ZPMC SMART SOLUTIONS GROUP

TECHNICAL SPECIFICATIONS
OF
AGSS AND PDS
(BASED ON DGPS)

ZPMC SMART SOLUTIONS GROUP

2017-05
 Table of Content
1. INTRODUCTION ........................................................................................................................ 3

1.1. GENERAL .......................................................................................................................... 3

1.2. OBJECTIVE ........................................................................................................................ 3

1.2.1 ABBREVIATION .................................................................................................... 3

1.3. FUNCTION INTRODUCTION ........................................................................................ 3

1.3.1 AGSS FUNCTION ................................................................................................ 3

1.3.2 PDS FUNCTION .................................................................................................. 4

1.4. RUNTIME ENVIRONMENT .......................................................................................... 4

1.5. PERFORMANCE INDICATORS ...................................................................................... 4

1.6. APPLICATION TECHNICAL DESCRIPTION ..................................................................... 5

1.7. SYSTEM BENEFITS ....................................................................................................... 5

2. DETAILED SPECIFICATION ......................................................................................................... 6

2.1 DGPS STRUCTURE ............................................................................................................. 6

2.2 DGPS BASE STATION .......................................................................................................... 7

2.2.1 EQUIPMENT INTRODUCTION.............................................................................. 7

2.2.2 INSTALLATION REQUIREMENT ............................................................................ 8

2.3 DGPS ROVER STATION ..................................................................................................... 10

3. WORKING SCHEDULE ............................................................................................................ 11

4. COOPERATION CONTENTS ...................................................................................................... 11

4.1 MAIN TASKS ................................................................................................................... 11

4.2 ASSISTANT AND SUPPORT FROM TERMINAL .................................................................. 11

4.3 OTHER ASSISTANT AND SUPPORT .......................................................................... 12

5. SPECIAL EXPLANATION ........................................................................................................... 12

6. APPENDIX .............................................................................................................................. 13
1. INTRODUCTION

1.1. GENERAL

This document defines the technical specifications of AGSS and PDS based on DGPS for
container terminals.

1.2. OBJECTIVE

It is the intent of this specification:

l To provide a description of the technical activities of engineering and design, and related
technical activities to enable customers to know detailed design and supply of the AGSS
and PDS.
l To describe the principal functions and features those are required for the proposed
AGSS and PDS function including the system structure and equipment, DGPS Base
Station and DGPS Rover Station (AGSS and PDS are running on it).
l DONN Technology is responsible for the design, construction, and commissioning of the
AGSS and PDS in accordance with the terms of the corresponding contract.

1.2.1 ABBREVIATION

l RTGC: Rubber-Tyred Gantry Crane

l QC: Quay Crane
l DGPS: Differential Global Position System
l AGSS: Automatic Gantry Steering System
l PDS: Position Detection System
l CU: Control Unit
l RU: Receiver Unit

1.3. FUNCTION INTRODUCTION

This product provides AGSS and PDS functions based on DGPS technology for RTG in container

terminals.

1.3.1 AGSS FUNCTION

Implement auto-gantry steering for RTG throughout the yard to reduce the labor intensity of
operators.
The AGSS function includes a gantry automatic correction function, gantry anti-collision
protection features, and other functions (such as the yard regional judgment and fault judgment
reminders), specifically as described below:
l Gantry Automatic Correction Function:
According to currently deviation, speed (given by operator) and movement tendency of
gantry, output the next stage of front and rear drive motor speed to achieve automatic
correction. Manual correction is the highest priority.
l Gantry Anti-collision Protection Function:
Provide a safe setting function, customer can set the value of deviation exceeds depend on
yard circumstances. Normally, 10cm gantry slow down, 20cm gantry stopped. System can
determine whether the container gantry crane for relying too close or deviate too far, and
automatically give the stop command to the PLC. System also has a minimum distance and
maximum distance stop protection.
l Yard Regional Judgment:
Automatically identify the yard area, using different correction parameters for different yard,
the yard to adapt to tilt and subsidence.
l Fault Judgment Reminders:
If the system is powered off or appears fatal fault (GPS antenna, controller, receivers, digital
radio broken, or any communication cable broken)) then cab indicator does not light green
and alarm sounds in operator's cab if course deviation exceeds +/- 100 mm.

1.3.2 PDS FUNCTION

Real time detects position of the gantry and trolley, confirm the exact location of the operated
container with TOS.
After the system is started, the Rover Station to obtain real-time precise positioning of the crane
by GPS receivers (accuracy less than 15mm). PDS building local coordinate system, the conversion
from the GPS latitude and longitude coordinates of the Rover Station to get into local coordinates
where the crane (relative coordinate system), calculate the current location of the RTG. And
according to the value of Lifting and trolley encoder, DGPS controller calculates RTG spreader
location (Stack, Bay, Lane, and Layer). In the meanwhile, it uses spreader Twist-lock signal to
determine the specific location of the current container. And send the determined current
slotting to the crane PLC and VMT. If the GPS loss signal or instability, PDS can still get the correct
container information by gantry and trolley encoder signal derivation.

1.4. RUNTIME ENVIRONMENT

The system should be installed in a dry and low electromagnetic interference environment,
usually in e-room of RTG. The operating temperature range of Rover Station is 0ć~50ć.

1.5. PERFORMANCE INDICATORS

l System initialization time: ≤ 1 minute.

l Position accuracy: <15mm, PDS reliability >99.99%, 100% if add reckoning by encoders,
position refresh rate: 1~20Hz;
l Auto-steering deviation in normal status: +-30mm, start and stop: +-80mmˈAGSS
reliability >99.8%, auto-steering controlling rate: 1~10Hz
l When start and stop, control the gantry acceleration and deceleration in 5~7 second to
protect driver system
l Auto-steering is control-transparent to the operator, up to 95% of gantry’s full speed
l Anti-collision control cooperates with PLC: if deviation is more than 100mm, alarm
sounds in operator's cab and gantry speed will be limited to half of full speed; if over 200mm,
gantry will automatic be stopped, these deviations can be configured.
l Auto adapt for reefer and normal yard, auto-support 20’, 40’ and 45’ yard
l Automatically adapt yard slope and venues height, especially good performance in old
terminals
l Linux platform in GPS controller, support remote software upgrade and configuration
update

1.6. APPLICATION TECHNICAL DESCRIPTION

In order to ensure efficient and stable system can service terminal. According to AGSS or PDS
working situation in terminal, DONN uses the following techniques for processing and
maintenance of the system during normal operation may encounter some problems.
l GLOBAL POSITIONING SYSTEM

l MOTION TRAJECTORY PREDICTION

l ENCODER DATA PROCESSING

l SIGNAL SHIELDING PROCESSING

l YARD ADAPTABILITY

l SELF-LEARNING SYSTEM

1.7. SYSTEM BENEFITS

Advancement of this system include: weather adaptive auto-correction, advanced algorithms,

fast re-acquisition, the unique control strategy, the standard interface protocol, multi-system

unified entrance. Along with real-time data collection and analysis process, adequate

protection, standard interfaces, scalability, and easy maintenance.

Deviation of the actual value results as shown below:

 
Figure 1 FAGSS deviation analysis chart of RTGC base on DGPS

2. DETAILED SPECIFICATION

The system uses the relative positioning of the precise GPS positioning method (RTK differential
positioning), composed of a Base Station and some Rover Stations, the Base Station is usually
installed in the roof of the office building, and the Rover Station is installed in the e-room of RTG.
Relative positioning (differential positioning) method is based on the observation data of the
Base Station, the Rover Station to determine the relative position compare to the observation
point.

2.1 DGPS STRUCTURE

Figure 2 Framework Principle of AGSS (Based on DGPS)

The DGPS on RTG is a GPS Rover Station, which uses two GPS receivers and its differential
positioning is done through radio data link between Rover Station and Base Station. The common
accuracy is 1cm. DGPS is composed of a control unit, two receiver units (including GPS OEM
receiver), a MDS radio, a linear DC power supply and some other supporting circuit. Its
organization is as right picture shows.
l GPS Control Unit: installed in the E-house.
l Two GPS receiver: installed in the E-house.
l Two GPS antennas:
Install on the left side (Diesel side) of the front of the gantry and the right side (E-house
side) of the rear respectively. Or install two GPS antennas on top of left and right RTG
leg in E-house side.
l Radio antenna: is responsible for the radio communication between GPS Base Station
and Rover Station, is installed at the right behind the top of the gantry.
l Cable: including GPS antenna cable, radio cable, and serial cable.

2.2 DGPS BASE STATION

The Base Station contains GPS receivers, radio modem and antennas. Base Station is use to
supplied the real-time to the differential data, in order to improve the accuracy of the data of
the Rover Station geo positioning. (For this project, the Base Station had been installed by
DONN Company during ZP08-1236 project)

2.2.1 EQUIPMENT INTRODUCTION

Figure 2 Drawings of DGPS Base Station

 Figure 3 Pictures of DGPS Base Station
According to the actual situation of and requirements of the terminal, only need to make the
Base Station in the right position, like on the top of office building.
Specifications
l Housing: Stainless steel
l Output Port: Monitor Port (Ethernet)
l Working temperature: -20 ~ +70ć
l Input voltage: 110~220V
l Power Consumption: 100W
l Weight: 20kg
l Dimensions (BOX): 750 × 680 × 200mm
l Dimensions (Backplane): 650 x 580mm
l Protection: IP65

2.2.2 INSTALLATION REQUIREMENT

Installation of Base Station should be done by Terminal, and ZPMC (DONN) will give support if
necessary.
In General, the Base Station equipment will be shipped with new RTGC. The ZPMC in site will
collect it, and DONN site engineer will check.
1. GPS and radio antennas of the Base Station needs to be placed where a height of not less
than 25 meters. Usually installed at the top of the engineering building, requiring no obstacles;
magnetic; high SNR power interference sources around. If the office building is not high enough,
a radio tower is also preferred, like below:
 Figure 4 Pictures of Base Station
2. DO NOT have any shelter around higher than GPS antenna.

Right installation Wrong installation

In upper picture, the angle of β is 15°, other things around GPS antenna should be lower than
B+E.
3. The distance between GPS antenna and the radio antenna should be more than 5M, and
make the GPS antenna higher the radio antenna. The installation like upper picture is not good.
4. After antenna installation, to ensure a certain degree of wind can withstand without shaking,
otherwise it will affect the accuracy of positioning.
5. The Base Station box should be better to install in an air-conditioned room, although it can
be installed outside like figure 4.
6. The distance between Base Station’s box and antenna bracket is better if shorter than 30
meters.
Note: Do not install the antenna at the highest point of the building to prevent lightning strikes.
2.3 DGPS ROVER STATION

Rover Station is composed of one GPS controller, two GPS receivers, two GPS antennas, radio
modem, radio antenna and power supply. Rover Station connects to PLC, control gantry goes
straight according to GPS location data and gantry command.
EQUIPMENT INTRODUCTION

Figure 5 Antenna drawings of GPS Rover Station

Figure 6 Drawings of GPS Rover Station

SPECIFICATIONS
l Housing: Steel
l Output Port: PLC and Debug port in RS232
l Working temperature: 0 ~ +50ć
l Input voltage: 110~220V
l Power Consumption: 130W
l Weight: 20~23kg
l Dimensions (BOX): 750 × 680 × 200mm
l Dimensions (Backplane): 650 x 580mm
l Protection: IP46

3. WORKING SCHEDULE

DONN’s engineer in site will work 6 days per week. If RTGC’s available for AGSS commissioning,
the calendar chart as following:
NO. Working Content Workdays
1 Establish the DGPS Base Station and test it. 2-3
2 Check the DGPS hardware on RTGs 3-4
3 Measure yard’s information and calculate parameters 10
4 Check the communication between DGPS and PLC 1-2
5 Test the DGPS functions in one of RTG 1-2
6 Test the other X RTG’s DGPS function One RTG per day
7 DGPS acceptance check 2
8 Training the Terminal’s related engineers 1
9 Signature for the Final acceptable of DGPS function 1

4. Working CONTENTS

4.1 Main TASKS

l Check the Base Station working situation

l Configure the devices (GPS UNIT, RADIO)
l Check the DGPS hardware on RTGC
l Measure yard’s information and calculate parameters
l Check the communication between DGPS and PLC
l Commission DGPS function in all of RTGC
l Training the Terminal’s related engineers

4.2 ASSISTANT AND SUPPORT FROM TERMINAL

l Arrangements of all 10 RTGCs to check the hardware of AGSS function

l Provide a RTGC to Judge the GPS antennas in one yard (with RTGC operator)
l Provide a RTG to measure the yard where will be used for AGSS (with RTGC operator)
l Arrange the yard for measurement one by one (stacked with containers is OK for us)
l Arrange the RTGC to test AGSS function (with RTGC operator)
l Arrange the yard for AGSS function commissioning
l Organize the training of personnel, and to provide training classroom

4.3 OTHER ASSISTANT AND SUPPORT

l Arrange the PLC engineer to help check the communication between DGPS and PLC
l Arrange the PLC engineer to help check the communication link from PLC to VMT

5. SPECIAL EXPLANATION

About the distance between QC and RTG

Theoretically, in order to ensure good performance of auto-steering, the distance between
RTGC and QC should be over 50 meters; otherwise QC shelter may affect GPS results. If
necessary, we will add the dead reckoning based on encoders function for double protect.
And the actual auto-steering effect is guaranteed.
Suppose RTG is too close to QC, such as the distance is less than 10 meters, or just below the QC
Ø If RTG coming from open areas without cover over and passing QC blocked area, the AGSS
function correction is no problem with dead reckoning activated;
Ø If RTG parked in the QC (GPS signal will lost), the AGSS function cannot be used in that time.
Because dead reckoning is also invalid.
In APMT Morocco terminal, we encountered the same problem. The RTGC is blocked by QCs. It is
very difficult to achieve contract requirements (100% whole yard available AGSS function). In that
case, the commissioning work spent exact six months to be finished.

To ensure auto-steering performance, we propose a minimum distance requirement 25

meters between yard and QC. According to the yard map you provide, the distance is OK in
Terminal. So AGSS function could work in that yard (nearest the QC) as following situation:
l Two GPS antennas in RTGC are installed far away from QC, like red arrows below;
l The RTGC never turn around 180 degree in these special yards near QCs.
l The distance between that yard and QC is more than 25 meters. please refer to red line
in picture below.
Note: The second and third requirements upper need confirmation from TERMINAL.

6. APPENDIX

GPS Antenna:
Width/Diameter: 185.00mm.

Height: 69.00mm.
Dimensions: 5.75 x 2.46

Weight: 0.48 kg (1.06 lb.)

Working temperature: -55 ~ +85 ć

LNA Gain: 29dB.

Environmental certified: ROHS.

Radio Antenna:
Housing: Fiber Reinforced Plastics
Nominal Impedance-Ω:50Ω

Dimensions: 1.8m
Weight: 2 kg

Working temperature: -30 ~ +60 ć

Gain - dBi: 7.8

VSWR: ≤1.5

Control Unit:
GPS Receiver Unit:

MDS Radio:

Power Supply: