Kalmar ECHs for ContainerCo
NewsKalmar will supply six empty container handlers to ContainerCo in New Zealand, with delivery starting in Q1 2025.
OCR on an empty handler – this is why
CERTUS’ major US customer reports that the first five empty handlers with OCR exceeded expectations, leading to an additional 28 being equipped.
Why apply Optimal Character Recognition (OCR) on an empty handler?
Ask one of CERTUS’ biggest customers in the US and they will tell you that the first five empty handlers equipped with OCR have proven themselves by performing consistently beyond expectations. Another 28 empty handlers are also now in line to be equipped with OCR.
Marc Marchal from CERTUS explains why there is a future for this technology.
“It is quite a novelty. OCR is in gates, cranes and rail portals, but CERTUS was among the first to apply the technology on an empty handler. It all started with finding a solution to prevent incorrect empty containers from being loaded onboard the vessels and understanding the potential value of OCR.
“The first design was made jointly with the terminal operator and deployed as a proof-of-concept on one empty handler at the terminal. From there the software and hardware were modified and optimised. CERTUS efforts did not stop at the agreed accuracy rate but continued after as they saw more room for improvement. Very satisfied with the results, the customer decided to equip another 28 empty handlers”, said Marchal.
Why apply OCR on a stacker?
The main equipment consists of only two cameras, a processing unit and illumination. The central PASS software enables exception handling and interfaces with the Terminal Operating System (TOS) and Position Detection System (PDS).
The direct results are gains in operational efficiency and accuracy, Marchal explains. “Look, an empty handler has a PDS, but the operator sometimes misplaces the container. Then, the wrong container is moved to the crane, which will detect the error, but at that point, it can already be on board the ship. It will have to be taken off, and this all takes time. By preventing this error, a good fifteen minutes is saved.”
Misplacement of containers happens regularly, he continues. “I think around two or three per cent of the containers are misplaced, so there is a lot to win here. With OCR on the empty handler, our software receives the information of the PDS right away, and the terminal operator will be able to intervene immediately before the container moves to the crane.”
It sounds straightforward and beautiful, but why wasn’t this done before? Because it wasn’t straightforward, explains Marchal. “There were some tough challenges to overcome.”
Take the camera for example. “Picking up a container is not a subtle procedure. The first ruggedised camera that was installed on an empty handler broke down almost immediately. We decided on a different and more robust camera designed to withstand significant physical shocks and vibrations, that could be placed on top of the spreader, where it remained.”
Another challenge that had to be solved was the connection between the processor in the cab and the camera, since the spreader picks up containers that are sometimes stacked seven tiers high. “We did not have the chance to run a network cable to the spreader. We tried to solve this with Wi-Fi, but this appeared to be unstable, because of all the metal in between. But we love a challenge, and we were able to tackle this in the end as well.”
The anecdotes illustrate the relevance of bringing a design into an operational environment. CERTUS designed, re-designed and verified until the system proved itself during a year of successful operations.
Satisfied customer
With the first satisfied customer, CERTUS wants to expand the service to other terminals. “There is a market for this technology, especially where terminals are not fully automated. In these terminals the stacker OCR can really bring an added value”, says Marchal.
After this successful experience at the first terminal, CERTUS is fully prepared to deploy the OCR Stacker technology at more container terminals and on various other container handling equipment such as top handlers and reach stackers.
With the ability to customise and adapt our solutions to diverse environments, the company is well-positioned to deliver significant improvements to terminals worldwide.