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Reference example

Airport Stuttgart
baggage handling system

Modernisation of the baggage handling system in terminal 1


| The project
The airport in Stuttgart planned to reorganise the old baggage handling system for the complete baggage inspection in terminal 1 on the basis of the legal requirements. As general contractor, Aberle Automation developed the solution. The MRKA (multistage baggage control system) had to be integrated into the baggage handling system of terminal 1 and terminal 2. Therefore a completely new system concept was necessary. The maximum sorting capacity in the baggage distribution of terminal 1 with 3000 pieces of luggage per hour had to be distributed flexibly to the check-in-systems in terminal 1 and terminal 2 without any restrictions by the conveyor technique. For this reason several X-ray machines had to be integrated into the baggage handling system. Due to the height and area ratio within the baggage distributor, the number of possible locations for the control machines was very small, as it should also be possible to transport the baggage to every control machine both from the check-in of terminal 1 and terminal 2. This possibility of flexible routing and the limited number of storage spaces for the X-ray machines had to be considered in the layout of the baggage handling system. The modernisation of the baggage handling system had to be realised without any restrictions of the running operation.

preperation mass test

| The integrated components


For the control of the complete conveyor technique (more than 400 drives), 4 controls from the company Siemens (type Simatic S7) have been used. A Safety PLC from the company Pilz was used instead of the classic emergency-off cabling, whereby the effort for the cabling has been reduced extensively. This combination is unique until now. Due to the requirements of 3000 GPS/h, three X-ray machines of type EDtS from the company Smith-Heimann were integrated into the baggage handling system. Due to the available space in the whole baggage compartment, the inflow and outflow of the baggage to / from the KST3-room was realised only by the integration of two baggage lifters. In order to be able to integrate the other conveyor technique and the X-ray machines into the baggage compartment, an intermediate level of about 2,80m above the ground has been constructed in the complete baggage compartment. By this steel construction a separation between the baggage handling system and the working area of the baggage loader was achieved. Due to this separation there will not be any impairment of the operation processes of the baggage handling system. About 100 tons of steel were needed for the installation of the complete steel construction. The installation time of the intermediate level has been reduced to a minimum due to the innovation of bolting the steel girders together.

| The solution
The modernisation of the baggage handling system including the construction of the intermediate level could only be realised during the running operation of the airport. Therefore the realisation was planned in 34 construction stages. In order to guarantee this realisation, a part of the old baggage handling system has been disassembled at first and has then been replaced by a part of the new baggage handling system. Thereby the baggage transport from the check-in to the sorting rotation system and hence to the plane could have always been maintained during the modernisation. However, an exact timing of the construction measures and of the delivery of the needed materials has been required for the installation of the new baggage handling system. Furthermore, it was not possible to block large ranges of the baggage distribution area over a longer period of time, for example for the installation of the intermediate level, as due to a blocking either the loading of the departing baggage or the unloading of the arriving baggage would have been affected to a great extent. Instead of that, small areas were blocked again and again for a short period of time for the assembly of the intermediate level and for the installation of the conveyor technique. Thereby the installation of the intermediate level took a lot of time which had to be considered during the time planning. The required flexibility and the reliability of the system were considered regarding the distribution of the conveyors to the single control units and regarding the planning of the routing. Therefore, a breakdown of a control unit or of an X-ray machine does not have any impact on the baggage transport and the baggage handling: 100% of redundancy.

| The advantages
After the modernisation of the baggage handling system, a complete baggage inspection in terminal 1 and terminal 2 could have been guaranteed. By the assembly of the conveyor technique on an intermediate level in the baggage distributor, the room was used in its full capacity. Therefore, the complete conveyor technique including the X-ray machines could have been installed without any impacts on the working processes for the arriving and the departing baggage and therewith without any impacts on the whole working processes of the airport. Due to the selection of the routing there is not only guaranteed a high degree of flexibility and redundancy, but also an optimal consideration of the maintenance and service routes. Therefore, the average ceiling height on the intermediate level is about 1,70 m despite the numerous binding girders. By the new planning of the baggage handling system, an exchange of the host computer became necessary. For this reason, the airport in Stuttgart installed a new host computer in terminal 1 and connected it with the existing host computer in terminal 3 in order to simplify and to improve the terminalcomprehensive planning of the baggage transport. Due to the excellent previous planning regarding the single construction phases in order to install the intermediate level and the conveyor technique, there were no complications during the construction process and so the baggage handling system could have been handed over to the airport of Stuttgart in due time. According to the airport, the biggest advantage was that during the whole time of the project it could have been felt that Aberle Automation GmbH & Co. KG had an above-average experience regarding modernisations during the running operation which has also been apparently appreciated by the involved partners and subcontractors.

Experts of Logistics
| Aberle Automation GmbH & Co. KG Daimlerstrae 40, 74211 Leingarten Germany Tel. +49(0)7131/9059-0 Fax +49(0)7131/9059-59 | E-Mail info@aberle-automation.com www.aberle-automation.com Branches Dahn, Dortmund Sindelfingen, Barcelona, Moscow