Next month (September) at InnoTrans 2012 in Berlin, the world’s leading fair for passenger and freight transport technology, Vollert Anlagenbau will be showing its new solutions for intra- plant shunting and loading operations.As part of a broader modernization project at the port of Hamburg, HANSAPORT Hafenbetriebsgesellschaft has recently put innovative hybrid shunting technology from Vollert in service for future growth at Germany’s largest port terminal for bulk material.
The port of Hamburg belongs to the most important transshipment points for bulk cargo worldwide. HANSAPORT, the largest seaport terminal in Germany for coal and iron ore annually moves approximately 15mt (million tonnes) of imported ship tonnage. Up to 100,000 tonnes of cargo can be unloaded every day along the 1,000m-long pier. For loading the goods in an open space of 350,000m2, it is necessary to have modern technology and intelligent automated processes between gripper bridges, conveyor belts, and shunting technology to work economically and to protect the environment.
HYBRID DRIVE TECHNOLOGY FOR MODERNIZED LOADING PROCESSES
For the modernization of the shunting and loading facilities that
have been in service since the late 1980s, particular attention was paid to the creation of a sustainable economic approach and energy-efficient processes with the objective of reducing costs. There has also been a major focus on keeping the environmental impact as low as possible. HANSAPORT has chosen a strategic integrated shunting system with innovative hybrid drive technology for the transshipment of growing bulk volumes from the gripper bridges onto the waiting train wagons and the logistical connection of the intra–plant operations to the rails.
Vollert, the shunting systems specialist, has developed the DER 240 robot as an optimally dimensioned shunting solution for the loading terminal, which uses an innovative diesel/electric drive technology. Key components are the electric motors, housing their own power station in the form of a generator driven by a diesel engine. At variable loading speeds and with a tensile load of 6,000 tonnes, a traction force of 240KN can be reached, says Uwe Krebs, project manager at Vollert. Infinitely variable power is transmitted at starting and braking via a frequency converter. Due to lower maintenance costs, braking is mainly carried out by means of the four electric drive motors. The electrical energy received at braking is retransformed to heat by use of braking resistors. Rubber-metal-suspension (MEGI-suspension), flanged wheel lubrication as well as sandboxes in case of bad friction conditions between the wheels and the rail provide safe and comfortable best running performances. Ultrasonic sensors constantly monitor the runways.
The drive aggregate as well as all technical components (pneumatic unit, etc.) are supervised and controlled via a central PLC system installed at an operation panel. The operational data, the current speed and the precise position can be comfortably read and adjusted by a touch panel. This enables a reliable and fully automatic loading process of block trains at the bulk bin 365 days a year and 24 hours a day, round the clock.
LOWER INVESTMENT, OPERATIONAL AND MAINTENANCE COSTS CONVINCE
Fewer legal restrictions (constructed according to BOA regulations) and a maximum speed rated at 10km/h mean considerably lower investments costs compared with traditional tractive vehicles running on the general railway network. By using fully automated and GPS-controlled loading processes it
was possible to sustainable rationalize logistical operations in the seaport terminal of Hamburg. The environmental also benefits due to significantly reduction of the CO2 emissions by lower fuel consumption. Highly sophisticated components as well as the robust, massive technology also decrease costs for maintenance and downtime significantly, which has already shown the trial run. “HANSAPORT achieves the desired cost and efficiency goals with that in a short time. The new hybrid drive technology has convinced us." explains Erhard Meller, managing director at HANSAPORT.
SOLUTIONS FOR ALL INTRA-PLANTS SHUNTING AND LOADING PROCESSES
At the InnoTrans 2012 Vollert shows more shunting and loading solutions, which are to find worldwide e.g. in mines and refineries. As general contractor Vollert develops stationary shunting systems (standard gauge, wheel acting and small pusher trucks, coupling chain), non-bound shunting systems with different drive technologies (diesel/electric/hybrid) as well as heavy duty conveyor carriages and travelling platforms.