Terminal Truck Alignment Using Reflective Distance Measurement
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Solution Overview
Problem
Existing systems for aligning terminal trucks with gantry cranes are inefficient due to inaccuracies in container positioning, reliance on expensive and weather-sensitive laser technology, and high maintenance costs, particularly in harsh harbor environments.
Innovation Solution
A system using a position determination unit, a receiver for container information, and a distance measurement unit based on reflective technology (such as ultrasound, Lidar, or radar) to accurately align containers with the crane's spreader, reducing the need for crane displacement and improving alignment accuracy to within 10 centimeters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser scanners are used to determine truck position, then measurement precision is improved, but device complexity and maintenance cost increase
Solution Approach 1:
The patent replaces mechanical laser scanners with a combination of radio location technology (electromagnetic field-based) and reflective distance measurement. This substitution eliminates moving mechanical parts while maintaining measurement precision, directly resolving the contradiction between precision and device complexity.
Solution Approach 2:
The patent uses simpler, more cost-effective components such as radio antennas and reflective distance sensors instead of expensive laser scanners. These components are more durable and require less maintenance, particularly in harsh harbor environments, thereby reducing both device complexity and maintenance costs while preserving measurement accuracy.
2Measurement precision
If laser technology is used for alignment, then alignment accuracy is improved, but reliability deteriorates due to weather sensitivity
Solution Approach 1:
The patent changes the physical parameter basis for measurement from optical (laser) to electromagnetic (radio waves) and acoustic/ultrasonic reflections. Radio waves and ultrasound are not affected by rain, fog, or humidity in the same way optical lasers are, thereby maintaining alignment accuracy while significantly improving reliability in adverse weather conditions.
Solution Approach 2:
By replacing optical laser systems with radio-based and reflective distance measurement systems, the patent eliminates weather sensitivity associated with optical paths. This substitution maintains measurement precision while ensuring consistent operation in rain, fog, and humid harbor environments.
3Measurement precision
If crane displacement is performed to align with container, then alignment accuracy is achieved, but productivity decreases
Solution Approach 1:
The patent implements preliminary positioning by providing driving instructions to the truck driver before the container reaches the crane. The system calculates the optimal stopping position and guides the driver to align the container with the spreader in advance, eliminating the need for time-consuming crane displacement operations and thereby maintaining high productivity.
Solution Approach 2:
The system provides real-time feedback to the driver through driving instructions, enabling continuous adjustment of the truck's position. This feedback loop ensures accurate alignment is achieved during the approach phase rather than requiring corrective crane movement, thus preserving productivity while achieving the required 10 cm alignment accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances container loading efficiency by providing accurate driving instructions, reducing maintenance costs, and operating reliably in various weather conditions, thereby increasing the number of containers loaded per unit time without crane displacement.
Implementation Method 1
a distance measurement unit configured to measure a distance between a reference point, line or plane at the tractor and a front surface of the at least one container based on reflective technology
Data Source
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AI summary
A system (115, 118; 125, 128; 135, 138; 200) enabling alignment of a terminal truck (110; 120; 130) relative to a gantry crane (101-108, 150, 151) comprises: - a position determination unit (211, 212) that determines the position of the tractor (111; 121; 131) relative to the crane (101-108, 150, 151); - a receiver (221, 222) that receives container information indicative for the size of a container (113; 123, 124; 133) carried by the terminal truck (110; 120; 130); - a distance measurement unit (213, 214) that measures the distance (117; 127; 137) between the tractor (111; 121; 131) and the container (113; 123, 124; 133) based on reflective technology; and - a computing unit (223) that generates driving instructions from the tractor position, the container information, and the tractor-container distance, enabling to position the container (113; 123, 124; 133) in a predetermined aligned position relative to the crane (101-108, 150, 151).