capability statement bcsas international 120111 - bcs group automated baggage system projects at the...

AIRPORT SYSTEMS

Capability Statement

General

BCS Airport Systems is a company specialising in the development, design, manufacture, installation and servicing of a broad range of innovative, state-of-the-art baggage handling systems (BHS) as well as other products and services for the aviation industry. BCS has implemented a wide range of BHS’ in many parts of the world. As a result of established engineering practices, quality manufactured equipment and a conscientious service department, the company is now an industry technical leader. BCS is also recognised as leaders for our control and software systems specifically developed for baggage handling applications. Verification of BHS design through simulation is an essential task for any modern baggage handling project. BCS’ own Sym3 is a revolutionary 3D simulation package, enabling the verification of BHS design, operational analysis, and complete pre-installation testing of low and high level control systems. The advent of Sym3 provides a tool that extends the value of simulation from BHS design verification into the implementation and integration phases of BHS projects, and through to operational functions. BCS specialise in supplying and integrating x-ray screening security systems, baggage sortation equipment and all types of standard conveyors and carousels to many regions of the world. We have developed an experienced, self sufficient capability to handle large, complex projects from concept development and simulation through to fabrication, system installation, commissioning followed by operation & maintenance, in any part of the world. Company History

BCS was formed in 1993 initially to provide control system specialist work for the BHS industry where it was instrumental in ensuring the successful completion of one of Australia’s first automated baggage system projects at the new Brisbane International Airport. This followed with the supply of control and software systems for various other airports in the region including the first automated baggage system at Auckland International Airport and the new Qantas Domestic Terminal in Sydney. In 1999, BCS was the first company to successfully install and commission the first Hold Bag Screening (HBS) project in Australia (Brisbane) and in 2000 supplied all of the electrical design and control systems for the Sydney International Terminal (BHS and HBS) in time for the Sydney Olympics. More recently, BCS has completed major control systems and turnkey baggage supply contracts in every major Australian airport including RFID implementations and the Air New Zealand bag drop solution. The BCS product range now includes the entire range of BHS conveyors, industrial control systems and software allowing us to provide total turnkey solutions for BHS projects. Currently, BCS has 85% of the Australasian baggage handling market and is a major player in the worldwide BHS industry with projects throughout Asia, Europe, Africa, the Middle East, North & South America. BCS is also the premier infrastructure support provider in many countries where we operate and maintain BHS/HBS systems.

BCS Group of Companies

BCS is a privately owned company with the majority shareholding owned by 20 senior managers. BCS currently has over 300 permanent staff spread around Australia, New Zealand, Asia, Europe, Africa, the Middle East and North & South America.

BCS Airport Systems focuses on airport and baggage handling equipment, manufacturing a complete range of conveyor products including, general transport types, metering belts, merges, power curves, pushers, diverters and other sorting technology. It is also a recognised supplier of specialist conveyor equipment to major airport suppliers as well as for its system programming and design skills and it is used as a technical support company for a number of major PLC suppliers. BCS expertise in software is across all major PLC systems including Omron C-series, Siemens S5 and S7 series, Allen Bradley PLC 5, SLC500, and ControlLogix, IDEC, as well as a number of other manufacturers. BCS Logistics Solutions specialise in the development, design, manufacture, installation and servicing of a broad range of innovative, state of the art material handling systems and components suitable for small manual sortation warehouses right through to large distribution hubs incorporating sophisticated sortation systems. BCS Services & Solutions has developed leading edge products for the airport industry (Airflow HLC and HBS Systems, ME stations, Sym3 for simulation and emulation and Data Warehousing Systems) and is focused on developing standard industrial products for the oil, photography and the motor vehicle industries as well. This division also manages specialised aviation products such as automatic bag drop and baggage reconciliation systems. BCS Infrastructure Support is aimed specifically at airport operations and maintenance and has developed a practical and cost effective way of operating the BHS systems at a number of international terminals. . BCS has its own manufacturing operations in Australia, New Zealand, China, Malaysia, Indonesia, Mexico and Brazil.

BCS Group

AirportSystems

Logistics Solutions

Infrastructure Support

Services & Solutions

The BCS Way

BCS’ business philosophy is centred on people. Since its inception, the company works hard on delivering what people want and need and today we continue to work on the words of our founder:

“What makes a company successful is honesty and integrity, and the focus on doing things right. We consider our customers as part of our business, and we must serve their needs in the most professional and efficient way.”

Our core business philosophies are:

• Customer focus – Understanding the customer’s requirements.

• People focus – People (internal and external) are our business.

• To develop innovative and superior products – we stand by our products and service.

• To deliver superior service – we respond quickly to customers’ requirements.

• Innovate and look beyond the obvious.

The belief in our people has enabled them to provide the company with tremendous strengths such as:

• Client and project management.

• Application and integration of leading edge technologies.

• Highly experienced and qualified personnel who understand the baggage handling industry.

• Stable and motivated personnel.

• BCS has developed a strong reputation for the quality of our work and the sales support that is provided to every client.

Company Strengths

• Very high levels of technical & mechanical design expertise.

• Excellent foundation of core products for all related disciplines of baggage handling projects.

• Personnel committed to optimal service delivery which is validated by our very high levels of repeat and referral business.

• Demonstrable experience in the application and deployment of a vast range of technologies.

• Expertise in all elements of project delivery.

• Market industry leader for the implementation of baggage handling systems and ongoing support.

Core Services

• Consultancy services at a business and operational level for a wide range of industries.

• System design and specification.

• Project management and system installation.

• Commissioning and user training.

• Maintenance and troubleshooting.

• System and asset auditing.

• Comprehensive documentation. BCS uses in-house developed software for simulating BHS designs and operational conditions. Simulation enables the client to view the proposed system and make decisions on the layout and product processing methodology. Engineering, controls design and field support capabilities are all contained entirely within the BCS group of companies. We have developed an experienced, self-sufficient capability to handle large, complex material and baggage handling system projects from concept development, system implementation through to operation & maintenance. BCS invests significant amounts annually into researching new leading edge technologies to ensure the solutions of BCS are best suited to the requirements of the various industries. This includes better and more accurate methods to achieve higher accuracies in tracking, RFID (radio frequency ID tags), new check in and security screening technologies, using Variable Speed Drive controls to minimise maintenance and operating costs and better ways of providing reporting and user information on system operations to support the customers with their cost justifications and achievement of KPI’s. Core Products

BCS offers a complete range of conveying products, systems and services. The company’s in-house capabilities provide for mechanical and electrical designs combined with full manufacturing and factory assembly facilities. BCS also provides a complete installation and maintenance service for our systems. BCS’ range of products and services enables us to be lead contractors for complete turnkey baggage projects and to meet industry challenges in:

• Providing solutions to Homeland Security enhanced security requirements leveraging particularly with our competitive edge in the field of software/automation.

• Catering for the on-going airport development resulting from air passenger number growth, green field site developments and existing airports refurbishments/upgrades.

Detailed technical sheets on each conveying and sorting product are available upon request.

BCS Belt Conveyors

TYPE OF CONVEYOR IMAGE

LENGTH (m)

BELT WIDTH (mm)

MOTOR DETAILS

SPEEDS (m/sec)

CAPACITY (kg/m) FEATURES CONSTRUCTION APPLICATIONS

Metering conveyors

1.0 - 2.5 600 800

1000

Direct driven Up to 3.0 Up to 90

Heavy duty construction Belt tracking rollers

Single sided belt tensioning

Low maintenance Side cladding available

High side walls available

Mild steel Stainless steel

Aluminium

Airport Baggage Freight

Warehousing

Heavy duty belt conveyor

1.0 - 30.0 Up to 3000 Direct driven Up to 3.0 Up to 90






Aluminium


Warehousing

Incline and decline belt conveyors




Low maintenance High side walls available


Aluminium


Warehousing

Belt curves

Various Up to 1200 Direct driven Up to 3.0 Up to 90

Heavy duty construction Low maintenance

High side walls available Mild steel


Warehousing

Belt spirals

Various Up to 1200 Direct driven

Specific to application Up to 90


High side walls available Mild steel


Warehousing

Belt merges

Various 600 800

1000

Direct driven Up to 3.0 Up to 90



Mild steel Aluminium


Warehousing

Check-in conveyors




Mild steel Stainless steel Airport Baggage

BCS Carousels


LENGTH (m)

USEABLE WIDTH (mm)

MOTOR DETAILS

SPEEDS (m/sec)

CAPACITY(kg/m) FEATURES CONSTRUCTION APPLICATIONS

Make-up carousels

Various Up to 1000 Caterpillar

chain drive

Up to 1.0 90

Heavy duty construction Sealed for life bearings Modular frame support

K3 polyurethane timber crescent shaped slat


Polyurethane threads for low noise Special guarding options for freight



Warehousing

Incline claim carousels

Various Various

Caterpillar chain

drive or new

friction drive

Up to 1.0 250

Heavy duty construction Sealed for life bearings Modular frame supports

Low maintenance Mild steel kick plate

Continuous drive linkage Polyurethane threads for low noise

Reverse curve configuration

Mild steel Stainless steel Airport Baggage

Overlapping slat carousels

Various Up to 1200 Caterpillar

chain drive

Up 1.0 90

Heavy duty construction Sealed for life bearings Modular frame supports

Low maintenance Mild steel kick plate Overlapping pallets

Can be inclined or declined



Warehousing

Sorting Systems


MAX PRODUCT LENGTH

(mm)SPEED (m/sec)

PRODUCT RATES

(Per Hour) Approx Only

CAPACITY (kg/m) FEATURES APPLICATIONS

Tilt tray sorter

1500 Up to 2.1 >8000 Up to 70

High product integrity Flexible and accurate

Can accommodate a variety of product sizes and shapes Low wear components


Warehousing

Camsort

1500 Variable 3600 per camsort Up to 70

High speed push rate Welded steel construction

Floor or overhead mounting Airport Baggage

Ploughs

1500 Variable 1800 Up to 70 Modular design

Motorised belt plough Mild steel construction

Airport Baggage

Shoe sorter

1800 Up to 3.0 >5000 Up to 40

Generally cartons only Left or right hand divert Flexible and accurate

High speed


Warehousing

Cross belt sorter

1200 2.4 >8000 Up to 30

High product integrity Flexible and accurate

Can accommodate a variety of product sizes and shapes Low wear components


Warehousing

Services

BCS’s range of services includes the following:

• Turnkey systems – all facets

• Conceptual and feasibility studies

• System simulation / emulation

• System design

• Project management

• Consultancy and business modelling services

• Operation and maintenance services

• Aerobridge maintenance

• Nose in guidance systems

• X-ray machine integration

• Cargo handling systems

• Hangar maintenance

• System audits

• Asset condition reporting and assessments

• Energy management and PLC controls

• PLC design and programming

• SCADA/HMI solutions

BCS Project Management Methodology

BCS has long been known for its project management and integration expertise. This success stems from the project managers’ ability to understand the client’s requirements from which BCS endeavours to exceed the expectations i.e. we “look beyond the obvious”. All projects follow our very simple but effective project management methodology. At the very outset, special care is dedicated to the selection of the best possible project team. The team will typically include a specialist senior engineer from each business division and be led by an experienced project manager.

Systems Requirements PhaseReview Tender documents and develop a Compliance

Matrix on all requirements

Functional Design SpecificationDevelop a document that specifies how the control

system will work to achieve the tender requirements.To be reviewed and accepted by the customer

Control System DevelopmentDevelop the PLC code and the SCADA / HMI systems to

confirm to the tender requirement

Factory Acceptance TestingTest complete system in the office to ensure that the

system conforms to the tender requirementsUse in-house system emulation software

Some of or all of the tests are witnessed by the customer

Site CommissioningInstall and commission the control system

Site Acceptance TestingTest each requirement from the requirements review to

ensure conformance to the system specificationSome of or all of the tests are witnessed by the customer

The BCS Edge

BCS invests significant amounts annually into researching new leading edge technologies to ensure that the solutions that BCS provides are best suited to the requirements of the industry. This includes better and more accurate methods to achieve higher accuracies in tracking, RFID (radio frequency ID tags), using Variable Speed Drive controls to minimize maintenance and operating costs, and better ways of providing reporting and user information on system operations to support the airports with their cost justifications to the airlines on achieving KPI’s. BCS has worked with all major X-ray suppliers and has developed control system interfaces to the machines for fully automated functionality. BCS has developed highly accurate and fault tolerant tracking algorithms that run on a Programmable Logic Controller (PLC). Standard and robust codes have also been developed by BCS for PLC communication with:

• Automatic Tag Reader (ATR) to receive barcode information about the bag or increasingly RF based solutions for more accurate information.

• Manual Encode Equipment for manually scanning the bag for its barcode.

• Hold Bag Screening equipment to receive screened information on the bag.

• Sortation software (such as Airflow) to determine where the bag needs to be sent.

The PLC uses Pulse Position Indicators (PPI) that monitors the conveyors movement for tracking. Each tracked conveyor is represented by a model within the PLC that is controlled by the PPI for that conveyor; this is referred to as the Tracking Model. Normally the entire length of a conveyor is considered to be one tracking model. The PLC uses this model to accurately track the bag down the conveyor but has built tolerance to allow for baggage that may slide or hold up slightly while travelling on the conveyor.

Software Systems

BCS Airport Systems has developed its own High Level Sort Allocation Software called Airflow. Airflow has proven interfaces to most airline / airport Departure Control Systems including SITA, ARINC, QUBE and CUTE. Airflow software is installed at many International Airports. BCS tailor every Airflow installation to the requirements of the project, and whilst BCS has developed standard product modules, these can and are adapted to every installation to meet the needs of the client. BCS has also developed Simulation Software, called Sym3, that allows BCS to virtually test a system design to ensure that it can meet the required system KPI’s. Once the design has been proven by the simulation, the design can be easily converted into an emulation tool to prove all control systems. With the entire system design and architecture being developed in house, BCS is able to design and test all of the systems and interfaces before coming to site. BCS recognizes that risk management is vital at airports and using Sym3 enables BCS to have better control of the commissioning process. This means that we are confident that the software we provide is fully tested and requires minimal conditioning to allow the system to be properly tested for live functionality.

PLCs

HLC Workstations

Sym3

MDS/SCADA

ME Stations

HLC Servers

GE FanucPWR

OK

RUN

BATT

SERIES 90-30

HIGH CAPACITYPOWER SUPPLY

PROGRAMMABLE CONTROLLERINPUT

100-240 VA C50/60HZ 100VA

125 VDC, 50W

~

+

_

24 VDCO UTPUT0. 8A MAX .

BATTERY

CPU340A 1 2 3 4 5 6 7 8

FB 1 2 3 4 5 6 7 8

A 1

A 2

A 3

A 4

A 5

A 6

A 7

A 8

B 1

B 2

B 3

B 4

B 6

B 5

B 7

B 8

XXXXXXXXX XXX XX

A 1 2 3 4 5 6 7 8F

B 1 2 3 4 5 6 7 8

A1

A2

A3

A4

A5

A6

A7

A8

B8

B7

B6

B5

B4

B3

B2

B1

XXXXXXXXX XXX XX

A 1 2 3 4 5 6 7 8F

B 1 2 3 4 5 6 7 8

A1

A2

A3

A4

A5

A6

A7

A8

B8

B7

B6

B5

B4

B3

B2

B1

XXXXXXXXX XXX XX

A 1 2 3 4 5 6 7 8F

B 1 2 3 4 5 6 7 8

A1

A2

A3

A4

A5

A6

A7

A8

B8

B7

B6

B5

B4

B3

B2

B1

XXXXXXXXX XXX XX

A 1 2 3 4 5 6 7 8F

B 1 2 3 4 5 6 7 8

A1

A2

A3

A4

A5

A6

A7

A8

B8

B7

B6

B5

B4

B3

B2

B1

XXXXXXXXX XXX XX

A 1 2 3 4 5 6 7 8F

B 1 2 3 4 5 6 7 8

A1

A2

A3

A4

A5

A6

A7

A8

B8

B7

B6

B5

B4

B3

B2

B1

XXXXXXXXX XXX XX

A 1 2 3 4 5 6 7 8F

B 1 2 3 4 5 6 7 8

A1

A2

A3

A4

A5

A6

A7

A8

B8

B7

B6

B5

B4

B3

B2

B1

XXXXXXXXX XXX XX

A 1 2 3 4 5 6 7 8F

B 1 2 3 4 5 6 7 8

A1

A2

A3

A4

A5

A6

A7

A8

B8

B7

B6

B5

B4

B3

B2

B1

XXXXXXXXX XXX XX

A 1 2 3 4 5 6 7 8F

B 1 2 3 4 5 6 7 8

A1

A2

A3

A4

A5

A6

A7

A8

B8

B7

B6

B5

B4

B3

B2

B1

XXXXXXXXX XXX XX

Emulation – testing with actual HLC, PLCs, ME Stations, Operator Stations, SCADA & virtual conveyors.

Company Organisation and Resources

BCS Group Ltd

Contact Details: Unit F, 7 Orbit Drive Albany, North Shore City 0630 NEW ZEALAND

Ph: +64 9 414 1350 Fax: +64 9 414 1355 Email: [email protected]

Key Personnel: Chief Executive Officer: Patrick Teo Email: [email protected] Mobile: +64 21 544 959

Chief Financial Officer: Steve Fullerton Email: [email protected] Mobile: +64 27 487 3080

BCS International Team



Key Personnel: General Manager: Brad Jackson Email: [email protected] Mobile :+61 434 318 329

Regional Manager – North America: Niall Teh Email: [email protected] Mobile: +64 21 445 583

Regional Manager - Asia : Mikkel Lindhardt Email: [email protected] Mobile: ++60 10 220 4496

Regional Manager – Latin America: Thiago Chaves E-mail: [email protected] Mobile: +55 (61) 8225 3865

BCS Services and Solutions



Key Personnel: General Manager: Marc Michel Email: [email protected] Mobile: +64 21 424 494

Special Projects: Rowan Cranmer E-mail: [email protected] Mobile: +64 21 618 143

capability statement bcsas international 120111 - bcs group automated baggage system projects at the...

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