime g p. 40

2

Yardareaproledetermination

The LMS511 2D laser scanner scans the

container stack below the gantry crane,

then the measurement points are used

to create a contour prole of the contain-

er stack. This is then used as the basis

for further software processing so as to

avoid collisions when using the spreader

to pick up and set down containers.

LMS511 g p. 28

3

Collision avoidance for

rail mounted gantry cranes

The DMT10-2 long range distance

sensor constantly measures the

distance between rail mounted cranes.

If the distance between two cranes is

too small, the DMT10-2 sends a signal

to slow down or stop the crane. This

distance sensor performs highly accu-

rate non-contact measurements.

DMT10-2 g p. 34

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Focus 2: Yard area

4

Access control at automated stacking crane (ASC)

In ports, interaction between man

and machine can be dangerous. For

example, truck drivers and straddle

carrier operators deliver containers

below an automated stacking crane.

Vehicle access can be enforced when a

laser scanner is positioned to create a

vertical monitoring area and an over-

height object can be detected when a

laser scanner is positioned to create a

horizontal monitoring area. The crane is

stopped to avoid collisions with vehicles.

If the crane is already located within

the transfer area, vehicles will be given

a stop signal at the entrance. The Flexi

Soft safety controller processes any sig-

nals and transmits them to the system

controller. The system can be expanded

with RFID, GPS, and other sensor types

to enable vehicle identication when

automated guided vehicles (AGVs) are

in use.

AOS Prime g p. 40

2

3

4

1

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Focus 2: Yard area

5

Prevention of tractor trailers being lifted by gantry cranes

When gantry cranes lift containers

from trucks, sometimes the truck

itself is lifted, too. There is a simple

solution available to detect when this

is happening – installing the LMS111

2D laser scanner next to the gantry

crane’s driving path. The LMS111 moni-

tors the area around the lorry’s front

and rear wheels at about 30 cm above

the ground when containers are being

unloaded. If the lorry starts to move

upward as the gantry crane lifts a con-

tainer, the crane operator will be sent

a signal to notify them of this and the

unloading process can be stopped.

LMS1xx g p. 26

6

Position determinaton of trolleys

The KH53 linear encoder operates

magnetically and is the ideal solution

for use in harsh environments and over

long distances. The position data of the

traveling crane determined by the KH53

makes it possible to stack containers

with as little offset as possible.

KH53 g p. 35

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Focus 2: Yard area

7

Electriedrubbertiredgantrycranelaneassistance

Electried gantry cranes must be kept a

certain distance away from the bus bar

in order to maintain the correct electri-

cal contact or to prevent damages.

Optical distance sensors are used to

perform non-contact measurements

near the bus bar. The DT35 distance

sensor measures the distance between

the bus bar and a point on the gantry

crane. When the rail surface is uneven,

a laser scanner is an excellent alterna-

tive. A laser scanner scans the bus bar

and the area surrounding it in real time

without any mechanical adjustments

and provides many more measurement

data points between the bus bar and

the crane. The crane controller can then

correct the distance immediately if it is

not correct. Laser scanners also provide

collision avoidance in the crane’s direc-

tion of travel.

Dx35 g p. 30

5

This graphic is not presented in the overview.

6

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Focus 3: Ground transportation

Ground transportation

Straddle carriers, automated guided

vehicles, terminal tractors, and heavy

trucks are used to transport containers

between several different areas in the

container yard. While some of these

moves are automated, others are not

and benet from sensors that assist in

operator performance and productivity.

SICK’s sensors are here to help.

1

Driver assistance using a laser

scanner on a reach stacker

The RAS Prime collision awareness

system monitors the entire area behind

a reach stacker without interruption –

during the day and night. If an object

enters the precongured warning elds,

RAS Prime alerts the operator with

visual and audible signals. Real-time

laser scans provide assistance in all

driving situations.

RAS Prime g p. 41

2

Protection of automated guided

vehicles (AGVs)

The AOS502 Prime advanced object

detection system avoids collisions

between automated guided vehicles and

other objects within the container yard.

When objects are detected in the moni-

tored areas, the AGV is slowed down or

stopped.

AOS Prime g p. 40

3

Length measurement on the boom

of a reach stacker

The BTF wire draw encoder measures

how far a reach stacker’s boom has

been extended. (90)

HighLine g p. 36

2

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Focus 3: Ground transportation

1

2

3

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Focus 4: Intermodal area

Intermodal area

Containers are transported at inter-

modal terminals and container yards

ready for shipment, with their onward

transportation generally taking place

on inland routes via river, rail or trucks.

SICK’s sensors assist in the highly auto-

mated processes involved in loading the

containers.

1

Determination of the spreader

height position

The DMT10-2 long range distance

sensor continuously transmits accurate

information about the height of the

spreader to avoid the spreader collid-

ing with container stacks. Best-suited

for outdoor environments, this sensor

performs highly accurate non-contact

measurements.

DMT10-2 g p. 34

2

Access protection

It is important to prevent access to

a dangerous area until all dangerous

movements are completed. The i110

Lock electro-mechanical safety locking

device protects access points against

unauthorized entry.

i110 Lock g p. 39

3

Collision avoidance

To help the crane operator avoid colli-

sions with objects on the route, the AOS

Prime object detection system provides

a reliable solution.

AOS Prime g p. 40

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Focus 4: Intermodal area

1

2

4

Position determinaton of trolleys

The KH53 linear encoder operates

magnetically and is the ideal solution

for use in harsh environments and over

long distances. The position data of the

traveling crane determined by the KH53

makes it possible to stack containers

with as little offset as possible.

KH53 g p. 35

3

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COLLISION AWARENESS IN PORTS

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Minimizing the risk of damage and preventing accidents

In order to reduce the risk of damage, port operators take organizational measures, such as

arranging regular training sessions which includes specic handling instructions. Port operators

also have to dene the areas in which people are permitted access – and those in which they

are not. As well as these measures, automated systems must include complete collision avoid-

ance systems. SICK has a wide range of sensors and sensor solutions available for overcoming

the challenges faced in ports and minimizing the risk of damage, such as its AOS Prime object

detection system.

1 %

Stack collisions

9 %

11 %

71 %

Spreader / twistlock issues

Gantry collisions

Others

Boom collisions

Other collisions (gantry, etc.)

Other spreader, hoist issues

Weight, twistlock, cell guide

Stack collisions

Twin-twenty issues

Others

32 %

17 %

12 %

13 %

17 %

6 %

3 %

Analysis – Yard crane claim costs distribution Analysis – Quay crane claim costs distribution

Source: Global analysis claims data (2010 – 2014), TT Club

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SICK PORT AUTOMATION AND RISK REDUCTION AT PORTS AND TERMINALS ARE NOT AT ODDS User guide

SICK PORT AUTOMATION AND RISK REDUCTION AT PORTS AND TERMINALS ARE NOT AT ODDS User guide

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