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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 round±15mm 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 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;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；Synchronous control of gantry usually is difficult to reach for large span RMG／QC 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. 3. 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 auto—steering 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. 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 large—span 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 can’t 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 dual—frequency 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 80—264VAC 50／60Hz *?initialization time<3 min *?measurement precision of GPS：around±15mm (for twin GPS system);for single GPS system， the?precision could be±1 5mm (recommended)or 0.5m; *?radio application range：3 km *?frequency：450—470MHz 223.025—235MHz or others; *?signal output：discrete I／O 8 pts，optically isolated * RS232 Interface 3．Series of GPS products for easy selection 1). Twin GPS system—Accuracy around±15mm for following application： ?* auto-steering of RTG ?* gantry auto—traveling of RTG ?* automatic container management for RTG ?* fault-free operation of RTG ?* “e—map” function for RTG ?* synchronous control of gantry for large—span RMG ?* AGV navigation 2). single GPS system-accuracy available at±15mm or 0.5m for following function ?* “e-map” function for RTG ?* automatic container management for RTG ?* fault—free operation of RTG ?* position monitoring for container truck  GPS在輪胎式集裝箱起重機(jī)上的應(yīng)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(dǎo)航和定位系統(tǒng)。通過空中均勻分布的24顆導(dǎo)航衛(wèi)星，保證了定位信號在全球任何地方任意時(shí)間全天候的可靠接收。自系統(tǒng)投入運(yùn)行以來，已廣泛應(yīng)用于國民經(jīng)濟(jì)的各行各業(yè)如石油勘探，船舶和航空導(dǎo)航，土建工程定位和重大軍事行動。 關(guān)鍵詞：GPS，起重機(jī)，港口機(jī)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(dǎo)航和定位系統(tǒng)。通過空中均勻分布的24顆導(dǎo)航衛(wèi)星，保證了定位信號在全球任何地方任意時(shí)間全天候的可靠接收。自系統(tǒng)投入運(yùn)行以來，已廣泛應(yīng)用于國民經(jīng)濟(jì)的各行各業(yè)如石油勘探，船舶和航空導(dǎo)航，土建工程定位和重大軍事行動。 ZPMC于兩年前開始進(jìn)行GPS在場橋上的應(yīng)用研究，使場橋既能保持原有靈活轉(zhuǎn)場的功能，又能象RMG(軌道式集裝箱起重機(jī))一樣保證大車可靠運(yùn)行和箱位管理功能。ZPMC研制的場橋用GPS系統(tǒng)，定位精度達(dá)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(yīng)用于香港、阿曼和上海的客戶。 GPS在場橋上的應(yīng)用 長久以來，由于RTG能夠通過輪胎轉(zhuǎn)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?yàn)闆]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(jī)的大車運(yùn)行日益變得困難，糾偏操作更加艱苦； 二、而隨著國際貿(mào)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(jì)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(cuò)誤安放而無法跟蹤——這種錯(cuò)誤．對于繁忙的集裝箱碼頭來說，造成的損失是嚴(yán)重的。 三、此外，RTG在大車方向上的不足．也嚴(yán)重阻礙了RTG在自動化功能上的發(fā)展。在當(dāng)前RTG的小車和起升機(jī)構(gòu)實(shí)行了相當(dāng)程度自動化的情況下，如何解決大車機(jī)構(gòu)的自動化變得更加迫切。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(jī)的使用性能和壽命。 機(jī)需要長時(shí)間低頭進(jìn)行手動糾偏的疲勞作業(yè)和RTG行大車時(shí)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(yùn)行功能。 四.RTG大車自動行走利用RTG的當(dāng)前位置和要求作業(yè)集裝箱的目標(biāo)位置，結(jié)合大車自動糾偏和位置監(jiān)控功能，可實(shí)現(xiàn)RTG的大車自動行走。屆時(shí)司機(jī)只要輕觸按鈕，就可以實(shí)現(xiàn)在同跑道上RTG大車位置的自動變換。RTG防誤操作功能利用RTG大車的精確位置，并結(jié)合小車和起升機(jī)構(gòu)位置，組成RTG吊具的三維信息，根據(jù)碼頭堆場的實(shí)際布置，可轉(zhuǎn)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(shí)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(jī)自動記錄統(tǒng)計(jì)，實(shí)時(shí)獲得RTG的各種操作數(shù)據(jù)，及時(shí)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(shí)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(yùn)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(jī)的使用性能和壽命。利用GPS系統(tǒng)可監(jiān)測大車兩側(cè)打滑情況，以利于同步控制。 七． AGV自動導(dǎo)航在廣闊的碼頭堆場上，可利用RTG用GPS移動站實(shí)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(shè)備如集卡等的位置監(jiān)控，便于調(diào)度。 GPS系統(tǒng)在碼頭管理上的應(yīng)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(dāng)日要裝卸的集裝箱，根據(jù)原先計(jì)劃安排好并儲存在碼頭主機(jī)中的位置通過對講機(jī)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(jī)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(jī)，司機(jī)再把車開到對應(yīng)位置操作。其中涉及的不足有: 1.RTG的位置不夠清楚，調(diào)度上容易產(chǎn)生舍近求遠(yuǎn)問題，增加生產(chǎn)成本；2. RTG實(shí)際吊具位置沒有可靠監(jiān)控,司機(jī)作業(yè)存在認(rèn)為錯(cuò)誤的可能性；3．司機(jī)作業(yè)完畢需要人工確認(rèn) 配備了RTG用GPS系統(tǒng)后，利用當(dāng)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(gè)生產(chǎn)過程由系列電腦實(shí)現(xiàn)閉環(huán)控制極大地提高碼頭生產(chǎn)的正確性和信息化水平，實(shí)現(xiàn)無紙化管理。此過程中每臺RTG都將充分應(yīng)用前述的箱位自動管理防誤操作等功能。 RTG用GPS系統(tǒng)技術(shù)參數(shù) 一、系統(tǒng)配置 ? 1.整個(gè)項(xiàng)目配備一個(gè)GPS基準(zhǔn)站，具體包括個(gè)GPS接收器和一個(gè)調(diào)制無線發(fā)射電臺，用于提供基準(zhǔn)位置信號給起重機(jī)上的GPS移動站； ??? 2每臺機(jī)配置一個(gè)GPS移動站，具體硬件包括兩個(gè)GPS接收器和一個(gè)公共無線接收電臺用于檢測當(dāng)前起重機(jī)所處位置，并接收基準(zhǔn)站差分信號從而獲得厘米級的檢測精度位置信號將在主機(jī)運(yùn)算后送至機(jī)上PLC進(jìn)步進(jìn)行箱位管理和自動糾偏等處理。 ??? 整個(gè)GPS系統(tǒng)結(jié)構(gòu)精巧，安裝簡單，系統(tǒng)具有很強(qiáng)的獨(dú)立性對RTG的設(shè)計(jì)不產(chǎn)生任何結(jié)構(gòu)上的影響。 二、技術(shù)參數(shù) ? * 工作電源輸入電壓：AC220V±10％50Hz／60Hz ? * 開機(jī)定位時(shí)間約3 min ? * GPS定位精度: ±15mm(雙GPS系統(tǒng)):(單GPS系統(tǒng)精度可選±1 5mm或0.5米，推薦±15mm) ? * 電臺有效范圍：3km ? *?電臺頻率可選范圍：450-470MHz； 223.025M-235M或其它用戶申請頻率 ? * 標(biāo)準(zhǔn)RS232接口輸出，適用于各種PLC裝置 ? * 狀態(tài)量8位,24VDC光耦隔離輸出 三、為了方便用戶選購，目前ZPMC可以提供兩種類型的RTG用GPS系統(tǒng)： 1．雙GPS系統(tǒng)——定位精度±15mm左右，主要應(yīng)用于： ?* RTG大車自動糾偏 ?*?RTG大車自動行走 ?*?RTG箱位自動管理 ?*?RTG防誤操作功能 ?*?RTG定位監(jiān)控(電子地圖)功能 ?* 大跨距RMG同步控制 ?*?AGV自動導(dǎo)航 2．單GPS系統(tǒng)——定位精度可選(±15mm或50厘米左右)，主要應(yīng)用于． ?*?RTG定位監(jiān)控(電子地圖)功能 ?*?RTG箱位自動管理 ?*?RTG防誤操作功能 ?*?集卡位置監(jiān)控 9