Report on Future Generation Drive and Automation Solutions for Airport Baggage Handling Operations

SPECIAL REPORT

Future Generation Drive and Automation Solutions for Airport Baggage Handling Operations Innovative Drive and Automation Solutions for Baggage Handling Systems How Mechatronic Drive Systems Are Changing Baggage Handling Under Strain: Major Challenges for Baggage Handling Installing New Drive Systems Powering Baggage in the Future

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Published by Global Business Media

SEW-EURODRIVE—Driving the world

MOVIGEAR®: the mechatronic drive system sets standards in cost-effectiveness and functionality

Our MOVIGEAR® mechatronic drive system combines a permanent magnet motor, MOVIGEAR®

gear unit and optimized drive electronics in an integrated housing design.

Your benefits at a glance: • Energy cost savings of up to 50% • Fanless design allows low noise operation

DRC.. electronic motor with helical-bevel gear unit

• Straightforward and cost-effective installation technology • Wide operation range minimizes the variants and reduces the number of spare parts Don’t hesitate to contact us – we will be happy to advise you.

SEW-EURODRIVE—Driving the world.

www.sew-eurodrive.de

More information about our products and solutions for this industry at: www.sew-eurodrive.de/airport

FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

SPECIAL REPORT

Future Generation Drive and Automation Solutions for Airport Baggage Handling Operations Innovative Drive and Automation Solutions for Baggage Handling Systems

Contents

How Mechatronic Drive Systems Are Changing Baggage Handling Under Strain: Major Challenges for Baggage Handling Installing New Drive Systems Powering Baggage in the Future

Foreword

2

Tom Cropper, Editor

Innovative Drive and Automation Solutions for Baggage Handling Systems

3

Tobias Nittel, Manager Industry Airport and Parcel Logistics, SEW-EURODRIVE GmbH & Co KG Sponsored by

Published by Global Business Media

Published by Global Business Media Global Business Media Limited 62 The Street Ashtead Surrey KT21 1AT United Kingdom Switchboard: +44 (0)1737 850 939 Fax: +44 (0)1737 851 952 Email: info@globalbusinessmedia.org Website: www.globalbusinessmedia.org Publisher Kevin Bell Business Development Director Marie-Anne Brooks Editor Tom Cropper Senior Project Manager Steve Banks Advertising Executives Michael McCarthy Abigail Coombes Production Manager Paul Davies For further information visit: www.globalbusinessmedia.org The opinions and views expressed in the editorial content in this publication are those of the authors alone and do not necessarily represent the views of any organisation with which they may be associated.

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Challenges for Airports Drive Solutions in Airport Industry IE Classification for Motors – Precisely Defined Tough Times Weaknesses Solving the Problem – Mechatronic Drive Systems from SEW-EURODRIVE Energy-Saving Mechatronic Drives Surpass Current System Efficiency Classes IES Classification in Line with EN 50598-2 Success Story – London Gatwick Airport Innovative System Topology and Infrastructure Solutions Benefits of SNI (Single Line Network Installation) Driving the Future of Baggage Handling Systems Gap Control and Tracking Module Solutions for the Airport Industry – Reliable, Efficient and Innovative

How Mechatronic Drive Systems 8 Are Changing Baggage Handling Tom Cropper, Editor

Advantages of Mechatronic Systems Setting New Standards A Variety of Systems

Under Strain: Major Challenges for Baggage Handling 10 Jo Roth, Staff Writer

Keep the Bags Moving Passenger Numbers Are Growing A Demanding Customer New Regulations Moving Forward

Installing New Drive Systems

12

James Butler, Staff Writer

Luggage Processing Finding the Right System New Systems

Powering Baggage in the Future

14

Tom Cropper, Editor

A Greener Future Bigger and More Complex

References 16

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

Foreword A

IRPORT BAGGAGE – its’s one of the most

Jo Roth explores the background which determines

important aspects of flying governing

the direction of baggage systems. The next 20 years

everything from how quickly aircraft can take off,

could see billions more passengers around the world,

to how happy passengers are at the end of the flight

with bigger and fuller aircraft placing enormous strains

- but it’s also an area which is much misunderstood.

on baggage claim systems. Whether they can increase

While plenty has been written about innovations

capacity while fulfilling commitments to reduce energy

such as automated self-service baggage drops and

consumption will determine how successfully airports

personal apps designed to expedite the process, it’s

can meet demand.

behind the scenes where many of the most important changes are occurring.

James Butler then looks into the commercial case for upgrading and what key issues operators should take

As our opening article from SEW-EURODRIVE

into account. They are having to balance conflicting

explains, the challenges of increased passenger

demands of operational efficiency, capacity, and

numbers, a requirement for faster throughput times

power consumption. To meet these challenges, they

and new environmental legislation will put enormous

will need to carefully select the right system and the

strains on drive engineering. Many existing motors

right supplier.

will be unable to offer the efficiency or performance

Finally, we cast our eye to the future. The landscape

levels required. They outline how their next generation

is moving quickly both in terms of the technology

of modular mechatronic drive systems can help

available and also the demands of the market. We’ll

airports reduce energy consumption while delivering

see how the next generation of technologies will help

the increased capacity needed.

airports continue to meet the pressing demands of

Elsewhere in this Report we look more closely at

the 21st century.

the next generation of mechatronic drives. We’ll see how they are working around the world and explore the improvements they offer over and above existing technologies.

Tom Cropper Editor

Tom Cropper has produced articles and reports on various aspects of global business over the past 15 years. He has also worked as a copywriter for some of the largest corporations in the world, including ING, KPMG and the World Wildlife Fund.

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

Innovative Drive and Automation Solutions for Baggage Handling Systems SEW-EURODRIVE – preparing airports for the future Tobias Nittel, Manager Industry Airport and Parcel Logistics, SEW-EURODRIVE GmbH & Co KG

Challenges for Airports A growing focus on capacity, safety and security issues as well as shorter ground times for aircraft pose enormous challenges for the airport industry. The situation is exacerbated by the increasing competition among airports and stricter environmental regulations. This means that airport operators in the future will need to transport passengers and their baggage even more quickly and efficiently and minimize aircraft downtimes if they are to remain competitive and attractive.

Drive Solutions in Airport Industry Airports that see hundreds of aircraft taking off and landing around the clock require perfect planning and coordination both on the apron and in the baggage handling system. One of the keys to reliably handling thousands of passengers and their baggage each day is custom-designed drive engineering that ensures the baggage is transported from check-in to the aircraft and back to baggage reclaim using the fastest route.

Today, the gearmotors of carousels are usually connected to the mains power supply directly and controlled using a contactor or motor starter.

In critical positions motors are already used in conjunction with a frequency inverter. The gearmotors themselves are generally motors from energy efficiency class IE1 or IE2 and are used in combination with right-angle gear units, for example helical-bevel or helical-worm gear units, with an output shaft perpendicular to the motor.

IE Classification for Motors – Precisely Defined IEC60034-30 classifies AC motors according to IE classes based on their efficiency. This classification is based solely on values measured at 100% load and full nominal speed under nominal conditions. A complex procedure is used to measure the losses and calculate and specify the efficiency for this operating point.

The IE classification can then be determined

by comparing the results with the limit values set out in the standard. Local authorities have also set minimum requirements for the energy efficiency and energy efficiency class required by motors to enable them to be sold in their particular regions. Currently, Regulation No. 640/2009 specifies in the 28 EU states that AC motors with a rated output of 0.75 to 5.5 kW must at least meet the requirements of energy efficiency class IE2 (high efficiency), while 7.5 to 375 kW motors must at least conform to IE3 (premium efficiency). Exceptions to this are IE2 motors that are operated with a frequency inverter and marked accordingly on their nameplate.

Switzerland and Turkey have also passed laws to adopt this EU legislation. From January 1, 2017, the power range to use IE3 motors then expands down to 0.75 kW. The typical power range in a baggage handling system is between 0.75 and 7.5 kW, which means all applications will have to be fitted with IE3 motors from January 1, 2017 if they are operated using the mains or a motor starter.

Tough Times Higher throughput and greater conveying speeds coupled with reduced energy consumption are just a sample of the customer requirements for drives in today’s baggage handling systems. Drives should also offer ever more functions while nonetheless remaining easy to operate. Naturally, it would be best to cover as many applications as possible with a single model and also minimize noise in sensitive areas such as check-in, for example.

As well as compliance with local laws with regard to motor efficiency classes, energy saving is also becoming increasingly important, as baggage handling technology – with drives numbering from several hundred to 10 000 – makes up a huge proportion of an airport’s total energy consumption and thus offers major potential for cutting energy costs and reducing CO2 emissions. Automation engineering has so far only been subject to standards and regulations

Gap Control & Tracking with MOVIGEAR® and Single Line Network Installation • Optimum baggage spacing • Maximum throughput • Energy saving www.sew-eurodrive.de

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

MOVIGEAR® doesn’t just offer high motor efficiency but efficiency in all the individual components and contributes toward maximum system efficiency

MECHATRONIC DRIVE SYSTEMS MOVIGEAR® AND ELECTRONIC MOTOR DRC..

on the energy efficiency of motors, especially asynchronous AC motors, directly connected to the three-phase grid. However, users often cannot be sure whether a particular product still counts as “energy efficient” when used in combination with other components under real operating conditions.

Weaknesses Generally, AC motors in belt-based baggage handling systems at airports are always used in combination with a gear unit, and only a very small number of motors are actually run at the rated operating point referred to above. In addition, the conveyors never run continuously but are started and stopped depending on the system requirements and are run in various operating situations (empty or loaded). Safety factors and transmission element factors resulting from loads that are difficult to predict and frequently change lead to motors being oversized to a greater or lesser degree. As well as higher investment costs and the installed load being too high, this in turn also leads to the drive operating in the partialload range during normal operation. This partialload operation makes the motor component less efficient compared to normal operation.

To avoid the drives being oversized, each motor could be individually designed and optimally configured. The disadvantage of this method is that it results in many different drive models.

To avoid this, an ideal drive system should have as large a work envelope as possible and a consistently high level of efficiency. To cover temporary overloads or clear jams, the drive must be able to withstand overloading for a protracted period. A compact, integrated drive design is also an advantage due to the space available in many systems.

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Solving the Problem – Mechatronic Drive Systems from SEW-EURODRIVE The highly efficient MOVIGEAR® drive system consists of a motor, gear unit and electronics in a single extremely compact mechatronic unit.

It is optimally adapted to the special requirements of baggage handling technology in the airport industry thanks to its outstanding overload behavior and thus cuts the number of models used, substantially reduces the installed power rating and generates energy savings. The benefits of the MOVIGEAR® product range can be found in the motor’s extremely high efficiency level even exceeding IE4 (super premium efficiency), making it an energy-saving and thus sustainable drive solution. However, MOVIGEAR® doesn’t just offer high motor efficiency but efficiency in all the individual components and contributes toward maximum system efficiency.

Energy-Saving Mechatronic Drives Surpass Current System Efficiency Classes Energy saving doesn’t end with a high energy efficiency class – in fact it’s just the start. Only a proportion of losses occur in the motor, with others being generated in the other components of the complete drivetrain. The total efficiency of a system can thus only be defined across the entire work envelope. To really save energy, it isn’t just the motor that needs to be as efficient as possible, but also the other components across the entire scope of work. This is a feature of the mechatronic drive system MOVIGEAR® and the DRC.. electric motor, which has a similar design to MOVIGEAR® but can be combined with a variable gear unit.

FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

MAXIMUM ENERGY SAVING DUE TO GREATEST POSSIBLE SYSTEM EFFICIENCY

IES Classification in Line with EN 50598-2 However, in terms of standards, too, there are trends toward extending the requirements to the entire drive system. Part 2 of the EN 50598 standard doesn’t just consider the energy performance of the motor and categorize it in efficiency classes (cf. IE classification in line with IEC 60034) – it specifies the entire drive system (PDS = power drive system) comprising motor, frequency inverter and accessories. To this end, EN 50598-2 defines system efficiency classes – IES classes – that provide information on a PDS’s energy efficiency at its nominal operating point compared to a standardized drive system.

Comparisons can therefore be made between different systems.

With the highly efficient MOVIGEAR ® mechatronic drive system, SEW-EURODRIVE is already one step ahead. The integration of motor, frequency inverter and gear unit, which has not so far been specified by EN50598, is already minimizing losses and increasing the efficiency of systems.

Success Story – London Gatwick Airport The operator of Gatwick Airport in London also appreciated the benefits of MOVIGEAR®. In July 2010 he thus selected SEW-EURODRIVE, as an innovative supplier of drive technology, to equip the north and south terminals with drive engineering.

As Alex Adams, Principal Baggage Systems Engineer at Gatwick Airport, explained: “For our new baggage handling systems at Gatwick Airport, it was important to install reliable and efficient drives. Our key criteria were therefore absolute reliability and energy efficiency to achieve the long-term environmental targets for Gatwick in the Decade of Change strategy, such as cutting carbon emissions.” Other criteria included reducing the number of drive types, minimizing the number of potential error sources, for example due to a lack of mechanical brakes and fans, and using straightforward control systems. “Our market research showed that the MOVIGEAR® drive series from SEW-EURODRIVE

MOVIGEAR® INSTALLATION AT LONDON GATWICK AIRPORT

best met our criteria. We thus installed 1200 drive units and adopted the specification into our technical standards.”

Around 2000 drives are now in use to ensure the systems run smoothly and reliably and provide quiet and energy-efficient transportation of baggage from check-in to the plane and to baggage reclaim.

Innovative System Topology and Infrastructure Solutions The need for higher throughput with the smallest possible number of drive configurations calls for maximum drive functionality and availability.

To plan, install and take systems into operation faster, areas such as decentralization and modularization of systems are more important than ever, including in the baggage handling environment. A number of carousels with the same functions are often found, in which case it is particularly useful to define and regularly re-use standard modules to minimize effort. Modules should also be networked intelligently to enable the provision of status data for optimum operation and maintenance that can be planned as far as possible without prior downtimes.

Vertical Sortation Unit with MOVIGEAR® and Single Line Network Installation • Significant improvement of energy efficiency and throughput • Reduced installation costs • Increased performance because of drive functionality www.sew-eurodrive.de

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

No separate laying and wiring of bus cables over long distances is needed, which eliminates the risk of hidden faults in wiring communication cables

SINGLE LINE NETWORK INSTALLATION

SNI stands for Single Line Network Installation and is an intelligent infrastructure solution for networking mechatronic drive systems based on using the power supply to transmit communication signals on the identical cable installed. The signals required for sharing information are modulated onto the power line in the high frequency range and enable communication with each connected station.

The innovative principle of Single Line Network Installation (SNI) makes for completely new system topologies, delivering consistent system decentralization with minimal installation effort.

Benefits of SNI (Single Line Network Installation) The key features of SNI, as a new infrastructure solution for networking drive systems, are installation cost savings and minimal installation times. The traditional installation with lines for the power supply and communication bus is replaced by a single power cable. No separate laying 6 | WWW.AIRPORTTECHNOLOGYREPORTS.COM

and wiring of bus cables over long distances is needed, which eliminates the risk of hidden faults in wiring communication cables. The system offers Ethernet-based access to each individual drive via central access points in the system network.

The SNI infrastructure solution offers further benefits above and beyond the straightforward installation. Not only can MOVIGEAR ® mechatronic drive systems and DRC.. be integrated into an SNI network – the intelligent CIO I/O system and CSW maintenance switch are other system components that are also available.

Thanks to their functionality, they expand the range of applications for MOVIGEAR® and DRC.. electronic motors with optimum results.

Driving the Future of Baggage Handling Systems The stricter requirements on drive systems and networking of these are increasing the pressure on system networks. To counteract this

FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

GAP CONTROL AND TRACKING SOLUTION FROM SEW-EURODRIVE

development, the trend is moving increasingly toward drives with integrated intelligence that perform tasks locally on request and merely report back their status instead of exchanging cyclical signals with the higher-level controllers at a very frequent rate. SEW-EURODRIVE already offers solutions for future needs, ranging from speed control to positioning and preprocessing of baggage items in the screening and handling environment. As well as solutions for standard carousels, more complex needs can also be met easily in this way. For instance, the “gap control and tracking” module is an optimum solution for the baggage feed of explosive detection systems, or EDS for short.

These screening machines must be installed at all European airports by 2020 in line with the Standard 3 framework of the European Civil Aviation Conference (ECAC).

Gap Control and Tracking Module All Explosive Detection System machines have a defined maximum throughput, which depends on baggage size, conveyor speed and gap between bags. This maximum throughput can only be achieved with optimum baggage spacing on the infeed of the machine to ensure the highest possible utilization.

SEW-EURODRIVE offers an automation hardware and software solution for gap control and tracking systems, which maximizes the throughput thanks to the high dynamic and the decentralized intelligence of SEW MOVIGEAR®SNI. The decentralized controller MOVIFIT®FDC-SNI uses an algorithm to calculate the necessary speed and acceleration per conveyor in order to reach the target gap between baggage items. In combination with an integrated high resolution encoder, which ensures precise baggage position tracking, the MOVIFIT®-FDC controller can also handle

other functionalities such as baggage height/ length monitoring.

Solutions for the Airport Industry – Reliable, Efficient and Innovative In addition to the gap control and tracking application module, SEW-EURODRIVE also offers solutions for standard and curve automation, the makeup and reclaim areas, vertical sorting mand diverters. Thanks to these standardized modules, customers only need to configure the functions of drives during startup and are not required to carry out any programming. The decentralization of functionality relieves pressure on the system network and cuts effort for installation (due to the Single Line Network Installation, SNI), startup and during operation (due to diagnostics and unit replacement).

With its MAXOLUTION ® system solutions, SEW-EURODRIVE also offers not only innovative technologies but risk-free and time- and cost-optimized project implementation by an experienced project manager, from planning and project management of the perfect drive solution through to startup and production monitoring.

Customers can use the in-house software platform to visualize and simulate their systems in advance and start them up virtually, giving them complete planning reliability.

System solutions are tested and validated at SEW’s own test center beforehand as necessary.

The risks of international projects are also minimized and their complexity reduced using professional project management and the decentralized sales structure.

SEW-EURODRIVE is acutely aware of airport industry requirements. Whether it’s baggage transportation, sorting or distribution, SEWEURODRIVE delivers proven and reliable application solutions from the modular system to ensure greater cost-effectiveness, flexibility and reliability in all airport industry processes.

Horizontal Diverting Unit with MOVIGEAR® and Single Line Network Installation • Significant improvement of energy efficiency and throughput • Reduced installation costs • Increased performance because of drive functionality www.sew-eurodrive.de

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

How Mechatronic Drive Systems Are Changing Baggage Handling Tom Cropper, Editor A new generation of drive and control systems is helping to revolutionize airport baggage systems.

The future contains the right mix of challenge and opportunity to create an environment ripe for innovation

M

ANAGING THE demands of the modern aviation market can sometimes seem to be an impossible task. Airports are being asked to use less energy, to increase performance and handle millions more passengers every year. To meet these goals, airports are investing heavily in every aspect of the operation from the moment passengers arrive to the time they take off. A new generation of technologies is coming to the fore which aims to provide the incremental gains operators need.

In terms of baggage handling, existing drive systems are increasingly struggling to meet expectations. They are inefficient. With European regulators set to demand energy efficiency ratings for some operations as high as IE3, many are still stuck at IE1 or 2. They may also struggle to deliver the increase in capacity airports need in order to maintain high service levels.

In searching for a solution, attention is moving to mechatronic drive systems. Most conventional solutions involve a combination of separate mechanical components such as gear units and electrical, such as motors, inverters and starters.

Mechatronic devices synergize mechanical, electronic and IT components - all within one system. They combine gear units and motors in one seamless package which can be used around the airport for specific applications. They are being used in applications across several different industries, in particular the automotive industry where their ability to save energy, provide smarter control, lower installation costs and higher performance give them a critical advantage over conventional and alternative systems.

Advantages of Mechatronic Systems Manufacturers are now producing a range of specialized products designed specifically for the aviation industry. They have a variety of obvious 8 | WWW.AIRPORTTECHNOLOGYREPORTS.COM

advantages. All components are smoothly integrated and offer optimized peak performance for specific applications. They can also be more reliable than systems consisting of separately specified parts. For a conventional conveyor belt, the system uses much more torque for start-up than during general running. This is because it has to pull mechanical sub components through a breakaway period of high friction and under-lubrication. Manufacturers might have to design the drive for peak load periods and accept the fact that, for the vast majority of its use, it will be operating at only half capacity.

Mechatronic drives can deliver much higher levels of torque for a limited period of time before falling back to a level which is closer to its specified limit. Because they are designed for specific tasks, software can be delivered to help engineers decide on the key parameters before they are built.

Setting New Standards For airports, these mechatronic drives are setting new standards in performance and efficiency.

One of the leading examples is the Movigear which combines motor, gear unit and electronics in one small compact system. Its manufacturers boast energy savings of up to 50% and a high performing motor adhering to IE4 super premium efficiency class. By seamlessly integrating all components within the unit, Movigear can offer a highly optimized and efficient system – all of which can be easily incorporated into an existing system greatly reducing the cost and the upheaval of installation.

Systems such as these are being used in airports around the world and are already proving their worth. At Gatwick, for example, the installation of an initial 1,500 units was credited with delivering a substantial saving in energy use – estimated at between 30% and 50%.

FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

AUTOMATION SOLUTION FOR DCV SYSTEMS FROM SEW-EURODRIVE

To cope with increased passenger numbers, Gatwick airport announced a £1bn expansion program to bring its capacity up to 24 million passengers per year.

Their focus was on saving energy, reduction of variants, reliable functionality and lowering installation and commissioning costs. The Movigear, which combines gear units and motors in one compact package, represented an ideal fit. Its main advantage was that it offered energy efficiency ratings of IE4 – placing it in the super premium category.

Speaking about the deal at the time, Alex Edwards, Head Engineer for luggage systems at Gatwick explained the key gains they were looking for. “For our new luggage transportation systems at Gatwick Airport it was important to install reliable and powerful drives,” he explained.

“As a result, our key criteria were absolute reliability and energy efficiency, in order to implement Gatwick’s envisaged sustainable environmental objectives, summarised under the “Decade of Change”, such as a reduction in carbon dioxide emissions.”

In short, compared to other systems the Movigear Mechatronic system delivered the following benefits: • Saving energy • Variant reduction to 7 installed drive configurations • Reduced installed power • Reduced installation and start-up costs •C ontrol via AS-Interface v3.0 with a maintenance switch for each drive • Faster and easier access to all parameters • Plug-in design ensures a quick exchange

•T wo sensor signals for light barriers and belt wear sensors are transmitted to the controller via the drive’s AS-I node The initial run of 1,500 units was successful and Gatwick quickly made the decision to install a further 2,000. The product has experienced similar success elsewhere in the world, where it fulfils the key goals of airport operators mentioned earlier in the article.

A Variety of Systems It’s efficient, cost effective and green, and has room for future development. The future contains the right mix of challenge and opportunity to create an environment ripe for innovation.

Mechatronic power systems are just one option coming to market. Other manufacturers are using different systems to answer the same questions and each of them has their own advantages and disadvantages. The problem for buyers is that, in this world of new and unfamiliar technologies, deciding on the best option for their individual airport can be challenging. As baggage systems become larger and more complex, the variation in requirements becomes that much greater.

At this time of rapid development, there is a growing difference among the technological capacity of various airports around the world.

Those which are ahead of the curve are managing to meet their performance targets, emissions obligations and reduce costs, while others are still struggling to keep up. In developing a system for the future, airports can learn a lot by looking at the success – or otherwise – of those early adopters.

Standard conveyor with MOVIGEAR® and Single Line Network Installation • Modular approach (up to 10 drives in one infrastructure segment) • Fast installation, commissioning, simple diagnostics and replacement • System performance ensures efficiency in material flow www.sew-eurodrive.de

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

Under Strain: Major Challenges for Baggage Handling Jo Roth, Staff Writer Increased passenger numbers, a need for greater capacity, tighter regulations and slimmed down profit margins – welcome to the future of aviation.

Airports – along with most other industries – are also coming under pressure to manage their impact on the environment

T

HE AVIATION industry faces a landscape of opportunity and challenge; opportunity because, after years in the doldrums, business is booming. Passenger numbers are growing by 4% per year with future prospects looking equally healthy. Challenge, because it has to find ways to accommodate all those additional passengers. On top of that, the market is becoming more competitive and passengers expect a better standard of service. Regulations are becoming tighter as airports around the world come under pressure to manage their energy consumption. It’s a difficult task and meeting it will depend greatly on the nuts and bolts of airport operations such as baggage handling.

Keep the Bags Moving Most passengers give little thought to what happens between the time they hand over their bags at the check-in desk to the moment they collect them (hopefully) in arrivals. However, the speed and efficiency with which an airport processes luggage can have a significant impact on its overall performance and reputation.

Operators have always been looking at two key metrics: speed, and reliability. Bags have to be processed as quickly as possible to prevent any delay and improve turnaround times. Naturally, they must also be processed accurately with minimal mistakes. Even though airports are generally winning the war against lost baggage1, when things do go wrong the PR fallout can be painful. For example, earlier this year the Daily Mirror published a list of the worst performing airports for baggage handling. Overall, the Civil Aviation Authority had received 1,500 complaints with Birmingham being the worst performer2.

This is why airports around the world are investing billions of dollars into upgraded baggage systems. Major airports such as Heathrow, Gatwick, LA and others have all made 10 | WWW.AIRPORTTECHNOLOGYREPORTS.COM

significant installations over the past few years. In designing these systems of the future, airports are having to allow for the following factors:

Passenger Numbers Are Growing According to IATA’s long term forecasts, passenger numbers could reach 7bn by 2034 – a year-on-year increase of 4%3. Growth is likely to be heavily influenced by emerging markets such as China, and India – which are all seeing substantial investment in new infrastructure. There are caveats; the aviation industry has made bold predictions in the past only to be blown off course by unforeseen events. At the end of the nineties, analysts, like now, were predicting a rapid growth of passenger and aircraft volume. However, the September 11th attacks and then the worldwide financial crisis, blew those predictions out of the water. Only in the last few years have passenger numbers picked up pace. Making future predictions is all very well and good, but they can’t account for events. Recent downturns in economic performance impacted growth in areas such as China and Brazil. The prospect of a British withdrawal from Europe could also have repercussions for global growth. Terrorism remains a sizable threat as evidenced by recent attacks in Belgium and Istanbul. Nothing can or should be taken for granted.

Even so, the signs are that airports will have to handle much higher volumes over the next few decades, and the problem is that, right now, it’s far from certain that they can. The obvious solution is to build new airports and expand existing hubs. That, though, can take years and is highly politically contentious. Heathrow’s Terminal 5 was over 30 years in the making, with almost 20 passing before planning permission was granted. Although a recent inquiry gave a green-light to further expansion, protests could still halt or delay work.

FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

DYNAMIC DRIVE SOLUTIONS FROM SEW-EURODRIVE FOR RELIABLE SORTING AT HIGH CONVEYOR SPEEDS

Capacity within existing airports must improve.

That means they will have to handle more flights per day and process more passengers. With existing infrastructure already coming under strain, that will be a tall order.

A Demanding Customer Airports are increasingly dealing with a new commercial reality – namely that competition is growing and passengers expect more. Where once they might have put up with certain inconveniences in order to get where they are going, they now have options. Most people have a choice of more than one international airport when travelling. They are showing themselves ready and willing to choose their hub on the basis of which one can offer the best customer experience. In shaping that experience, baggage handling is crucial. People will complain if they have to wait to reclaim their bags and they will definitely be unhappy if their luggage goes missing.

New Regulations Airports – along with most other industries – are also coming under pressure to manage their impact on the environment. Aviation is one of the least environmentally friendly human activities on the planet. Despite EU regulations, for example, the air around Heathrow remains dangerously toxic4.

As a result, every airport has to reduce energy consumption. Baggage handling systems run night and day and so represent a major part of that output. Moves to reduce those power demands will be crucial. Airports are looking at solutions such as variable power systems, which can shut down some belts during quiet periods, more efficient power supplies and even belt materials made of less resistant materials.

Each of these innovations can provide a series of incremental gains which could prove crucial in helping to improve the energy efficiency of the entire airport.

Moving Forward Each of the factors discussed in this article have serious implications for baggage handling systems. They will have to handle more bags per hour per day; they will have to reduce mistakes even further than they already have, and they will have to reduce turnaround times – not only to improve customer satisfaction, but also to increase the number of flights which can come in and out of an airport each day. Just increasing capacity by one flight per day represents an improvement of hundreds over the course of a year.

This, indeed, is the secret of aviation in the future. It’s a game of multiple small wins – of a series of minor improvements which lead to substantial and important overall gains.

Make-up and reclaim • Multi-Motor control with load sharing function to ensure smooth operation in all conditions • Drive technology without fan ensure minimum noise emission and most silent operation • Modular and configurable solution for simple start-up www.sew-eurodrive.de

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

Installing New Drive Systems James Butler, Staff Writer New drive solutions for airport baggage handling offer a host of benefits, but how do airports assess the real benefits?

The average consumption of electricity of a large airport is 100 to 300GWh per year. A major part of this consumption comes from baggage handling belts

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IRPORTS ARE spending huge amount of money upgrading systems and processes to cope with the demands of modern aviation.

However, in a world in which profit margins are tight, any expenditure will have to be justified.

New drive engineering systems are coming to market which offer a range of exciting benefits including higher capacity, greater efficiency and lower operational costs. Even so, airports will be wary of installing a new system before they have identified a return on investment and how it can best be incorporated into an existing airport.

Luggage Processing Modern baggage systems are bigger and more complex than ever. Dubai Airport’s Terminal 3, for example, boasts the largest and deepest baggage handling system in the world: 90km of conveyor belts, 21 screening injection points and 49 make-up carousels can handle 15,000 items per hour at speeds of more than 27kms per hour.

Powering such a system is a major challenge and presents different demands at different points in a bag’s journey.5 To begin with, we have the moment every passenger sees – the check-in desk. Here the bag is placed on a conveyor and weighed before being whisked away to its destination. The requirements here are for motors which are quiet, efficient, and reliable. From here bags are put into interim baggage storage where the system must be flexible enough for any items to be recalled at any time. Baggage sorters then whisk them away at high speed. They need motors which are quick, accurate and offer high levels of speed control.

Large airports may also need high speed conveyors for transportation between terminals.

They must offer high speed, controllability, and low wear to reduce maintenance. Once outside, airports are increasingly turning to automated baggage loaders to do most of the heavy work.

They require exact positioning and high mobility to reduce the amount of manual lifting required.

For arrivals, bags will also need to go to the 12 | WWW.AIRPORTTECHNOLOGYREPORTS.COM

pick-up conveyor belts. These move slowly and quietly allowing passengers to pick bags up with no risk of injury.

Finding the Right System Across each of these processes the main overriding aim is for systems which can offer increased efficiency, low energy consumption, high speed and accuracy to increase throughput and reduce turnaround times.

Many existing systems struggle to cope with these demands for a number of reasons.

•T hey are inefficient: Most baggage handling systems are currently powered by an AC motor, used alongside a gear motor unit. These have served well for years, but, increasingly, their deficiencies are being exposed. They are typically over-sized, which pushes up installation and running costs.

•R egulations are changing: The EU is making major strides to increase the efficiency of industrial electrical motors. These account for 70%6 of industrial motor emissions and the EU Commission forecasts it can save 1 million tons of CO2 each a year. Under the changes, all electrical motors sold within the EU will be required to conform to IE 3 – premium efficiency. Smaller motors may be able to conform to IE2. From a wider perspective, the EU is moving to reduce emissions from all aviation activity, which continues to be among the fastest growing producers of greenhouse gas emissions in the world.

Many older motors may struggle to conform and those used in combination with other equipment may struggle to achieve the desired efficiency rating.

What really drives operators is less the thought of conforming to regulations, and more the prospect of reducing operating costs. Although the aviation industry has grown considerably over the past few decades, profit margins have tightened as passengers expect low cost fares.

To remain competitive, airports must either raise revenue from new areas or reduce operating

FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

TEST INSTALLATION FOR AUTOMATED BAGGAGE HANDLING PROCESSES

costs. According to CASCADE, a European Research Project funded by the EU, the average consumption of electricity of a large airport is 100 to 300GWh per year7. A major part of this consumption comes from baggage handling belts. Airports have already invested millions in cost saving innovations such as smart controls and more efficient motors.

New Systems Airports have been working hard to upgrade baggage systems for years, and they offer a range of improvements. They are more efficient, use less energy and contribute towards emission targets; they are integrated, offering full functionality within a single compact package, reducing installation costs and they offer smarter controls allowing operators to ensure they only use as much power as required.

All these come with some costs and in a pricesensitive environment such as aviation, that may be enough to persuade some operators to think again. They must balance the improvements and cost savings against the bottom line. For this they need to be able to demonstrate value, but that can be easier said than done. The processes of

baggage handling can be extremely complex so measuring any real improvements can be difficult.

As with any new system, much also depends on the provider as well as the package itself. Those manufacturers who have greater experience and knowledge of the challenges facing airports will be better placed to offer tailored systems that deliver value where it is needed most. Developing systems which are optimized for the future as well as the present will also drive greater efficiencies going forward. The environment is in a constant state of motion; the challenge is to avoid being left behind.

As with so many commercial decisions, it is a delicate cost versus rewards calculation. Potential buyers must understand what they need, and what savings a new system can bring; they will need to be sure any new solution can offer real and measurable improvements over the old – and work out how to get the best out of any innovations which come their way. The rewards for airports which get this right can be considerable.

As new technology comes into play, there is a growing variation in the sophistication of different airports. This in turn provides those who are quick to adapt a critical competitive edge.

Gap Control & Tracking with MOVIGEAR® and Single Line Network Installation • Optimum baggage spacing • Maximum throughput • Energy saving www.sew-eurodrive.de

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

Powering Baggage in the Future Tom Cropper, Editor Bigger, faster and more efficient – meet the future of airport baggage handling systems.

Today’s systems represent a sizable step forward from yesterday’s – tomorrows products will be even more advanced

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IRPORTS FACE a host of challenges over the next 20 years or so and baggage handling will be at the front line of many of them. The industry will come under increasing pressure to manage its carbon footprint and become more energy efficient.

More passengers will place a greater strain on capacity, increasingly demanding passengers will insist on a better flying experience and finance departments will need costs to be driven down as much as possible. It’s a challenging proposition and every aspect of aviation will have a role to play in addressing it, but one of the keys could be in the way baggage systems are powered.

The scale of the problem was illustrated by recent figures from the Civil Aviation Authority.

Q3 in 2015 represented the busiest summer on record. The figures for the period July to September saw a new peak of 78 million with rolling 12-month passenger totals passing 250 million for the first time. However, as a result, punctuality ratings dropped sharply. The pressure on infrastructure saw on-time performance dip by three percentage points to 73% - the lowest figure since 2010. It outlines the issues facing airports: business is booming, but this is placing a strain on infrastructure. Moving into the future it is likely to get even worse8.

For baggage handling, everything is going to get bigger, faster and more intense. Aircraft are growing in size and taking on more passengers.

According to that same CAA report, larger and fuller aircraft are key contributors to increased passenger numbers. As airports try to cram a greater number of flights into the day, and with greater passenger numbers per flights, baggage handling systems will have to work more quickly and process more bags per flight than ever before.

They will have to achieve all this while also offering lower power outputs, reduced costs, and better environmental performance. For that to happen, a fresh generation of technologies across the board will be crucial. Some of

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these are coming to market already – others are in the pipeline.

Part of the future lies in intelligent control systems. These can control the movement of a belt to ensure it only uses the correct amount of power. The CrisBag system from Crisplant, for example, uses a bag and tote system. This contains all the tracking information for the bag to ensure complete traceability throughout the journey. When a tote is approaching, the system senses it and will only start in time for it to be up to speed when the tote arrives and can stop as soon as it has left. This compares with a conventional conveyor system which will often have to continue running for an entire length before it is certain it’s empty. Taken over the course of hundreds and thousands of bags throughout a day this can result in a significant energy saving.

At Helsinki Airport, meanwhile, intelligent control is also at the center of a major upgrade to its baggage handling systems. It can react to delayed flights so transfer luggage can be transferred quickly to the connecting flight, even when time is limited9.

A Greener Future Much of the focus for today’s airport operators revolves around equipping their airports to address their environmental credentials.

Regulators are demanding the aviation industry reduces its carbon emissions at the very time when it is struggling to cope with rapidly increasing demand.

That means a tough balancing act – somehow it has to use less power while massively increasing speed and performance. Airports can achieve this with fresh thinking in the design of conveyor belts and motors. New rubber materials for belts can reduce friction and extend wear time.

This means, not only reduced maintenance requirements, but also lower energy consumption as the belt wastes significantly less energy through regular operation. Linear motors can also generate motion through electromagnetic energy. This means no physical interaction

FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

THESE AIRPORTS HAVE ALREADY CHOSEN THE MECHATRONIC DRIVE SYSTEM MOVIGEAR® AND THE ELECTRONIC MOTOR DRC.. FROM SEW-EORODRIVE

between mechanical parts which again reduces friction and energy consumption. This can be particularly useful in high speed areas such as baggage transfer between terminals, where high speed frictionless motion is a major bonus.

Bigger and More Complex Making predictions about the future of aviation can be fraught with difficulties. Past predictions have proved to be wide of the mark, but every available piece of evidence points to more passengers, larger aircraft and more pressure on time in the future. Baggage handling systems will have to become larger and more complex to meet these challenges. Drive systems which can offer more functions within a single unit will have a distinct advantage. In this Report we’ve already examined the rise of mechatronic drive systems. These can combine electrical, mechanical and IT components within a single unit. They can offer locally based power supplies,

specifically designed to the requirements of that area. They deliver just the right amount of power at the right time and have already been shown to deliver highly promising results. This market shows every sign of growing – not only in demand, but in the scope of products being developed. Today’s systems represent a sizable step forward from yesterday’s – tomorrows products will be even more advanced.

The challenge of airport logistics in the 21st century is severe and will require innovative and sophisticated solutions. With so many different procedures across the entire operation, though, there are numerous opportunities for improvements. It can be a case of multiple small gains; a little power saved here, a performance boost there – it all adds up. For airport operators, the fast moving nature of the market means it will become increasingly important to stay in touch with the latest trends and developments to ensure an airport remains highly competitive.

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FUTURE GENERATION DRIVE AND AUTOMATION SOLUTIONS FOR AIRPORT BAGGAGE HANDLING OPERATIONS

References: 1

Airports are Winning the War on Lost Luggage:

http://www.wsj.com/articles/baggage-claim-airlines-are-winning-the-war-on-lost-luggage-1401922595 2

Revealed Worst British Airports: http://www.mirror.co.uk/news/uk-news/revealed-worst-british-airports-complaints-7983648

3

IATA Long Term Passenger Forecast: http://www.iata.org/pressroom/pr/Pages/2015-11-26-01.aspx

4

Government Agrees to Clean up Britain’s Toxic Air:

http://www.businessgreen.com/bg/analysis/2404372/government-agrees-to-clean-up-britains-toxic-air-in-supreme-court-showdown 5

6

Dubai Airport Baggage: http://www.airport-technology.com/features/featurebaggage-handling-dubai-international-video/ Are you up to Speed: http://www.crestpumps.co.uk/news/date-eus-motor-efficiency-rules/

7

Our Future is Green Baggage: http://airportfocusinternational.com/our-future-is-green-baggage/

8

UK Airport Passenger Numbers

https://www.caa.co.uk/News/UK-airport-passenger-numbers-continue-to-break-records-but-punctuality-hits-five-year-low/ 9

Helsinki Airport Case Study: https://www.beumergroup.com/uploads/tx_bbbrochures/Crisplant_Helsinki_Airport_Case_Study.pdf

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