Introduction of RTG & RMG Automation

1. Core Concepts of RTG & RMG Automation

RTG & RMG automation retrofitting involves the intelligent transformation of traditional manual equipment through the integration of advanced sensing, control and information technologies. This enables the equipment to possess capabilities such as remote monitoring, autonomous operation and independent decision-making. This initiative aims to drive a strategic transformation of port loading and unloading operations, shifting from human control to intelligent control and achieving a revolution in port operations.

The core concept focuses on four dimensions:

1.1  Enhancing operational efficiency by eliminating manual processes to enable continuous, highly efficient operations;

1.2  Ensuring inherent safety by removing personnel from high-risk environments;

1.3  Addressing industry challenges by mitigating the pressures of rising labour costs and a shortage of skilled talent;

1.4  Empowering management upgrades by constructing a digital traceability system that covers the entire process.

RTG & RMG automation's core value lies in establishing an intelligent closed loop of "perception – decision – execution", transforming individual equipment into intelligent nodes that collaborate and interact within the smart port network. This provides crucial technological support for the high-quality development of ports.
 

2. Analysis of the Collaborative Architecture of Automation Systems

The efficient operation of automation systems depends on the collaboration between the Terminal Operating System (TOS), Equipment Scheduling System (ESS) and single-machine control system. The TOS acts as the decision-making layer, overseeing overall resource planning and issuing production instructions. The ECS acts as the scheduling level, handling instruction interpretation and equipment coordination. The single-machine control system functions as the execution level and carries out specific actions.

Key data exchange between these systems is achieved through standardized protocols. The TOS sends task instructions containing coordinate information and job attributes to the ECS, which decomposes them and sends action instruction sequences to the single-machine control system. This system then provides real-time feedback of status data and job confirmation information to the upper-level systems. Through continuous data exchange, the three systems maintain dynamic synchronization between the virtual system and physical operations.

The exception handling mechanism is crucial for ensuring system reliability and requires pre-defined emergency plans for fault reporting, authority switching and process interruption. When anomalies in identification, positioning deviations or equipment failures occur, the system should initiate a graded response in accordance with established protocols to ensure operational safety and system availability.

As the nerve centre of system collaboration, the communication network must meet the requirements of high reliability, low latency and a large bandwidth. To achieve full-area coverage and provide a stable channel for real-time control instructions and high-definition video transmission, it is recommended to adopt industrial optical networks or 5G private networks.
 

3. Key Requirements for Assessing Basic Implementation Conditions

The yard environment must meet the following requirements: Ground flatness and rail straightness must comply with the relevant standards and specifications for automated yards. For example, the ground slope in the corner areas of container stacks should ideally be set between 0.3% and 0.5%. The slope of the container yard can generally take the lower limit, but should not exceed 0.5%. A communication network route from the central control room to the yard should be reserved. The physical identification system in the yard must be standardised and complete, with a minimum container spacing of 400 mm.

The operational area must undergo functional optimisation. Dedicated automated and HMI areas should be clearly demarcated using electronic fences or physical barriers. Passage routes for container trucks should be optimised reasonably. Container stacking should adhere to standardised patterns to create favourable conditions for automatic identification.

Before modifying the equipment itself, an assessment must be conducted. The equipment must meet the relevant technical standards and specifications. Where possible, the electrical system should adopt a PLC + VFD control method with industrial communication protocols used between the PLC and the VFD.