CORDIS Archive

Project Coordinator: 3T Design Limited

Linpac Material Handling GmbH
Chep UK Limited
ABG Limited

Project Duration: 1st January 1998 to 31st March 1999

Date: 17th May 1999

1.0    Project Title
2.0    Partnership
3.0    Objectives of the TACTICS Programme
4.0    Technical Description
5.0    Technical Results and Issues
6.0    Conclusions
7.0    Collaboration and Exploitation

The Automated Conveying and Transfer of Intermodal Cargo Shipments

The TACTICS project was established to show that by research, analysis and demonstration, loading bay and intermodal transfers of palletised goods can be fully automated, electronically managed and networked into existing computer based logistics without changes to established transport systems.

The programme set out to demonstrate that it is viable to transfer palletised goods in an uninterrupted recyclable intermodal distribution chain. Goods can be packed at source and delivered in returnable packaging in a fully automated, monitored and audited cycle. Current practices require excessive packaging and multiple handling operations at numerous points in the transport chain.

4.1 The Automated Intermodal Distribution Cycle

The research and development stages yielded two strategically important results for the TACTICS group;

• a seamless automated distribution cycle for palletised intermodal freight transfer and return cycle.
  
  
• an integrated range of solutions for small loading units, automatic transfer equipment and electronic management methods.

4.2 Small Load Units (SLUs)

To achieve reliable automation the system has to be based on uniform defined loading units SLUs. The loading systems and SLUs used in the TACTICS system are base on the majority of standard ISO pallet formats.

4.3 Bulk Load Units (BLUs)

The TACTICS material handling systems will also enable bulk loads to be transferred in the same automated intermodal cycle. Bulk loads can be transferred as complete vehicle consignments either as a matrix of SLUs or as a single customised load.

4.4 TACTICS Automated Loading Units (ALUs)

• MAGNUM ALU for intermodal transfers at one fixed location.

• EXCALIBUR ALU for intermodal transfers between two different locations.
• SHOTGUN ALU for complete vehicle single load intermodal transfers.

All ALUs can be used in the principal intermodal locations to complete the more common transfers;

• loading bay to semi-trailer

• loading bay to container

• loading bay to railwagon

• vehicle to vehicle (vehicle = semi-trailer, rail wagon, container)
• cross docking

4.5 Electronic Management Systems

The TACTICS system uses embedded radio frequency (RF) electronic tags to identify the SLU, the vehicle or container during the distribution cycle. The tags are used as basic coding devices to reduce complexity and cost in this application. They can be read or rewritten at a terminal located at every transfer point.

Each intelligent terminal has the possibility of being networked using telecommunications networks or the Internet, to assist remote logistics management.

5.1 Future Pallet Trends - The Europallet

Standardisation of the Small Loading Unit (SLU), most generally the pallet, has been considered by European standards authorities for many years. This has established a commitment to ISO formats which SLU manufacturers adhere to. Consequently most major transport and intermodal distribution groups use the Europallet formats.

5.2 Customised Small Loading Unit

The European distribution of freight is largely influenced by the profit to be made from the daily distribution of consumer products and overnight courier services. The principal markets are perishable products, consumables, consumer goods, automotive, and parcel distribution but there are many more.

The design of the Small Loading Unit is influenced by many factors. These are listed, not to create a solution but, to show the social, economic and commercial influences on any SLU design.

Influences:

• The efficient recycling of SLUs.

• The need to maintain and clean SLUs during each cycle.

• The elimination or reduction of disposable product packaging.

• The elimination of product handling in the distribution cycle.

• The increasing adherence to health and safety directives.

• The reduction of storage at source and destination.

• The need to reduce transport and distribution costs.

• The reduction of in-transit damage to goods.
• The need to better exploit existing transport systems.

The pallet system for supermarkets was adopted for the TACTICS programme as it created the greatest number of new design and performance parameters. The TACTICS system developed by the group is compatible with this advanced pallet system as well as standard pallet formats.

5.3 The 'Virtual Portal' - Creating a Secure Electronic Transfer Pallet Transfer

In developing the ideal radio signal environment in to which interrogate each pallet at point of transfer an innovative concept evolved. At each pallet transfer on and off a TACTICS loading unit, the load has to enter then exit the RF control environment. This gives the TACTICS system the unique ability to electronically monitor every load transfer in any complete distribution cycle.

The important features of this facility are;

• the total monitoring and management of data throughout the TACTICS distribution cycle.

• a security feature that can be used to monitor any load at any point of its transport cycle.

• with the future addition of global positioning systems (GPS) logistics managers can have 'real time' control of distribution.

• with 'real time' management it is possible with the associated use of IT networks to provide live or instant checks on stock, stock location and financial audits.

5.4 The Development and Integration of TACTICS Automatic Loading Units.

At the start of the programme the TACTICS group had a single solution for the automated transfer of palletised loads. The SHOTGUN loader has been designed to transfer a complete vehicle load in one operation. The aim of this project was to demonstrate and evaluate the SHOTGUN technology for greater exploitation in Europe.

The group recognised the lack of real intermodal solutions so more analysis was completed to see how the TACTICS technology could be more widely adopted. Within three months, analysis of pallet distribution patterns revealed two other automatic loading solutions. These have been designated the MAGNUM and the EXCALIBUR, as described later.

Prior to the engineering phases the group had identified and assessed the three ALUs which can provide solutions for nearly all high volume palletised distribution transfers.

5.5 Common Factors in the Use of ALUs in the TACTICS System.

As a conclusion to the research phase a specification was established for all three loading units which have common features essential for automated intermodal transfer of SLUs. These features can be summarised as follows;

• the ALU acts as an intermediary surface linking one intermodal platform to another,

• the platform may be any static or transportable surface on to or from which a load may be transferred.

• the ALU may be permanently located to link two loading platforms so that transfers are made in a repeatable manner.
• the ALU may also be a mobile device such that it can automatically load between two remote platforms.

5.6 Three Automatic Loading Unit Solutions for Intermodal Transfers

5.6.1 MAGNUM

The most versatile of the TACTICS ALUs the MAGNUM can replace existing dock levellers or scissor lift platforms used in loading bay and cross docking applications. The MAGNUM can be installed in a number of different ways.

The basic MAGNUM ALU is placed in a fixed location and fixed height. This could be a loading bay or adjacent to a supply conveyor. The transfer is by simple rotation from one point to another.

With the basic ALU placed on the MAGNUM adjustable platform it acts as both dock leveller and loader.

The addition of a chassis and drive wheels at the base of the MAGNUM adjustable platform enables the ALU to be indexed along the side of a loading bay, semi-trailer or rail wagon to allow side to side or end to side transfers.

5.6.2 EXCALIBUR

The EXCALIBUR has the same loading functions as the MAGNUM but uses an extended beam to transfer loads from one platform to another. The ALU lifts the load and does not need to have contact with the platform as do the other solutions.

Height, lateral and angular adjustments are made by changing the length and attitude of the beam.

5.6.3 SHOTGUN

The original ALU has been developed to transfer complete vehicle consignments in one fast automated cycle. The ALU can transfer from loading bay, semi-trailer, or container on an end to end configuration. The SHOTGUN loader is designed to transfer regular bulk loads to or from an automated production line or warehouse.

Alignment and height adjustment is similar to the MAGNUM ALU. Screw jacks are used instead of the scissor lift.

The end to end transfer is achieved without rotating the ALU platform by a novel deployment of the lifting fingers either end of the platform.

3T completed an engineering assessment of all three systems and concluded that the MAGNUM solution provided the most applications for intermodal transfers. The TACTICS group adopted this solution in preference to the original SHOTGUN system.

The TACTICS group set out to demonstrate the viability and benefits of an automated intermodal palletised distribution system by integrating state of the art technology for automated pallet handling, advanced pallet systems, and RF tagging.

The integration of these technologies has generated intermodal solutions far beyond the original expectations of the programme. The group's research has shown a range of Automatic Loading Units and a combination of standard and advanced pallet systems that enable a comprehensive entry in the European market for intermodal distribution.

The availability of fully automated distribution solutions identified by the TACTICS group makes it viable to fully exploit the benefits of total electronic management of freight distribution. The long term benefits lead to 'live ' or 'real time' audit of freight movements. Virtual management of freight distribution will allow instant access to goods location, goods identity, stock taking and financial audit.

The potential efficiencies of the TACTICS systems will bring significant improvements to road and rail freight utilisation, reductions in intermodal transfer times and costs, improved logistics management and advances in automating and managing freight terminals and warehousing.

The TACTICS group would like to complete the demonstration phase but see that with the wider application of the core technologies this phase will be better introduced in a future programme.

7.1 Collaborative Effort

The key partners, 3T , Chep and Linpac have combined the technology in order to mutually promote the TACTICS system and the component technology embodies in the various solutions.

Consequently the TACTICS group will sustain a collaborative effort, having concluded the current programme. Each partner will individually represent their technology and product base, but collectively all partners will promote the TACTICS system applications.

Responsibilities are

• Automatic Loading Units    3T
• Pallet Systems    Linpac
• Trading and pallet management    Chep

The group do intend to maintain some mutual collaboration and are enthusiastic about working with new groups to exploit the TACTICS technology.

7.2 Exploitation and Dissemination Plans

The TACTICS group are planning to create a CD-ROM based Interactive Demonstrator of all TACTICS hardware and system technology.

Manufacturing partners are being established in Europe and Scandinavia to exploit the loading systems technology.

Chep have established a European Group to assess the development of intermodal pallet distribution and tracking.

Linpac will continue to develop their advanced pallet systems, including pallet tagging.

The group are proposing additional researching Fifth Framework programmes and similar privately funded programmes.