Automated Guided Vehicles - Robotics for cargo operations efficiency
In forecasting the future of container terminal cargo handling, Automated Guided Vehicles (AGVs) are seen by some as a logical progression of chassis operations and straddle carrier operations.
An automated guided vehicle (AGV) in Container Terminal Altenwerder (CTA), Hamburg
(Image credit: HHLA)
While the adoption of AGVs has been slow in container terminals due to their high initial cost and infrastructure requirements, AGVs have been active within container terminal operations for over 20 years.
This article delves into the transformative role of AGVs in enhancing cargo operations productivity and their consequential effect on vessel departure times, emphasising their performance characteristics and real-world applications.
Basics of AGVs
An AGV design
(Image credit: Kalmar)
AGVs are unmanned, autonomous vehicles with advanced navigation systems that enable them to transport containers between quay cranes and the container yard without human intervention. Their deployment in container terminals is an automation design choice to boost operational efficiency, reduce human error, and improve workplace safety.
They usually consist of a significant chassis, with their drive-unit powering independently steered axles. This lets them make tighter turns and ‘crab’ diagonally for precision positioning. Modern AGVs are capable of transporting containers at speeds up to 25 kilometres per hour (15.5 mph), with the ability to carry one or two TEUs (Twenty-foot Equivalent Units) or one FEU (Forty-foot Equivalent Units).
AGVs navigate using a mix of sensors and digital guidance embedded within the terminal apron. Older AGVs used to follow buried cables, whereas more modern terminals use buried beacons to allow AGVs to calculate their local position. AGVs are highly capable machines that use radio technologies such as GPS and 5G for localisation and sensor technologies such as LiDAR and radar for positioning and collision avoidance.
“By minimising productivity peaks and troughs, autonomous AGV operations run consistently, 24 hours a day, 7 days a week. ”
A critical part of AGV functionality isn’t the machine itself but the software that controls them. This is usually an extension of the container terminals Terminal Operating System (TOS) and is responsible for creating tasks, routing and deploying a fleet of AGVs to work harmoniously.
The AGVs described require automated or semi-automated quay gantries and/or yard stackers for operation. Where a container terminal is looking to automate an existing labour-intensive terminal, a new generation of automated straddle carriers is now operational. The benefit is that not all of the existing terminal infrastructure needs to be automated.
Why would a container terminal choose AGVs?
Increased Throughput: AGVs operate around the clock, unaffected by human fatigue or shift changes, significantly increasing the container handling rate. Their precision and reliability translate into more consistent loading and unloading of vessels, ensuring more confidence in vessel turnaround time forecasting.
Optimized Yard Management: Equipped with sophisticated TOS software, AGVs can be dynamically rerouted in response to real-time conditions, minimizing congestion and ensuring optimal placement of containers in the yard. This level of efficiency is pivotal in preventing bottlenecks and ensuring smooth cargo flow.
Reduced Operational Costs: AGVs contribute to lower labor costs and reduced overheads. With most AGVs being converted or designed directly for electric operation, it also means lower fuel costs and a smaller carbon footprint, aligning with the growing emphasis on sustainability in the maritime industry and a shipping company’s scope 3 emissions.
Improved Safety: Automating container movement reduces the risk of workplace accidents, leading to a safer environment for terminal and ship staff.
Real-World Applications
Several leading ports worldwide have successfully integrated AGVs into their operations. Here are some of the most notable:
Port of Rotterdam, The Netherlands
ECT Delta in Maasvlakte was one of the original AGV terminals and has operated for over 20 years. Recent additions to the automated terminal portfolio include Rotterdam World Gateway (RWG) and APM Terminals Maasvlakte II.
These terminals report significant improvements in container handling speeds and reductions in vessel turnaround times, showcasing the tangible benefits of AGV deployment, with both terminals currently undergoing expansion projects.
The AGVs at the Rotterdam World Gateway terminal, Port of Rotterdam
(Image credit: Wired UK)
Port of Hamburg, Germany
Hamburg's Container Terminal Altenwerder (CTA) is renowned for its high degree of automation, with AGVs playing a central role. The terminal boasts one of the highest productivity rates globally, attributed to its efficient use of AGVs in operations. Recently, they completed a full upgrade of their AGVs to battery power.
Port of Shanghai, China
Home to the world's busiest container port, Yangshan Deep Water Port, the Port of Shanghai has been at the forefront of port automation. This port features a highly automated terminal where AGVs are critical in maintaining efficiency and throughput. The AGVs are integrated with a sophisticated port management system, enabling real-time adjustments to operations and enhancing the port's ability to handle large volumes of visiting vessels.
Port of Singapore
The Port of Singapore started to embrace AGVs in its operations in 2016. PSA Singapore's Pasir Panjang Terminal was equipped with AGVs as a test bed for future developments, with 30 AGVs making up their test fleet.
These tests were prepared for operations in Tuas, where the island’s container terminal operations will eventually be consolidated.
Phase 1 of Tuas opened in September 2022 with the project’s four phases scheduled for completion in 2040. As of February 2024, over 200 battery-powered AGVs were in operation.
AGVs in Tuas container terminal, Port of Singapore
(Image credit: Mediacorp)
Impact of AGVs on Cargo Operations and Vessel Departure Times
The deployment of AGVs directly influences vessel departure times through enhanced terminal efficiency. By minimizing delays in cargo handling, AGVs contribute to more predictable and streamlined scheduling for vessels, reducing idle time at berth and enabling better adherence to shipping schedules. This predictability is crucial for vessel operations managers and schedulers.
For an automated system reliant on electricity, local power cuts/brownouts and cybersecurity incidents can mean all operations cease for the duration of the issue.
While AGVs can generally be relied upon through their consistency and system resilience to individual AGV breakdowns, the potential for delay on departure is then shifted to the other tasks within cargo operations.
This can include lashing operations, out-of-gauge/breakbulk loading and unloading, and non-cargo operations such as bunkering or loading stores.
How can I be informed if AGV operations are below expectation and/or vessel completion time is in doubt?
Depending on your relationship with the container terminal, they may inform you when the completion time has changed, but they are unlikely to let you know when or why delays have happened. The cause of the delay may only be shared once operations are complete and the terminal departure report has been shared with the shipping company. At this point, the potential for remedial action has been lost.
Proactively monitoring and collaborating with the container terminal as they work your vessels can be the difference between on-time and costly, delayed departures.
Utilising a cargo operations monitoring platform such as CargoMate can provide a real-time view of the operations without needing the terminal to provide regular updates.
There are two details CargoMate measures which can indicate when there are issues with AGV operations:
Gantry performance for a single gantry is notably slower than the other gantries operating on the vessel
The crew and/or senior officers onboard have observed and noted an issue with the AGV operations
Using these two features, CargoMate ensures that vessel operations managers can monitor cargo operations with the right information at their fingertips.