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Application of GPS on Yard Cranes Abstract: GPS is a satellite navigation and positioning system developed by America. Through 24 satellites evenly distributed in the air, the system ensures that positioning information could be well received all over the world at any time. Since the system was put into operation, it has been widely applied to uses such as oil surveying, ship and aircraft navigation, construction positioning and military operation. Key Words: GPS , cranes, Port Machinery GPS is a satellite navigation and positioning system developed by America. Through 24 satellites evenly distributed in the air, the system ensures that positioning information could be well received all over the world at any time. Since the system was put into operation, it has been widely applied to uses such as oil surveying, ship and aircraft navigation, construction positioning and military operation. ZPMC began the study of GPS application on yard cranes two years ago with the purpose of providing the RTG with functions such as reliable straight traveling of gantry and automatic container management like RMG (Rail Mounted Crane) while keeping the RTG of its flexibility on yard changing(through longitudinal traveling). The GPS products developed by ZPMC have a positioning accuracy a round15mm and could be widely applied on yard cranes for functions like gantry auto-steering,gantry auto-traveling and automatic container management More than 50 sets of GPS products have been operating on ports in Hong Kong, Oman and Shanghai. Application of GPS on Yard Cranes Application of GPS on Yard Cranes It has been long known that the RTG, due to its ability of changing operation yard easily via wheel turning and longitudinal travel, is the favorite choice of many ports when ordering new equipment Due to the fact that RTG has no fixed rail however, the function of the gantry steering and position tracking are not well solved,which brings the following drawback: 1.Gantry steering work is becoming more difficult following that the RTG is becoming large r and quicker; 2.Rapid growth of international trade and container transshipment are making the stacking arrangement and operation management of containers more difficult; if the RTG is not tracked, it is inevitable that the container may be misplaced-such a mistake will result in expensive loses; 3.Automation development of RTG is being hindered due to the shortcoming of gantry it now becomes critical to developing gantry automation while trolley and hoist of RTG has been automated to some extent; 4.Synchronous control of gantry usually is difficult to reach for large span RMGQC In the case that gantry on seaside and landside don t travel at same speed, the crane will present skew phenomena and its performance will be degraded. such as “critical path method” to manage the operation more efficiently. 2. Auto-steering of gantry for RTG No maker how high and quick the RTG is, by making use of the “vitual rail” from GPS, excellent gantry autosteering of RTG could be realized thus the RTG Could travel very straight like an RMG and potential gantry collision with other RTG vehicles is eliminated; operators also could be relieved from the fatigue of manual steering. 3. Gantry auto traveling of RTG with position data (initial and destination position) from the GPS system the RTG could have gantry auto traveling function at the same lane. 4. Fault free operation of RTG By combining gantry position from GPS and positions from trolley and hoist an “e-map” of containers on the yard could be set up The RTG could be so designed that its operation is only possible when the directed container from control center is coincide with the real container(by comparing the positions) 5. Automatic container management with gantry tro1ey hoist position information of the RTG messages including the operation status, current position etc could be sent all the time to the control center; In that way stacking profile of the yard could be continuously updated and manual operation statistics could be reduced to a minimum; 6. Synchronous control for largespan RMG or QC large span RMG or QC is liable to having slipping problem during gantry t raveling which in turn resents skew phenomena; then the performance of the crane will decrease. With position monitoring on both seaside and land side Synchronous control could be used to remove this problem; 7. AGV navigation traveling of AGV could be remotely controlled with the help from GPS data; 8. Position monitoring for container truck the GPS product could also be applied on container trucks for position monitoring. Application of GPS on container operation management The traditional mode of container operation in many ports is: firstly, in the operation department, information on the containers to be operated would be stored in a main computer; Secondly, the operation message for a certain container with container ID and its position will be sent via radio to an RTG Thirdly the RTG operator will drive the RTG t finish the operation; Finally, the completion of the operation will be acknowledged by the operator in that sequence, some potential problem may occur: 1.the positions of the RTGS are not clearly indicated and RTG having optimal path cant be selected; the cost then increases; 2. there is no monitoring of the container, then the container may be misplaced: 3. manual interference for acknowledgement is required. However the whole operation could be made in a closed loop by computers without any potential mistake involved by equipping RTGs with GPS. Also the efficiency could be raised greatly See the charts for details. Technical data of the GPS from ZPMC 1 System configuration 1). The whole project of RTGs will be equipped with one GPS base station it consists of a dualfrequency GPS receiver and a modulating radio transmitter. The function of the base station is to send correction data of GPS position to each crane station. 2). Each crane will be equipped with a GPS rover station which consists of two GPS receivers and a common radio receiver. This rover station will check the current position of the RTG with a precision at centimeter level. The position signal will be sent to the main PC to be dealt with for functions of container position and auto steering control etc. The whole GPS system is compact, simple and independent and it is easy to be 1nstalled on RTG without imposing any influence on the mechanical design. 2. Technical data * power supply: 1 80264VAC 50 60Hz * initialization time<3 min * measurement precision of GPS: around15mm (for twin GPS system);for single GPS system, the precision could be1 5mm (recommended)or 0.5m; * radio application range: 3 km * frequency: 450470MHz 223.025235MHz or others; * signal output: discrete I O 8 pts, optically isolated * RS232 Interface 3 Series of GPS products for easy selection 1). Twin GPS systemAccuracy around15mm for following application: * auto-steering of RTG * gantry autotraveling of RTG * automatic container management for RTG * fault-free operation of RTG * “emap” function for RTG * synchronous control of gantry for largespan RMG * AGV navigation 2). single GPS system-accuracy available at15mm or 0.5m for following function * “e-map” function for RTG * automatic container management for RTG * faultfree operation of RTG * position monitoring for container truck GPS 在輪胎式集裝箱起重機上的應用 摘要 : GPS(全球衛(wèi)星定位系統(tǒng) ),是由美國開發(fā)創(chuàng)建的衛(wèi)星導航和定位系統(tǒng)。通過空中均勻分布的 24 顆導航衛(wèi)星,保證了定位信號在全球任何地方任意時間全天候的可靠接收。自系統(tǒng)投入運行以來,已廣泛應用于國民經(jīng)濟的各行各業(yè)如石油勘探,船舶和航空導航,土建工程定位和重大軍事行動。 關鍵詞 : GPS,起重機,港口機械 GPS(全球衛(wèi)星定位系統(tǒng) ),是由美國開發(fā)創(chuàng)建的衛(wèi)星導航和定位系統(tǒng)。通過空中 均勻分布的 24 顆導航衛(wèi)星,保證了定位信號在全球任何地方任意時間全天候的可靠接收。自系統(tǒng)投入運行以來,已廣泛應用于國民經(jīng)濟的各行各業(yè)如石油勘探,船舶和航空導航,土建工程定位和重大軍事行動。 ZPMC 于兩年前開始進行 GPS 在場橋上的應用研究,使場橋既能保持原有靈活轉場的功能,又能象 RMG(軌道式集裝箱起重機 )一樣保證大車可靠運行和箱位管理功能。 ZPMC 研制的場橋用 GPS 系統(tǒng),定位精度達到 15mm 左右,具有高度的自動化特征,可廣泛用于場橋的自動大車行走,自動大車糾偏,自動箱位管理等功能。自開發(fā)成功,已有近 50 多套產(chǎn)品應用于香港、阿曼和上海的客戶。 GPS 在場橋上的應用 長久以來,由于 RTG 能夠通過輪胎轉向功能,靈活地改變箱區(qū)位置而深受碼頭用戶喜愛。然而也因為沒有固定軌道, RTG 在大車方向上的糾偏和定位功能一直沒能很好解決,從而帶來以下幾方面的問題 一、 隨著 RTG 變得越高越快司機的大車運行日益變得困難,糾偏操作更加艱苦; 二、而隨著國際貿易的發(fā)展和集裝箱數(shù)量的迅猛增長,碼頭集裝箱的堆放安排和作業(yè)統(tǒng)計管理也變得日益困難。成千上萬集裝箱的數(shù)據(jù)記錄 手工工作量是巨大的,另外 RTG 缺乏有效位置監(jiān)控,難免造 成集裝箱的錯誤安放而無法跟蹤 這種錯誤對于繁忙的集裝箱碼頭來說,造成的損失是嚴重的。 三、此外, RTG 在大車方向上的不足也嚴重阻礙了 RTG 在自動化功能上的發(fā)展。在當前 RTG 的小車和起升機構實行了相當程度自動化的情況下,如何解決大車機構的自動化變得更加迫切。 四、對于大跨距 RMG 和 Qc其大車同步控制是令人頭疼的問題。同步控制不好,則會造成大車車輪打滑或“啃軌”現(xiàn)象,從而降低起重機的使用性能和壽命。 機需要長時間低頭進行手動糾偏的疲勞作業(yè)和 RTG 行大車時同集裝箱或其它車輛相撞的隱患:從而使 RTG 具有 同 RMG 一樣的大車運行功能。 三 RTG 大車自動行走利用 RTG 的當前位置和要求作業(yè)集裝箱的目標位置,結合大車自動糾偏和位置監(jiān)控功能,可實現(xiàn) RTG 的大車自動行走。屆時司機只要輕觸按鈕,就可以實現(xiàn)在同跑道上 RTG 大車位置的自動變換。 四 .RTG 防誤操作功能利用 RTG 大車的精確位置,并結合小車和起升機構位置,組成 RTG 吊具的三維信息,根據(jù)碼頭堆場的實際布置,可轉換成具體的集裝箱大車箱位、小車堆位和起升層高 (BERTH, BAY, LANE STACK, TIER)等信息此信息同要作業(yè)的集裝箱比較如不符則禁止吊具 動作,只有信息致才允許作業(yè)。這樣就保證了 RTG 無故障操作; 五 RTG 箱位自動管理利用 RTG 的三維位置,可隨時隨地發(fā)布 RTG 的操作信息譬如作業(yè)箱量作業(yè)位置, RTG 狀態(tài)等信息。信息通過無線系統(tǒng)發(fā)送到中控室,由主機自動記錄統(tǒng)計,實時獲得 RTG 的各種操作數(shù)據(jù),及時更新堆場集裝箱分布情況從而節(jié)省大量的人工登記工作,并消除各種誤差,實現(xiàn)了自動信息化管理有利于信息保存歸檔。 六大跨距 RMG 和 QC 的同步控制大跨距的 RMG 或 QC 在大車運行過程中容易產(chǎn)生因車輪而引起的 “ 啃軌 ” 現(xiàn)象,從而降低起重機的使用性能和壽命。利用 GPS系統(tǒng)可監(jiān)測大車兩側打滑情況,以利于同步控制。 七 AGV 自動導航在廣闊的碼頭堆場上,可利用 RTG 用 GPS 移動站實現(xiàn)對 AGV的自動行走控制。 八集卡位置監(jiān)控 RTG用 GPS移動站也可用于碼頭裝卸設備如集卡等的位置監(jiān)控,便于調度。 GPS 系統(tǒng)在碼頭管理上的應用 傳統(tǒng)的碼頭堆場集裝箱作業(yè)模式為理貨操作部把當日要裝卸的集裝箱,根據(jù)原先計劃安排好并儲存在碼頭主機中的位置通過對講機系統(tǒng)或理貨員 (有些碼頭通過無線電系統(tǒng)把信息顯示在司機室監(jiān)控屏上 )把箱子代碼和位置 (如幾號箱區(qū)幾號位置等信息 )告知某臺 RTG 司機,司機再把車開到對應位置操作。其中涉及的不足有 : 1.RTG 的位置不夠清楚,調度上容易產(chǎn)生舍近求遠問題,增加生產(chǎn)成本;2. RTG 實際吊具位置沒有可靠監(jiān)控 ,司機作業(yè)存在認為錯誤的可能性; 3司機作業(yè)完畢需要人工確認 配備了 RTG 用 GPS 系統(tǒng)后,利用當前普遍的無線電系統(tǒng),可以有效消除 RTG 作業(yè)中存在的各種人工因素整個生產(chǎn)過程由系列電腦實現(xiàn)閉環(huán)控制極
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