CONTROLS: Emulation of Container Terminal Control Software

The Terminal Operating System (TOS) of a container terminal forms the heart of the terminal operation.

It keeps track of all container positions in the stack and it handles large quantities of information. It decides, using a number of control strategies, on container grounding locations and equipment deployment and dispatching.

A number of off-the-shelf solutions are available on the market for new terminals. Implementing a new TOS is a high impact activity for any terminal and, as the system change happens while the terminal is in operation and needs to continue performing, it is essential that problems are kept to an absolute minimum.

Container Terminal Optimised Logistics Simulation System

TBA has developed a methodology in which the TOS is tested before it is actually deployed using advanced simulation models. This approach is addressed as "emulation". TBA's CONTROLS (CONtainer TeRminal Optimised Logistics Simulation), is an innovative emulation tool. It is designed for the testing and tuning of control software, such as Terminal Operating Systems, as well as for the training of the human operators of the TOS.

The emulation is realised by linking the physical computer hosting the TOS to another, whereby the second computer runs a simulation model of the real terminal that comprises all relevant terminal processes. Using the identical protocols used for communicating between the control software and the vehicles that this software is controlling, the TOS thinks it controls the real system, rather than a mere model of the system.

CONTROLS Terminal Operations Simulation

The TOS operator, i.e. the yard planner, the dispatcher or the vessel planner, operates the normal user interface of the TOS, and can perform his work as if controlling an actual operation, therefore rendering the tests as realistic as possible. The simulation model of the terminal operations is comprehensive and includes regular as well as special operations, such as reefer handling, empty handling, traffic to customs inspection or the CFS, and so on.
CONTROLS aims to achieve three different objectives:

• Testing and validating the TOS functionality, thus ensuring error free operations by extensively assessing the complex conditions before going live.
• Tuning the TOS parameter settings (yard and equipment control settings) in order to get the highest possible performance.
• Training the human TOS operators without hindering live operations, and allow the operators to prepare for all kinds of irregular operations.

Terminal Operating System Testing and Emulation

When a terminal purchases a new Terminal Operating System, it is needs to ensure that the TOS is without bugs and performs smoothly during live operations, under all possible circumstances. In current practice it is very difficult to test the TOS when the terminal is in business, as this would immediately change the current state of play and significantly hinder operations. However, without thorough testing beforehand only a part of the potential problems that may arise at implementation are uncovered.

Issues may then surface just after the go-live date, or even following a longer period. As a consequence the operating routines are disrupted, resulting in high costs and a considerable loss of time and effort. In the CONTROLS emulation set-up, the TOS is linked to a simulation model in such a way that the TOS thinks it controls a real terminal, and thus it allows for extensive detailed testing under all kinds of circumstances without influencing the actual operation.
The emulation approach aims at (and has proven to accomplish):

• Shorter lead times while implementing a TOS and a reduction in the need for testing with real equipment;
• Higher performance at commencement of operations;
• A significant reduction in errors while operating the TOS, leading to an equal reduction in the disturbance of terminal operations;
• An ability to take endeavours to the next level by focussing efforts on optimising performance, rather then by necessity directing them solely on getting the TOS to function at its basic level.

Tuning Day To Day Terminal Operations

Besides testing, the link between TOS and CONTROLS allows for:

• The running of future operations ("the next shift") in order to validate the planning results, and compare various options, such as crane splits or equipment deployment ("2 or 3 strads per crane").
• The replay of past operations in order to review experiences and compare different system settings (expert decking, equipment control and deployment, crane split).
• The creation of (fictitious) future terminal operation scenarios in order to check the operating strategies under higher densities and/or volumes.

Screenshot CONTROLS application for straddle carriers

Terminal Operating System Operator Training

The staff in the control room form a critical part of today's terminal operations. It is therefore advisable, if not essential, to train staff members in vessel and yard planning, as well as equipment deployment and dispatching. Particularly in dense operations, the risk of deploying untrained staff can lead to serious errors, with a resulting loss of productivity, and is therefore unacceptable.

CONTROLS allows for training and preparation for even the most complicated and rare situations, without the risk of mistakes and the resulting negative impact on the real operation. It immediately provides visual feedback and demonstrates the effect on the achieved level of productivity.

Features of CONTROLS

• Faster than real-time testing, thus allowing for error detection months in advance;
• Detailed on-line visualisation of equipment and container movements, both in actual as well as in replay mode.
• Detailed on-line and off-line statistics regarding equipment and equipment status;
• Creation of future scenarios, using the scenario management capability;
• Loading and reloading real data from past operations, allowing for testing and tuning based on the terminal's needs;
• Integration with various TOS packages, such as SPARCS from NAVIS, TOP-X/TOP-O from RBS, and SPACE / TRAFIC from COSMOS.