Technical description of the fully automated pallet-moving parking system (Robocar)

AUTOMATIC PALLET MOVING PARKING SYSTEM (ROBOCAR)

The Automatic Pallet Moving Parking System, also known as Robocar technology, is a fully automated parking system. With this technology, drivers simply park their vehicle on a pallet in the car lift cabin, and the system automatically finds an available spot and moves the pallet with the vehicle to that spot. This allows for maximum utilization of parking space, making it ideal for high-rise buildings with limited space (where using ramps would consume all parking space or require multiple underground levels) in major city centers such as Hanoi, Ha Long, Hai Phong, Vinh, Da Nang, and Ho Chi Minh City. The system can be installed with multiple parking levels within a single basement level, eliminating the need to construct ramps. By installing a smart parking system, the project can save on construction costs by reducing the basement depth and ME costs (due to a reduced number of basement levels).

Advantages of the Automatic Pallet Moving Parking System:

1. Multiple parking levels can be installed in a single basement or above-ground structure >>> Reduces ME system installation costs (fire protection, ventilation, low-voltage systems, water supply, and drainage, etc.).
2. Maximum parking level height is 2100mm for SUVs and 1600mm for sedans >>> Lowers construction costs by reducing the need for deep excavation.
3. No need for ramps >>> Maximizes parking space.
4. Utilizes a car lift combined with an automatic car transport system >>> Drivers only need to park their vehicle on the pallet in the lift cabin, and the system handles the remaining steps for parking and retrieving the car.
5. Each vehicle is securely placed on a pallet >>> Eliminates collision-related issues during system operation.
6. The system is programmed for automatic operation >>> Reduces labor costs for security and operation.
7. Smart parking system >>> Enhances the building’s or project’s image, attracting customers.

Disadvantages of the Automatic Pallet Moving Parking System:

1. Uniform pallet size >>> Only vehicles that fit the system’s pallet size can be parked, meaning oversized vehicles cannot be accommodated. These larger vehicles must be parked in designated areas.
2. Vehicles are parked and retrieved in the lift cabin without using ramps >>> Only one vehicle can be parked or retrieved at a time per lift entrance. If the parking facility has many spaces but few lifts, it may cause congestion (especially during peak hours like the start or end of the workday). Each lift should only serve up to 40 parking spaces.
3. The transport paths for vehicles are straight lines >>> Projects with uneven or angled parking areas will not be able to fully utilize the parking space. The system is best installed in rectangular areas; for non-rectangular spaces, other parking technologies should be considered.
4. It is a mechanical parking system >>> Additional maintenance costs are required.

Key Features of the Tân Phát Smart Parking System (ETEK Parking)

1. Imported Machinery (lifts, transport vehicles, turntables, rotators, etc.) from South Korea >>> High quality, stable operation.
2. Electrical systems and sensors designed and assembled by ETEK >>> Easy maintenance and repair, not dependent on foreign suppliers.
3. Control software developed by ETEK >>> Customizable according to investor requirements, with the ability to connect to building management software when needed, without reliance on foreign suppliers.
4. Smart parking system integrated with virtual reality technology (AOA) for maintenance and repair >>> Easy system inspection, maintaining stability in the automated parking system.
5. Smart parking integrated with remote monitoring software (IoT) >>> Easy management and supervision of the system anytime, anywhere, shortening repair times when the system encounters issues.
6. Automated parking system integrated with vehicle access control and automated parking fee collection >>> Efficient management of vehicle entry and exit, as well as parking revenue, reducing labor costs for system operation.
7. ETEK provides comprehensive solutions for car parking lots >>> Investors do not need to manage multiple contractors for the parking component of the project.
8. Over the past three years (2018, 2019, 2020), ETEK has consulted, designed, programmed, installed, and repaired smart parking systems for nearly 20 projects, with approximately 1,500 parking spaces across Vietnam (Hanoi, Ha Long, Hai Phong, Vinh, Da Nang, and Ho Chi Minh City) using a full range of parking technologies. >>> Investors can be fully confident in ETEK’s capability to execute projects and its mastery of parking technology.

PRICE OF THE SMART PARKING SYSTEM, or the cost of investing in an automated parking lot, mainly depends on the number of lifts and car transport vehicles (equivalent to the number of parking levels). The total value of the lift and transport vehicle components constitutes a significant portion of the cost, while the cost of each parking space, including the mechanical frame and pallet floor, is relatively low. Therefore, the installation cost of a smart parking system varies from project to project, leading to different investment costs for each parking lot.

For example:

• Lift: 2,000,000,000 VND/unit
• Transport Vehicle: 750,000,000 VND/unit
• Turntable: 400,000,000 VND/unit
• Mechanical Frame: 30,000,000 VND/position

Parking Lot 1: Uses 2 car lifts, 4 car transport vehicles, 2 turntables with 80 parking spaces. Total cost: 10,200,000,000 VND >>> Investment cost per parking space: 127,500,000 VND/position

Parking Lot 2: Uses 2 car lifts, 4 car transport vehicles, 2 turntables with 100 parking spaces. Total cost: 10,800,000,000 VND >>> Investment cost per parking space: 108,000,000 VND/position

Parking Lot 3: Uses 1 car lift, 2 car transport vehicles, 1 turntable with 26 parking spaces. Total cost: 4,680,000,000 VND >>> Investment cost per parking space: 180,000,000 VND/position

*The prices mentioned are for reference only.

SMART PARKING LOT DIMENSIONS

The dimensions of an automated parking system largely depend on the layout and cross-section of the parking lot.
In this article, we provide the standard dimensions of a smart parking lot in the Technical Specifications section (below).

SMART PARKING LOT DESIGN

To design an automated parking lot, we require the following basic information: the smart parking lot drawings, including layout and cross-section (in CAD format), the number of parking spaces required, and any specific requirements (VIP parking spots, automatic car wash area, or other functional areas within the parking lot).
Once the smart parking lot solution is finalized, we will provide the following documents: Parking space allocation drawings (Layout, Cross-section), technology description, and a cost estimate.
During the automated parking solution design phase, we offer free support.
Any actions related to charging design fees at ETEK are strictly prohibited. Please call our hotline for consultation if such issues arise.

TECHNICAL SPECIFICATIONS OF THE AUTOMATIC PALLET MOVING PARKING SYSTEM (ROBOCAR)

I. SYSTEM CAPACITY

• Total parking capacity across the entire parking lot: Depends on the specific project
• Number of parking levels: Depends on the specific project
• Vehicle dimensions including mirrors (LENGTH x WIDTH x HEIGHT): Depends on the specific project
  • SUVs: 5300x2150x1900mm
  • Sedans: 5300x2150x1550mm
  • Vehicle weight limit: ≤ 2200kg

II. MAIN COMPONENTS OF THE AUTOMATED PARKING SYSTEM

1. Lift: This component is responsible for lifting and lowering vehicles to allow entry and exit. The lift includes an automatic door and can be integrated with a turntable to change the vehicle’s direction at the top of the lift.

2. Steel Frame System: This system consists of steel beams connected by bolts/welding to form a structural frame that supports and contains the vehicles

3. Pallet Vehicle Platform: This is the area where vehicles are stored, divided into compartments. Each position is constructed similarly and can hold a maximum of one vehicle.

4. Car Transport Vehicle (Cart):

The Cart is a device that operates within each level, with one Cart per level responsible for transporting vehicles from the lift to each storage compartment in the steel frame and vice versa to retrieve vehicles for customers. Additionally, the Cart may be integrated with a turntable to change the vehicle’s direction.

5. Pallet Transfer Device PPD:

This device is a frame that pulls pallets inside positions with two or more layers of vehicles.

III. OPERATION PRINCIPLES OF THE SMART PARKING LOT

1. Vehicle Parking:
   • Step 1: Drive the vehicle to the lift cabin door.
   • Step 2: The automatic door detects the vehicle’s arrival and opens automatically when the system is ready.
   • Step 3: Drive the vehicle into the lift cabin according to the parking instructions. After parking the vehicle correctly, the driver exits the vehicle and leaves the cabin.
   • Step 4: The driver exits the cabin and presses the parking confirmation button on the control screen. The automatic ticket dispenser will issue a ticket containing vehicle information (license plate, parking location, entry time, etc.).
   • Step 5: The lift automatically moves the vehicle to the designated level. The horizontal transfer device will move the vehicle from the lift to the horizontal transport vehicle at each level.
   • Step 6: The horizontal transport vehicle moves the vehicle to an available parking space, and the horizontal sliding mechanism will move the vehicle from the horizontal transport vehicle into the empty parking spot.
2. Vehicle Retrieval:
   • Step 1: The vehicle owner arrives at the lift cabin door and inserts the parking ticket into the automatic ticket reader.
   • Step 2: The control screen displays the parking fee. The driver pays the parking fee using an electronic wallet via QR code or cash through the automatic payment terminal. The system will print a parking receipt for the driver.
   • Step 3: The system simultaneously activates the horizontal transport vehicle to move the vehicle to be retrieved and the lift to the level where the vehicle is parked.
   • Step 4: The horizontal transport vehicle uses the sliding mechanism to move the vehicle from the retrieval position to the lift and then moves the vehicle from the horizontal transport vehicle to the lift.
   • Step 5: The lift raises the vehicle to the lift cabin.
   • Step 6: The door will automatically open when the lift reaches the top of the cabin.
   • Step 7: The driver enters and drives the vehicle out of the lift cabin, and the door automatically closes when the vehicle exits the cabin.
3. Special Cases:
   • For vehicles with monthly passes, VIP passes, or pre-issued tickets that do not require a new ticket, the system will automatically skip the payment, ticket issuance, and ticket collection steps.

IV. SAFETY FEATURES OF THE SMART PARKING LOT

• Occupant Detection Sensors: If the driver remains in the vehicle while parking, the system’s sensors will detect this and provide an audible and visual alert on the control screen.
• Vehicle Size Detection Sensors: If a vehicle exceeds the size limit, the system will issue a warning and refuse to accept the vehicle.
• Misalignment Detection Sensors: If a vehicle is misaligned in the cabin, the optical sensors will alert the driver of the misalignment on the control screen, prompting the driver to adjust the vehicle’s position.
• Emergency Stop System: The system will completely stop if any issues occur during operation, with alerts for the operator to handle the situation.
• Fault Warning and Guidance: The control screen will display any faults that occur during operation.
• Automatic Stop Function for Cable Breakage: In the event of a cable break, the system’s sensors will detect the break and automatically stop the system.
• Electrical Leak Protection: Includes measures to prevent electrical leakage.
• Audible and Visual Alerts During Operation: Provides sound and light warnings during system operation.
• Intrusion Alert: Alerts when someone enters the system while it is operating.
• Over-Movement Protection: Prevents movement beyond safety limits.
• Phase Loss Protection: Safeguards against phase loss issues.

V. TECHNICAL SPECIFICATIONS OF THE SMART PARKING SYSTEM

VI. SOFTWARE AND FEATURES OF THE AUTOMATED PARKING SYSTEM

1. Control Software: The software is programmed by ETEK.
   1.1. Modes of Operation: Three modes are available: Fully Automatic, Semi-Automatic, and Manual.

Fully Automatic Control: The process is fully automated for both parking and retrieving vehicles. The driver only needs to swipe their card; no additional actions are required to select a parking spot. The system will automatically find an available space within the system to park the vehicle. Each vehicle parked in the system is monitored with a unique code (vehicle number plate) used by the operator for vehicle retrieval and inspection.

Semi-Automatic Control: Operated via the control panel.

Manual Control: Operated manually using a button box.

Car Lift Manual Control

1. Emergency Stop Button
2. Button to Move Up/Down
3. Reset Button to Clear All Previous Selections
4. Operation Mode Selection
5. Mode Selector Switch (MENU: Manual Mode, AUTO: Automatic Mode)
6. Button to Select Fast Operation Mode
7. Channel Selection for Lift Operation

PPD Manual Control

1. Mode Selector Switch
2. Switch to Activate PICKING Motor
3. Switch to Activate SHIFTING Motor
4. PPD Position Selection Channel
5. Fast Operation Mode Button
6. Reset Button to Clear All Previous Selections
7. Emergency Stop Button

Cart Manual Control

1. Mode Selector Switch
2. Switch for Cart Movement or Pallet Movement
3. Switch to Activate LEFT SHIFTING Motor
4. Switch to Activate RIGHT SHIFTING Motor
5. Indicator Light for Operation Direction
6. Operation Direction Switch
7. Switch to Select Operation with Standard Position or PPD Position
8. Fast Operation Mode Button
9. Emergency Stop Button

1.2. Automatic Maintenance Warning Feature Based on the Frequency and Duration of Operation for Each Component of the Parking System

Purpose: Components that are used more frequently will receive maintenance sooner and more often than those used less frequently. This feature allows for detailed monitoring of each component’s operation, including: lift motors, horizontal sliding motors, bearings, chains, safety hooks, and more.

1.3. The System Can Be Programmed According to the Investor’s Requirements.

Advantage: Not dependent on foreign suppliers in case of issues.

2. Virtual Reality Software Supporting Warranty/Maintenance for the Automated Parking System (AOA):

2.1. System Error Alerts on the Control Screen

2.2. The Virtual Reality System Supports Inspection, Maintenance, and Repair of the Parking System.

Purpose: Provides guidance on system usage, maintenance instructions for each component, checks the system’s operational status, detects system faults, and suggests troubleshooting methods. This is achieved through the use of smart mobile devices (phones, tablets) to scan images of the parking system via the device’s camera on the virtual reality software platform:

Displays Equipment Status Information (specifications, operational status, etc.)

Support for System Maintenance

Alerts for Equipment Requiring Maintenance

Guidance on Maintenance Procedures

Error Notifications:

Guidance on Diagnosing and Resolving Errors

Display of Documents (Drawings, datasheets, videos, website links, etc.)

Update Error Status and Store Repair History

View Internal Equipment Blocked by Other Devices

Advantages of the Software:

• Enhances Operational Efficiency and Maintenance: Provides necessary information on-site.
• Reduces Human Error: Offers visual guidance for steps and tools needed for system operation or simple maintenance and repairs.
• Saves Time in Diagnosing Errors.
• Supports Personnel: Ensures that users and managers are proactive and not passive when issues occur.

2.3 Central and Online Parking Monitoring and Control System

The system monitoring setup is installed in the technical room.

It monitors the entire operation of the system, including the operating frequency, vehicle occupancy rate, etc.

Display system errors on the central screen.

Alert the scheduled time for parking system maintenance.

Besides the monitoring system in the control room, the parking lot manager can remotely monitor the system (IoT) via the Internet on smartphones, tablets, and computers. The system includes the following functions:

• Remote system monitoring
• Remote advanced fault diagnosis
• Remote program modification/adjustment as needed
• Remote management settings, including user account creation
• The software complies with cybersecurity standards such as ISA99 and IEC 62443 or equivalent and is certified to ensure cybersecurity by international organizations such as ISACA, Protectem, and CompTIA within the last two years.

2.4 Vehicle Entry and Exit Monitoring System

• Monitor vehicle entry and exit times
• Automatic license plate recognition and image capture
• Lane switching feature, comparing license plates at entry and exit
• Revenue report updates by time, shift, and employee
• Revenue aggregation
• Server alert to view reports via Internet Explorer or on mobile devices
• Advanced and on-demand search functionality
• Multi-level access control
• Vietnamese interface
• User hierarchy: Admin, Manager, Security, etc.
• Automatic license plate recognition and image capture
• Customized reporting as per customer requirements
• Automatic card issuance
• Automatic payment (cash or electronic)
• Receipt printing
• Integration with the automatic parking system for car retrieval and storage commands

3. UPS System:

Current Situation: When there is a power outage, the system stops operating and must wait for power restoration (via a generator) before resuming operations. This causes delays for users needing to retrieve their vehicles. Occasionally, the system might stop while the vehicle is in a dangerous position. Additionally, the parking sensors become disoriented due to sudden power loss. To ensure safety, the system switches from automatic to manual mode, which only trained building technicians can operate.

Solution: When equipped with this feature, the system will support incident handling during power outages, allowing the parking system to continue operating normally in automatic mode until the last command is completed. Once power is restored, the system resumes normal operation without requiring the building technicians to reset the program. Furthermore, using the support device ensures stable power supply to the parking system, preventing issues caused by unstable building power supply.

4. AI Facial Recognition Software:

Developed by ETEK, the system features:

• AI-based facial recognition for vehicle retrieval/storage operations

Purpose:

• Update outdated parking ticket management methods
• Enhance security and asset safety
• Improve the building’s modern image

VII. MAINTENANCE OF AUTOMATIC PARKING SYSTEM

1. Overview
To perform maintenance in the parking lot, the operator/maintenance personnel must enter the parking area. Individuals without responsibility or duty may face severe danger when entering the parking system. Therefore, all maintenance tasks must be performed by maintenance specialists.
Maintenance plays a crucial role in extending the lifespan of equipment; therefore, when using the system, it is essential to follow the maintenance procedures established by both the Contractor and the Equipment Manufacturer.
When performing maintenance in areas with a risk of falling, safety harnesses must be worn before commencing work.

2. Inspection Requirements

For the Investor:

• The system operator should inspect the system’s condition daily.
• The Contractor provides technical support solutions, enabling the Investor to self-check the operational status of the equipment and detect system faults, along with methods for rectification using a smart mobile device on the AOA virtual reality software platform, by directly scanning the parking system’s image via the device’s camera.
• For minor issues, the Contractor can guide the Investor to self-correct; for more significant issues, the Contractor will visit the site to rectify them through the support of IoT technology (remote operation and control support) and AOA virtual reality software platform technology (maintenance support) to minimize repair and fault correction time for the Investor.

Example:
When using a phone to scan the camera on the system’s lifting motor, information about the motor will be displayed on the phone screen, including the manufacturer, capacity, operational status (e.g., how many times the motor has lifted/lowered, whether the motor is due for maintenance, etc.). If the motor is malfunctioning, the information section will flash red or yellow to alert the operator. Clicking on the flashing icon directly on the screen will bring up detailed information, including the name of the motor fault, the cause of the fault, and repair methods.

For the Contractor:

Inspection and Maintenance Frequency

• Monthly inspections are carried out by the Contractor’s professional maintenance specialists.
• Inspections are based on the frequency and operational time of each piece of equipment.
• Issues must be addressed as requested by the Investor or based on clear error warnings displayed on the control or central screen through the local network and via the internet outside the parking area.

Inspection Components

a. Elevator (Lift)

• Steel Frame:
  • Elevator column
  • Connections to the wall
  • Connection bolts
• Lift Platform:
  • Platform shape (check for any deformation or alteration during use)
  • Safety brake mechanism when moving beyond limits (upper and lower brakes)
  • Height difference between the lift platform and parking floors
  • Rotation mechanism of the turntable (if applicable)
  • Guide rollers for pallet alignment
  • Lift locking motor when rotating (if applicable)
  • Lift platform guide wheels
  • Connection bolts

b. Lifting System:

• Lift Motor:
  • Insulation and current of the lift motor
  • Noise level during operation
  • Brake
  • Gearbox
  • Oil leakage and oil level in the gearbox
  • Noise level during operation
  • Guide rails and guide shoes
  • Wear of lifting cables/chains
  • Wear of sprockets and lift pulleys
  • Bearings and couplings

c. Shuttle (Vehicle Transport Device):

• Moving Parts:
  • Insulation and current of the motor and brake
  • Drive shaft coupling
  • Track rail
  • Drive wheels
• Pallet Pulling System:
  • Insulation and current of the motor and brake
  • Tension of the horizontal drive chain
  • Pallet drive wheels
• Pallet Receiving Unit:
  • Insulation and current of the motor and brake
  • Rack & pinion drive
  • Guide wheels

d. Pallet:

• Deformation of the pallet during use
• Peeling and rust
• Pallet stopper
• Pallet wheels

e. Pallet Support Frame:

• Deformation of the pallet support frame during operation (column straightness, flatness, parallelism of pallet support rails)
• Connection bolts

f. Electrical Equipment:

• Check the condition of each electrical component in the control cabinet
• Inspect the control panel
• Verify the operation of lights, warning horns
• Check LED guide lights
• Inspect sensors and limit switches

g. Other Components:

• Unusual noise during operation
• Automatic doors
• Rotation mechanism of the turntable

3. Lubrication

The timing for oil replacement depends on operational and external conditions (specific temperature).
Lubricant that has lost its properties and functions must be replaced with new lubricant to ensure longer machine and equipment life.

Types of Oils Used:

• OMALA 220 (SEW Gearbox)
• OMALA 150 (SAMYANG Gearbox)
• ALVANIA EP R (DSK Gearbox)
• Replacement Time: After 100,000 hours or 3 years of use

VIII. INCIDENT PREVENTION AND RESPONSE

If you detect any malfunction or error in the parking system, users should not attempt to repair the issue themselves. Instead, contact a maintenance specialist or the manufacturer for assistance.

Common causes of incidents include incorrect installation of mechanical structures according to the design, leading to errors in automated control. Therefore, the first step in preventing incidents is to closely monitor and inspect the mechanical installation process.

Electrical Equipment Incident Prevention:

• Electrical equipment and gear motors for the parking system should be sourced from reputable manufacturers such as those in Korea, Japan, or Germany. These components have been evaluated and tested in various projects, and have become standard products of their brands, known for stability and high quality.

PLC Software Programming Incident Prevention:

• Before operation, the system undergoes test runs with all possible vehicle retrieval scenarios that may occur in reality.

Power Outage Incident Prevention:

• The parking system should be equipped with backup generators or a UPS system to ensure continuous vehicle retrieval and storage.

Flood Prevention:

• The building should have a water drainage system and automatic pumps in the basement to prevent flooding that could damage electrical equipment. Additionally, transverse grooves with cast iron covers should be installed on the ramp leading to the basement to prevent water from entering.

ETEK Automation Solution JSC specializes in providing smart parking solutions for both large and small projects. With a commitment to professionalism and dedication, ETEK is always committed to delivering the highest quality products at reasonable prices and ensuring timely delivery.