e-RTG Solutionsby VAHLE

eRTG/en 2014

Up to 95% savings in diesel fuel costs - the ECOLOGICAL solution.

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Your benefits from the VAHLE eRTG system:

Economic• Savings up towards 95% of diesel consumption

(results based on factual terminals)

• Reduction of maintenance and operation costs up to 70% can be achieved

• Reduction of repair and replacemant costs, e.g. diesel generators

• No manual plugging - increase safety and reduce labour costs

Efficient• Quick automated drive-in / drive-out

for increased container handling productivity

• Tailor made solutions available, e.g. short entry zones

• Maximized resource utilization by reduced idle time

Ecological• Significant reduction of environmental pollution (CO2 emissions)

• Increased safety for personal working in the terminal

• Reduced noise pollution

9 Pay back can be achieved after less than two years of operation

Rubber Tired Gantry Crane

The work-horse of the contai-ner handling industry is the Rubber Tired Gantry (RTG) crane. Since the first RTG was introduced in the late 1950’s there has been constant development in improving the technology. VAHLE’s engineers have developed system solutions that consi-der the following drivers for improved container handling performance:

• Productivity

• Cost of operation

• Reliability

• Environmental aspects

• Total Cost of Ownership

• Local service support

• Safety and security

Lazaro Cardenas, Mexico

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Single connection arrangement Outboard

Back-to-Back connection arrangement

Single connection arrangement Inboard

Container Yard Electrification

From the first installation of conductor systems for RTG electrification in China, the concept has not changed. Cur-rently, over 75% of all conver-ted and new eRTG systems are electrified by conductor bars.

The two types of plugin solu-tions are either manual or automated. Conductor bars are installed parallel to the container blocks with only the connection being conducted by a plug.

RTG Yard Layout options

Depending on the type of ope-rations and number of block changes from one container block to another, VAHLE has the configuration to suit your requirements.

Features:• Space savings due to vertical arrangement, 330 mm

single sided and 600 mm double sided (2+2 conductors)

• Electrification of two aisles from one steel structure

• Lightweight and robust tubular steel structure

• “Diabolo” roller design for multi-dimensional guidance

• Minimized moving wear parts (3 rollers only)

• Proven and reliable conductor bar systems MADE IN GERMANY by VAHLE

• Heavy-duty components for tough port environment

• Various installation configurations available

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Manual PLUG-IN SOLUTION

The concept of an eRTG with a plug connection is relatively simple. Electrical energy is provided through a conductor bar system running alongside the container block. The sup-port structure of the conductor bars also includes a guidance for a collector trolley. The trol-ley, which holds the current collectors for 3-phase and earth connection, is pulled by a towing rope attached to the travelling RTG. The connection between the RTG and the bar system is realized by a cable and a plug.

Plug-In systems are well-proven as a practical, safe and reliable system, with several hundred installations world-wide.

The most economical solution if:• Only a few cranes are in operation

• The RTG rarely realizes block changes between the container rows and aisles

• PLC is not required (simple design)

Features• Operator assisted drive-in / drive-out

• Elimination of electrical hazards due to safety connector

Mardas, Turkey

Additional eRTG features:• Auto-steering system

• Anti-collision system

• Data communication system

• Positioning system

• Energy recovery system

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VAHLE Conductor bar systems

Proven over many decades, conductor bar systems are deemed to be reliable for providing energy to moving equipment - even under harsh environmentional conditions, such as ports and container terminals.

Current collector trolley Safety connector

eRTG Electrification:Many container terminal operators view conductor bar solutions as a significant benefit. With advances made in smarter TOS (Terminal Operating Systems), improved education and training for the RTG staff, it is viewed that the management of container terminal yards is complex, requiring smart solutions that are part of the system rather than stand alone.

VAHLE eRTG solutions integrate easily and seemlessly with your current RTG systems.

As the retrofitting of an existing RTG can be a complex pro-ject, the container management decisions are driven by operational requirements. Some of the major challanges raised by container terminals in using cable reels include:

• Significant additional weight and possibly mechanical structural modifications on the RTG

• The need to unplug and plug in again to change aisles

• Cable alignment between RTG and container stack and additional cable protection to avoid damage

• Additional measures have to be taken if a number of RTGs are to operate in any one lane

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Automated Electrical Connection System (AECS)

The AECS also operates via a conductor bar system that is elevated in various heights to suit the customer’s need, but the collector trolley is allowed to leave the system at each end of the block through special ‘drive-in zones’ and mechanical assistance from the RTG.

eRTG Technology• Current technology allows the connection process to be managed

from the cabin requiring less than 60 seconds to connect.

• The AECS solution offers the full benefits of the conductor bar system by powering the RTGs without losing the flexibility of RTGs moving between container blocks.

• Many greenfield installations world wide are ordering RTGs that are specifying automated connection to the conductor bars.

• Retrofitting of existing facilities with conductor barss are increasingly being outfitted with AECS.

Lazaro Cardenas, Mexico

Additional eRTG features:• Seamless synchronisation

• Auto-steering system

• Anti-collision system

• Data communication system

• Positioning system

• Energy recovery system

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Space saving Telescopic arm

Telescopic Arm

The telescopic arm is desig-ned by VAHLE engineers to optimise the limited space between an RTG and contai-ner stacks so as to maintain or increase productivity.

Using electrical drives ensure reliability and high perfor-mance without risk to the operations in the container terminal.

Key Features of the fully automated telescopic arm• Fully electrical driven

• Max. horizontal stroke: 1700 mm

• Due to modular systems various sizes for particular customer needs

• Robust design for use in container ports

• Vertical track tolerances: ± 150 mm

• Cable arrangement via energy chains

• Reduction of wear parts

• Siemens S7 control system of the telescopic arm

The most economical solution when:• The RTG changes aisles frequently (block changes)

• Several RTGs are used

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eRTG OEM test site, Finland

Key Features of the SMG - Slotted Microwave guide• Immunity to interference due to isolation of the SMG profile from the

surroundings.

• Maintenance-free due to contactless transmission technology.

• Common assembly of the SMG profile with all VAHLE conductor bar system and the CPS® system.

• Error-free transmission of high data rates up to 100 Mbit/s.

• Simultaneous transmission of up to six data channels full duplex.

• Transmission paths of up to 1000 m without intermediate amplification due to high dynamic response of transceivers.

• EMERGENCY-OFF transmission according to stop category 1, safety level 3.

• Coupling of several mobile subscribers to one SMG profile.

• Transmission independent of traveling speed of mobile subscriber.

• No negative effects on transmission quality due to environmental influences, e.g., temperature, humidity, clouds, dust, etc.

Slotted Microwave Guide

VAHLE has over 1000 instal-lations successfully in ope-ration worldwide using SMG (Slotted Microwave Guide) data transmission system. SMG is proven in automation technology for contactless and interference-free transmission at high data rates up to 100 Mbit/s and opens up a wide range of applications through its variable design.

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Conductor system with SMG operating at -25 °C

Even under harsh climate conditions, VAHLE SMG will ensure communication to and from your RTG.

Antenna moving into the SMG profile

3 Steps towards Container Yard Automation

Data communicationThe current challenge for container terminal operators is to transmit information alongside the electricity and already terminals are putting phrases like ‘full scale failsafe data communication’. While customers are initially consi-dering low density ‘process’ data being transmitted to the terminal operating system (TOS) or other control soft-ware, this seems to be a step on the way to full automation of eRTGs .

Therefore the issue is to help ports put in place a system that is not just able to be integ-rated into the TOS as it stands, but can also be a platform for the further development of remotely operated, semi or fully automated eRTGs; posi-tion control already being a function of TOS systems. To this end, ports are looking at a high data transfer rate, around 100 mbps, which can send real, lifelike images to the control room that could enable the eRTG to eventually be driven remotely.

FULLY AUTOMATED E-RTGsAnother trend set to emerge is the development of fully auto-mated and electrified RTGs. The ultimate goal is to operate the RTG inside the block either remotely or without any driver on board, while running on electricity. One critical factor for the automation of RTG cranes is data communication using SMG. This can be done parallel to the conductor bar system.

This development for RTGs made possible based on the experience of over 1.000 applications worldwide using VAHLE conductor systems and SMG.

Electrification

Conductor systems

Communication

SMG connection to:

• sensors

• software

• apps

AutomationConductor systems

+

SMG

+

Software

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SERVICE & SUPPORTOur VAHLE engineers are educated and trained in Germany to provide our customers the satisfaction in which container terminals demand for:

• Service for installation

• Commissioning

• Training

• Up to date manuals and documentation

• Consulting services

• Education and training at all levels for maintenance and repair

• Knowledge sharing at our Corporate Trainining Center

• Worldwide network

Our service - Your benefit• Product / service consulting for customers

(trained experienced personnel)

• Local language / culture / timezone

• Spare parts stock

• Installation support

• Troubleshooting, maximizing availability and efficiency, safety of local installations

• Minor assembly / modification works in local workshops

IMPLEMENTATION SOLUTIONS• Retrofit of existing RTG fleets

• New cranes (crane OEM)

• Cooperation with your local crane service partner

• Optional local sourcing of structural steelwork and installation services

• Worldwide VAHLE service network

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Mobile Electrification in ports

VAHLE develops, manu-factures and implements customized power and data transmission systems for various material handling applications including port technology. Here VAHLE pro-vides a complete range of products that are required to electrify different crane types, such as STS and RTG cranes.

VAHLE Port Technologies

VAHLE´s product range comprises trench systems, cable reels, festoon systems, conductor bars and data transmission systems. The latest innovation is a fully-automated solution for RTG electrification.Festoon Systems

Heavy Enclosed Conductor Systems

Cable Reels

Conductor Bar Systems + SMG

Over 100 years in mobile electrificationVAHLE has been Electrifying mobility since 1912 and Cra-nes are our business. Whether is RTGs after RETROFITTING or POWERING new RTGs, VAHLE is the preferred supplier to our customers in the port crane business for over 40 years. Today we are considered when container terminal operators need to:

• Reduce emissions

• Increase efficiency

• Apply Technology leading to Sustainabilty

VAHLE is helping our partners and clients to realize their energy efficiency goals. Demonstrating our proven techno-logy, many of our technologies are being adopted by ports and terminals world-wide.

eRTG

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Mexico

Panama

GermanyUnited Kingdom

NorwayFinland

TurkeyHong Kong

Singapore

WE HELP TO ELECTRIFY YOUR PORT!• 3 of the TOP 5 Global Terminal operators come to VAHLE

• 3 of the 5 largest suppliers of RTG cranes employ VAHLE eRTG systems

• 5 of the TOP 7 Container Terminals in Turkey have installed VAHLE eRTG systems

• Over 300 RTGs are now electrified with VAHLE eRTG systems, every day our customers are saving money by paying less for energy to power their RTGs

How would YOU like to save on energy?

VAHLE Inc • 1169 Brittmoore Dr • Houston, TX 77043 • 713-465-9796 • www.vahleinc.com •salesinbox@vahleinc.com