ABB - Cranes Systems

DOC NO
Rev.
2007
Approved
ABB Automation Technologies AB,
Page: 1
Hans Cederqvist
2007-04-02
AAPA
Facilities
Engineering
Seminar
November 9,2007
Dept.: K
Hans Cederqvist
Equipment for yard

automation
Introduction & experience
2.
Automation features
3.
Crane mechanical design
2007-04-02
4.
Interfaces
5.
Conclusion
Rev.
DOC NO
2007
Approved
Page: 2
Hans Cederqvist
1.
Dept.: K
Topics
Rev.
DOC NO
2007
Approved
Page: 3
Hans Cederqvist
Dept.: K
2007-04-02
Key facts about ABB
Headquarters: Zurich, Switzerland
About 108,000 employees in

around 100 countries
Orders in 2006: $28.4 billion
Revenues in 2006: $24.4 billion
Listed on Stockholm, Swiss & New

York exchanges; traded on virt-x
Hans Cederqvist
Dept.: K
2007-04-02
ABB Crane Systems A brief history
Page: 4
Approved
Rev.
2007
Company ASEA was founded in Sweden
1897
Delivery of first crane equipment
1968
Delivery of first container crane with thyristor drives
1979
ASEA concentrates on electrical equipment

Divests mechanical part of manufacturing
1981
First sway control patents
1987
STS crane with AC drives, Electronic Load Control System
1997
Unmanned stacking cranes introduced (Singapore)
2002
CTA, Hamburg in commercial operation
2005
Order for EUROMAX
2007
DOC NO
1883
Order for TPCT/Taiwan and Busan + PNC/Korea
ABB scope
Rev.
DOC NO
2007
Approved
Page: 5
Hans Cederqvist
Dept.: K
2007-04-02
Electrical & automation equipment to crane builder:
System integration
Drives & motors (hoist, trolley, gantry)
Trafos & HV/LV switchgear
E -house
Process controllers & CMS
Interface to TOS
Sensors (LPS, TPS)
Cameras
etc
ABB Experience auto RMGs in operation
Site
Project Crane mfg
W Vehicles Yard/rail Comment
15
24
8
6
52
105
8
8
6
5
4/5
12
10
12
11
10
Rev.
DOC NO
2007
Approved
Page: 6
Hans Cederqvist
Dept.: K
2007-04-02
Singapore PSA
NKK
Singapore PSA
Mitsui
Tokyo
Wan Hai
TCM
Kaohsiung Evergreen Chin-Pan
Hamburg
CTA
Knz
T = External trucks , C = Internal chassis, A = AGVs
T/C/A
T/C/A
T/C
T/C
T/C/A
Good
Good
Slope
Fair
Bad!
Cantilever
Cantilever
Cantilever
Cantilever
Front -end
ABB Experience auto RMGs on order
Site
Rev.
2007
Approved
Page: 7
Hans Cederqvist
Dept.: K
2007-04-02
Rotterdam Euromax
Taipei
TPCT
Busan
Hanjin
Busan
PNC
DOC NO
Project Crane mfg #

ZPMC
ZPMC
ZPMC
ZPMC
58
20
42
31
151
H W Vehicles Yard/rail Comment

5
5
6
5
10
13
10
9
T/C/A
T/C
T/C
T/C
Fair
Fair
Fair
Fair
Front-end
Cantilever
Cantilever
Cantilever
DOC NO
Rev.
2007
Approved
Page: 8
Hans Cederqvist
Dept.: K
2007-04-02
CTA Hamburg - overview
52 auto RMG - 10 wide - 1 over 4/5
Commercial operation since March 2002
Capacity today about 3 TEU/year
QC productivity 25-30 mph
2007-04-02
LS truck service 20-25 min
Peak around 2000 trucks / day
Rev.
DOC NO
2007
Approved
Page: 9
Hans Cederqvist
Dept.: K
CTA - Operating experience
CTA auto RMGs
Availability > 99%
Container positioning and transport excellent

No collisions involving automatic cranes
> 15 000 000 moves
15- 20 000 moves/day for auto RMGs
Hans Cederqvist
2007-04-02
Total ARMG operating hours > 1 500 000
Dept.: K
Rev.
DOC NO
2007
Approved
Page: 10
Gantry travel distance > 8000 miles/y (13 000 km/y )
EUROMAX, Rotterdam
Owner
Hutchison Port Holdings 100%
Hong Kong
(via ECT)
Dept.: K
2007-04-02
Capacity
Phase 1:
Phase 1-4:
Rev.
DOC NO
2007
Approved
Page: 11
Hans Cederqvist
Data
Quay
Depth
2 100 000 TEU/y

5 000 000 TEU/y
1500 m
17,5 m
EUROMAX Rotterdam
2007-04-02
Rev.
DOC NO
2007
Approved
Page: 12
Hans Cederqvist
Dept.: K
Scope phase I
12 double trolley STS
4 barge/feeder QC
58 automatic RMGs
2 rail RMGs
Time-schedule:
Delivery from fall 2006 2009
Start commercial operation 2008/07
Mechanical crane part by ZPMC, Shanghai
All automation and electrical equipment from ABB
DOC NO
Rev.
2007
Approved
Page: 13
Hans Cederqvist
Dept.: K
2007-04-02
Site view 2007
DOC NO
Rev.
2007
Approved
Page: 14
Hans Cederqvist
Dept.: K
2007-04-02
EMC - Kaohsiung
DOC NO
Rev.
2007
Approved
Page: 15
Hans Cederqvist
Dept.: K
2007-04-02
EMC - Kaohsiung Auto RMGs
AUTO
All moves within marked area are fully automatic
2.
Automation features
3.
2007-04-02
4.
Interfaces
5.
Conclusion
Rev.
DOC NO
2007
Approved
Page: 16
Hans Cederqvist
1.
Dept.: K
Topics
CTA Container flow WS <-> LS

Fully automatic operation
2007-04-02
Stack 37x10x4-5
Dept.: K
Interface controlled
via manual remote
Rev.
DOC NO
2007
Approved
Page: 17
Hans Cederqvist
Fully automatic
interface
Auto RMGs on
separate tracks
Automatic Stacking
Trolley direction,
skew included
2007-04-02
Max +/- 100 mm absolute dev
Max 50 mm to underlying
Dept.: K
Max +/-100 mm absolute dev
Gantry direction
Hans Cederqvist
Rev.
DOC NO
2007
Approved
Page: 18
Max 50 mm absolute dev

Max 50 mm absolute dev
Stack reference point, absolute
Stack reference point, absolute
Automatic RMG challenge
Rev.
DOC NO
2007
Approved
Page: 19
Hans Cederqvist
Dept.: K
2007-04-02
Problems to solve
Automatic job order handling
Anti-collision between cranes
Path control for avoiding

obstacles
Efficient load control with

centimeter accuracy
Finding the target position

with centimeter accuracy
Handle ground/rail conditions
Handle crane dynamics
Automatic landing
Crane Dynamics Crane Deflection

Only Trolley & Gantry
absolute position
If positioning is made based on

gantry and trolley positions only,
Dept.: K
2007-04-02
Actual position
Requested position
Rev.
Requested
Landing position
DOC NO
2007
Rail position and slope
Trolley rail slope
Girder deflection
Gantry wheel position on rail
Trolley wheel position on rail
Structure deflection
Load center of gravity

influence on rope system
Load oscillation
Approved
Page: 20
Hans Cederqvist
With TPS measurement

relative the ground
The result will be influenced

by:
Actual
Landing position
Automation system lay-out

TOS
Remote Desk
Switch
Switch
E-House
Trolley platform
Router
Router
Switch
Switch
TPS 1
TPS 1
LPS
Hoist
position
system 1
Trolley
position
system 1
Hoist
position
system 2
Trolley
position
system 2
TCP/IP
2007-04-02
CS1
CMS
AC800
CS2
AC800
I/O
Dept.: K
I/O
Profibus
Modem
Modem
Modem
Profibus
Profibus
Hans Cederqvist
I/O
Rev.
Approved
Gantry
position
system 1
DOC NO
2007
Page: 21
Drivebus
LS
Gantry
position
system 2
Drive
WS
Modem
Positioning system is important for

automatic cranes
Most critical for the anti-collision

systems
Very important for placing first

container unless ground markers
are used.
Trolley
Reading head
Dept.: K
2007-04-02
Positioning System Absolute Position
Hans Cederqvist
Magnets
Rev.
DOC NO
2007
Approved
Page: 22
Measuring
wheel
Gantry
Optical system for calibration
Encoder for precise

positioning
ABB - Crane Sensor System
Dept.: K
2007-04-02
Developed by ABB crane

organization
More than 200 systems in

operation
In operation since 1988
Target Position Sensor
Developed by ABB crane

organization
More than 200 systems in

operation
In operation since 1997
Rev.
DOC NO
2007
Approved
Page: 23
Hans Cederqvist
Load Position Sensor
Load position control system (LPS)
Rev.
DOC NO
2007
Approved
Page: 24
Hans Cederqvist
Dept.: K
2007-04-02
Control of the load position

and motion relative trolley
position
Sway control
Positioning / Path control
Skew control
4 "directions":
Trolley position
Gantry position
Hoist position
Skew angle
Rev.
DOC NO
2007
Approved
Page: 25
Hans Cederqvist
Dept.: K
2007-04-02
Target Position Sensor (TPS)
Anti collision (stack, vehicles)
Stack position measurement
Stack profile scanning
Vehicle position measurement

(AGV/truck/chassis)
DOC NO
Rev.
2007
Approved
Page: 26
Hans Cederqvist
Dept.: K
2007-04-02
TPS job order

Pick up anticollision scan
TPS2
TPS1
DOC NO
Rev.
2007
Approved
Page: 27
Hans Cederqvist
Dept.: K
2007-04-02
TPS job order

Pick up anticollision scan
DOC NO
Rev.
2007
Approved
Page: 28
Hans Cederqvist
Dept.: K
2007-04-02
TPS job order

Pick up fine alignment in gantry direction
DOC NO
Rev.
2007
Approved
Page: 29
Hans Cederqvist
Dept.: K
2007-04-02
TPS job order

Pick up fine alignment in trolley direction
Find position of top container
TPS job order

Set down fine alignment in trolley direction
Rev.
DOC NO
2007
Approved
Page: 30
Hans Cederqvist
Dept.: K
2007-04-02
Find position of top and bottom container
TPS job order
Rev.
DOC NO
2007
Approved
Page: 31
Hans Cederqvist
Dept.: K
2007-04-02
Set down measure difference between

reference and landed container
Set down redo landing if necessary
Solution for very demanding yard/rail conditions
2007-04-02
Dept.: K
Hans Cederqvist
Page: 32
Approved
Rev.
2007
TPS
Ground markers
Used to determine the

position of the first
container
DOC NO
Remote Control Cameras On Crane

Fixed cameras on the
trolley
Dept.: K
2007-04-02
Four fixed cameras

on the spreader
Rev.
DOC NO
2007
Approved
Page: 33
Hans Cederqvist
SCANIA
Rev.
Approved
Good,
DOC NO
2007
Page: 34
Hans Cederqvist
Dept.: K
2007-04-02
Remote Control
office style working environment

Adjustable seat and control desk
Remote operator can sit or stand
2.
Automation features
3.
2007-04-02
4.
Interfaces
5.
Conclusion
Rev.
DOC NO
2007
Approved
Page: 35
Hans Cederqvist
1.
Dept.: K
Topics
Rev.
DOC NO
2007
Approved
Page: 36
Hans Cederqvist
Dept.: K
2007-04-02
EUROMAX - ARMG (ZPMC)
rope tower
rail gauge 32,3 m
lifting height 18,1 m
gantry 4,5 m/s

trolley 1 m/s
hoist 1,5 m/s
DOC NO
Rev.
2007
Approved
Page: 37
Hans Cederqvist
Dept.: K
2007-04-02
CTA - ARMG block (Knz,Austria)
DOC NO
Rev.
2007
Approved
Page: 38
Hans Cederqvist
Dept.: K
2007-04-02
Taiwan auto CRMG (ZPMC and local crane mfg)
DOC NO
Rev.
2007
Approved
Page: 39
Hans Cederqvist
Dept.: K
2007-04-02
US/Kone reeving and micro-motion
Width 8 13 containers
Height 4 8
Single beam & double beam
Weight : 170 390 tons
Hinged /fixed leg & fixed legs only
Gantry wheels : 8 - 16
Gantry speeds up to 1000 feet/min (5 m/s)
Hans Cederqvist
Rope reeving : rope tower / straight ropes with sheaves
Micro motion : hydraulic/electric/auxiliary ropes
Front / side loading
Rev.
DOC NO
2007
Approved
Dept.: K
2007-04-02
Page: 40
Mechanical crane designs for automation

-
2.
Automation features
3.
2007-04-02
4.
Interfaces
5.
Conclusion
Rev.
DOC NO
2007
Approved
Page: 41
Hans Cederqvist
1.
Dept.: K
Topics
Hans Cederqvist
Dept.: K
2007-04-02
Stacking
Container position should be checked after

each landing. Effects of leaning ground to
be handled.
Minimum distance between the stacks is

affected by:
Accuracy of the first container placement
Size of cameras and guides on spreader
Approved
Page: 42
(350 450 mm) trade off with cycle time.
Rev.
2007
Stacks are built to a vertical reference
Typical distance between stacks is 14- 18.
DOC NO
Automatic stacking better than manual.
DOC NO
Rev.
2007
Approved
Page: 43
Hans Cederqvist
Dept.: K
2007-04-02
Staggered stacking
Yard slope up to about 1,0 %
400 mm yard slope!
DOC NO
Rev.
2007
Approved
Page: 44
Hans Cederqvist
Dept.: K
2007-04-02
Ground conditions - the rail challenge
Test track in CTA for

performance test !
Yard Preparation CTA experiences
Rev.
DOC NO
2007
Approved
Page: 45
Hans Cederqvist
Dept.: K
2007-04-02
Due to land-fill in the yard difficult soil conditions were expected
Simple and adjustable rail + sleeper design employed
Much larger tolerances than typical in land moving direction

specified (5 10X)
The RMGs were tested on rails prepared with max specified

geometry
Worst conditions due to that the two RMGs operate on different rail
tracks (span 31 & 40,1 m)
Specified function made possible by forgiving RMG design
No piling required!
Yard Preparation Test in CTA 2002

Rails
Railslocated
locatedat
atmaximum
maximumallowable
allowabletolerances
tolerancesfor
fortesting
testingpurposes
purposes
Dept.: K
2007-04-02
Designations
Designationsaccording
according
to
toVDI
VDI3576
3576
Rev.
DOC NO
2007
Approved
Page: 46
Hans Cederqvist
A+B
D+
E
Technical Data Rail Tolerances
CTA - Tolerances
VDI 3567
A = +/- (5+0,25 * (s-15)

mm
(3+0,25 * (s-15) mm
Position of rail in ground

plan
B = +/- 10 mm
b = 1 mm
+/- 5 mm
Height of the rail (axial

slope)
C = +/- 100 mm
c = 50 mm
+/-10 mm
c = 2 mm
Hans Cederqvist
Dept.: K
2007-04-02
Track gauge centre
Rev.
DOC NO
2007
Approved
Page: 47
Height of the rail to each

other (lateral slope)
Inclination of the rails to
each other (converging)
Dmax = +/- 100 mm
E = +/- 1%
+/-10 mm
0,5%
DOC NO
Rev.
2007
Approved
Page: 48
Hans Cederqvist
Dept.: K
2007-04-02
CTA, Hamburg Truck interface
DOC NO
Rev.
2007
Approved
Page: 49
Hans Cederqvist
Dept.: K
2007-04-02
CTA, Hamburg AGV interface
DOC NO
Rev.
2007
Approved
Page: 50
Hans Cederqvist
Dept.: K
2007-04-02
EMC - Kaohsiung
DOC NO
Rev.
2007
Approved
Page: 51
Hans Cederqvist
Dept.: K
2007-04-02
Transfer Zone (TZ)
Interface to vehicles
AGVs fully automatic
Shuttle carriers fully automatic
Internal tractors/chassis fully automatic with supervision
Road trucks manual set-down/pick-up via cameras
2007-04-02
Dept.: K
Positioning requirements:
Front - loading
Hans Cederqvist
Side loading
Rev.
2007
Approved
Page: 52
DOC NO
Within lane
+/- 200 mm for min cycle time
DOC NO
Rev.
2007
Approved
Page: 53
Hans Cederqvist
Dept.: K
2007-04-02
Communication
Rev.
DOC NO
2007
Approved
Page: 54
Hans Cederqvist
Dept.: K
2007-04-02
TLC <-> automatic RMG
Work order received by the

crane
Crane automatically moves to

the target destination
After work order is completed a

job performed message is sent
Block modification message
Status message triggered on

predefined events
TLC
Task division TLC/RMG
2007-04-02
Dept.: K
Hans Cederqvist
Rev.
Approved
DOC NO
2007
Page: 55
Decide container location in stack

Issue work-order
Confirm work-order
Calculate optimal path
Control crane movements
Confirm stack profile
Confirm storage conditions
Crane-crane optimization
Crane-crane collision avoidance
Confirm container location
Report work-order finalized
Up-date block map
Request manual intervention
TLC
X
X
RMG
X
X
X
X
X
X
X
X
X
X
X
2.
Automation features
3.
2007-04-02
4.
Interfaces
5.
Conclusion
Rev.
DOC NO
2007
Approved
Page: 56
Hans Cederqvist
1.
Dept.: K
Topics
DOC NO
Rev.
2007
Approved
Page: 57
Hans Cederqvist
Dept.: K
2007-04-02
Requirements on crane design I
Precise positioning systems
-> to minimize cycle time

2007-04-02
Rev.
2007
Approved
Page: 58
Hans Cederqvist
Dept.: K
-> to work with the forces of nature
DOC NO
Possibility to accommodate for changing geometry

2007-04-02
Dept.: K
Hans Cederqvist
Page: 59
Approved
Rev.
2007
Mechanically robust
- > to allow operation in high winds
DOC NO

2007-04-02
Dept.: K
Mechanically robust
Hans Cederqvist
- > to allow operation in high winds
Rev.
2007
Approved
Page: 60
-> to facilitate a high availability
DOC NO
High quality
DOC NO
Rev.
2007
Approved
Page: 61
Hans Cederqvist
Dept.: K
2007-04-02
Requirements on crane design II
Proper installation
- > no unexpected disturbances
Proper installation

2007-04-02
Rev.
2007
Approved
Page: 62
Hans Cederqvist
Dept.: K
- > no driver on the crane
DOC NO
Efficient Crane Management System (CMS)
Proper installation

2007-04-02
Dept.: K
Rev.
2007
Approved
Page: 63
Hans Cederqvist
- > to ensure a high productivity
DOC NO
Possibility to handle work orders from TOS/TLC
Proper installation

2007-04-02
Dept.: K
Hans Cederqvist
- > to ensure a high productivity

Proper camera surveillance system
Approved
-> to minimize time for manual operation

Rev.
2007
Page: 64
DOC NO
Possibility to handle work orders from TOS/TLC
Rev.
DOC NO
2007
Approved
Page: 65
Hans Cederqvist
Dept.: K
2007-04-02
Conclusion
Automated crane designs exist that can fit basically

any type of terminal (lay-out, operational mode, etc)
The challenge is the systematic approach required

(planning, exception handling etc)
The cooperation auto RMG and TLC/TOS is vital
The automation concept must be able to handle

unexpected conditions, rails, yard, wheather etc

ABB - Cranes Systems

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DOC NO

ABB Automation Technologies AB,

Equipment for yard

Introduction & experience

Crane mechanical design

ABB Automation Technologies AB,

ABB Automation Technologies AB,

Key facts about ABB

Headquarters: Zurich, Switzerland

About 108,000 employees in

Orders in 2006: $28.4 billion

Revenues in 2006: $24.4 billion

Listed on Stockholm, Swiss & New

ABB Crane Systems A brief history

Company ASEA was founded in Sweden

Delivery of first crane equipment

Delivery of first container crane with thyristor drives

ASEA concentrates on electrical equipment

First sway control patents

STS crane with AC drives, Electronic Load Control System

Unmanned stacking cranes introduced (Singapore)

CTA, Hamburg in commercial operation

Order for EUROMAX

ABB Automation Technologies AB,

Order for TPCT/Taiwan and Busan + PNC/Korea

ABB Automation Technologies AB,

Electrical & automation equipment to crane builder:

Drives & motors (hoist, trolley, gantry)

Trafos & HV/LV switchgear

Process controllers & CMS

Sensors (LPS, TPS)

ABB Experience auto RMGs in operation

Project Crane mfg

W Vehicles Yard/rail Comment

ABB Automation Technologies AB,

T = External trucks , C = Internal chassis, A = AGVs

ABB Experience auto RMGs on order

ABB Automation Technologies AB,

Project Crane mfg #

H W Vehicles Yard/rail Comment

ABB Automation Technologies AB,

CTA Hamburg - overview

52 auto RMG - 10 wide - 1 over 4/5

Commercial operation since March 2002

Capacity today about 3 TEU/year

QC productivity 25-30 mph

LS truck service 20-25 min

Peak around 2000 trucks / day

ABB Automation Technologies AB,

CTA - Operating experience

CTA auto RMGs

Availability > 99%

Container positioning and transport excellent

> 15 000 000 moves

15- 20 000 moves/day for auto RMGs

Total ARMG operating hours > 1 500 000

ABB Automation Technologies AB,

Gantry travel distance > 8000 miles/y (13 000 km/y )

ABB Automation Technologies AB,

2 100 000 TEU/y

ABB Automation Technologies AB,

12 double trolley STS

Delivery from fall 2006 2009

Start commercial operation 2008/07