Project overview: a new benchmark for port automation in Europe

A landmark smart port crane upgrade project has recently been completed in the Port of Rotterdam, the Netherlands, Europe's largest port and pioneer in the development of automated container terminals. The project equipped the port cranes of the Port of Rotterdam Group, a leading global supplier of high-end lifting and lifting equipment for the marine, offshore oil and gas and wind industries, with BASCO's robust HMI system, enabling a comprehensive transformation from traditional manual operation to fully automated container handling and digital scheduling.

As one of the oldest crane manufacturers in the world, Port of Rotterdam products are widely used in marine engineering, offshore oil and gas development, wind power installation, operation and maintenance, etc. This upgrade project aims to meet the efficiency challenges posed by global trade growth, transforming traditional cranes into intelligent operating units by introducing advanced automation technology and digital management systems, integrating them into the increasingly complete smart port ecosystem of the Port of Rotterdam.

Core challenges in project implementation

Equipment reliability issues in harsh environments

The port operating environment is extremely complex, and cranes are exposed to harsh climatic conditions such as sea fog, salt spray, and storms for a long time. Traditional HMI devices are prone to failure in such environments, affecting job continuity and safety. As Europe's leading container terminal, the Port of Rotterdam has extremely high requirements for equipment reliability, and any downtime can cause significant financial losses.

The efficiency bottleneck of human-machine collaborative operation

According to the research on the allocation of man-machine functions of shore container cranes, excessive intelligence can easily lead to increased operator dependence and reduced situational awareness, while insufficient intelligence will lead to excessive workload and decreased work efficiency of operators. The project needs to find the best balance between automated control and human supervision to achieve efficient human-machine collaboration.

Multi-system integration and data interoperability problems

Port operations involve multiple independent platforms such as crane control systems, terminal operating systems (TOS), vehicle scheduling systems, and customs inspection systems. How to achieve seamless docking and real-time data sharing between these systems has become the key to the successful implementation of digital scheduling. In particular, the "new generation logistics" digital platform that has been put into use at the Port of Rotterdam needs to be deeply integrated with the crane system.

Pressure on operator skill transformation

The shift from traditional cab operations to remote monitoring and exception handling places new demands on operator skills. The project required an intuitive HMI that reduced the learning curve while ensuring that operators could quickly intervene and effectively handle anomalies in the automation system.

Innovative solutions: comprehensive application of BASCO HMI system

Breakthrough in environmental adaptive design

BASCO's rugged HMIs are designed for harsh port environments and are IP65 rated and 810G impact-resistant. The equipment adopts a fully sealed structure and anti-corrosion materials, which can operate stably under extreme conditions such as salt water, fog, frost, and storms. The 10.1-inch high-brightness industrial-grade touch screen displays clearly even in strong daylight, ensuring that operators can accurately capture information in various lighting conditions.

Intelligent human-machine function distribution system

Based on the multi-attribute fuzzy decision theory, the project team developed an intelligent human-machine function allocation model. The system analyzes the complexity of the operation task, environmental conditions, equipment status and other factors in real time, and dynamically assigns the scope of responsibility of the bridge crane driver and the automatic control system. For example, in standardized operations such as the horizontal movement of the trolley, the system automatically executes; In complex docking or abnormal situations, operators are prompted to intervene in supervision and treatment.

Integration of digital scheduling of the whole process

As the "central control unit", the BASCO HMI realizes deep connection with the "new generation logistics" platform of the Port of Rotterdam. The system can receive the operation instructions issued by the terminal operating system in real time, automatically plan the optimal loading and unloading path, and return the operation progress, equipment status, container information and other data in real time. Through the 5G high-speed network, operators can monitor the operating status of multiple cranes simultaneously in the remote control center.

Multi-level fault diagnosis and early warning

The system integrates advanced fault intelligent diagnosis functions to monitor equipment status in real time through multiple sensors such as vibration, temperature, and current. Based on big data analysis and machine learning algorithms, the platform can warn of potential failures of key components such as motors and brakes 7-10 days in advance, significantly reducing the risk of sudden downtime. When a fault occurs, the interface visually displays the fault location and treatment suggestions in graphical and text form.

Intuitive operation experience design

In response to the needs of operator skill transformation, the BASCO interface is designed to be ergonomically interactive. The main interface is divided into four modules: operation monitoring area, equipment status area, alarm information area and control operation area, which supports gesture operation and voice command. The system also provides virtual training modules to help operators quickly master remote monitoring and exception handling skills.

Project implementation effect: double improvement of efficiency and safety

The operation efficiency has been significantly improved

The upgraded smart crane has achieved a remarkable 50% increase in operational efficiency. The cycle time of a single machine is shortened from about 120 seconds to less than 90 seconds in traditional manual operation, and the loading and unloading efficiency of the whole ship is increased by 25-35%. Through automated and precise control, the accuracy of container grabbing, positioning, and stacking reaches more than 99.5%, greatly reducing the adjustment and repeat operation time.

Optimal allocation of human resources

After the implementation of the project, the number of quay bridge drivers and automated rail crane operators has been reduced by 65%. One operator can manage up to 6 rubber tyred gantry cranes at the same time, with an operating ratio of 1:6. This not only alleviates the pressure of labor shortages in the port industry but also frees operators from high-risk, high-intensity work environments to technical supervision and management roles.

The safety performance has been comprehensively improved

Through the application of technologies such as automatic anti-shake control, centimeter-level precise positioning, and intelligent windproof devices, the operation safety of the equipment in bad weather has been greatly improved. The intervention rate of system abnormalities was only 2.78%, and the potential safety hazards were reduced by 50%. Operators no longer need to climb tens of meters high cab, completely eliminating the risk of working at height.

Significantly reduced O&M costs

The application of predictive maintenance systems has increased the availability rate of equipment from 92% to 98%. By detecting and dealing with potential faults in advance, production losses and emergency repair costs caused by sudden downtime are avoided. The application of the energy feedback system reduces the energy consumption of a single box by 12-18%, and the annual electricity cost of 18 intelligent gantry cranes is about 2.4 million yuan.

The level of digital management has leapfrog

The project realizes the digital control of the entire process of port operations, and the entire circulation process of containers from ships to yards can be tracked and optimized in real time. The system processes an average of 20,000 instructions per day, increasing resource scheduling efficiency by 40%. By coordinating with the Port of Rotterdam's container exchange route, the container transshipment time has been saved by 1/5.

Customer evaluation and industry impact

Rotterdam Port Group Project Director commented:

"The introduction of BASCO's rugged HMI system was a key success factor in our port crane automation upgrade project. This system not only solves the problem of equipment reliability in harsh environments, but more importantly, provides an intelligent platform for human-machine collaborative operation. Our operators have reported that the new interface is intuitive and easy to use, making it much easier to transform skills. After the completion of the project, the comprehensive efficiency of the equipment has increased by more than 35%, and customer satisfaction has been significantly improved. ”

The Rotterdam Port Authority Operations Manager said:

"This batch of upgraded smart cranes is perfectly integrated into our smart port ecosystem. Through deep integration with the 'new generation logistics' platform, the crane is no longer an isolated operating unit, but an intelligent node of the entire port logistics chain. The implementation of the digital scheduling system has increased the utilization rate of terminal resources by 40%, providing strong support for consolidating the position of the Port of Rotterdam as a global container hub. ”

Industry experts say:

"This project represents the latest in the development of port automation in Europe. In particular, in terms of intelligent processing of human-machine function allocation, the assignment model developed by the project team based on the multi-attribute fuzzy decision theory provides an innovative solution for the human-machine collaborative operation of automated terminals. BASCO's HMIs set a new benchmark for industrial control equipment in extreme environments due to their environmental adaptability and operational experience. ”

Summary and prospect

The successful implementation of the Dutch smart port crane automation upgrade project is a testament to the excellent performance and application value of BASCO's rugged HMI system in the field of industrial control. By combining advanced automation technology, digital management platform and professional human-computer interaction design, the project not only solves the efficiency bottleneck and safety risks in traditional port operations, but also creates a new model of human-machine collaborative intelligent operation.

The successful experience of the project has been promoted in many European ports, providing a replicable solution for the construction of smart ports around the world. With the continuous development of technologies such as the Internet of Things, artificial intelligence, and digital twins, port cranes will evolve towards a higher degree of autonomous intelligence and cluster collaboration in the future. BASCO HMI systems will play an even more critical role in this process as a bridge between physical devices and the digital world.

For the industrial control industry, this project case profoundly reveals an important trend: in automation, digital transformation and upgrading, the human-machine interface is no longer just an operation terminal, but a comprehensive management platform that integrates multiple functions such as intelligent decision-making, collaborative control, condition monitoring, and fault diagnosis. Only by combining hardware reliability, software intelligence, and user experience can we truly unleash the potential of industrial equipment and promote the development of the industry in a more efficient, safer, and sustainable direction.