COLLISION AVOIDANCE
locate the exact position and size of the target container, check the clearance to adjacent stacks and
verify the positions of the containers as they are stacked. It uses a high precision laser beamthat is directed by a series of controlledmirrors to enable three-dimensional scanning. The Load Positioning System(LPS) comprises a
camera equipped with a video processor and an infrared transmitter box. The transmitter includes a number of infraredmarkers, each of which the camera identifies to an accuracy of better then 1mm. The control systemthen uses the positions of the
markers to calculate the position and orientation of the load relative to the trolley. This information is used as feedback into the position andmotion controllers to ensuremaximumprecision. The LPS and TPS jointly enable the yard cranes to
swiftly and reproducibly build stacks of loaded containers of up to 25min height with a tolerance of just a few centimetres.
RADAR TRACKING Symeo’smulti-level anti-collision systemfor cranes relies on continuous tracking of all crane positions and heights using radar. It also tracks vehicles such as rail-bound transfer cars coming in fromthe side. The systemallows the user to reliably and repeatedly configure their own warning and stop zones and flexibly change restricted areas. In addition to determining the exact position of
the crane or crane trolley, the systemcan simultaneously transmit the cranemeasurement data using only a single wireless sensor. A separate communication systemis not required. The positioning and data transmission functions are integrated in a single device. Using Symeo’s LPR-1D24 wireless sensors, the
crane position is determined dynamically with continuous distancemeasurements – such as to adjacent walls or cranes. The wireless distance measurements are based on patented technology which operates in the license-free 24 GHz ISMband. Since themeasurement antenna is integrated in the 1D24 housing, it only takes an approximate alignment of the wireless sensors to receive precise measurement results. The Collision Control Center (CCC), amodular
assistance system, assumes responsibility for the centralmanagement tasks and enables interaction with the user. All of the devices are configured, updated andmonitored through the CCC, which can be easily called up via a web browser interface without installing special software.
PREDICTIVE MAINTENANCE By analysing the vibration data fromcrane gearboxes, it is possible to detect any damage to gearbox components early, therefore reducing any costly, unplanned downtime and prolonging the life of the gearboxes. One port operator observed that two ageing
gearboxes on one of the cranes were beginning to experience high vibration issues. Excessive noise and vibration were coming fromthe two gearboxes when
16 /// Environmental Engineering /// December 2017
the crane was going through its lifting and lowering movements.Due to this excessive noise and vibration, the crane was operated at a slower speed, which caused delays to port operations as ships were spendingmore time docked while they were being unloaded by this slower working crane. The port operator contacted SchaefflerUK for
help inmonitoring and analysing vibration data of gearbox components (bearings and gears), which would allowmaintenance to be scheduled and damaged components replaced before they failed. Now, SchaefflerUK provides for the port operator
regular (every four to sixmonths) on-site vibration monitoring and analysis services. The three basic measuring parameters are velocity (ameasure of overallmachine vibration that responds to mechanical issues such as imbalance,misalignment and looseness), acceleration (typically used to monitor gear defects and progressing bearing defects) and enveloped acceleration (ameasure of high frequency, impact-type events, typified by early bearing or gear faults). Themeasurements aremade and stored
using the FAGDetector III handheld vibration monitoring device. This has a database ofmore than 20,000 different bearing products from different suppliers. EE
Measurement data analysed by the Schaeffler field service engineer, who then writes an analysis report and recommended action list for the port operator, top; overhead cranes in manufacturing and logistics sites must be risk-assessed for the possibility of collision, above
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