AERO-MATRIX CUBE SYSTEM 42,000 TEU’s
The major components are: A) Automated High Rise storage “Cube”, B) Inbound and Outbound X-ray and C) automated truck, rail and trans-shipment systems.
- Component one is a structural steel automated storage rack (Cube) system that houses approximately 42,000 shipping containers (TEU’s) used to ship freight onboard ships. 42,000 TEU’s on 31 Acres versus the 42,000 TEU’s on 170 Acres. The Cube can be configured into multiple Cube’s spread out over the wharf’s water bulkhead and interconnected by a two level bi directional conveyor to interconnect the multiple Cubes to work as one large cube as above. Multiple Cube systems are typically required in larger ports that have long ship mooring bulkheads. This design allows for simultaneous loading and unloading of ships and their containers. The Multiple Cube design enables the CLW system to operate as one total system and accommodates rapid transshipments. This automated “cube” has the ability to automatically “sort” containers into any sequence required. Some of the “sorts” are created to facilitate local and regional distribution from the port, direct trans-shipment to a ship or to awaiting rail transportation and “sorting” to facilitate the nearly simultaneous reloading of a ship thus shortening the ships time in the port. Sorting can be done by suspect containers requiring further manual inspection to identify contraband items or illegal substances. No containers can be moved without the systems direct control by high level management or Customs (CBP). The cube is built in smaller modular sections to accommodate current land use needs and yet support significant future container storage needs.
- The next component is the installation of third party automated x-ray and nuclear detection equipment that inspects 100% of the containers arriving into a port. The CUBE can be configured to also x-ray 100% of the containers being shipped out of the port. Part of this unit is an elevated storage deck for the ships Hold Covers. Each set of covers will be in alignment with the ships holds.
- The last major component of the CLW system is the over the road truck loading and/or the loading of rail cars in an integrated transshipments rail area. Loading and Unloading of outbound trucks and rail cars happens with simple automation.
A typical CUBE system size for a large port like Long Beach CA would have multiple Cube’s approx. 10,000 TEU’s each with 4 totaling 1220 feet long by 922 feet. Built from the Quay Crane apron to the outside of the truck staging areas having 10 LEVELS tall and has a total square footage on all floors 11,248,400 ft.² (ten floors). The CUBE is modular based construction allowing future expansion in sections or smaller sizes can be built (10,000 min.). The rack system holds 42,960 TEU’s (twenty-foot equivalent unit, a measure used for capacity in container transportation). CLW has designed the entire systems automated CUBE equipment and operating/tracking software. The system has built-in antitheft prevention. X-Ray and Nuclear detection is performed as the inbound containers come off of the ship in line from the Quay Crane to the Cube. Outbound containers are x-rayed as they enter the cube on the input side and sorted for loading onto the correct outbound ship. The entire system (Cube, X-Ray, Load and Unloading) is scalable downwards for smaller ports or upwards for ports such as Port Miami, Savannah and Rotterdam.
The heart of the CLW system is (See matching numbered sections for details)
- CUBE management software
- Transfer shuttles
- Up/down Elevator loader which transfers containers to another CUBE level/floor and to and from truck/rail loading elevators
- Carrousel roller bays with side shifting, all Powered by Rockwell Automation
- Simultaneous ground level loading for trucks and rail. All the following components are completely automated robotics by proven AS/RS (Automated Storage/Retrieval System) software.
CUBE Management Software (CMS)This is proprietary coded software performing the complete management of all the container movements, sorting requirements of the cube, memory/documentation of shipments, sequencing of containers for land, outgoing containers, transshipments to mention only a few.
Transfer Shuttles (TS)There are from 2 to 8 or more shuttles on each level of the CUBE. These machines are capable of transporting and transferring out of each carousel containers into another sorted carousel and/or move containers to an up/down transfer elevator. Each shuttle is capable of moving and transferring the heaviest container shipments at fast speed and accuracy.
Up/Down Elevator Loader (EL)These machines are high speed versions of 100 year old technology used for freight elevators in high rise buildings and factories but Computer Controlled for speed and accuracy. Each up/down elevator loader accepts or discharges containers between levels of the CUBE and or is capable to load and unload rail cars or trucks on the ground level of the CUBE. These machines travel at a rapid rate of speed from 0 to 20 feet per second. That means that in a 180 foot tall structure the elevator will load a container handed off to the elevator by a transfer shuttle in < 20 seconds. That equates to an average cycle time in the CUBE in the up or down movement is 10 seconds. These Elevators are interfaced through the CMS and computers to assure that each container is located in the correct spot and loading containers onto the correct rail car or truck for ultimate delivery to the owner of the freight within each container. These EL’s will be outboard of the main cube to keep truck traffic a “safe” distance away from the CUBE structure itself. Depending upon loading and unloading requirements at each installation the EL’s can be set up in multiple arrangements on each end of the CUBE to meet throughput requirements.
Carousel Roller Bays (CRB)In most CUBES holding 42,960 containers there will be 50 per floor container CRB’s that are approximately 377 feet long by 20 feet wide and 12 feet tall levels. Each of these CRB’s has two sets of modular container transfer tables. The transfer tables are capable to move either forward or backwards to allow containers to rotate either in a clockwise or counter clockwise rotation. On the aisle end of the CRB is a section that allows the lifting and then side shifting of containers on the carousel. This side shifting operation creates a constant circular flow motion within each of the 50 CRB’s per floor within a standard 42,960 container CUBE. The use of an individual CRB can be to store all refrigerated containers for monitoring of their refrigeration units, storage of Bulk Containers such as those used to transport loose Nickel pellets for use in foundries and steel mills, sort containers by their shipping point such at Wal-Mart or Dillard’s Department Stores. The containers can be stored within CRB’s for being shipped out on a new outbound ship so that loading of that ship can occur rapidly and accurately. Any reason to sort can be accomplished with a CRB or series of CRB’s. These units define flexibility of the CLW Cube Systems. Agricultural and hazardous cargo will have its own storage area as designated by insurance and Port Customs rules. Current container storage requires often 2 or 3 containers be moved to access a container needed often at or near bottom of stack. This wastes tremendous time and adds significant costs that our Cube/CRB system eliminates.
Powered by Rockwell AutomationOur motion control, system management and computer partner is a NYSE, 7 Billion dollar per year in sales and global company. R.A is the exclusive power supplier to CLW. PLC (Programmable Logic Controllers –computers), electric motors, drives (units that control speed/RPM, direction, horse power and torque, position of the motor shaft for maintaining location, laser for safety and location of humans, containers, rail cars and all other aspects of the system are manufactured by RA. Rockwell Automation is the sole owner of Allan Bradley motors and controls which is also an American company that has been in business for over 108 years. Rockwell Automation supplies CLW Clients worldwide with local service throughout the World for CLW. RA, with its staff of over 3,000 technicians and over 1000 part depots from New York, Miami, Atlanta, Houston, Dallas, Chicago, Los Angeles, Singapore Honolulu, Melbourne, New Delhi, Dubai, Cape Town and too many more to list is a world class leader in the field of powering automation equipment. Within North America RA controls over 60% of all motion systems made or supplied. Needless to say “the sun never sets on our parts supplier and service organization”.
Total Maintenance & Repair Centers ( TM&R ) (Including Preventative Maintenance (PM) )The system will require preventative and operative maintenance services. All components are modular so inter-changeable. In system designs having multiple CUBE’s each CUBE will have its own maintenance building contiguous to the CUBE. Here spare parts for all components will be warehoused and disassembly and assembly areas will be available to have complete inter-changeable modules available for immediate exchange in the CUBE, CRB’s and virtually all components of the machinery. These services will be provided by the CLW and our powering partner, Rockwell Automation. Within the CUBE are integrated component “cranes” for quick exchange for system modules.
The CUBE by CLW is all electric which will significantly reduce fuel consumption of diesel fuel and oils including reduced trucks, fork lifts, wheeled cranes and other management vehicles currently required with in any of the large Ports around the world.
SUMMARY OF BENEFITS
- 100% X Ray Inspection detecting Cargo, Nuclear and explosive sniffing in line as containers are loaded or removed from ships.
- Significant Increase to Port Container through put efficiency
- Shorter delivery time to import customer
- Reduced direct labor force per TCU
- Increased through put of containers so exports/imports can be increased at lower cost maximizing profit.
- Land Savings - CLW is unique as “we create land” and a huge amount of land/space from the existing property by utilizing air space. Think of the CLW equipment as a “Vending Machine” for the world’s sea going freight containers.
- Reduction of the Carbon Foot Print emitted by the ports equipment as diesel equipment is minimized and some eliminated.
- Shortens Import and Export Cycle times.
- Reduce the impact that the increased number of truck trips would have upon the regional highway loads by Ghost Truck Traffic Control. ( CLW’s Traffic Master system )
- Increases the Ships fuel efficiency as it relates to cost per container delivered. This is because the shorter time the ship is in the port the less fuel is burned just to keep the ships systems operating instead of making flank speed progress towards the next port-of-call.