Enhancing Container Handling Efficiency at Hamburg Port Terminal
Location: Container Terminal, Port of Hamburg, Germany
Timeframe: Implementation March 2024 - Operational Review May 2024
Personnel Involved:
- Klaus Schmidt: Terminal Operations Manager
- Hans Weber: Senior Maintenance & Electrification Engineer
- Operations Team: Crane Operators & Maintenance Technicians
Challenge:
The container terminal faced persistent challenges with its aging fleet of Rubber-Tyred Gantry (RTG) cranes. Operators reported issues with container sway during high-wind operations, leading to longer positioning times and safety concerns. Downtime was increasing due to motor control faults and brake issues, particularly during frequent start-stop cycles and load changes. The existing drives struggled with the demanding duty cycle, lacked precise anti-sway control, and their large size complicated cabinet space management. Noise from the drives was also a growing environmental compliance concern near residential areas bordering the terminal.
Solution:
Seeking a reliable and feature-rich solution specifically designed for heavy lifting, the terminal's engineering team, led by Herr Weber, selected and implemented HV610 series inverters on 12 RTG cranes during a scheduled upgrade window in Q1 2024.
- Anti-Sway Control: The HV610's dedicated Anti-Sway algorithm was configured to significantly dampen container oscillation during hoisting and trolley travel, especially in windy conditions common near the Elbe river.
- Slack-Rope Protection & Brake Control: Enhanced safety was achieved through the integrated Slack-Rope Protection, preventing dangerous slack during lifting initiation, and the precise Brake Control logic, ensuring the brake engages/disengages optimally only when sufficient motor torque is present, eliminating "creeping" or "dropping" incidents.
- Multi-Motor Switching & Hoist Macro: Utilizing the HV610's support for 4 motor parameter sets and the dedicated Hoist Macro parameter group, the drives seamlessly managed the main hoist motor and the separate spreader motor/controls through simple command switching.
- VFD with OLVC & High Starting Torque: The Open-Loop Vector Control (OLVC) mode provided the necessary high starting torque (0.5Hz/150%) for smooth container lifts under varying loads, crucial for handling both empty and heavily laden containers efficiently.
- Reduced Footprint & Noise: The HV610's compact book-sized design (approx. 40% smaller than replaced units) allowed easier installation within the crane's existing electrical cabinets. The adjustable Random PWM Depth feature noticeably reduced the high-pitched whine from the motors.
- Reliability Features: The independent air duct design and conformal coating (3-Proof Paint) process were critical factors, given the terminal's harsh environment with salt air, dust, and temperature fluctuations (-5°C to 35°C). The drives' wide voltage tolerance (-15% to +10%) accommodated occasional grid fluctuations.
- Safety Integration: The Operation Lever Zero-Point Detection feature prevented unintended crane movement upon power-up, enhancing operator safety.
- Encoder Redundancy: Encoders installed on the hoist motors utilized the HV610's encoder card (SLOT2) and its automatic fallback to OLVC mode in case of encoder failure, maintaining crane operability.
Results (May 2024 Review):
- Increased Productivity: Container positioning time improved by an average of ~40% due to reduced sway and faster, smoother load handling enabled by features like Load-Dependent Speed (随载随速) and precise control.
- Enhanced Safety: Zero incidents related to load dropping, unintended movement on startup, or brake failure were reported post-implementation. Operators expressed higher confidence, particularly during adverse weather.
- Reduced Downtime: Maintenance downtime related to crane drive systems decreased by approximately 15% within the first two months of operation, attributed to the HV610's robust thermal design and protection features.
- Improved Reliability: The drives demonstrated stable operation despite environmental challenges, validating the effectiveness of the independent air duct and conformal coating.
- Noise Reduction: Complaints regarding operational noise decreased substantially following PWM depth adjustments.
- Space Optimization: The smaller drive size provided valuable cabinet space for future upgrades or additions.
Quote from Senior Engineer Hans Weber: The HV610 wasn't just another inverter; it felt engineered for cranes. The specific features like the integrated anti-sway, the robust brake logic, and the multiple motor setup capability addressed our core pain points directly. The reliability in our salty, dusty environment has been impressive from day one, and the operators immediately noticed the smoother, safer handling. It's proven to be a solid investment in both performance and safety for our RTG operations.
Quote from Operations Manager Klaus Schmidt: Seeing containers land precisely and quickly, even with a crosswind, makes a tangible difference to our turn-around times. The reduction in unplanned stops and the peace of mind regarding safety features like the slack-rope and brake control have been significant operational wins. This upgrade has delivered on its promise of efficiency and reliability.
