LASE GmbH - Moderne Lasermessgeräte & hochentwickelte Softwareapplikationen // State-of-the-art laser sensors & sophisticated software applications

Project completion for laser volume measurement systems on conveyor belts and yard stacking machines at Vale’s S11D in Brazil

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(LASE GmbH) (Wesel, 09.04.2018)

LASE has finished a further project for volume measurement of stockpiles at Vale’s S11D Complex in North Brazil. In this huge plant iron ore is measured on different storage and regulation yards by 2D and 3D laser scanners, which deliver exact data about the volume, height and position for the management of seven stockpiles. Totally four 3D- and nine 2D laser scanners have been equipped on seven stacker and reclaimer machines resp. material yards.

After finishing the first project with a volume measurement system for 15 conveyor belts at S11D in the Brazilian municipality Canaã dos Carajas (Federal State of Para), LASE has equipped 2D and 3D laser measurement systems as well as a specific yard management software (LaseBVH - Bulk Volume Heap) for seven storage and regulation yards in the world’s biggest mining facility. Due to the project success and in order to fulfill the increasing demand on the automation of stacker or reclaimer machines for material handling, 2D- and 3D laser measurement technology has been chosen as key solution again.

In the regulation yard each of the three machines is equipped with three 2D laser scanners, which measure the stockpile in a vertical scan plane parallel to the machine boom. While the stacker machine is moving on the railway along the yard as well as during the stacking process, the laser scanners scan the stockpile permanently. With the knowledge of the exact machine position by using DGPS systems, a 3D image profile of each stockpile with incl. height and volume data is generated. These data are displayed in a specific manager software where all stockpiles are divided into zones.

In the other yard for storage operations four reclaimer machines are provided with each one 3D laser scanner, which are mounted at the highest point of the machine. By collecting all 3D measurement data and the exact position (DGPS) of the machine, a 3D image of the surrounding stockpiles is created here as well. The LaseBVH application software also contains special filter algorithms to extract machine construction parts (e.g. boom, struts) out of the scan data and shows the real volume and profile information accurately.

All data from the GPS system, laser scanners and the machines are collected by a specific LASE Control Unit (LCU) and are forwarded to the central control station by an Ethernet connection. This system architecture allows a permanent digital monitoring of all machines for a frictionless operation. Because of its robust design the application LaseBVH allows reliable operations even at rough outdoor conditions like in this iron ore facility at Vale’s S11D.

Find out more on our product website…

 

Image on top: View over a mining yard at S11D Complex / © LASE

Further 6 LaseTLP systems for Truck Lifting Prevention at SNCT Incheon, South Korea

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(LASE GmbH) (Wesel, 03.04.2018)

The system LaseTLP for Truck Lifting Prevention has been installed and put in operation on 6 HHMC RMG cranes at NewPort at SNCT (Sun Kwang Container Terminal) in Incheon, South Korea. In this automated Asian hub the highly accurate 2D-Laser scanners (in direction to the truck lane) detect truck liftings, which occur when any twistlock is locked or jammed, before the lifting from a truck has begun. Around Q2 another 14 systems will be installed as well which totals in finally 28 systems in this terminal.

Two 2D-Laser scanners out of the LASE 2000D-11x Series are mounted on the side of the gantry with a vertical scan plane, whereby the general difficulty of measuring above/through a fence with a height of 1,0 m could be solved – by using 2 x 2D-Laser scanner. The mounting position of both laser scanners is in the middle of the crane in a height of approx. 1,5 m facing the truck lane. In the case that a truck is in front and the hoist lifts up the container, the measurement system detects whether the trailer is still connected to the container by any locked or jammed twistlock(s) - and stops the operation.

The biggest advantage of LaseTLP is the fast detection of the trailer lift. Other methods mostly use horizontal scan planes and look whether the wheels are up in the air or not. But just one connected twistlock makes it possible to lift up the truck cabin to a height of already 4m until the wheels will be lifted up, therefore the systems have a poor performance. Severe injuries as well as huge damage claim costs will be prevented by the LaseTLP.

Further systems for the existing cranes at Incheon terminal have been ordered again. Due to good operation experiences by the customer he purchased another 14 LaseTLP systems in order to replace the current systems. All in all 28 LaseTLP system will be installed around the first half of the year then.

More information about the application LaseTLP can be found on the product page here...

 

Image on top: Container yard area with ARMG cranes at SNCT (© LASE GmbH)

 

Successful start-up of 8 LaseTLP systems for Truck Lifting Prevention at SNCT Incheon, South Korea

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(LASE GmbH) (Wesel, 30.01.2018)

The system LaseTLP for Truck Lifting Prevention has been commissioned at overall 8 ARMG cranes in the finally prepared NewPort at SNCT (Sun Kwang Container Terminal) in Incheon, South Korea. In this automated Asian hub highly accurate 2D-Laser scanners (in direction to the truck lane) detect truck liftings, which occur when any twistlock is locked or jammed, before the lifting from a truck has begun.

Two 2D-Laser scanners out of the LASE 2000D-11x Series are mounted on the side of the gantry with a vertical scan plane, whereby the general difficulty of measuring above/through a fence with a height of 1,0 m could be solved – by using 2 x 2D-Laser scanner. The mounting position of both laser scanners is in the middle of the crane in a height of approx. 1,5 m facing the truck lane. In the case that a truck is in front and the hoist lifts up the container, the measurement system detects whether the trailer is still connected to the container by any locked or jammed twistlock(s) - and stops the operation.

The biggest advantage of LaseTLP is the fast detection of the trailer lift. Other methods mostly use horizontal scan planes and look whether the wheels are up in the air or not. But just one connected twistlock makes it possible to lift up the truck cabin to a height of already 4m until the wheels will be lifted up, therefore the systems have a poor performance. Severe injuries as well as huge damage claim costs will be prevented by the LaseTLP.

Further systems for the existing cranes in the terminal have already been ordered after this successful commissioning and first good operation experiences by the customer.

More information about the application LaseTLP can be found on the product page here...

 

Image on top: Trucks in line for unloading operation under ARMG crane at SNCT (© LASE GmbH)

 

Safe Traffic Control for Straddle Carrier operations

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Straddle Carriers are one of the most simple but also effective systems to handle container load. They can easily be managed and have a high flexibility because they can be sent to nearly every corner of the terminal. Container transport can be done independent from the STS or Yard Crane operation and they can also be the stacking machines for the Yard. Nevertheless, high flexibility can only be managed by ensuring high safety in the operation area. The elimination of human error is the main benefit and leads to high improvement in workplace safety by applying an assistance system for Straddle Carrier drivers - SAFE TRAFFIC CONTROL.

The product LaseSPC - Straddle Carrier Positioning Crane is a 2D measurement system for exact Straddle Carrier positioning under STS cranes and is applicable for multi-lane operations with up to two Straddle Carriers simultaneously. The system controls the traffic under the crane to avoid that lifting units collide with Straddle Carriers.


 HOW IT WORKS...

  

Two 2D-Laser scanners are installed each on the land- and waterside gantry and create a horizontal scan plane in a height of approx. 7m. Two pairs of LED displays are also installed on the gantry crosswise above the buffer in the height of the SC driver cabin. Above each operation lane traffic lights are mounted on the portal girder, too. The 2D-Laser scanners measure onto reference markers (equipped on all four legs) and calculate the exact position of the SC.

 

Operation 1: Straddle Carrier approaches the portal area

When the LaseSPC system recognizes a SC approaching the portal area or almost under it, the lifting unit is not allowed to be lowered in the portal area and the hoist will be stopped.

  

Operation 2: Spreader already positioned in the portal area

When the crane spreader moves within the portal in order to pick or drop a container, the approaching SC is recognized within the surveillance area in front of and behind the portal area. The access of the SC will be denied by giving the SC driver a visual feedback with a red light from the traffic lights above the relevant lane.

  

Straddle Carrier Positioning with visual guidance

The driver of the SC gets a visual feedback of his relative position to the centre line of the crane and also of the final target position via LED displays.

A deviation of the SC position to the centre will be shown as numeric information on the display in order to move forward or backward and to align the SC perfectly.

  

Pre-adjustment of spreader & trolley

The positioning results could be used to do pre-adjustments of the trolley and spreader in order to have a perfect container pick-up.

Pre-adjustments are especially important for double hoist and/or twin operations.

 

 Further information about this and other solutions can be found here or sent us a message via the contact form here...

High market demand for LaseTLP - Truck Lifting Prevention in different international ports

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(LASE GmbH) (Wesel, 20.11.2017)

The safety application LaseTLP generated a high demand in different international ports in the last quarter, especially in Asian hubs. The system helps to prevent trailer lifting, which occurs when any twistlock is locked or jammed before RTG/RMG operation. Laser scanners in direction to the truck lane are able to detect liftings when even only one twistlock is locked.

More information about the application LaseTLP can be found on the product page here...

 

 

Slab positioning system at automatic slab cranes from Danieli

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(LASE GmbH) (Wesel, 20.11.2017)

LASE has delivered both a slab position and size measurement system to the Italian manufacturer Danieli Centro Cranes for the automatic operation of a slab crane. The system consists of 4 laser scanners attached to the crane trolley and measure slabs under the tong from all different sides. The customer, a big steel manufacturer, can now realise very accurate pick and drop operations. Data about the slab dimension and position are sent by Ethernet to the SPS.

Within this installation the measurement system LaseSPY - Slab Positioning Yard consists of four laser scanners out of the LASE 2000D-11x Series attached to the crane trolley. The laser scanners measure from all different sides onto the slab, which hangs under the tong. The pick and drop position of the slab is determined (in cooperation with a warehouse management system - WMS) and furthermore the width, length and number of slabs are recorded, too. A safe acquisition of single slabs is also possible. The data from the laser scanners are processed by a LASE Control Unit (LCU) and sent by Ethernet to the supervisory stock control management system. Due to this measurement system an automatic operation of the yard is ensured. The solution LaseSPY - Slab Positioning Yard is a measurement system that works differently either for pick or for drop operations.

Pickup of Slabs

For a pickup of a slab the crane moves to the nominal target position. If the crane is very close to this position, the dimension of the slabs for pick operation will be measured. By knowing these results the center position for the picking process will be calculated. The center position will be compared to the actual crane position (delivered by the SPS). The delta values in width and length direction will be sent to the PLC. With this information it is possible to move the crane to the best possible position for picking up the slabs.

Deposition of Slabs

The deposition of slabs is different because the transportation of a slab in the tong makes it more difficult to measure the ground for the target position. For this reason the target position will be measured during the crane movement to this position. This information will be saved in the data memory of the LaseSPY application. Later on, by having this information, it’s also possible to determine the delta values in length and width direction. Additionally the length and width values also allow the calculation of the best possible stacking position.

The pickup either can be done from a train, from the yard or any other transfer vehicle. A deposition of the slabs can only be done in the yard or from a transfer vehicle because trains do not have an automated operation process.

More information about the application LaseSPY can be found on the product page here...

 

LASE delivers to Vale’s world’s biggest mining project at S11D Complex in Brazil

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(LASE GmbH) (Wesel, 21.03.2017)

LASE has provided the delivery of 15 LaseBVC conveyor belt measuring systems to history’s biggest iron ore mining project by Vale in the S11D Complex in North Brazil. In this huge plant the material volume, which is being transported on conveyors needs to be determined by specific measurement applications from LASE.

In the Brazilian municipality Canaã dos Carajas (Federal State of Para) the mining company Vale has opened the world’s largest mining project in history in last December. After starting with the commercial operation in January, LASE has already begun with the rollout of the application LaseBVC (Bulk Volume Conveyor) and delivered 14 volume measurement system for conveyors in the so called  S11D Eliezer Batista Complex. Together with our longstanding Brazilian partner company C+ Tecnologia the laser-based bulk material measurement systems will be commissioned for end customer Vale properly. This prestigious project sets a new standard in the mining industry where advanced technology meets high productivity.

In order to measure the height of iron ore on conveyors as well as its volume, one laser scanner is mounted above each conveyor belt. The scan direction of the laser systems runs across the transfer direction of the conveyed material and generates 2D profiles. These are compared to so called zero-profiles, which have been stored during the initial commission of a conveyor belt. By knowing the individual difference and the belt speed, the exact volume can be determined consequently. Additionally, if the bulk density is known, the mass flow can be calculated, too.

By the use of high-resolution laser scanners with a scan ratio of up to 100 scans per second the material can be recorded even at high transportation speeds. Special algorithms within the LaseBVC software application for the adjustment and calibration ensure high measurement accuracy. The system can be operated intuitively due to an user-oriented dialogue control and configuration wizards for a simple commissioning. For integration in production plants these common interfaces are already integrated: Ethernet TCP/IP, Profibus DP, Analog 0...20 mA and Serial RS 422. Because of its robust design the application LaseBVC allows a reliable operation even at raw environmental conditions.

Find out more on our product website…

 

Image on top: Overview of the mining area at S11D Complex / © LASE

LASE launches LaseSPC for exact straddle carrier positioning

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16.03.2017 // LASE launches “LaseSPC” for exact straddle carrier positioning

LASE launches its new product “LaseSPC - Straddle (Carrier) Positioning Crane” for the exact positioning of straddle/van carriers (SC) under STS cranes. Besides to other positioning systems for trucks and AGVs this product development completes the offer of applications for positioning tasks under STS-Cranes. By the development of this easily retrofittable application, LASE offers laser-based positioning systems for all horizontal modes of transport now.

The application LaseSPC - Straddle Positioning Crane is a 2D measurement system consisting of two 2D laser scanners (LASE 2000D Series) mounted on the water and landside sill beam. The straddle carriers are equipped with reference markers on all four legs and after the straddle carrier is under or approaches the crane, the measurement system detects them and calculates the exact position of the SC. By the use of LED displays the straddle carrier driver receives a feedback about his relative position to the crane centre and the final target position. Possible corrections of the position will be shown as numeric displacement information in order to move forward or backward. Furthermore the information of the straddle carrier will be hosted to the crane control system – consequently to prevent that the hoist is lowering into the lane where the straddle carrier is.

The system offers an exact positioning of straddle carriers and is even applicable for multi-lane operations, whereby max. two straddle carriers can be measurement at the same time. Like many other LASE products, this solution is also retrofittable and can be applied into existing crane infrastructures easily.

In order to support the easiest handover between straddle carriers and STS cranes LASE has developed this innovative solution. The main intention is to continue the mission for safer and more efficient container operations in ports and terminals. All in all the launch of LaseSPC covers all modes of horizontal container transport by this laser-based positioning system and builds an easy interface to the vertical operations.

 Visit the product page for further information...

Image on top: Laser scanner on sill beam while SC approach for operation (© LASE GmbH)

Qualification by German BG for Performance Level d Cat. 3 for LaseLCPS-3D-2D

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20.02.2017 // Qualification by German BG for Performance Level d Cat. 3 for LaseLCPS-3D-2D

The product LaseLCPS-3D-2D (Load Collision Prevention System -3D-2D) has been qualified for the Performance Level D - Category 3 by the German BG (Employers' Liability Insurance Association). The certification by this statutory institution sets a milestone in the product development and meets today’s requirements on Performance Levels for safety standards in the port industry.

The Performance Levels to EN ISO 13849-1 are parameters for the reliability how a control system complies with safety functions. By reaching one of the highest parameters, the application LaseLCPS-3D-2D confirms its high development status and also the acceptance on the market. In regards to safety it is important to run systems which have a reliable protection against malfunctions.

This specific version of the application LaseLCPS-3D-2D - Load Collision Prevention is a combined 3D/2D laser measurement system consisting of each one 2D- and one 3D- laser scanner mounted under the trolley. The LaseLCPS application software collects the scan data, does all needed calculations and sends the results to the machine PLC. In order to measure all relevant stacks a 3D profile scan in gantry and trolley direction will be processed before the first move. The scan planes of the 2D- and 3D laser scanner are projected orthogonally to each other.

Additionally the laser scanners scan over the yard during the movement in order to measure into shadow areas, which have been covered by higher stacks in front before. Within this collision prevention check a dynamic surveillance cube around the load proves an overlap with the container profiles in the yard. In the event of an overlap, the system retard the movement by slowing down the crane travel and even finally stops the container move.

On top of all, the system also has a soft-landing function for gentle container handling that leads to less spreader wear and a reduction of the operation noise.

Find out more on our product website...

 

Image on top: Mounting example for LaseLCPS-3D-2D with protection hood (© LASE GmbH)

Further order of Korean port for LaseTLP at eight RMG cranes

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10.12.2016 // Further order of Korean port for LaseTLP at eight RMG cranes

LASE received an order from another Korean port for the installation of LaseTLP (Truck Lifting Prevention) at in total eight RMG cranes.

One year before, together with the successful product release, a Korean port already has ordered this safety-related system for container operations in truck lanes. By the implementation of LaseTLP - Truck Lifting Prevention - hoist movements will be interrupted immediately when the laser measurement system detects a lifted container chassis at even 100 mm. It is not unusual that truck-trailers are lifted up by the crane hoist when one or more twistlocks are still locked or not completely loosened. In order to prevent such accidents this system detects the lifting of the trailer at the earliest stage. Such incidents of lifted container chassis or trucks are not harmless and can lead to severe injuries as well as huge damage claim costs.

The measurement system consists of one laser scanner from the LASE 2000D Series which is mounted at the crane gantry with a vertical scan plan towards the truck lane. The scanner tracks the objects (container and trailer) and compare the position of the lifted container and trailer structure. In case that both objects move upwards simultaneously due to one or more locked twistlocks, the system generates an alarm signal immediately. Thus the hoist movement stops before any damage or injury can occur. Either different existing container chassis types do not mean any problem for the LaseTLP application or changing environment conditions. Through the vertical orientation of the laser scanner a continuous system operation can be performed reliably. Further advantages of the system are its high sensitivity (reacts fast in case of lifting) and its elimination of false alarms - both make it to a reliable and highly accepted system by port operators. Less wear and the easy possibility of an adaption for retrofitting purposes are an additional plus.

Find out more about our port solutions...

 

Image on top: Truck unloading operation under crane without lifting incident (© LASE GmbH)

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