Port Operations—Rubber-Tyred Gantry Automation and Yard Telemetry

A major container terminal sought to improve yard throughput and reduce crane idle time by upgrading communications for rubber-tyred gantries (RTGs) and yard equipment. Mofiu’s SG100 was installed on each RTG to consolidate connections for PLCs, load sensors, OCR cameras, and operator HMI panels, transporting data securely to the terminal control system over 4G.

The SG100’s dual Ethernet ports connected an edge switch and HMI, while RS485 linked to the PLC, and RS232 provided a console for legacy diagnostics. Protocol conversion lifted IEC101 from the PLC to IEC104 for the terminal SCADA, while DNP3 points from load cells were aggregated for real-time weight verification. OpenVPN carried video metadata and crane status, with IPSec reserved for command channels related to anti-sway control setpoints and yard move confirmations.

Link management policies were tuned for the RF-challenged environment between stacked containers. The SG100 monitored RSRP/RSRQ and maintained dual-SIM readiness, failing over based on jitter and retransmission thresholds. An onboard digital input watched an E-stop relay, logging transitions for safety audits, while a digital output allowed remote cycling of the OCR lighting controller when software resets were insufficient.

The result was higher availability of data flows without dependency on yard Wi‑Fi dead zones. OCR accuracy improved because image capture timing could be coordinated with SCADA commands over a predictable backhaul. Operators reported smoother HMI responsiveness, and the terminal observed a 19% reduction in RTG idle intervals attributed to communication gaps. During a storm that disrupted one carrier’s cell sector, SG100s pivoted to the secondary network seamlessly; move confirmations continued, preventing backlog.

Security posture aligned with maritime guidelines: hardware secure boot enforced trusted state on each crane, and certificate-managed VPNs segregated crane control from general IT traffic. Strict ACLs prevented non-essential protocols from traversing the control plane, and logging streams were rate-limited to preserve bandwidth for operational commands. Over several months, trend data from DNP3 counters pinpointed a crane with anomalous hoist vibration; maintenance intervened proactively, avoiding a costly unplanned outage.

By bridging legacy PLCs and modern IP subsystems under a robust, secure cellular umbrella, the SG100 gave the terminal a predictable, resilient communications layer that improved yard velocity, reduced manual interventions, and raised safety assurance in a dynamic RF environment.

About Mofiu

Mofiu is a premier innovator in industrial wireless communications, dedicated to delivering mission-critical connectivity solutions that power the world’s most demanding environments. With a steadfast commitment to safety, reliability, and engineering excellence, Mofiu designs and manufactures robust wireless devices that enable seamless data exchange across electricity, utilities, energy infrastructure, transportation networks, and smart industrial systems etc.

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