Emulation in the Terminal: How Automation and Autonomous Systems Are Safely Introduced
Why emulation is becoming a key success factor for modern container terminals
By Michael Kugler
Three terms at the center: prediction, simulation and emulation
In the context of the digital transformation of ports and terminals, several terms usually come into play: emulation, prediction and simulation. All of them revolve around how a terminal and its processes can be digitally mapped, analyzed, digitally tested and optimized. But which term describes what exactly?
Prediction
In the prediction, a forecast of further data is given on the basis of a fixed database. This is to predict future developments. Historical data is used to predict arrival times, weather developments, volume flows or seasonal fluctuations, for example. This approach is particularly relevant for strategic and operational planning.
Simulation
The simulation goes much deeper. The aim is not only to predict further data, but also to calculate processes in advance. To this end, processes and sub-processes are reproduced in detail mathematically, including their dependencies and random influences. The goal: to replicate a complex system as close as possible. For example, traffic flows in the terminal, parking space capacities or the use of equipment can be realistically examined. Simulation helps to play through scenarios without having to make physical changes. Simulation is often used when a terminal or port is designed or before a TOS goes live, for example to check the storage space capacity or to make sure that enough equipment is planned.
Emulation
Finally, emulation connects the virtual world with real IT systems. Instead of just replicating processes, existing systems – i.e. the Terminal Operating System (TOS) in the terminal environment – are integrated directly into an emulated environment. The TOS or an ECS is therefore tested against emulated live operation. The emulated systems react to simulated events as if they were in live operation. Errors, vulnerabilities, interface integration issues and inefficient processes become visible long before they occur in real operation. Emulation is therefore the most deeply integrated image into real operation. With emulation, the TOS and the overall environment can be tested in great detail, including all interfaces. This shows whether the process flow actually works during automation. Emulation can as well be used e.g. to setup complex training scenarios to train TOS users in a close to real environment.
In the following, I will discuss emulation and its application mode and scenarios.
1. Emulation can test complex systems
Today, "mixed operations" are often found in the automation of container terminals: automated systems are operated in parallel with manual processes and, in the future, autonomous vehicles as well. This mixed operations adds to the complexity. All data on each individual container, on each device, must always be unique and up-to-date. To do this, interfaces must transmit this data correctly, synchronize processes and thus enable decisions to be made in real time. Even small errors can have far-reaching consequences, so that a container is incorrectly assigned, for example. Here, emulation makes it possible to test and optimize precisely these interfaces and connected processes under realistic conditions. This allows integration problems to be identified and eliminated at an early stage before going in live equipment testing or even real live operations.
2. Emulation and exception handling
An often underestimated aspect of terminal automation is the handling of exceptional situations. While standard processes are relatively clearly defined, the biggest challenges arise in the deviations: What happens if a truck takes the wrong route? When container data is incomplete or doesn't correspond to reality? When new regulatory requirements are introduced? Such scenarios are unavoidable in real operation. At the same time, it is difficult to fully capture them in advance. Many critical errors only become visible when systems are tested in dynamic interaction. With emulation, precisely these exceptional cases can be created and analyzed in a targeted manner.
3. Continuous optimization via iterative emulation
Emulation goes far beyond classic testing. It enables full validation of processes, system logic, and integrations. Companies can use it to check the following before commissioning:
- whether planned processes work
- how systems react to change
- and what optimizations are necessary
An important advantage is the ability to repeat: changes in one area often have an impact on other areas. For example, new TOS or ECS setting or new customs regulations are coming that will change the processes at the terminal. Emulation makes interactions visible and makes it possible to improve systems step by step in a safe environment. This results in a continuous optimization process that goes far beyond the initial planning.
4. Autonomous vehicles: The next step in development
In addition to classic automation, autonomous vehicles are increasingly applied in ports and terminals. They make decisions independently on the basis of sensors and software/AI and have to interact with centrally controlled or manned internal or external vehicles. The advantage: terminal processes can be made more dynamic, and changing conditions can be reacted to quickly. It is imperative to comprehensively test the autonomous vehicles and the modified processes at the terminal before they are used in real operation. These scenarios can also be tested excellently with emulation.
Conclusion: Emulation as the basis of successful terminal automation
The automation of container terminals is to be understood as an extremely complex system integration because the processes are usually more connected and dependent. The more components interact with each other, the more important it becomes to understand and test these interactions in advance. Emulation offers exactly this possibility. It creates a realistic test environment in which systems, processes and interfaces can be validated under real conditions. Emulation is used independently of physical infrastructure. This allows terminals to test and optimize processes before devices or systems are purchased or installed. This reduces risks and creates a sound basis for decision-making.
No automation without emulation!
