Intermodal Yesterday, Today, Tomorrow
0 U S Rail Intermodal
Historical Perspective
Began as trailers moved from highway to railcars “Piggyback” in 1950’s
Many movements were “Circus Style” Trailers were driven on /off railcars
Railroads provided most trailers
In early 1960’s lift equipment for rail intermodal was invented
Jack Lanigan Sr. Built first stabilizer beam cranes for lifting trailers and containers
Railroad owned subsidiary trucking companies provided most of the terminal labor forces
Piggyback cars moved in mixed fright trains
1 Mid 1960’s to mid 1970’s
First intermodal unit train initiated Santa Fe Super C from LA to Chicago in 42 hours
Cranes and sideloaders evolve from other industries to intermodal
First intermodal interchange gate “Checkpoint Chico” at Chicago Santa Fe
All Piggyback ramps evolve from parts of railroad switching yards
Piggyback consolidators evolve to sell to carload quantities, ITOFCA,
Some international containers began moving via rails
2 Modified boat hoisting gantry crane in 1956
3 Historical Perspective
1920s-New York Central RR, wooden containers for LCL. - Smithsonian Institution
4 “Piggyback” Trailers in 1960s
5 What were the driving forces that lead to the industry growth in 80’s, 90’s?
Deregulation Inception of Intermodal service companies, terminal operations, truckers Development of intermodal lift equipment Development of articulated intermodal railcars Development of international containerization Development of the Double-stack railcar Development of the domestic containers Intermodal unit trains Major truckload carriers convert business and equipment to Intermodal domestic containers Development of the RF terminal operating systems; EDI Development of Auto Gate Systems Railway mergers
Most innovations came from within the Industry
6 Double-Stack Unit trains
7 J B Hunt changed the game for Intermodal
8 North American Intermodal Loadings 1993 to 1999
12
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0 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003
Trailer Container
9 Growth Rates for North American Intermodal Loadings
25.00% e t
a 20.00% R
h 15.00% t
w 10.00% o r
G 5.00%
e g
a 0.00% t n
e -5.00% c r
e -10.00% P -15.00% 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003
Trailers Containers Total
10 Trend Analysis Conclusions
Containers will continue to be the Primary Intermodal Vehicle
Conversion from Trailers to Domestic containers will continue
Double-Stack Train efficiencies are REAL and here for the long term
Intermodal Car Fleet of the Future is being built for containers
11 Chassis, Chassis, Chassis everywhere ! Pack’em, Stack’em, Rack’em ! (Whack em and Crack em)
Chassis can use up to 35% of terminal parking capacity
12 Other Capacity Support Machines
Empty Container Handlers Stack empty containers up to 8 high
Chassis Rotators Stack chassis 4 high horizontally
Chassis Rackers Places chassis into vertical rack, 9 chassis to one wheeled space
13 Stacking cranes following examples from Ports
Technology to improve safety, efficiency, versatility, and damage-free performance for Facilities Operations. 14 Today…. Containers, containers, and more containers….
Conversion to containers continues
Over 250,000 53 ft. domestic containers in service today
Intermodal terminals growing up, not out
Space at a premium
Between 1996 and 2006 intermodal volumes increased by over 80%
Containers went from 60 % to 90% of volumes
Recession of 2007 over as volumes are up by 20% in 2010
How do we handle the re-newed growth?
15 Wide Range of Solutions..
16 Conventional crane versus stacking crane versus wide spans
17 Memphis Wide Span Operations
18 Memphis Overview
19 Memphis Crane configuration
Production cranes: Double cantilever, 261 ft. Stacking Cranes: Single width, can accommodate 8 ramp tracks @ 20 ft. cantilever, 166 ft. width, track centers, three truck lanes, four rows of four accommodates access to stack high container stacks. Trolley can rotate container rows of production crane (4 high, 4 270 degrees, allowing one-way truck lanes. wide) and can transfer to 5 high, 5 wide stacking rows under span, , 3 truck lanes. “Pitch and catch” container transfer between cranes
20 “I – CAN” Yard Management
Intermodal - Crane Automation Network
Designed to provide required applications for wide-span crane operations
Automated inventory system for railcars, container, trucks, and other equipment using GPS
Distributes work assignments to cranes, trucks, other equipment
Provides logic for organized container stacking operation
Provides safety for all equipment
Provides means to semi-automate crane operations
Same functionality could be applied to RTG’s for aligning over tracks, track pads
21 GPS Automated Inventory, Accuview
MJ and BNSF have co-developed an automated GPS inventory system for use on lift, hostling tractors, and other Hub vehicles Prototype tested / demonstrated at Corwith in Nov. 2007 Aerial photographs are used for display of Hub, parking slots, tracks, buildings, etc. GPS grids are used to identify exact parking slot locations Hostling trucks are tracked throughout Hub, disconnect from tractor fifth wheel indicates new inventory position Other vehicles tracked using GPS; lift equipment, IBC carts Relative positions of equipment will be used as safety alert to operators Lift machine location and steering using GPS Sensors on cranes determine “Y” and “Z” movement determined by latch /unlatch of twist locks, pins or arms Potential to provide exact “Real Time” ramp/ deramp, movement to parking slots, spotting of chassis events Wide Span cranes use sensors to center above tracks, specific railcar wells. Semi-automates loading of railcars
22 GPS using aerial photos
23 Hostler with container in parking stall
24 Memphis Stacking Crane
25 Memphis – Production Cranes
26 Portable GPS Locator (PGL) protection for occupied locomotives
Portable GPS Locator controls A Portable GPS Locator (PGL) will be installed on the front bridge of lead locomotive before the locomotive enters a ramp track. A PGL can also be installed on the lead car of railcars being shoved into a track to protect a worker riding on lead railcar of shove move. The PGL will provide a moving GPS Safety Zone that will prevent any crane movements of suspended loads over the occupied locomotive. This protective zone will be 20 foot wide and extend 400 ft. in front of and behind the lead locomotive The PGL will be installed by placing on the front bridge in center of locomotive by activating the four magnets, and turning on the PGL The PGL will be removed from the locomotive when the engine stops and is no longer under cranes. The PGL can be used for protecting other men and equipment working on tracks under the cranes. Ultimately, it is the production crane operator’s responsibility to ensure that suspended loads are not moved over locomotives or men riding cars on lead cars of shove moves. Movement of suspended loads over locomotives or lead cars of shove moves is prohibited for 400 ft. in front of lead car or locomotive and 400 ft. behind locomotive or lead car of shove move.
27 Portable GPS Locator (PGL) placed in correct position of lead locomotive
Correct placement of PGL on lead locomotive
Correct position to lift and carry PGL (weight 24 lbs)
28 GPS devices on equipment working under cranes will provide safety protection from suspended loads
Moving Work Zone (MWZ) is 300 ft. x 60 ft. using C/L of crane and providing protection from movement of suspended loads 30ft. On each side of C/L for Y and 150 ft. on each side of crane C/L for X. Indicated by red lines . Production crane operators should not move suspended loads within the MWZ of wheel change crane 150 ft 150 ft Crane C/L
Track 1 FWZ(Fixedworkzone) = =300ftx60ft 30 ft Crane C/L Track 2 30 ft
Track 3
Track 4
Track 5 Portable GPS tracker placed on first locomotive
BNSF ENGINE BNSF ENGINE BNSF ENGINE BNSF ENGINE First Platform Track 6
Moving Work Zone for locomotives is 400 feet in front of lead locomotive and protects to the first full platform behind locomotives. Zone is 20 ft. wide. Portable GPS tracker placed on first locomotive Production crane operators should NOT move suspended loads within the MWZ of locomotives
29 “RED” lights over Cart Path= STOP - Do Not Drive Under Crane
1 2 3 4 5 6
Cart Path 3
30 Traffic signals in Truck lanes
Truck lane traffic lights change from green to red in advance of suspended load movement over the truck lanes. Trucks stop to prevent passing under suspended loads. Each light is able to change from red to yellow to green. Loading lane is always yellow, red light in left by-pass lane during loading in truck spots.
31 CSX Wide Span Design Baltimore, Ohio
CSXI wide span facility will open in Jan. 2011. Facility will have five wide span cranes each 301 ft. across, over 8 ramp tracks with 22 ft. track centers, 2 straddle carrier lanes with up to 6 straddle carriers which can clear two stacked containers while carrying one container. Additionally there will be four row four high container stacks available with 2 truck lanes. The facility is designed to be combination of local delivery in Ohio as well as a major re-work facility for combining /consolidating container traffic by lifting and moving containers to new car assignments using straddle carriers as conveyance longitudinal along the 8,000 ft. long ramp tracks. Cranes will be electric RMG’s very similar to Memphis production cranes, but larger. As result of the massive structure, understand cranes will require a superstructure above the top beam to stabilize the structure ad 60 ft. long cantilevers on each end.
CSXI 5 Wide Span cranes 301 ft. span Kunz / Mi Jack Cantilever 60 ft. Cantilever 60 ft. Straddle carriers CAB 1 over 2 high Container stacks 1 over 4 Wheel Change crane
DS Two Truck car lanes 4 rows , 4 high TRACK 1 2 3 4 5 6 7 8 2 drive aisles for straddle carriers Eight ramp tracks on 22 Kunz will build the wide span cranes. The straddle carriers will be ft. centers able to travel up to 17 mph. CSXI will also install a wheel change crane similar to the Memphis WCC. CSX will also use up to 8 IBC WS crane lifts 1 over 4 carts and will use the same GPS safety and worker alert systems we containers developed for Memphis. Mi Jack will provide maintenance for all cranes and GPS systems. Terminal Operating system is not determined at this time, but considering RMI / Oasis I CAN product. Two Straddle carriers lift and carry I over 2 containers
32 2010 and Beyond
Challenges = Environmental, Safety, Productivity Electric cranes, Hybrid cranes Automation Labor force Safety More and improved work processes Work rules and definitions Continued containerization UPS, England and Hunt Reefer containers Flatracks, CSU’s, Tank container, other new and specialized containers “CALs” (Container Auto Lock Systems) Conjoined / oversized containers More AGS Efficient, Cost effective, more information Continued learning curve for better utilization Damage-Free Handling Alternative container movement technologies MJ Pathfinder Container conveyors Electric container carriers similar to commuter trains Full Integration the Intermodal Networks to Improve efficiencies for all
33 Hybrid Cranes
Built by MJ First unit to be installed on UPRR at ICTF this month. Powered by 108 “truck batteries” Small diesel engine (180 HP) is used to re-charge batteries as required. Runs up to 45 min. per hour or estimated 30 lifts and computer initiates re-charges automatically No “Down Time” for re- charge Uses cables instead of “hoist chains” All electric motors No hydraulics Quiet smoother operational functions Faster speeds
34 Specialized containers
35 AGSAGS Process: Process:
Trucks pass through Portal with line scan Trucks then proceed to kiosks to complete digital cameras equipped with Optical input for gate transaction. Character Recognition, OCR
36 Driver completes transaction at Kiosk
In-Gate Biometric ID (2 fingers) Out-gate: Uses bar code from and inputs seal number ingate, inputs Pick-up number
37 Roof and rear views
Images provide views of roof, sides, front and rear of containers, chassis, tractors. Storage of equipment images for claim resolution for one year.
38 MJ Pathfinder 2HiLab04KMiJack.wmv
Pathfinder Possibilities
Automatic Container Stacking / Racking System
Drive activates lifting of container to / from chassis
Can “Rack” containers up to 4 high
All sizes
Integrated with crane into “Skybridge”
Adds automatic lift / flip capacity
Full scale prototype in operation at MJ
Lift capacity in every truck space
39 WIDE Range of Solutions…
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