Research on Architecture of Intelligent Simulation System for Automatic Quay Crane Training Based on Embedded Digital Twin Technology

Abstract

AbstractThe training of automated container gantry crane drivers faces with challenges, such as high safety risks, difficult training, and high learning cost. Therefore, we have designed an intelligent simulation system architecture for automated container quay cranes training based on embedded digital twin technology. This system can be directly embedded into the real quay crane remote control console without changing the original quay crane hardware equipment. It enables real-time switching between virtual quay crane remote control operation simulations and real gantry crane remote control operation, providing training for quay bridge drivers while also accounting for the real quay crane operation in time. To achieve seamless switching between real control and simulation training, we have designed two types of controllers: an automatic quay bridge remote control operation simulation system based on OPC UA communication protocol, and a real quay crane automation controller based on PLC control bus. Both controllers can communicate bidirectionally with the remote control room operating station PLC. Practical application at a wharf has demonstrated that our designed system offers high safety, real operation experience, and significant training effectiveness, effectively improving automated quay crane training outcomes, efficiency, and effectiveness.