The task
Pneumatic unloaders have been proven to be a reliable solution for unloading low-density materials from grain to fertilizers to alumina. Especially in the non-food sector, terminals are frequently located in harsh environments, which creates additional challenges and limits the availability of skilled operators.
 
With the exception of fewer than 20 grab ship-unloaders — which were exclusively automated by iSAM — all ship-unloaders worldwide, whether pneumatic, grab or continuous bucket chain, still need to be manned by an operator, and only basic teach-in procedures are available to support manual operation.
 
To allow truly autonomous operation, an automation system must not only be capable of controlling the pneumatic suction process, but also have a real-time 3D view of the vessel, the material distribution inside the hatch and all ship movements caused by tides, waves from other vessels and the unloading process itself (trim tanks, weight distribution etc.).
 
 

HMI (human–machine interface) for supervision of two autonomous pneumatic unloaders from Central Control Room, bulk carrier and product as ‘seen’ by the system


 
 3D ship model view of two unloaders operating autonomously.
 
The solution
iSAM utilized its existing and well-proven autonomous control system for grab ship-unloaders (GSUs) and combined it with its 3D model used for shiploaders. From a geometric standpoint, a shiploader and pneumatic unloader are very similar, which is why this approach significantly reduced development costs and time to market.
 
All these systems require a combination of the latest 3D LiDAR technology originating in self-driving cars, highly accurate RTK GPS systems for machine positioning, and internally developed leading-edge control technology including sophisticated filtering algorithms allowing the use of LiDAR in reduced visibility conditions.
 
One of the key components of the systems is the 3D ship model, which is based on a high resolution (128 lines) real-time laser scanner, and mounted on a tightly synchronized turntable. This enables a complete hemispherical view even when right above the vessel in high air draught situations.
 
By combining data from multiple scanners, the ship model not only ensures a safe operation close to hatch covers and deck cranes, but also measures the material distribution inside the hatch, thus enabling an efficient unloading process all the way down to the bottom of the hatch.
 
While the 3D scanner is the ‘eyes’ of the automation system, iSAM’s leading-edge control technology connected with the PLC is the ‘brain’. The optimal unloading strategy is automatically determined on the basis of the known material properties and the current sensor data of the machine environment, thereby minimizing machine movements and optimizing continuous unloading performance.
 
The first two systems were transferred into full operational use in February 2026 after an extensive trial period in all weather conditions. The technology is available for commercial delivery as of now.

Highlights
  • real autonomous operation, not a remote control;
  • autonomous control all the way down the bottom of the hatch including ‘directed digging’ and ‘floor-sweeping’, effectively minimizing the time required for front-end loaders in the hatch;
  • very uniform and steady unloading performance, which minimizes the idle times of the equipment;
  • driverless operation even very close to the hatch coaming, under virtually any weather conditions; 
  • operation of all equipment from a central control station, i.e. minimum stress for the supervisory operator thanks to a maximum degree of automation (easily up to 6 cranes by one operator);
  • possibility of manual intervention from the central control station by remote control; and
  • lower wear and tear because mechanical performance limits are always respected in autonomous mode

About iSAM
iSAM AG, Gesellschaft fuer angewandte Kybernetik, located in Muelheim an der Ruhr, Germany, develops and implements automation solutions that enable industry, commerce and service suppliers to increase their performance.
 
iSAM’s team includes specialists from the engineering, computer science and physics sectors as well as business economics, focusing on increasing customer value. The company’s customers can be found all over the world and in almost every industry, such as mining, coal handling, transport and logistics, steel and metal manufacturing and processing, tube welding and pipeline construction, mechanical engineering and plant building, electronics and aerospace.
 
The company is a subsidiary of HHLA AG, the main operator of the Port of Hamburg.
 
For more information, visit iSAM.