In June 2012 iSAM AG finished commissioning its first shiploader for barges and seagoing vessels at Europees Massagoed- Overslagbedrijf (EMO) BV in Europort Rotterdam, Netherlands. In line with other equipment at the largest transshipment terminal for iron ore and coal in Western Europe, the new shiploader has a maximum throughput capacity of 6,000tph (tonnes per hour) for iron ore and will be fully automated for man-less operations by the end of 2012. Even at lower rates, like 2,500tph, the new machine enables EMO to load barges and combined barges in under two hours. Stacking on land is possible, too. To reduce the impact of the machine on its environment it is designed for low electrostatic discharge (ESD) and sound emissions. To prevent dust nuisance it is equipped with a position-controlled dust chute.
The automation system for shiploaders is the newest product of iSAMs high tech portfolio, which co-operates perfectly with the coherent solutions for stacker reclaimers and grab unloaders. iSAM’s
product line now offers unique automation and optimization solutions
for man-less operations in every business handling dry bulk materials
like import/export terminals or mines. At EMO all eleven machines, which
were automated
by iSAM, can be controlled by only one operator from a central control room.
Like the iSAM solution for grab unloaders and stacker reclaimers the new automation for shiploaders is based on the same main components as existing equipment on the terminal, minimizing the effort for maintenance training and spare part management. The positions off all four axes including the telescope are detected by a state of the art RTK GPS system offering a availability of 99,9% and an accuracy of one inch, while positioning of the machine is controlled by an industrial type PC. The environment, including ships and stockpiles, is scanned by a high performance 3D-laser. Due to its low remission, coal greatly limits the detection range of optical systems. Being the most sophisticated 3D-laser scanner available, it overcomes this obstacle offering a scan radius of up to 100 metres. As the laser is a class-1 system no further personal protection equipment, like goggles, is necessary to work in the operating range. The collected data of the 3D-laser scanner can be displayed on a site map, offering accurate and reliable information about the stored material. It can also be linked to existing site management systems, delivering updated data without having the planning department get accustomed to a new system.
To allow communication between the ship’s loadmaster and the automation system, for example to request hatch changes or to trigger a quick stop, the shiploader is equipped with a remote panel, communicating through Wi-Fi. The panel can also be used to display useful information like the amount of loaded material overall or per hatch.
To protect the shiploader from collision with vessels or stockpiles a work proven collision protection system was put into place, supplemented by new features for the unique situation of a shiploader. It consists mainly of sonar sensors on selected positions and a microwave barrier to protect the length of the boom. New to the system is a 2D-radar scanner which spans a defined area underneath the boom to protect it against floatation of ships, in case of rising tide, or to fast emptying of the ship’s ballast tanks. In addition two radar probes at the tip of the boom will trigger an emergency lifting if their readings fall below a safe distance. During normal operation the radar probes are used to detect and monitor the dropped material to assure an optimal loading or stacking result.
To fulfil today’s requirements for electrical efficiency, but also availability and maintenance the whole electrical equipment of the new shiploader was redesigned, integrating only components of the newest generation. The safety PLC, the frequency drive converters and also the motors are from one supplier, to guarantee the highest possible interoperability. All major brands are possible and for the customer to choose from. No matter if it is a complete new design or an automation upgrade, the assignments of the new European machine directive are fulfilled in every aspect.
One highlight of the shiploader project was the on-time delivery of the manual control system within a very tight schedule. With a motivated and experienced team of electricians and automation engineers and a project management which worked together with EMO closely, from the conceptual phase until completion, it was possible to achieve this goal. Every company and every machine are different and so iSAM is continuing its efforts for optimization to make it the perfect machine for its everyday tasks.
Apart from automation solutions for bulk material handling equipment iSAM AG, Gesellschaft fu¨r angewandte Kybernetik develops and implements automation solutions that enable industry, commerce and service suppliers to increase their performance in the field of mining, transport and logistics, steel and metal making and manufacturing, tube welding and pipeline construction, mechanical engineering and plant building, electronics, aerospace etc. all over the world. Accordingly, iSAM's business and turnkey solutions are available all over the globe.
The company itself is located in Mu¨lheim an der Ruhr, a city in the Ruhrgebiet, Germany’s renowned centre of high technology. Here, company experts are concentrating efforts to keep on increasing customers value. iSAM’s team covers specialists from the sectors engineering, computer sciences, physics, as well as business economics, best skilled and ready to create customized solutions.