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Automation system PSS 4000 monitors container transshipment in the Khalifa Port in Abu Dhabi.

Automation system PSS 4000 monitors container transshipment in the Khalifa Port in Abu Dhabi.

“With the automation system PSS 4000 we achieved a great deal more than we originally intended. Conventional concepts would never have reached the same level of performance. Our customer is also convinced by the chosen solution; in fact it exceeds their expectations", Javier Rizo, Material Handling Sales Manager at TMEIC (Toshiba Mitsubishi-Electric Industrial Systems Cooperation), is keen to stress.

Intelligent, safe handling

The modern container port is located between the cities of Abu Dhabi and Dubai and uses the very latest technology in matters of handling, control and safety. To minimise waiting times for freight and container ships, the logistical procedures are mostly automated. So too are the waterside and landside stacker cranes; those on the landside load and unload the HGVs, while those on the waterside prepare the containers from the block interior for the mobile shuttle units, ready for retrieval.

Automation of the port cranes requires innovative and flexible automation and safety technology.

Reliable and sophisticated crane automation

The automation system PSS 4000 monitors all the safety-related functions in port logistics. The decentralisation / distribution of control functions plays a key role. In contrast with a centralised control system, a modular user program is available within a centralised project. This enables simple, standardised handling across the whole project. This was particularly important in the container transshipment system in Khalifa Port.

There are 19 "blocks" in the central transshipment zone. Each block consists of a stacker crane on both the waterside and landside; these run on shared rails. The individual blocks each have an integrated control system PSSuniversal PLC and two decentralised systems PSSuniversal I/O.

Monitoring port logistics safely

Each control system PSSuniversal PLC monitors all the safety-related functions for its zone, such as E-STOP, safety gates, position monitoring, light grids and scanners. Digital inputs and outputs are also used, as are relay contacts. The automation system PSS 4000 also processes non-safe data in the overall system: the control system PSSuniversal PLC reads in all the inputs and forwards the status to the higher level control system via a further protocol. The higher level control system processes this information and returns it to the PSSuniversal PLC, which then switches the standard outputs accordingly.

“Initially we only wanted to process the safety-related signals via PSS 4000. However, when we realised the diverse range of options available from such a flexible system, we decided to implement the standard I/Os via the PSS 4000 as well. That was an advantage because it meant there was no need to add even more IO modules into already cramped control cabinets. So ultimately we saved space and money", confirmed Javier Rizo from TMEIC.

Real-time Ethernet SafetyNET p is used as the protocol for safety-related networking, for reliable exchange and synchronisation of control data, failsafe data and states.

Details

  • Abu Dhabi - United Arab Emirates
  • Pilz