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1 INTRODUCTION
Globalization of business activity, which is a factor
generating the growth of cross‐border flow of good
hasledtotheincreaseinthevolumeofthecontainers
servicedintheseaports.Theseaterminals,playingan
importantroleininternationaltransportTEUmustbe
ready for the
service of growing number of the
containers [9],[15], and to achieve higher efficiency,
they must follow the directions of „4th Industrial
Revolution” and idea of „Industry 4.0”. One of the
waysofincreasingefficiencyistheautomationofthe
processesusingenergy fromrenewablesources[13],
[1]. The
handling terminals in the chains of
intermodal transport use modern automated
technologiesintheprocessofunloading.Oneofthem
isautomatedguidedvehicles(AGV)forrelocationof
thecontainersfromortotheshipfromstorageplaces.
ThereliabilityofpositioningandnavigationofAGV
vehiclescanbeachievedin
manyways,andthefactor
responsible for choosing a method is working area
(internalorexternal).
Themostpopularnavigating methodsinclude[3],
[5],[6]:
Amethodofinductionloopusingflowofcurrent
inthewireandgeneratingmagneticfielddetected
bytrolleysensors.
A method of
magnetic loop, which is similar to
inductionloop,butthesourceofmagneticfieldis
different. In this method, a band made of
ferromagneticmaterialthatallowsquickchangeof
therouteoftransportisusuallyapplied.
Amethodofreflectivelineusingcameratracking
thelinespaintedwithreflective
paintorliningthe
roadwithreflectiveband.
Amethodoflasernavigationdetermininglocation
coordinates towards laser beam emitted by the
scanneronthetrolleyandregisteringenvironment
looking for the points reflecting laser beam and
identifyinglocationofavehicle.
Gyroscope method, which requires additional
device
–gyroscope,placedonthetrolleyinorder
to detect changes of driving direction and
transpondersplacedinthecrucialdrivingpoints–
arcs,stops,etc.
Technological Process of Spreading Coatings Over
Structural Details of Automated Guided Vehicles Used
for Relocation of the Containers
Z.Łukasik,A.Kuśmińska‐Fijałkowska,J.Kozyra&P.Czajka
UniversityofTechnologyandHumanities,Radom,Poland
ABSTRACT:Theauthorsofthisarticlepresentedtechnologiesofspreadingcoatingsoverstructuraldetailsof
automatedguidedvehiclesusedinthehandlingterminals.Technologicalprocessofpaintingwiththeuseof
powder paints was presented, as well as innovative methods of surface preparation with
the use of
BONDERITEM‐NT2011technologyandOXILAN9807preparation.Modernmethodsofsurfacepreparation
withproductionofsilaneconversioncoatingswerepresentedandanalysed.Theauthorsofthisarticleselected
asystemofguaranteedpowersupplyoftheprocessinglines.ABCUSsoftwarewasappliedtocheckthe
timeof
batterybackupofUPSunitsinselectedN+1system.
http://www.transnav.eu
the International Journal
on Marine Navigation
and Safety of Sea Transportation
Volume 12
Number 4
December 2018
DOI:10.12716/1001.12.04.19
788
A method of a coordinate system based on the
reference points placed on the floor of the object
allowingtocoordinatethelocationofa trolleyin
space.
Ultrasoundmethodemittingand„listening”ofthe
return of signal reflected from vertical surfaces
allowingtoestimatedistancesfromthe
object.
GPS method using satellite system and GPS
receiverplacedonthevehicle.
2 AUTOMATEDGUIDEDVEHICLESUSEDFOR
RELOCATIONOFTHECONTAINERS
Theapplicationofautomatedguidedvehicleslargely
affects optimization of flow of goods, improving
general operational efficiency in the terminals and
competitiveness of the seaports (Fig.
1) [14]. Due to
various sizes of the containers, the dimensions of of
AGV vehicles must provide transport in many
configurations (Fig. 2). The sizes fluctuating around
15meterslong, 3meterswideand2metershighofa
loading platform provide load capacity up to 70
tonnesandloadingof
[7],[8],[9]:
1 One container of total weight fluctuating around
40tonnes(20,40,45‐footcontainers).
2 Two containers of total weight up to 70 tonnes
(two20‐footcontainers).
Figure1.Maritimecontainerhandlingterminal
Figure2.Automatedguidedvehicles
Thecollisionsinroadtrafficarepreventedthrough
transhipmentcontrolsystemusuallyoperatinginthe
Just‐In‐Time mode (JIT) cooperating with other
components of a terminal, for example, mobile
transhipmentcranes[8],[9].
The advantages of implementation of
transhipmentcontrolsystem:
Preventionofcollisionsbyusingthesensors.
Traffic improvement by eliminating the need of
slowing down, stopping or accelerating in the
interchanges of high driving frequency
(crossroads,narrowsections).
Optimizationoftimeneededfortranshipment.
24‐hoursupervisionoftheprocess.
Energysaving(thereisnoneedtoilluminatefully
automatedzones).
Properoperation
ofinspectionsystemisbasedon
theset ofsensors, whichis an additionalequipment
oftheplatformsselectedindividuallytotheneedsof
theprocess.Theapplicationofstructuralelementsof
AGV vehicles (engine, battery, sets of sensors and
transmission antennas) sensitive to damages forced
theirprotectionwiththeshields
resistanttodamages
and weather conditions. The metal sheets that they
aremadeofmustundergo theshapingprocesseson
the automatic press brakes changing their initial
shape. Formation process depends on the size and
shape of automated guided vehicles. Basic set of
shields consists of front, back and side
shields, and
their number and arrangement depend on the
structure of a vehicle, location of a drive unit and
other elements of its structural system. Then,
processed shields are transferred to subsequent
phasesoftheprocess–varnishingandassembly.The
orderof varnishingprocesswas presentedon figure
3.
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Figure3.ThephasesoftheprocessofvarnishingthedetailsofAGVvehiclesintheautomatic processinglines
3 TECHNOLOGICALPROCESSOFSPREADING
COATINGSOVERTHEDETAILSOFAGV
VEHICLES
Technologicalprocessofpaintingwiththeuseofthe
powderpaints takes place in modern automatic line
inaccordancewithfollowingphases[2]:
The process of washing and degreasing of the
detailson thecrossbars (PHASE II) with production
ofsilaneconversioncoatingstakesplaceinfive‐zone
automatic spray washer that includes the following
stages(Fig.4)[4]:
1 Washinganddegreasingofthesub‐assemblies.
2 Rinsingintapwater.
3 Rinsingindeionizedwater.
4 Passivation with production of BONDERITE M‐
NT2011conversioncoating.
5
Rinsingindeionizedwater(„demi”).
Figure4. The stages of the process of washing and
degreasingBONDERITEM‐NT2011
Alternativestages(Fig.5)[10]:
1 Washing and initial degreasing of the sub‐
assemblies.
2 Fundamentalwashinganddegreasing.
3 Rinsingintapwater.
4 Rinsingindeionizedwater(„demi”).
5 Passivation with production of silane conversion
coatingOXILAN9807.
Figure5. The stages of the process of washing and
degreasing OXILAN 9807 depending on the type of the
process
Rinsing in deionized water in this technology is
veryimportantbecauseitremovesallionicpollutants
from the surface and increases the level of
anticorrosiveprotectionofthesub‐assembliesofAGV
vehicles. After drying operation, the details are
painted automatically and hard‐to‐reach places are
manuallydusted.Inthe
processofpainting,colourof
powder paint can be quickly changed without
technologicalstoppages.Painteddetailsareputinto
thestove,wherecoatingsarehardened.Finalphases
(VI, VII) of the process include cooling down and
unloadingfromthecrossbarsofpainteddetailswith
visual inspection. During technological process, the
details are transported by automated overhead
transport.
Thefollowingdevicesarenecessaryforcontrolling
technologicalprocessofpowderpainting:
1 pH meter measuring pH of analysed chemical
substances.
2 Adeviceexaminingwaterconductivity.
3 Adeviceexaminingadhesionofthepaintcoatings.
4 A device examining thickness of the paint
coatings.
5 Time andtemperature recorder in the stove with
fourmeasuringprobes(3onthedetails+1air).
6 Chemicalfumehoodforchemicalanalyses.
Technologicalprocess ofpaintingwith theuseof
powder paints with preceding process of preparing
theirsurfacesmaketheproducts(s tructuralelements
of automatic AGV vehicles used in the handling
terminals for relocation of the containers) properly
protectedagainstcorrosion.
4 APPLIEDTECHNOLOGIESINTHEPROCESSOF
SPREADINGCOATINGSOVER
STRUCTURAL
DETAILSOFAUTOMATEDGUIDEDVEHICLES
ANDTHEIRQUALITY
Technology of electrostatic painting with the use of
powder paints and preceding process (phase II) of
preparing the surface of the details based on
innovativetechnicalandtechnologicalsolutionswere
appliedforpaintingdetailsofthevehicles.
Technology of electrostatic painting
with the use
ofthepowderpaints
Technology of electrostatic painting with the use
ofthepowderpaintsusespowerofelectricfieldin
the process of spreading paint particles over the
details [16]. Unlike electrostatic painting with
liquid paints in powder technique, coating
material, which is the so‐called
overspray, is
790
returned again through recovery system (cabin,
cycloneand/orfilter)totheapplicationdevice.Itis
possible to use it completely – between 85% and
99% depending on the type and efficiency of
recoverydevices.
Thepowderpaintsandtechnologyofelectrostatic
paintingperfectlycomplywithrecentdirectivesof
the European
Union, having all features of
modern manufacturing technology. Harmful
componentsarenotemittedtotheatmosphereand
working environment in the process of
application. Whereas, the coatings made of
powder paints belong to the group of „high
performance”coatings–verydurableandhaving
unique protective and decorative properties.
Technology
of electrostatic painting with the use
of the powder paints is called the best available
technique(BAT).
Technology of preparing the surfaces of the
detailsforpainting
In the process of anticorrosive protection of the
products – production of protective layers, the
fundamental element preceding painting is
ground preparation [17].
The main goal of this
processingisachievementofsuchsurfacefeatures
ensuring good adhesion and slowing down the
corrosion processes. Even the best painting
material spread on poorly prepared surface has
poorer protective properties and worse adhesion
tothegroundmanifestingin(afterrelativelyshort
period of time of
product exploitation)
delamination (loosening) of the coating from the
ground. The methods of surface preparation
applied in practice can be divided into two
fundamentalgroups:
mechanicalmethods;
chemicalmethods.
In practice, mechanical and chemical processing
are usually combined. Knowledge and specialist
literatureofsurfacepreparationshowthatpopular
technology
of preparing metal grounds (steel,
galvanized, aluminium) for varnish coatings
(powder)isferric(amorphous)orzinc(crystalline)
phosphating – in the cases whenbetter corrosion
resistance is required. In the engineering and
automotive industry, where better corrosion
resistance is required, the so‐called tri‐cationic
phosphating (zinc‐manganic‐nickel) is
applied. It
isanunstableprocessthatformslargeamountsof
sludge (pollution) containing heavy metals (Zn,
Mn i Ni) that are hard to utilize. Despite the
defects of phosphating process described above
(sludging, content of heavy metals, high
temperatures of the process), due to very good
anticorrosivepropertiesofa
conversioncoatingin
combinationwith paint coatings, this process has
been applied in the industry so far and it was
difficult to find any substitute. The aspects of
environmental protection and safety rules in the
workplaces have become fundamental now. The
actionsofmanyspecialistsleadtodevelopmentof
agents
for surface preparation, of which
fundamentalfeatureiseliminationorreductionof
pollutions to the environment (gas, liquid and
solid pollution). In the implemented line of
spreading coatings over structural details of
automatedguidedvehicles,surfacepreparationis
automatic processing with the use of innovative
preparationsdevelopedbythecompanies:Henkel,
Chemetall. Technology developed by Henkel is
based on newly‐developed zirconic preparation
Bonderite M‐NT 2011, whereas, technology
developed by Chemetall is based on silane agent
Oxilan9807[1].
4.1 Technology‐Henkel
The processes of washing and degreasing with
production of zirconic conversion coating take place
infive‐zonewasher
withtheuseofnewly‐developed
BONDERITE M‐NT 2011 preparation. Applying this
technology allows to eliminate the process of
universally applied standard ferric phosphating,
whichformsalotofsludging,thatis,largeamountof
wastethatneedstobeutilized(costs),whichposesa
threat to environment (in some
countries, the plants
applying ferric phosphating must get a license
allowingtouseit)(Fig.6)(Fig.7)[1].
The main advantages of this technology in
comparisonwithferricphosphatinginclude:
reduction of formed sludge – reduced
environmentalpollution;
longertimeofbath„life” (even2–3
times);
reduceduseofrinsingwater;
the option of processing of steel, galvanized and
aluminiumproducts;
energydemandloweredbyabout30%;
thinner protective layer improving quality of
preparationofthesurfacesbeforepainting.
Figure6. The comparison of the capabilities in the case of
zincphosphatingwithBONDERITEM‐NTresults[11]
Figure7.Thecomparisonofthicknessofthecoatings[12]
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Technology of preparing the surfaces of the
productsbeforepaintingbasedonBODERITEM‐NT
2011processisontheofthebestavailabletechniques
(BAT) and it is of innovative character. It was
developedin2011andlaunchedtotheSwissmarket
in 2012 [1]. It was implemented
for the first time in
Polandin2013.
4.2 Technology‐Chemetall
Thistechnologyisbasedontheendprocesswiththe
use of OXILAN 9807 preparation. It belongs to the
groupofsilanechemicalagents,siliconcompoundsof
generalformulaRSi(OX)3.Itconsistsofpolysiloxane
andzirconiumintheform
offluoridecomplex.These
compoundsreactwith surfaceofthemetals forming
thin,conversioncoatingpermanentlyconnectedwith
thegroundandvarnish coating. Thewholeprocessof
surface preparation takes pla ce in four to six stages
dependingon the typeofselected process. OXILAN
9807 does not contain heavy metals
and phosphates
[1].
The main features of OXILAN 9807 are the
following:
itdoesnotcontainheavymetalsandphosphates;
shortprocessingtime(afewseconds);
nosludge(solidpollutants);
final rising is not required – no use of water
(significantproblemandcostofprocessingof
the
groundsbeforepainting).
Technologywiththeuseofthispreparationisan
importantstepforwardincomparisonwithstandard
processingofphosphating.Theresultsoftheresearch
on corrosion properties (research in the aerosol
chamber)of conversioncoatings producedinOxilan
9807processaregoodenoughtobecomparable
with
coatings obtained as a result of cataphoresis, which
are popular in the automotive industry (the highest
requirements).
Just like the one above, technology of preparing
thesurfacesoftheproductsbeforepainting
based on OXILAN 9807 process is one of the best
available techniques (BAT) and it is of innovative
character.
Going through all phases of the process of
technological powder painting guarantees
appropriate quality, long‐term operation and
durability of the details. Quality acceptance of the
details produced in technology of electrostatic
painting with the use of powder paints includes
checkingspecificvalues demandedbytheclients.In
order to meet expectations of the clients, painted
parties are checked by controlling the values of
micronsofspreadcoatingandadhesion ofthe paint
coatings. The details come into use if they meet
minimumassumedbeforetechnologicalprocess.
5 THESELECTIONOFGUARANTEEDPOWER
SUPPLYOFPROCESSINGLINEOFSPREADING
COATINGSOFTHEDETAILSOFAGV
VEHICLESUSEDFORRELOCATIONOFTHE
CONTAINERS
N+1systemwasacceptedfortechnologicalprocessof
spreading coatings over the details, in which the
higherpriorityofacceptance,thehigher necessityof
using solutions that are not based on static
workaround [18]. Parallel redundant configuration
allows for failure of one of UPS units without
transition to power supply directly from network.
Twoormoreunitsofthesametypeworkatthesame
time. This configurationrequiresforeveryUPSunit
tohavepowerhigherorequaltopowerdemandedby
the receivers. Therefore, UPS units
may work
synchronously and parallel, that is, load must be
divided.Everyunitmaybeputawayfortheperiodof
service in the uninterruptible way. Service
workaroundisstillrequiredintheeventofserviceof
a bus‐bar [2]. Among many advantages of this
solutionis,aboveall,
highdegreeofreliabilityofthe
system– higherthaninthecaseofN configuration.
Oneofthe main defects is creation from single bus‐
bar a system point, which, in the event of a failure,
causesfaultyoperationofthewholesystem.ABACUS
softwarewasappliedinorderto
determinethetime
of battery backup for accepted UPS units in N+1
system.Anoutlineofthesystemofguaranteedpower
supply N+1 and time charts of battery backup for
designedsystemwerepresentedonfigure8a,b.
Figure8. Guaranteed power supply of processing line of
spreadingcoatings:a)anoutlineofN+1system,b)timeof
batterybackupofUPS1andUPS2unitsforthevariantsof
15 minutes and 30 minutes of supplying processing line
obtained in ABACUS software, ATS‐Automatic Transfer
Switch,PDU‐PowerDistributionUnit
6 CONCLUSIONS
Systematizationofoperationofthehandlingterminal
largely contributes to increasing the efficiency of
logistic operations and improving transhipment
works. The use of automated guided vehicles and
automationoftransportareaswillleadtoincreasing
the level of competitiveness and constant
improvement of transport processes. Modern
methods of spreading
surfaces largely improve
varnishing process and affect the quality of the
coatings.
792
Thebasicadvantageoftechnologyofelectrostatic
painting with the use of powder paints used in the
handlingterminalforrelocationofthecontainersis:
Noemissionofsolvents‐100%reductionofVOC
(VolatileOrganicCompounds).
Reductionofsolidpollutantsthroughrecyclingof
powder.
No emission of harmful
substances during the
processes of coating production (painting) is very
important for the workers doing painting works
(health and safety rules at work). The order of the
MinisterofEconomyandLabourofOctober20,2005
Dz.U. [Journal of Laws] no. 216, item 1826
implementing recommendations of the Directive
2004/42/EC
on reduction of emission of volatile organic
compoundsasaresultofapplicationoforganicsolventsin
somepaintsand varnishesandproductsforrenovationof
the vehicles imposes high requirements concerning
reduction of the content of volatile organic
compounds(VOC)inthevarnishingproducts.These
compoundscontributetodepletionof
ozonelayerin
stratosphere and formation of summer smog in
troposphere.
An important issue in the manufacturing
technological processes is the aspect of guaranteed
power supply. The main objective of selection of an
appropriatesystemistheabilityofselectedsystemto
increase the reliability of power supply in order
to
prevent stoppages during technological process.
Battery system is supposed to guarantee, above all,
uninterruptible power supply in specific time for
failure removal. N+1 of UPS system selected and
recommendedby theauthors guarantees completion
ofcommencedoperationofspreadingcoatings,which
can be continued without losses after power
restoration. However,
it must be taken into account
thatacceptedvariantofguaranteedpowersupplyfor
consideredtechnologicalprocessfor15and30‐minute
backup, will considerably increase the costs of not
onlyofUPSsystemwiththebatteries,butalsoofthe
wholeelectricityinfrastructure.
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