Port automation: Enhance safety, reliability, and efficiency
Port automation is the integration of advanced technologies in port operations to improve safety, operational efficiency, and return on investment. As maritime trade surges, ports face mounting pressure to safely and efficiently handle more cargo than ever before. Automating port equipment and digitizing port terminals helps port operators:
- Boost efficiency and safety
- Reduce costs and enhance asset management
- Adapt to evolving regulatory requirements
- Expand traditional security and cyber-security needs
- Meet increasing customer expectations
Keep reading to explore:
Advanced automation technologies significantly optimize port efficiency and operational performance in five key ways:
Safety and reliability
Sensors and automation tools promote safety and enhance visibility around large equipment. For example, a report from one location in the U.S. indicated multiple instances of equipment damage attributed to operator error over the course of a year.
Operational efficiency
Automation reduces delays and increases throughput by streamlining port operations. Condition-based monitoring of critical equipment, particularly humidity, oil quality, temperature, and vibration, enhances productivity and minimizes downtime.
Real-time tracking and reporting
Port automation provides transparency between port operators and logistics personnel both land- and sea-side. Real-time tracking systems improve overall efficiency by ensuring transparency and allowing for timely interventions. They provide accurate, up-to-date information on cargo movement and status.
Rapid return on investment (ROI)
Despite high initial costs, automation reduces labor costs, increases productivity, and minimizes errors. Better operational efficiency with less downtime cuts costs almost immediately and leads to significant long-term savings.
Operational visibility
Detailed and consistent data across your operation enables better decision-making and resource usage. Advanced data analytics and monitoring systems provide comprehensive visibility and transparency into all port operations. They also facilitate reporting operational performance to stakeholders.
Challenges for the port industry include:
- Container terminal safety
- Capabilities shortages
- Limited data availability, security, and quality
- Exceptions, disruptions, and silos
Here’s how a highly-automated port addresses these:
Container terminal safety
Challenge: Port operations are complex and hazardous. They pose risks to personnel and equipment in container terminals.
Solution: Automation improves safety by reducing human intervention in dangerous tasks. Automated mooring systems and collision avoidance systems protect equipment, workers, and cargo.
Products:
- ifm’s 3D cameras detect obstacles near port equipment like reach stackers and horizontal transport equipment. They alert the driver to prevent collisions.
- Safety encoders for AGVs, cranes, and spreaders.
- Photoelectric sensors are used for safe twin-twenty container lifting, and height indication sensors are used for soft landings.
- Inductive sensors prevent accidents by ensuring, for instance, that all four corners of a spreader are locked in and secure.
- Inclination sensors maintain balance for straddle carriers and reach stackers.
- Vision systems, distance measurement sensors, and twin lift detection solutions based on technologies like pmd (photonic mixer device), radar, and ultrasonic sensors prevent injuries, collisions, and machine damage
- The ZZ1103 collision avoidance kit from ifm provides terminal operators with active or passive assistance systems that protect equipment, shipping containers, and workers by preventing dangerous crashes.
Capabilities shortage
Challenge: Ports often lack skilled technical personnel to manage and maintain automated systems. These shortages lead to accidents, operational inefficiencies, and increased downtime.
Solution: Port automation reduces dependency on manual operations and highly specialized technical skills. More data and information about equipment health reduces maintenance work and costs. Automation tools and programs require minimal human intervention. And, automated training programs and simulation-based training help upskill the existing workforce.
Products: ifm's ecomatmobile series controllers with integrated PLC can process sensor signals quickly and reliably. This enables automation with minimal human intervention. The IEC 61131-3 programming software allows for easy adjustment of controller functions. And, all relevant data from various machine parameters is visualized on a local HMI or via SMS text alarm messages.
Limited data availability, security, and quality
Challenge: A lack of standardized data formats makes it difficult to collect, analyze, and use data effectively. Safe, secure data transfer is also challenging in harsh environments.
Solution: Port automation tools provide accurate, real-time data collection and processing for container terminals. Consistent and accurate data enhances decision-making and operational efficiency.
Products:
- ifm’s CAN mobile communications improve operational efficiency by reducing errors caused by poor data quality.
- We also support AS-I infrastructure, the industry standard for spreaders, cranes, and other port equipment for 20+ years. AS-i can include safety devices with the least necessary wiring to PLC systems like Profibus, Profinenet, Ethernet, and more.
- ifm is the industry leader for IO-Link, which is on track to become the standard connectivity upgrade from CAN.
Exceptions, disruptions, and silos
Challenge: Unexpected delays, equipment failures, isolated workflows, incompatible systems, and lost connectivity due to shock and vibrations, oil ingress, or moisture seeping into sensors or connectors lead to inefficiencies and delays.
Solution: Robust equipment and condition-based monitoring minimize disruptions and maintain smooth operations. Automation optimizes all port activities across the terminal process chain. Predictive analytics and real-time monitoring help proactively identify and resolve potential issues.
Products: ifm's vibration sensors reduce downtime and maintain smooth operations by detecting anomalies in equipment operation and signaling them to the PLC.
Ecolink connectors, including standard cables, offer superior ingress resistance and vibration protection for sustained connectivity.
1. Set-up 2. Vibration / Friction 3. Noise 4. Heat 5. Smoke 6. Failure
ifm is your partner in creating and maintaining a customized smart port infrastructure that’s ideal for your facility’s unique needs. Whether you’re looking to validate technology for a particular use case or design a terminal-wide system, we can help.
Our combination of innovative technology, industrial expertise, and commitment to customer service means you get the best tools available with seamless integration and measurable results.
Starting with a discovery process, we’ll understand your port’s main priorities and opportunities for improvement. Then, we’ll help you create the network of sensing and reporting tools you need to take control of your terminal’s operations. Finally, we’re always available to help integrate new products, address concerns and continue fine-tuning or updating your system.
Some of the ifm tools used in smart ports are:
Mobile hardened controllers for safety and HMI controllers for controlling port machines through CAN bus
moneo Cloud IIoT platform for visualization of processed data and insights on port machines
Vibration sensors for condition monitoring of port equipment
RFID track and trace sensors for tracking
3D collision warning systems for machine assets and personnel protection
Laser distance sensors and photoelectric sensors for gap detection and twin-lift detection on spreaders
Inductive sensors for container handling safety
"Smart ports" encompass the broader concept of advanced technologies and data-driven solutions in port operations. Port automation is a critical component of smart ports.
Smart ports and port automation intersect at four significant points:
Intelligent transportation system
An intelligent transportation system (ITS) is an infrastructure that enhances safety, communication, and the flow of goods and vehicles in and around a port. It does so using automation, wireless communication, industrial sensors, vision systems, and other technologies.
Intermodal freight transport
Automated systems manage and synchronize cargo movement over multiple transportation methods. Seamless communication reduces delays, lowers costs, and enhances supply chain reliability.
Ubiquitous computing and IoT
Ubiquitous computing and the Internet of Things (IoT) help implement intelligent maintenance systems. Real-time data collection and analysis move machine upkeep from predictive models to condition-based maintenance. Anticipating equipment failures and intervening before they occur provides improved efficiency by ensuring continuous and efficient operations.
Supply chain management
Smart ports enhance supply chain management with real-time visibility into the movement and status of goods. Wireless communication protocols send seamless data between port systems and supply chain partners. The result is improved coordination and reduced delays.
Friction is common when implementing port automation. These four challenges must be carefully managed to ensure a successful transition:
Technology standardization
Ports use a variety of equipment and systems, often from different vendors. This leads to compatibility issues, which makes collecting, monitoring, and analyzing data challenging.
Standardizing technology protocols and adopting interoperable systems streamline the integration process and ensure smooth operations.
ifm’s sensors, IIoT and sensor-to-cloud technology integrate with most third-party systems for seamless access. Our IO-Link Y-path sends data to multiple destinations without duplicating networks.
Labor opposition
Workers may resist automation projects because they fear job losses and changes in working conditions. To mitigate this, ports must engage with labor unions and involve employees in the transition process.
Retraining programs and new opportunities within the automated environment can help alleviate these concerns and foster a collaborative atmosphere.
ifm’s close collaboration makes it easier to address labor concerns. We include your workforce as stakeholders when developing your new system. And, we assist with retraining to maximize each employee’s potential.
Initial productivity issues
Productivity slowdowns are common with new automated systems. Workers and systems must adjust to the new processes. This adjustment period can lead to temporary operational disruptions.
To minimize these impacts, ports should conduct extensive testing, training, and phased rollouts of automation technologies. This approach allows for troubleshooting and refining processes before full-scale implementation. It reduces the risk of significant productivity losses.
ifm’s implementation strategy hinges on finding a Proof of Value early in the process. We work with a trusted experienced employee to develop and refine each process. Once it’s successful, we help you roll it out to entire teams. This buy-in and customization reduces productivity losses during roll-outs.
Operational disruptions
Operational disruptions during the transition to automation can affect the entire supply chain. These disruptions can stem from machine breakdowns or equipment failure, integration challenges, or unforeseen problems during the implementation phase.
Effective project management and a robust contingency plan mitigate these risks. Ports should ensure they have backup systems and processes in place to handle any interruptions and maintain smooth operations during the transition.
ifm’s real-time monitoring and asset reliability tools give you insight into potential problems before they occur. Robust condition monitoring sensors and wireless communication help manage planned maintenance and reduce unplanned downtime.
Port automation contributes significantly to sustainability goals. They contribute to a greener and more sustainable port environment by enhancing operational efficiency and reducing environmental impact. Automated systems optimize energy use, minimize waste, reduce emissions, and improve resource management. They promote sustainability in three key areas:
Energy efficiency
Automated equipment, such as electric cranes and automated guided vehicles, consume less energy compared to traditional diesel-powered equipment. Real-time monitoring and data analytics help optimize energy use. This practice ensures that equipment operates at peak efficiency, reducing unnecessary energy consumption.
Waste reduction
Automated systems reduce damage and spoilage by improving precision in cargo handling and inventory management. Automated processes can streamline recycling and waste management operations within the port, contributing to overall waste reduction efforts.
Benchmarking and regulatory compliance
Automated systems help ports achieve regulatory compliance and corporate sustainability targets. Detailed monitoring and reporting make it easy to track environmental impact. And, digital data from sensors and systems can identify improvement opportunities.
How ifm can help
ifm’s product lines include modules that track battery use, RFID tracking for streamlining processes, and accurate reliable data collection for reporting, benchmarking, and identifying areas for improvement. We’ll work with you to find the best ways for these and other tools to help you meet your sustainability goals and regulatory requirements.
Choosing ifm as your port automation partner means gaining access to a world-class team that focuses on the safety, reliability, and efficiency of your operation.
From the initial concept through full implementation and improvements, we help you create a tailor-made system for your unique needs.
Our innovative technologies, deep industrial expertise, and customer-first approach drive seamless integration with existing infrastructure. This results in minimal downtime and measurable operational performance improvements. And our durable, value-driven products are backed by exceptional customer service and a global network of support.
Whether you’re looking for a replacement part, a new maintenance program, or a full-blown system overhaul, ifm is more than a supplier. We’re a partner committed to your port’s long-term success.