simocrane cesar slewv0403 e

7/27/2019 Simocrane Cesar Slewv0403 e

http://slidepdf.com/reader/full/simocrane-cesar-slewv0403-e 1/119

Preface

Description 1

Installation 2

Integration in the cranecontroller 3

Commissioning the swaycontrol system 4

Parameter and Error List 5

Maintenance 6

Appendix 7

SIMOCRANE CeSAR slew/CeSAR slew blindSway Control System

for slewing cranes

Operating Instructions

Valid for

Hardware:- Camera As of Board Revision V-MHPC-

251D

Image sensor: Omnivision 7120,Revision 1.0 Operating System: WIN 32 CE3.0

Software:- CeSAR slew As of version V4.3.2.8- CeCOMM As of version V4.4.1.16

08/2011 EditionV0.07-E



Safety information

This manual contains information that you should observe to ensure your own personal safety as well as toavoid material damage. The notices referring to your personal safety are highlighted in the manual by a

safety alert symbol; notices referring to property damage only are displayed without a safety alert symbol.Depending on the hazard level, warnings are displayed in descending order as follows.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or serious injury could result if proper precautions are not taken.

CAUTIONith a safety alert symbol indicates that minor personal injury can result if the proper precautions are notaken.

CAUTION

ithout a safety alert symbol means that damage to property may occur if the proper precautions are notaken.

NOTICE

indicates that an undesirable result or state could occur if the corresponding instruction is not followed.

In the event of a number of levels of danger occurring simultaneously, the warning corresponding to thehighest level of danger is always used. A warning on a warning triangle indicating possible personal injury

ay also include a warning relating to property damage.m

Note

Routines or advice for the efficient use of the device and the software optimization.

Qualified personnel

The associated device/system must only be set up and operated using this documentation. Adevice/system/software must only be commissioned and operated by qualified personnel. For the purpose of the safety information in this documentation, a "qualified person" is someone who is authorized tocommission, ground, and tag equipment, systems, and circuits in accordance with established safetyprocedures. A further requirement is the successful participation in a commissioning training course held bySiemens AG.

Proper handlingote the following:N

Siemens AG Copyright © Siemens AG 2011 Automation and Drives Subject to change without prior noticeP.O. Box 48 4880437 Nuremberg, GermanyGermany



Siemens AG Copyright © Siemens AG 2011 Automation and Drives Subject to change without prior noticeP.O. Box 48 4880437 Nuremberg, GermanyGermany

WARNING

This equipment/software is only allowed to be used for the applications described in the catalog and in thetechnical description, and only in conjunction with third-party equipment and components recommendedor approved by Siemens. This product can function correctly and safely only if it is transported, stored, setup, and installed correctly, and operated and maintained as recommended.

WARNING

The electronic sway control system assists in the transportation of loads by almost completely eliminatingswaying movements. The crane driver is still responsible for monitoring movements of the load on thecrane and for switching off the system should any hazardous situations occur.

If the sway control system fails, the crane operator must ensure that the crane is stopped without any injury topersons or damage to objects. The functionality of the sway control system must be disabled and the craneoperated manually without sway control until the fault has been corrected. If the fault cannot be corrected withthe aid of the product manual, please contact the Siemens AG.

Registered Trademarks

All names shown with the trademark symbol ® are registered trademarks of Siemens AG. If third parties useany other names in this document which refer to trademarks for their own purposes, this might infringe uponthe rights of the trademark owners.

Exclusion of Liability

We have verified that the contents of this document correspond to the hardware and software described.However, since deviations cannot be precluded entirely, we cannot guarantee full consistency. Theinformation given in this publication is reviewed at regular intervals and any corrections that might benecessary are made in the subsequent editions.



SIMOCRANE CeSAR slew Sway Control SystemOperating Instructions, 08/2011 Edition, V0.07-E 5

Preface

Contents

This document contains instructions on how to commission the SIMOCRANE CeSAR slew/CeSAR slewblind sway control system which is typically used to eliminate load swaying movements on slewing cranes. Itincludes information about connecting, operation and commissioning.

Note

The product is referred to simply as CeSAR slew in the rest of the document.

Additional information

ServiceI CS LS MC CR

Tel.: +31 70 333 1369 or +49 (9131) 98-4415

E–mail: [email protected]

Technical Support

I DT MC CR APTel.: +49 9131 98 5233

E–mail: [email protected]

mailto:[email protected]








Table of Contents

1 Description................................................................................................................................................. 9 1.1 Fields of application .......................................................................................................................9 1.2 Versions .........................................................................................................................................9 1.3 Interfacing with the crane control system ....................................................................................10 1.4 Camera measurement (CeSAR slew only)..................................................................................10 1.5 System requirements ...................................................................................................................11 1.6 Operating principle of the sway control system ...........................................................................11 1.7 Operating modes .........................................................................................................................12

2 Installation ............................................................................................................................................... 19 2.1 Overview......................................................................................................................................19 2.2 Camera settings...........................................................................................................................19 2.3 Mounting ......................................................................................................................................19 2.4 Connections .................................................................................................................................22 2.5 Calibrating the camera measuring system ..................................................................................23 2.6 Connecting up ..............................................................................................................................23 2.7 Operating the gateway.................................................................................................................26 2.8 Operator control of the hub ..........................................................................................................27 2.9 Parameter assignment / addressing ............................................................................................28 2.10 Installing the software ..................................................................................................................28 2.11 CeCOMMdiagnostics program.....................................................................................................29 2.12 Diagnostics with terminal program...............................................................................................33

3

Integration in the crane controller ............................................................................................................ 35

3.1 Overview of CeSAR slew integration structure............................................................................35 3.2 Sample interface..........................................................................................................................35 3.3 General requirements, overview..................................................................................................37 3.4 Preparing the PLC program.........................................................................................................37 3.5 Application examples...................................................................................................................52 3.6 Geometry of the luffing gear ........................................................................................................58 3.7 Acceleration and deceleration behavior.......................................................................................62 3.8 Hydraulic drive .............................................................................................................................63




Table of Contents

SIMOCRANE CeSAR slew Sway Control System8 Operating Instructions, 08/2011 Edition, V0.07-E

3.9 Preparing the converters............................................................................................................. 64 4 Commissioning the sway control system ................................................................................................. 67

4.1 Brief guide................................................................................................................................... 67 4.2 General information..................................................................................................................... 68 4.3 Preparations in CeSAR............................................................................................................... 69 4.4 Overview of the commissioning steps to be performed.............................................................. 74 4.5 Commissioning steps in the Commissioning menu .................................................................... 74 4.6 Checking and fine adjustment of the camera.............................................................................. 85 4.7 Checking and fine adjustment of the sway control system......................................................... 87 4.8 Commissioning the positioning system....................................................................................... 89

5 Parameter and Error List ......................................................................................................................... 91 5.1 Parameter list .............................................................................................................................. 91 5.2 Error messages......................................................................................................................... 107 5.3 Troubleshooting ........................................................................................................................ 114

6 Maintenance.......................................................................................................................................... 115 6.1 Reflector maintenance .............................................................................................................. 115 6.2 Camera maintenance................................................................................................................ 115

7 Appendix................................................................................................................................................ 117 7.1 Operation of CeCOMM menu ................................................................................................... 117 7.2 Order numbers.......................................................................................................................... 119



Description 1

1.1 Fields of application

The CeSAR slew sway control system for slewing cranes is used to eliminate load swaying movements onslewing cranes. This is achieved by controlling acceleration and deceleration processes.

The sway control system reduces the risk of collisions and accidents while ensuring faster and more accuratepositioning of the load.

It can be employed in manual or automatic crane operation.

The CeSAR slew sway control system can suppress swaying motions in the luffing and slewing directionssimultaneously.

The sway control system is suitable for slewing cranes with rigid boom and also for double jib slewing cranes.

Preconditions for use of the sway control system are that the load is largely guided in parallel by ropes andthat the crane is equipped with continuously controllable luffing and slewing drives.

The CeSAR slew sway control system is designed as an add-on for new or existing crane control systems.

No mechanical damping (sway control) elements are used in conjunction with the CeSAR slew sway controlsystem.

1.2 Versions

1.2.1 Standard version with camera (CeSAR slew)

The standard version of the CeSAR slew swaycontrol system comprises a twin camerasystem with integrated Power PC plus anEthernet-PROFIBUS gateway and RS 232diagnostics module as additional components.

To simplify installation, the additional

components (including power supply) can beshipped preinstalled in a connection box.

A reflector of which the dimensions aredependent upon the working radius of thecrane will also be required.

Fig. 1-1: Standard version with camera




Description

1.3 Interfacing with the crane control system

1.2.2 Special version without camera (CeSAR slew-blind)

CeSAR slew-blind is designed for use on cranes which cannot be equipped with a camera for design-related

reasons, or which operate in extreme environmental conditions such as extremely dusty atmospheres or atvery high temperatures.

This unit calculates sway solely by means of a mathematical model.

CeSAR slew-blind comprises a Power PC and an Ethernet-PROFIBUS gateway (when it is interfaced toPROFIBUS). The modules can be integrated in any type of control cabinet. No reflector is required.

The special version without camera is capable of eliminating most swaying movements which are generatedby luffing and slewing motions. However, it is not capable of suppressing sway caused by external forcessuch as diagonal pull or wind.

All the functions referring to the camera which are described in this document are deactivated in theCeSAR slew-blind version.

1.3 Interfacing with the crane control system

The sway control system is interfaced with the crane control system by means of Profibus-DP or, optionally,via Ethernet with Internet Protocol (IP) and embedded UDP protocol.

The logical interface is implemented in the form of a defined data structure which is exchanged via the bus.

1.4 Camera measurement (CeSAR slew only)

1.4.1 General

In order to measure load swaying movements, the camera unit must be installed on a horizontal plane closeto the rotary axis of the crane. The angle of aperture is approximately 45°. A reflector must be attached to the

load carrying device.The camera calculates the position of the reflector relative to the crane for as long as it remains within thefield of vision. The data measured in this way are used to determine the swing angle in the tangentialdirection and, by means of a precision distance measurement, in the radial direction.

The advantages of taking measurements by camera as opposed to other measuring methods are listedbelow:

• the camera measuring system is contact-free and thus also wear-free,

• the measurement has an extremely high resolution and

• the actual load position relative to the crane is measured.

1.4.2 Reflectors

For more effective suppression of disturbances caused by sunlight (especially shading and reflections on thereflector) and the suppression of artificial (low-infrared) light sources, the reflectors are equipped with infraredLEDs as well as an infrared-blocking filter for the camera. As a result, the camera evaluates only lightinformation within a wavelength range of approximately 850 nm, which is invisible to the human eye.

The reflector is designed for use under the environmental conditions defined for the scope of application.These include vibration and sea water in particular.

In the event of a measuring system malfunction, the sway control and positioning systems use the swingangle calculated by the internal oscillation model. As soon as measured data become available again, theoscillation model is corrected (if necessary).




Description

1.7 Operating modes

• During slewing operations, the luffing drive eliminates swaying movements in the tangentialdirection,

• In positioning operation, the load only overshoots the target position by a very small amount

The sway control system is configured by means of parameters.

The sway control system receives the required process information via a defined data structure. The inputand output data are normally supplied and further processed by a PLC.

The sway control system calculates speed control values that are forwarded to the drives by the PLC.

In this coupling, the PLC is the master, which uses the sway control system as a service computer tosuppress the swaying of the load.

NOTICE

After an emergency stop, the sway control system must not be reactivated until it has been ensured (onsystems operating without a camera) that the load is not swaying and that the travel signal is brieflycanceled. Refer to Section 3.5.3 for details.

1.7 Operating modes

1.7.1 Speed control mode

1.7.1.1 Manual speed control

In speed control mode, the speed setpoint is specified by the crane driver. The crane is accelerated or decelerated to this setpoint in such a way that the load has ceased to sway once it is reached.

Speed control mode is activated by setting the corresponding operating mode bit.

In speed control mode with active sway control system (activated by input bit "AS_ON“), the internal setpointacceleration of the slewing gear is dependent upon the current position of the luffing gear. (See illustrationbelow)

Fig. 1-2: Correlation between internal setpoint acceleration (slewing gear) and boom position in speedcontrol mode.

The sway control system can be activated or deactivated by means of command bit "Sway Control ON".When the function is switched off, the controller generates standard ramps according to the set accelerationrates.

Position Boom

Internal Setpoint Acceleration

Slewing




Description

1.7 Operating modes

When the CeSAR blind version is installed, sway caused by diagonal pull or wind can only be eliminated bythe crane driver. In this case, the sway control system must first be disabled (by means of bit "AS_On"). Thecrane drive must then carry out compensating movements until the load is stationary. Finally, the travel signal

must be briefly canceled in order to reference the oscillation model to 0. The crane can then be operatedagain with active sway control system.

Internal activation of the sway control system is displayed by means of status bit "Sway control ON".

The sway control function is disabled internally under the following conditions:

• The bit "Sway control ON" is reset.

• The activation speed has not been reached.

• The activation time has not yet expired.

• The bit "Sway control only when stopping" is set. The sway control system is only active whenstopping.

• The hoisting gear is outside the set upper and lower sway control limits.

Hoisting gear movements are possible in active speed control mode and have very little effect on the quality

of the sway control.

Fig. 1-3 shows the slewing operation of crane with a 20 m working radius and 40 m rope length.

Fig. 1-3: Sway control for a slewing motion

The recommended chronological sequence of the signal exchange between the crane PLC and CeSAR aswell as the operator actions during the travel operation are illustrated in the following diagram.




Description

1.7 Operating modes

Fig. 1-4: Signal sequence in speed control mode

For example applications of the signal exchange to be implemented in the PLC, refer to Section 3.5.

The luffing gear must always be activated when a slewing motion is performed to allow the sway controlsystem to eliminate load sway movements in the radial direction.

1.7.1.2 Speed control in Cartesian coordinates

In narrow areas of the vessel or when working in close proximity to a neighboring crane on a vessel, it can beuseful to move the boom tip back and forth along a straight line between the vessel and the land. Control of the slewing crane along straight lines is referred to as "control in Cartesian coordinates". The boom tip

performs a linear movement when the joy stick is deflected.To enable this method of control, the bit "Control in Cartesian coordinates" must be activated in speed controlmode. The direction of the coordinate system (Y°) must be specified as "Slew setpoint position" in the swaycontrol system configuring data.

The diagram below illustrates the action of the setpoint speed or joy stick.




Description

1.7 Operating modes

Fig. 1-5: Speed control in Cartesian coordinates

For example, if the value 8000 (80°) is transferred as the "Slew setpoint position", deflecting the joy stick"Slew" on its own will produce a motion in direction 80°/260° and deflecting the joy stick "Luff" on its own willproduce a motion in direction 170°/350°. It is also possible to actuate both joy sticks simultaneously.

1.7.2 Positioning mode

1.7.2.1 General

Positioning control mode allows the load to be positioned automatically in the slewing and luffing directions. Inposition control mode, a specified target position is automatically approached with active sway control. Load

sway is eliminated both when maximum speed is reached and on completion of the positioning operation.The appropriate operating mode bit must be set in order to activate positioning control mode. Positioningcommences when the travel signal is activated. The luffing gear must always be activated when a slewingmotion is performed to allow the sway control system to eliminate load sway in the radial direction.

The positioning operation can be aborted at any time by setting of the "Controlled stop" signal.

The maximum and minimum positions of position control mode can be defined for the luffing gear by meansof parameters P7 and P8. It is not possible to position loads outside these limits.

In addition to the target position, a slewing direction can also be specified for the slewing gear (see commandbits for luffing and slewing in Table 3-3). The crane then moves to the target position in the selected slewingdirection. If no slewing direction is selected, the crane traverses the path with the smaller slewing angle. It isnot possible to set slewing gear position limits in the sway control system.

NoteThe PLC must monitor the validity of the target position and prevent the crane from travelling throughprohibited slewing zones by specifying the slewing direction bit. If the maximum permissible 360° slewrange of a crane is restricted, the relevant limits must be configured in the PLC.

Fig. 1-6 shows an example of the chronological signal exchange sequence for positioning mode.




Description

1.7 Operating modes

Fig. 1-6: Signal exchange sequence for positioning

1.7.2.2 Positioning in Cartesian coordinates

In positioning mode with Cartesian coordinates, the load is guided along a straight line from the start positionto the target position with active sway control.

To enable this method of control, the bit "Control in Cartesian coordinates" must be activated in positioningcontrol mode.

It must be ensured that the straight line between the start and target positions is positioned such that it doesnot pass closer to the center of rotation of the crane than the minimum luffing gear position. Otherwise, anerror message is output.

WARNING

hen a controlled stop command is issued during a positioning movement in Cartesian coordinates,Cartesian mode is deactivated internally in the sway control system and the axes are stopped separately

ith active sway control. In this case, the crane departs from the programmed straight line.

Parameters P84, P94 and P95 must also be taken into account in relation to parameterization of Cartesianpositioning mode.




Description

1.7 Operating modes

WARNING

It is not permissible to switch over to Cartesian positioning mode when the crane is traveling according to

polar coordinates, nor is it permissible to change between target positions while a Cartesian positioningmovement is in progress. Either of these actions can cause the crane to move unpredictably.

1.7.2.3 Automatic inward luffing (polar coordinates)

Automatic inward luffing functionality is provided in order to optimize positioning travel times.

In most cases, the maximum possible slewing speed of a crane increases in proportion to the proximity of theboom to the center of rotation. Automatic inward luffing makes use of this characteristic.

An example (see Fig. 1-7: Automatic inward luffing) is provide in order to explain the general principle:

During positioning, the luffing gear travels from a start position of 30 m to a target position of 30 m, while theslewing gear travels from a start position of 0° to a target position of 180°. Without automatic inward luffing,the crane travels along the blue line. With automatic inward luffing, the crane travels along the red line.

P92Centerofrotation

Startpoint

Targetpoint

Motionwith

automaticinward

luffing

Movementof

suspensionpoint

withoutautomatic

inwardluffing

Fig. 1-7: Automatic inward luffing

Automatic inward luffing can be activated via parameter P92. It defines the radius of forward and reversetravel of the luffing gear during positioning.

If the start and target points do not lie within a circle with the radius defined in P92, automatic inward luffing isactivated.

If both points are located within this circle, automatic inward luffing has no effect and the axes are positionedindependently of one another.

It is therefore possible to deactivate the inward luffing function by setting P92 > P8.

Other aspects of the automatic inward luffing function can be programmed with parameter P93 (see Chapter "Parameter description").




Description

1.7 Operating modes


NOTICE

Instructions for use of automatic inward luffing function and switchover of target positions

he following must be implemented in the PLC:If the target position is changed while positioning is still in progress and automatic inward luffing is active,a controlled stop command must first be issued for both axes.

hen the crane has stopped and the travel signal has been canceled by means of signal "Positioningcomplete", the new positioning process to a new target with active automatic inward luffing can be started.

hen automatic inward luffing is deactivated, target positions can be changed at any time.

1.7.3 Sway neutralization mode

The sway neutralization mode (with CeSAR slew only) is used to eliminate swaying movements of the loadfrom standstill.

Sway neutralization is linked to a positioning scenario in which the target position corresponds either to thecurrent boom position or the load position at the instant of activation of sway neutralization.

Sway neutralization results in slight travel movements to both sides of the target position. The signalsequence corresponds to that of positioning.



Installation 22.1 Overview

The following connections are available on the camera:

Fig. 2-1: Overview of connections

2.2 Camera settings Aperture setting with passive reflector in outdoor area = 7

With an active reflector, always 1.4 (IR)

These values are appropriate for most applications. For particularly dark conditions, the aperture value canbe reduced (open aperture), or increased for very bright ambient light (close aperture). In addition to thissetting, an automatic gain and offset control ensures optimum image brightness.

DANGER

The casing can fall when it is opened.

2.3 Mounting

2.3.1 Mounting the camera

The camera casing must be installed close to the rotary axis of the crane (normally near the crane driver'scabin) on a horizontal plane with direction of view along the boom. The reflector should lie within the field of vision of the camera when the crane is traveling in the main work area.

The camera mounting position is illustrated in the sketch below:




Installation

2.3 Mounting

Field of vision

Slewing axis

Fig. 2-2: Field of vision of the camera

The camera positions can be adjusted by means of brackets in the camera casing.

See photos below:

Fig. 2-3: Front view of cameras in casing




Installation

2.3 Mounting

Fig. 2-4: Side view of cameras

DANGER


The interface modules or the connection box (400 mm x 300 mm x 210 mm) must be installed directly next tothe camera casing.

NOTICE

The maximum permissible distance between camera casing and connection box is 22 m.

2.3.2 Setting the camera focus

If the camera image is not in focus, the distance setting on the lens must be changed.

DANGER


r (within field of vision).Move the luffing gear to the maximum distance between the camera and reflecto

djust the focus setting until a focused image is obtained in this position. A

2.3.3 Mounting the reflector The reflector should be attached close to the center of gravity of the load swin

he reflector must be attached to the mountings provided.

g.

T

CAUTION

Improper installation can damage the reflector. It must be clearly visible from the axis of rotation and mustnot be concealed by other structural elements.




Installation

2.4 Connections

2.4 Connections

V AC or 24 V DC power supply. An active reflector must be connected to a 230

NOTICE

Please observe the supplied circuit diagrams!

When a connection box is supplied, the cable from the camera must be inserted through the heavy-dutycable glands provided and connected to the Ethernet hub or RS-232 module. The connectors aremechanically keyed. The connection box must be connected to the 230V/50 60Hz mains supply.

When interface modules are supplied as individual units, they must be installed in a suitable control box tohich the camera cables must be connected.

us (of the crane) must be connected to the PROFIBUS-Ethernet gateway (at "Profibus" connector)

w

The Profibby means of a 9-pin sub-D connector.

NOTICEIf the Profibus is not to be routed further, a terminating resistor must be inserted in the bus connector.

The PROFIBUS address of the modul

The heating system is se

e can be set by means of DIP switches.

lf-regulating. If the ambient temperature does not fall below 0 °C, a heating systemd n to be connected.

P F ctor

oes ot have

RO IBUS conne

Pin Name

3 RxD/TxD-P

8 RxD/TxD-N

V c era

Pin Name

GA onnector of cam

1 Video output red

2 Video output green

3 Video output blue

4 Digital input 0

5 Ground

6 Ground

7 Ground

8 Ground

9 Digital input 1

10 Ground

11 Digital output 0

12 Digital output 1

13 Horizontal synchronization

14 Vertical synchronization




Installation

2.5 Calibrating the camera measuring system

15 Digital ground

2.5 Calibrating the camera measuring system

OTICE

The camera is calibrated in commissioning step 6.

N

The camera must be calibrated during initial commissioning, or subsequently after camera realignment or replacement of the camera or reflector.

It is irrelevant whether position 1 or position 2 is approached first.

The hoisting gear position applicable to position 1 or position 2 is defined by parameters. The value for position 1 is entered in P68 and the value for position 2 in P69. When commissioning step 6 is completed,positions are automatically a

theccepted and stored in P68 and P69.

The camera calibration process determines the settings of parameters P70, P71, P74 and P75.

Once the camera has been completely calibrated, the parameter changes are automatically stored in the

2.6.1

All the modules for the CeSAR slew/blind system are attached to a rail and prewired to one another. After therail has been installed, the PROFIBUS link and power supply must be connected.

For commissioning and diagnostic purposes, the diagnostic PC/laptop is connected to the hub.

parameter lists.

2.6 Connecting up

CeSAR slew/blind

Fig. 2-5: Connection diagram for CeSAR blind




Installation

2.6 Connecting up

2.6.2 CeSAR slew with master and slave cameras

For a CeSAR slew system with master and slave cameras, the individual components must be connected upas illustrated in the diagram below.

Fig. 2-6: Connection diagram for CeSAR slew

Dashed lines represent a temporary connection for commissioning and diagnostics. Solid connection linesrepresent a permanent communication link.

Each camera must be connected to the hub by means of the uncrossed Ethernet cable supplied with the unit.

All other outgoing camera cables with preassembled connectors must be connected to the appropriate RS232 module. These cables carry the operating voltage, the digital input and output signals and the diagnosticdata.

The gateway must be connected to PROFIBUS and, using an uncrossed Ethernet cable, to the hub. Thisconnection links the camera to the PLC.

The diagnostic PC must be connected to the hub by means of an Ethernet cable. Alternatively or as anadditional connection, the serial port on a diagnostic PC/laptop (e.g. COM1) is connected to the serial port onthe diagnostic module.




Installation

2.6 Connecting up

The pin assignments of the serial cable can be found in the product manual.

The gateway, Ethernet hub and RS 232 module must be connected to the 24 V supply.

NOTICE

If two cameras are employed, it must be ensured that both cameras power up before the gateway isitched on after the power supply to the PLC is restored.sw

The terminating resistor on the diagnostic module is active in normal operation (DIL switch "Terminalresistance" = ON). The cable pin assignments can be found in the product manual. If the diagnostic module

connected to a PC for diagnostics and parameterization, the terminating resistor must be deactivated (DILisswitch "Terminal resistance" = OFF).

NOTICE

After the work has been completed and the cable removed, it is absolutely essential to set the DIL switch

erminal resistance" to the ON position again (earlier version: insertion of connector with integrated"Tterminating resistor).

The sway control system software will not otherwise restart after a reset.

The PLC communicates exclusively with the master. The master and slave cameras communicate with one

he task of the slave is to identify the reflector, perform the conversion to millimeters and transfer the

relative to an imaginary reference height.

nly

another in the background via Ethernet.

Tmeasured data to the master. For the purpose of converting pixel values into millimeters and for calibration,the slave receives the actual height data

If the master cannot find the reflector, it utilizes the data received from the slave. The slave transmits owhen it has detected the reflector.




Installation

2.7 Operating the gateway

2.7 Operating the gateway

2.7.1 LED displays

Table 2-1 LED displays

LEDs

Name Type State Meaning

OFF No supply voltagePower Green

ON Supply voltage ok

Flashing Network activity in EthernetStatus Green

Blinking Valid connection to another Ethernet node

OFF No PROFIBUS communication: Check cables, parameter assignments and configuration

Com Yellow

ON PROFIBUS communication is established

Error Red Flashingcode 1

No link pulse received from hub: Check cable and hub port.

2.7.2 Setting the PROFIBUS address

The node address in PROFIBUS is set on the coding switch labeled "Address" on the Ethernet PROFIBUSgateway.

The address setting does not take effect until the voltage supply has been switched off and on again.




Installation

2.8 Operator control of the hub

Table 2-2 Gateway switch positions

2.8 Operator control of the hub

Two LEDs are provided for each port. The bottom (Transmit) LED indicates whether the connected node(gateway or camera) is transmitting data.

Table 2-3 Meaning of LEDs on hub

LEDs

Name Type State Meaning

OFF No valid connection to another Ethernet nodeStatus

(top)Green

ON Valid connection to another Ethernet node

OFF No network activity by the Ethernet nodeTransmit

(bottom)Yellow

Flashing Network activity by the Ethernet node




Installation

2.9 Parameter assignment / addressing

2.9 Parameter assignment / addressing

The measuring system is interfaced by means of Profibus-DP or, optionally, via Ethernet with InternetProtocol (IP) and embedded UDP protocol.

An Ethernet-PROFIBUS Gateway 692 DP is used as the fieldbus module. Each device must have its own IPaddress for communication in the Ethernet network.

NOTICE

he IP addresses of the camera and the gateway must not be changed or used for another device withinhe network.

The IP addresses of the CeSAR slew camera can be changed in the Parameters menu in the diagnosticsoftware. The Parameters menu must be opened with the "P" key and the function "I – Change IP address of

the peer" called. The screen instructions must then be followed.The following IP addresses must be set:

CeSAR slew/blind

Device designation Default setting Change

Controller 192.168.1.155 Any

Gateway 192.168.1.140 Any

CeSAR slew

Device designation Default setting Change

Master 192.168.1.155 No change permitted

Slave 192.168.1.157 No change permitted

Gateway 192.168.1.140 Any

The PROFIBUS address can be set on the gateway to between 0 and 63 by means of DIP switches. Thedefault setting in the delivery state is Profibus address 4.

Number of input bytes: 8 header, ≤ 160 user data, 2 trailer (see GSD file)

Number of output bytes: 8 header, ≤ 160 user data, 2 trailer (see GSD file)

Baud rate: max. 12 Mbaud

2.10 Installing the software

The CD contains the commissioning and diagnostics program "CeCOMM.exe" which can be installed on anyPC by running "Setup_CeComm.exe".

Note

The program can run under the WINDOWS 2000 and WINDOWS XP operating systems. This requiresthat the user is logged on to the PC as administrator.




Installation

2.11 CeCOMMdiagnostics program

The following are firmware files and are stored in directory /FlashFx/ on the flash EPROM in the camera:

HPCeSAR.exe Controller and diagnostics program

Par0.txt, Par1.txt,Par2.txt, Par3.txt Parameters. Each file contains one of the four parameter sets. The files are

read when the program is started. If they do not exist, the parameters are setto the default values.

IP.txt This file contains the IP address and port of the peer.

HPStart.exe Start program. On system start, this copies HPCeSAR.exe into the RAM andlaunches it.

Elautos.ini System start file. Contains system start information.

Schl.ini Key file with the activated ID. This file must not be deleted, overwritten or transferred from one camera to another.

Sprache0.txt, Sprache1.txt Language file in German and English

The files "wippen.txt" (see Chapter 3.6) and (optionally) file "hydraulik.txt" as well are added during the

commissioning process.

WARNING

The key file Schl.ini in directory /FlashFx/ has a copy protection function and must not be deleted,overwritten or copied from one device to another.

Note

Deletion of the key file "Schl.ini" is indicated by the empty main menu (space bar) in the diagnostic tooland the error is also displayed on the "Faults" screen ("E" key).

Note

Write protection must not be assigned to any of the files in directory /FlashFx/ (except for Schl.ini). If anyof these files is write-protected, it will not be possible to permanently store any changes to settings madein the terminal.


2.11.1 General

Using the CeCOMM HMI software, it is possible to perform the following tasks:

• Check and change the current parameter settings

• Check the current camera image

• Record curves

• Transfer updates

• Save parameters




Installation


The icons provided for establishing a communication link are arranged underneaththe menu bar.

After program start, one of these icons must be used to establish the connection to the devices using theCOM or Ethernet interface.

Note

The IP address of the laptop/PC must be within the range 192.168.1.1 to 192.168.1.150.

WARNING

Uploading or downloading files to or from the camera can cause the SwayControl system to fail. Files mayonly be uploaded/downloaded while the crane is at a standstill.

After communication has been successfully established, the following functions are available on the tabs:

Monitor Dis stic information, change parame

Load the current camera image

play all diagno ters, display error messages, etc.

Camera image

ger sFile mana User interface for copying, renaming, editing, etc. file

Interface for recording, saving and loading analog and digital signalsDiagram

Web server Use of the Web server available on the target system This function is available only if the PCand hub are connected via an Ethernet cable

Telnet Telnet interfac o the camera

Calibrate hoisting height Tool for calibrating the hoisting height

e t

Note

A detailed description of the diagnostic tool CeCOMM can be found in file "Diagnose_CeCOMM_E.pdf"

which is stored on the CD.

2.11.2 Monitor - basic functions

When the space bar is pressed, all available keyboard comma

tions can be divided into three groups:

nds are displayed in the main screen.

The basic monitor func

• Display screens

• Parameterization menus

• Special functions




Installation


The display screens arecalled from the main menu

using the appropriate keys(e.g. "2" for "DisplayProfibus"). These keys can beused at any time to changebetween display screens "1","2", "3", etc.

The menus and specialfunctions can be called fromthe main menu and from thedisplay screens.

Fig. 2-7: Monitor - basic functions

The "P" key displays the "Parameters menu" and the "I" key displays the "Commissioning menu". The menusare closed with the ESC key to return to the previous display screen.

Starting in display 1, for example, it is possible to change the setting of parameter P0 by entering "PC0"(equals: Parameters menu – Change Parameter 0) and <ENTER> and then inputting the new value andpressing <ENTER> twice to confirm.

On completion of commissioning work, the diagnostic routine should be stopped with the "!" key in order to

free up all computing capacity for use by the controller.

2.11.3 Traces with CeCOMM

The following two tables describe the CeSAR system variables which can be recorded.

Table 2-4 CeCOMM recording

CeCOMM display Unit Explanation

Ext. Speed Luffing mm/s Speed specification from PLC (v_set) referred to drive.

Int. Speed Luffing mm/s Internal setpoint speed referred to boom.

Speed Outp. Luffing mm/s Control speed output by the CeSAR system (v_pos).

ActSpeed Luffing mm/s Actual speed derived from actual position by discretedifferentiation. (smoothed by P130)

Model Luffing mm Radial load deflection of the internal oscillation model. If injection of camera measuring signals is activated, themeasurements influence the model.

Angle Luffing mm Radial load deflection measured by the camera.

RefPos Luffing mm Internal setpoint position.

ActPos Luffing mm Actual position supplied by the PLC (s_act).

DelPos Luffing mm Internal position variable.

DelSpeed Luffing mm/s Internal speed variable.




Installation


P111 Luffing See parameter description.

Ext. Speed Slew cgr/s Speed specification from PLC (v_set).

Int. Speed Slew cgr/s Internal setpoint speed.

Speed Outp Slew cgr/s Control speed output by the CeSAR system (v_pos).

ActSpeed Slew cgr/s Actual speed derived from actual position by discretedifferentiation. (smoothed by P131)

Model Slew mm Tangential load deflection of the internal oscillation model. If injection of camera measuring signals is activated, themeasurements influence the model.

Angle Slew mm Tangential load deflection measured by the camera.

RefPos Slew cgr Internal setpoint position.

ActPos Slew cgr Actual position supplied by the PLC (s_act).

DelPos Slew cgr Internal position variable.DelSpeed Slew cgr/s Internal speed variable.

P111 Slew See parameter description.

The table below shows the bits which can be recorded for the luffing gear. Equivalent bits can also berecorded for the slewing gear.

Table 2-5 CeCOMM display

CeCOMM display Explanation

Drive Luffing Table 3-3, Bit no. 1

OM Pos. Luffing Bit No. 2

OM Speed Luffing Bit No. 3

OM AS Load Luffing Bit No. 4

OM AS Luffing Bit No. 5

PLS FORW Luffing Bit No. 6

PLS BACKW Luffing Bit No. 7

Stop Luffing Bit No. 8

Brake Luffing Bit No. 9

AS Stop Luffing Bit No. 10

AS On Luffing Bit No. 11 Active Luffing Table 3-6, Bit no. 1

Pos compl. Luffing Bit No. 2

AS compl. Luffing Bit No. 3

FORW Luffing Bit No. 4

BACKW Luffing Bit No. 5

AS On Luffing Bit No. 6




Installation

2.12 Diagnostics with terminal program


Trace display in x-y-coordinate system

Apart from the time curves of the variables listed in the following table, it is also possible to display a number of variables in the x-y-coordinate system. This can be done by selecting the "F11 y=f(x)" button in the tracemonitor of CeCOMM. The x-y-coordinate system is displayed. Two curves are visible. The setpoint position isthe curve of the internal setpoint position (see table above) inserted in the kinematic transformation of theslewing crane. The actual position is the same, but based on the actual positions from the table above.

Note

In Cartesian positioning mode, the setpoint curve does not need to describe a straight line, but it isimportant that the actual values are plotted as close as possible to the desired line.

2.12 Diagnostics with terminal program

If the CeCOMM program is not available, a simplified diagnostics process can be carried out with anyterminal program (e.g. HyperTerminal).

The following parameters must be set in this case:

Bits per second: 38400

Data bits: 8

Parity: None

Stop bits: 1

Protocol: None

Emulation: VT100

Note

After setting changes have been confirmed with "OK", the new settings must be saved again with menucommands File and Save and reloaded before they can become effective.



Integration in the crane controller 33.1 Overview of CeSAR slew integration structure

The sway control system must be integrated into a conventional crane control system. Data are exchangedbetween the crane PLC and the sway control system by means of a bus system. The PLC remains Master and distinguishes between conventional operation and operation with sway control.

Fig. 3-1: Overview of CeSAR slew integration structure

3.2 Sample interface

The sample interface consists of several functions (FC), function blocks (FB) and data blocks (DB).

The most important relationships are shown in the following figure. All data are stored in data blocks DB83and DB84. The function blocks FB83 and FB84 prepare these data and make them available to the PLCprogram.




Integration in the crane controller

3.2 Sample interface

Fig. 3-2: Sample interface

The blocks have the following specific tasks:

1. FB83 Sends current data to the sway control system

Checks the message frame counter received via PROFIBUS and thus whether the last message frame hasbeen sent.

Loads the header data (IP address and port of message frame receiver, control/status word) and the user data from the appropriate data area (DB85) to the I/O output area.

WARNING

Not all data may be transferred as consistent data.

Increments and loads the message frame transmit counter. This counter must be changed if data are to betransferred to the sway control system from the Ethernet-PROFIBUS gateway.

2. FB84 Receives current data from the sway control system

Checks the current receive counter, the IP address and the port of the message frame sender.

Loads the received user data from the I/O input area into the appropriate data area (DB86).

Monitors the watchdog bit.

3. FC1 Jump distributor

Calls the receive block (FB84), the block for the preparation of general data (FC80), the axis-related data(FC81) and the send block (FB83).

4. FC80 Processing of general data

Loads the general send data into the data block (DB85) and returns the receive data from the receive datablock (DB84).

5. FC81 Processing of axis-related data (trolley, bridge, slewing gear)

Loads the axis-related send data into the data block (DB85) and returns the axis-related receive data fromthe receive data block (DB84).

6. FC82 Height above ground

7. DB83 Instance DB for FB83

8. DB84 Instance DB for FB84

9. DB85 Send data to CeSAR slew

10. DB86 Receive data from CeSAR slew





3.3 General requirements, overview

Note

If an interface other than the sample model described above is employed, it is important to note that

the bytes of a word (high-order and low-order bytes) must be used in the correct sequence. Thisapplies to the command, status and error words.

3.3 General requirements, overview

The CeSAR slew sway control system has been tested on both electrical and hydraulic luffing and slewinggear drives.

WARNING

The drive system and all safety functions of the crane, especially limit trips, safety interlocks,EMERGENCY STOP functions and load monitoring must be commissioned and functional.

The following requirements for the commissioning of the sway control system must be satisfied:

All components of the system must be installed, connected, functional and interconnected.

- Prepare the PLC program

- Calculate the crane geometry

- Warm up hydraulic drives

- Prepare the electrical slewing gear drives

- Start the diagnostic program and establish the connection between the commissioning PC and the camera

- Set the access code and the language of the diagnostic program

- Check the communication link between the PLC and the camera measuring system

- Check the camera image

3.4 Preparing the PLC program

3.4.1 Integration into the hardware configuration (GSD file)

Variant 1 (recommended):

Open the sample interface project stored on the product CD (432DWKed) with the Simatic Manager. Copythe Ether Gate 692DP from the hardware configuration and paste it into the hardware configuration of your own crane control project. (In the example project, the PB address is set to 8 by default.) Prepare the PLCprogram such that it can supply all signals for the sway control system and process all output data in therequired way.

Variant 2:Open the hardware configuration of your own crane control project, click on button "Tools", "Install GSD files"and specify the path to the GSD file stored on the product CD. Now install the GSD file. You can load it bydragging it from the "Profile catalog" ("View"Æ“Catalog", "Profibus-DP"Æ"Additional FieldDevices"Æ"Kuhnke"Æ"Ether Gate 692DP") and dropping it into the hardware configuration of the cranecontrol program. You then need to adjust the "Object properties" of the Profibus node. To do this, select theEther Gate 692DP, open the window "Assign parameters"Æ"Device-specific parameters". You must nowaccept and save the settings displayed in the screenshot below.






Fig. 3-3: Hardware configuration of the Ethernet gateway in S7

3.4.2 Inserting interface blocks:

Copy all OB, FC, FB, DB and SFC blocks from the block folder of the sample interface project and pastethem into the block folder of your own crane control project. If this folder already contains blocks with thesame function or title, they must be overwritten or renamed. If it is necessary to rename blocks, existing blockcalls must be programmed with the new titles.

3.4.2.1 Adapting the interface blocks:

Open block FC1 "F_Call_RuntimeGroup".

Check the required timers T1 and T5 in networks 1 and 6 for double assignment elsewhere in the PLCprogram and change them if necessary.

The input and output addresses in networks 1 and 6 must also be adapted. Enter the required addressesfrom the HW configuration of the Ether Gate 692DP (Header Module, Data in 1st Block, Data in 2nd Block,Trailer Module) correctly at the inputs of networks 1 and 6. (Symbol designations of network 1 inputs:I_Adr_Head, I_Adr_DatMod1, I_Adr_DatMod2, I_Adr_Trail, O_Adr_Trail; Network 6: O_Adr_Head,O_Adr_DatMod1, O_Adr_DatMod2, OI_Adr_Trail, I_Adr_Trail)






3.4.2.2 Network 1: Receive data from camera

InstanceDBforFB84

"IDB_FB84"

ReceiveCeSAR_maxx

withDW

"Data-recv"EN

T_SE_PB

Time_PB_err

T_SA_UEWD

T_SE_UEWD

Time_WD

T_SE_FEWD

Time_WD_err

I_Adr_Head

I_Adr_Dat

Mod1

I_Adr_Dat

Mod2

I_Adr_Trail

O_Adr_Trail

Err_Time

Err_port

Err_WD

ENO

...

T1

S5T#200MS

T2

T3

S5T#300MS

T4

S5T#1S

10

256

288

30

40

#dummy_0_bool(datamessageframeerror)

#dummy_0_bool(addresserror)

#dummy_0_bool(watchdog)

Fig. 3-4: Instance DB for FB84 (input data from DB 86)






3.4.2.3 Network 2: General send and receive data

Generalinterfacedata

"Common"

EN

Par_Set

Calib_above

Calib_down

Save_picture

Loadtype

Cartesian

Load

S_Hoist

Parset

Cal_above

Cal_down

ENO

...

#dummy_I_INT

#dummy_I_bool

#dummy_I_bool

#dummy_I_bool

#dummy_I_bool

#dummy_I_bool

#dummy_I_INT

#dummy_I_INT

#dummy_O_INT

#dummy_O_bool

#dummy_O_bool

#dummy_O_INTErr_PD

Fig. 3-5: FC80 (input data from DB 85, 86)






3.4.2.4 Network 3: Send and receive data for luffing gear


CAUTION

The limit switches of the sample interface set only the control value to zero. The limit switch signalsare not transferred to the CeSAR system.

Note

During positioning operations from standstill away from the limit switch in the direction of the limit switchwhich has not been actuated, the axis will begin to move only if the correct direction is selected ("Dir_Forwor Dir_Backw"). The signal must then remain active until the axis has moved away from the limit switch.






3.4.2.5 Network 4: Send and receive data for slewing gear

...

2

Axis-specific

interfacedata

"Axis"EN

Axis

Seenetwork3


3.4.2.6 Network 5: Send and receive data for height above ground

FC 82

Height above ground

„S_Hoist2“

EN

S_Hoist2 ENO

...

#dummy_I_DINT

Fig. 3-8: FC82

3.4.2.7 Network 6: Send data to camera

Fig. 3-9: FB83 (input data from DB 85):






3.4.3 Input and output signals:The PLC program must now be prepared such that it can supply all signals for the sway control system andprocess all output data in the required way. For this purpose, all the required input and output formaloperands (dummies) in FC1 must be exchanged for the corresponding signals used in the program.

The structure of the data transferred from the PLC to the CeSAR computer is as follows:

Table 3-1 Profibus-DP input data

Name Type Description Unit

General

- uint16 General command bits Refer to Table 3-2Load uint16 Load weight 1 increment for each 10 kg

s_Hoist int32 Actual position, hoisting gear + mm

Luffing

s_act int32 Actual position, luffing gear (boom)

± mm

s_set int32 Setpoint position, luffinggear (boom)

± mm

v_set int16 Setpoint speed, luffing gear (drive)

NormalizedDefault: - 32.767 ... +32.767

v_maxb int16 Maximum speed (driveretracts cylinder)

NormalizedDefault: - 32.767 … 0

v_maxf int16 Maximum speed (driveextends cylinder)

NormalizedDefault: 0 ... +32.767

- uint16 Command bits for luffing gear see Table 3-3

Slewing

s_act int32 Actual position, slewing gear ± 1/100 °

s_set int32 Setpoint position, slewing gear ± 1/100 °

v_set int16 Setpoint speed, slewing gear Normalized

Default: - 32.767 ... +32.767

v_maxb int16 Maximum speed, slew to left NormalizedDefault: - 32.767 ... 0

v_maxf int16 Maximum speed, slew to right NormalizedDefault: 0 … +32.767

- uint16 Command bits for slewing gear see Table 3-3

General

s_Hoist2 int32 Height above ground ± mm






Load weight Load weight (load carrying device plus load) in 10kg steps. The difference between the load weight and loadcarrying device (P89) must not be less than 0 or greater than 100,000 kg.

Various parameters which control how the load weight is handled internally can be set during commissioning.For details, refer to Chapter 4.7Section "Compensate load carrying device".

Actual hoisting / luffing / slewing position The actual hoisting / slewing / luffing positions can increase in any direction. The hoisting gear position inparticular can increase from the ground upwards. The conversion to the effective pendulum length isperformed internally by means of parameters.

The sway control system calculates internally with increasing position values during outward luffing andslewing to right motions. The internal position is calculated (e.g. for slewing) on the basis of

s_act_intern = P25 * s_act + P26.

The parameters P25 and P26 (as well as P5 and P6 for the luffing gear) must be adjusted accordingly toensure that the internal representation corresponds to the real movement.

P80*s_Hoist + P81 is the internally applied hoisting gear position (without load offset). It is limited by

parameters P85 and P86.

Note

The crane control system must monitor the transferred position values for errors, i.e. it must, for example,check the hoisting height for abrupt changes.

Note

The actual values of the luffing gear must not exceed certain limits. For details see Chapter 3.6

Luffing, slewing setpoint positions The setpoint positions refer to the coordinate system of the actual positions. The setpoint positions are

internally represented and converted in the same way as actual positions.

Luffing, slewing setpoint speed The setpoint speed is evaluated in speed control mode. The normalizing value can be set with a parameter.When the default is set, the setpoint speed ranges between +32.767 and –32.767.The setpoint speed must be positive for slewing to right. The luffing gear speed setpoint refers to the luffingdrive. Positive values can thus indicate both inward and outward luffing depending on the kinematiccorrelation between drive and deflection (see also Chapter 3.6).

Note

The input values for v_set must be greater than or equal to -P109 and less than or equal to P109.

Maximum speed

The permissible maximum speeds can be transferred as a function of the working radius and loading of thecrane. The maximum speed for slewing to right and outward luffing must be greater than zero, and less thanor equal to zero for slewing to left and inward luffing.

When these input variables are changed during operation, the internal setpoint speed is reduced at thesetpoint acceleration to the new limit value and the control speed adapts itself to the new limit with activesway control. This means in particular that a certain period of time will elapse until the control speed hasdropped to the level of the new speed limit.






Note

The maximum speed values supplied by the PLC while the crane is in motion should always change

continuously (smoothly) as a function of the luffing gear or slewing gear position. Abrupt changes cancause the control speed to change suddenly and thus cause the crane to behave incorrectly. Especially inCartesian mode, abrupt speed changes can cause the crane movements to depart from the programmedstraight lines.

Note

In the case of motion towards the prelimit switch inside the prelimit switch range, the maximum speedvalue is not relevant. Instead, the appropriate prelimit switch speed parameter (P13/P33) applies.

Note

The maximum speeds v_maxf and v_maxb refer to the normalizing value P109 and must not exceed it.

Height above ground In order to calibrate the camera, the current height of the load hook above a fixed reference plane is requiredin addition to the current pendulum length (actual position of hoisting gear). There is a fixed difference inheight between the reference plane and camera. The transferred values can refer, for example, to the heightabove the quay or the upper carriage.

This input variable is needed to perform internal calculations. Its influence can be viewed under "Const. -s_Hoist(2)" in Monitor 1. The value displayed there is the variable A contained in the description of E34("Error hoisting height above ground").

The value "Const. - s_Hoist(2)" must decrease in proportion to the increase in height above the ground and itis relevant only in relation to single-jib cranes.

General command bits

Table 3-2 General command bits

Bit no. Name Meaning

0 Parameter set selection bit 0

1

Par_Set

Parameter set selection bit 1

2 -

3 -

4 Save_picture Save current image

5 Loadtyp Activate digital hoisting distance correction6 Cartesian Control in Cartesian coordinates

7-15 - Not used

"Parameter set selection .." bit

00 Parameter set 0

01 Parameter set 1

10 Parameter set 2

11 Parameter set 3






The parameter "Parameter set locked during travel" can be used to specify whether switchover of the currentparameter set is permissible at any time or only when the crane is at standstill.

"Save current image" bit When the signal edge changes from 0 to 1, the current camera image is stored in a file named from Img0.jpgto Img9.jpg. With each new edge change, the digit in the file name is incremented by 1. When Img9.jpg isreached, the process starts again at Img0.jpg. The image data can be accessed via the File Manager inCeCOMM.

NOTICE

Please do not perform this operation while the crane is moving because there is a risk that cycletimes will be exceeded.

NOTICE

To reduce the load on the computer, the "save current image" function should be used only for diagnostic purposes.

Activate digital hoisting distance correction When this bit is activated, a shift in the center of gravity is applied to the effective pendulum length by thedigital hoisting distance correction function (P87). In this way it is possible to manage two different loadcarrying devices and the different influence they have on the effective pendulum length.

Control in Cartesian coordinates Manual operating mode:The joy stick commands are evaluated as control commands on straight lines in an x-y-coordinate system.The origin of the Cartesian coordinate system [0,0] coincides with the origin of the polar coordinate system[0,0]. The position of the Y axis corresponds to the "Setpoint position for slewing" (see Section 1.7.1.2) and

the direction of motion when the "Slew" joystick is actuated.In Cartesian control mode, the travel signal must be set for both axes until the sway control system returnsthe "Positioned" bit for both axes.






Command bits for lugging and slewing

Table 3-3 Command bits for luffing and slewing


0 Release Release

1 Travelling Travel signal

2 Position control mode

3 Speed control mode

4 Sway neutralization mode, load position

5

OM

Sway neutralization mode, boom position

6 ALS_F Prelimit switch forward

7 ALS_B Prelimit switch backward

8 Stop Controlled stop

9 Brake_closed Brake closed

10 AS_Stop Sway control only when stopping

11 AS_ON Sway control On

12 Dir_Forw Automatic positioning forward

13 Dir_Backw Automatic positioning backward

14-15 - Not used

"Release" Bit

0 No release, control value is set directly to 0 when the brake is closed (=1) or

release = 0

1 Operating modes and travel signal are evaluated.

"Travel signal" bit

0 No travel command, control value is set directly to 0. The travel motion is ended according to the

ramp programmed in the converter.

1 Activation of the specified operating mode

The travel signal is set at the beginning of a travel movement (e.g. deflection of joy stick

or start of automatic travel).

CAUTION

The travel signal must not be reset until the travel operation has been completed by the sway controlsystem, i.e. when the "Positioning complete" output signal has been issued by CeSAR slew. See3.5.3.

CAUTION

Exactly one of the operating mode bits must be set to select the corresponding operating mode. Anyother combination is considered to be an invalid operating mode and initiates an emergency stop.






"Operating Mode .." bits

0 Operating mode deactivated

1 Operating mode activatedNote

The operating modes "Sway neutralization load position" and "Sway neutralization trolley position" are notavailable in Cartesian control mode.

"Prelimit switch .." bits

0 Actuated, reduction in control speed

1 Not actuated

"Controlled stop" bit

0 No stop

1 Stopping at normal deceleration rate and with active sway control

CAUTION

With Controlled stop, all travel signal bits (Release, Travel signal, Operating mode, Brake closed)must remain set as for normal travel and may only be reset after output of the signal "Positioningcomplete".

"Brake closed" bit

0 Brake is open

1 Brake is closed, control value is set to 0

Note

The signal generation time should consider the actual brake opening time.

"Sway control only when stopping" bit

0 Sway control is always active

1 Sway control is only active when stopping

Note

The "Sway control only when stopping" function can be used only in conjunction with speed controlmode.

"Sway control ON" bit

0 Sway control is not active

1 Sway control is active; "Release" bit should be set.

"Automatic positioning forward"; " … backward" bit

0 Direction is not selected

1 Direction is selected.

Note

For slewing gear only. Specifies the direction of approach to a target position: Forward/slew right or backward/slew left. (when looking down onto crane)If both bits are equal, the shortest route is calculated.






Note

The PLC must monitor the validity of the target position and prevent the crane from travelling through

prohibited slewing zones by specifying the slewing direction bit. If the maximum permissible 360° slewrange of a crane is restricted, the relevant limits must be configured in the PLC.

Output data of CeSAR slew

Table 3-4 Profibus-DP output data

Name Type Description Unit

General

- uint16 General status bits see Table 3-5

Err_PD uint16 Error bits Binary-coded

Luffing

a_pos int16 Control acceleration, luffinggear

NormalizedDefault: - 32.767 … +32.767

int16 Not used

Angle int32 Swing angle luffing gear ± mm

v_pos int16 Control speed, luffing gear NormalizedDefault: - 32.767 … +32.767

- uint16 Status bits, luffing gear see Table 3-6

Slewing

a_pos int16 Control acceleration, slewinggear

NormalizedDefault: - 32.767 … +32.767

int16 Not used

TorsionAngle Int32 Swing angle ± 1/100 °

v_pos int16 Control speed, slewing gear NormalizedDefault: - 32.767 … +32.767

- uint16 Status bits, slewing gear see Table 3-6

General status bits Refer to Section 3.3.3.1

Error bits cf. Section 7.5

Control acceleration for luffing, slewing Control acceleration for the luffing and slewing drives. Can be used as additional setpoint for the current or torque control loop of the converter.

If a1 is the boom acceleration in mm/sec^2, then the following applies:

a_pos = a1 * P109/P4.

By the same principle, the following relation applies in the case of a slewing acceleration rate a2 in cgr/sec^2:






a_pos = a2 * P109/P24.

Swing angle, slewing angleRelative positional difference between boom tip and load.This value is the angle of the internal oscillation model which is influenced by the camera measurements if the camera is activated.

Control speed luffing, slewing Control speed for the luffing and slewing drives.

General status bits

Table 3-5 General status bits


0 Parameter set selection bit 0

1

Par_Set

Parameter set selection bit 1

2 -

3 -

4 WATCHDOG Watchdog (flashing signal 200 ms)

5-15 - Not used

"Parameter set selection .." bit

00 Parameter set 0 selected




"Watchdog" bit The signal is negated cyclically after 200 ms. It confirms that the endless loop of the controller is beingprocessed






Status bits for luffing and slewing gear

Table 3-6 Status bits for luffing and slewing gear


0 Ready Ready for operation

1 Active Active

2 Pos_complete Positioning complete

3 Antsw_compl Sway neutralization complete

4 Travel_F Forward travel direction (outward luffing or slewing to rightwhen looking down onto crane)

5 Travel_B Backward travel direction (inward luffing or slewing to leftwhen looking down onto crane)

6 AS_State Sway control On

7-15 - Not used

"Ready for operation" bit

0 The control speed is 0, emergency stop has occurred.

1 The drive axis is ready for operation and is activated through setting of an operating mode

and the travel signal.

"Active" bit

0 The control speed is zero.

1 The drive axis is active and outputs the currently required control speed.

"Positioning complete" bit

0 The target position has not yet been reached.

1 The target position has been reached in position control and sway neutralization modes, the

positional deviation is less than the specified tolerance. In speed control mode, the speed setpoint

zero has been reached.

Note

The positioning accuracy (P9, P29) specifies the tolerance between the actual and target positions withinwhich the output bit "Pos_complete" can be signaled. (See also Chapter: 4.8.3)

"Sway neutralization complete" bit0 The swaying motion of the load is greater than the specified tolerance.

1 The swaying motion of the load has been neutralized within the specified tolerance.

"Forward travel direction" bit (outward luffing or slewing to right when looking down onto crane)

0 Control signal is negative or "0".

1 Control signal is positive.

"Backward travel direction" bit (inward luffing or slewing to left when looking down onto crane)

0 Control signal is positive or "0".

1 Control signal is negative.





3.5 Application examples

As long as the control signal is zero, the direction of travel is set (depending on operating mode)as a function of the setpoint speed or the difference between the setpoint and actual positions.

If the internal zero speed signal is not active or if the bits "Positioning complete" or "Sway neutralizationcomplete" are not set, the direction of travel is output if a travel signal is active.

"Sway control ON" bit

0 The sway control function is deactivated.

1 The sway control function is activated.

Under certain circumstances, the sway control function can be disabled even if the "Sway controlON"

command is active (cf. Section 2.2.1).

NOTICE

he feedback bits from FB 83 (send) and FB 84 (receive) must be evaluated in all circumstances.

The IP address of the camera is generally

192.168.1.155

If the default IP address is changed, the IP address must be adjusted on the camera (diagnostic tool, monitor menu function "P", "I") and in blocks FB83, FB84 in the PLC program.

Note

The error bits and the watchdog signal must be evaluated in all circumstances in order to detectmalfunctions and initiate appropriate responses.


3.5.1 Status bit direction of travel and brake control in the sway control system

A set "Direction of travel" bit describes the following state:

• The operating mode and the travel signal are set

• The target position or zero speed has not been reached for the relevant axis or

• The sway on the axis has not been neutralized yet

Fig. 3-10: Internal generation of "Direction of travel" signals

3.5.2 Status bit active and control signal in the sway control system

A set "Active" bit describes the following state:

• The operating mode and the travel signal are set

• The brake is open or the target position or zero speed has not been reached






Note

The control signal must be passed to the drives while the active bit is set.

Fig. 3-11: Internal generation of the "active" signal

3.5.3 Travel signal in the control system

Note

The travel signal must be set while the travel request exists or the "Positioning complete" signal hasnot yet been set.

≥1S

R

Prioritysetting

≥

1

Button Start positioning

Joy stick deflected

Travel signal

slewing gear*

Pos_complete

Ready

Active

Travel signal

slewing, luffing

gear*

*Additional remark about generation of the travel signal for luffing gear:

The luffing gear must always be activated for slewing motions so that radial

swaying movements can be neutralized

Fig. 3-12: Generation of the travel signal

The following must be noted in relation to operation without a camera: It must be ensured that the load is notswaying as the travel signal is set from 0 to 1. This is because the internal oscillation model was set to zerowhen the travel signal was previously canceled. Furthermore, the oscillation model does not take naturaldamping into account. The effect of this in the following situation, for example, is as follows: If the load is

swaying at the end of a movement both in the oscillation model and in reality (e.g. in the case of stoppingwithout active sway control), an oscillation with constant amplitude persists in the model for as long as thetravel signal remains active. In reality, however, the sway continues to diminish over time. If a new movementis initiated after a prolonged period without resetting the travel signal, the sway control system does not workproperly. In this case, it is necessary to wait (as described at the beginning of this paragraph) until the loadsway has been completely neutralized and then briefly set the travel signal to zero. Only then is it permissibleto initiate a new travel movement.

In Cartesian control mode, the travel signal must be set for both axes until the sway control system returnsthe "Positioned" bit for both axes.

If the target position is changed while positioning is in progress, the travel signal must be reset.






3.5.4 Brake control in the PLC

Opening and closing the brake

The brake must be closed if the signal "Positioning complete" is set and output of direction signals hasceased.

Fig. 3-13: Closing the brake

NOTICE

The brake must be opened while a direction of travel signal is set.

Brake control and travel signal

Allowance can be made in the PLC for the scenario in which the crane is not immediately ready to travel after the travel signal has been set, but instead reacts with a delay to control signals issued by the sway controlsystem (e.g. due to the magnetization period required by the drive). To do this, a time delay must beconfigured between cancelation of the "Brake closed" signal and setting of the travel signal. In this case, theCeSAR system will compute the control values only after the "Brake closed" signal has been canceled.

3.5.5 Differences in behavior of internal oscillation models in operation with andwithout activated camera

When the sway control system is operated without active camera measurement (P112=1), the oscillationmodel is set to zero every time the travel signal is canceled. For this reason, the user must ensure that theload is not swaying at the moment the travel signal is set and a movement started. The control values will nototherwise effect correct sway neutralization while the crane is moving.

If camera measurement is active (P112=0), the internal oscillation model is not reset because it can beupdated at any time by measurements. This is obviously completely dependent on proper functioning of thecamera measurement system. If the user wishes the sway control system to behave like a "blind" system inthe event of a camera measurement error (E9 is active), in which case the internal oscillation model will bezeroed when the travel signal is canceled, then this behavior can be implemented by means of a parameter

set switchover. When E9 is active, the input bits Par_Set (Table 3-5) should be used to switch from theexisting parameter set over to a parameter set in which P19 and P39 equal zero. If E9 disappears again, theoriginal parameter set should be selected again.






3.5.6 Control in the "Manual control" mode

In manual control mode, the travel signal is set by operation of the joy stick. If all input signals are error-free,the Sway Control system responds by setting the active signal. With this active signal, the output speed canbe connected as a setpoint source.

If one of the two direction signals is active, the brake must be opened. As long as the brake is closed, nocontrol speed value is output.

The travel signal can be reset when "Positioning complete" is signaled.

Fig. 3-14: Speed control for luffing gear (slewing gear)






3.5.7 Speed control signal sequences

a – Releaseb – Start travelc – Brake openedd – Start deceleratione – Travel operation completef – Brake closedg – No operating mode, no sway controlh – Release canceled






3.5.8 Positioning signal sequences

a – Releaseb – Start positioningc – Brake openedd – Travel operation completee – Brake closedf – No operating mode, no sway controlg – Release canceled





3.6 Geometry of the luffing gear


The sway control system offers a feature which makes it possible to take into account the non-linear relationship between the positions of the luffing gear drive and boom on slewing cranes. For this purpose, thegeometric relationship between the boom and drive must be described in a text file "wippen.txt". Using theinformation in this file, the sway control system can perform an internal conversion from boom position, speedor acceleration into drive position, speed or acceleration. A step in the commissioning process ensures thatthis file is correctly identified and read by the sway control system. There are two possible structures of the"wippen.txt" file. With one structure, the file contains a table. With the other, geometry parameters aredefined. The latter structure can be used only for cranes with a very specific geometrical design.

Each line in the text file which starts with a hash (#) is interpreted as a comment and has no influence onoperation.

WARNING

he content of the file "wippen.txt" has a significant influence on the motion behavior of the crane. It isherefore essential to ensure that the data are correct and have been read in correctly by the sway controlsystem. See also Section 3.6.3

3.6.1 "wippen.txt" with table

When the table is used, the "wippen.txt" file must be structured as follows:

[Table]

47

0 6000 155511 7000 15489

2 8000 15425

.

.

.

45 51000 9977

46 52000 9367

The first line always contains the same keyword, the second the number of entries with geometricrelationships. The actual table starts at the third line. Each of its lines contains three numbers exactly. The

table can contain a maximum of 100 lines. The first column of the table contains a consecutive number whichstarts at zero and increases by one with each line. The second column contains the positions of the boom inmillimeters. It must increase by exactly 1000 mm in each line and cover the entire range of motion of theluffing gear. The associated drive positions (e.g. cylinder position) are listed in the third column, also inmillimeters.






Note

The luffing gear of the crane must not move outside the range limits defined by the minimum and

maximum boom positions specified in the wippen.txt file. The sway control system cannot accuratelyconvert data outside this range and the actual position value supplied by the PLC is therefore limitedinternally to this range. The limit switches in the PLC must be set accordingly.

3.6.2 "wippen.txt" with geometry parameters

The structure with geometry parameters can be used only for single-jib cranes with the geometriccharacteristics illustrated in the diagram below. In this case, parameter P73 must be set to 1 or 2.






F

D

H

Slewing

axis

VG

L

Z

A–Boomradius

D–Boomdiagonal(distancebetween

boomfulcrum/topendofcylinder)

H–Systemheightofboom

F–Verticaldistancebetweenboomfulcrum

andcylinderfulcrum

G–Horizontaldistancebetweencylinderfulcrumanduppercarriage

L–Boomlength

V–Horizontaldistancefromboomfulcrum

DR–Diameterofboomropepulley

DS–Diameterofrope

Z–Cylinderposition

DR A

Fig. 3-15: Geometric characteristics of the single-jib crane for which geometric parameters can be used.






The text file "wippen.txt" with geometry parameters must be structured as follows:

[Geometry]1

0 <D> <E> <F> <G> <L> <V> <DR> <DS> <name>

In this case, <D>, <E>, etc. are place holders for the values (in millimeters) of the lengths represented in thediagram above. <Name> should be a string containing the name of the crane. For example, if the values for acrane "K1" are

D = 4950, V = 1565,

E = 3500, DR = 1250,

F = 12050, DS = 38,

G = 2400,

L = 50000

the file structure is as follows:

[Geometry]

1

0 4950 3500 12050 2400 50000 1565 1250 38 K1

A table is also computed internally, i.e. the minimum boom position, which equals E+V, is rounded up to thenext whole meter. The maximum boom position, which equals L+V, is rounded down to the next full meter.

When the sway control system has been restarted, it equalizes the non-linearities of the luffing hydraulicsystem.

NoteThe sway control system does not check whether the values of the geometry parameters are consistentwith the crane geometry illustrated in the diagram above. It is the responsibility of the user to check thevalues.

Note

Even when geometry parameters are used, the actual position is restricted in the sway control system.The Note contained in Section 3.6.1 above also applies when geometry parameters are used. In thiscase, the table is generated automatically and the minimum and maximum positions of the luffing boomcan be seen in the commissioning step described in Section 3.6.3.

3.6.3 Commissioning step to check file "wippen.txt"

The sway control system cannot check whether the geometry parameters have been correctly read in fromfile "wippen.txt".It simply displays an error message (E7) if it has failed to read in the data. In this event, theluffing gear cannot be moved.

If data have been read in without issue of error message E7, the commissioning engineer must checkwhether the system has read the correct values. This is done in commissioning step a, see Section 4.5.2.





3.7 Acceleration and deceleration behavior

3.6.4 Limit switches and prelimit switches for the luffing gear as defined in the

sample interface supplied

The limit and prelimit switches for the luffing gear must always be referred to the boom, as illustrated in thediagram below.

Fig. 3-16: Arrangement of limit and prelimit switches.

One exception applies as regards the processing of limit switches in the PLC. If the geometry of the luffinggear is such that the drive position sinks as the boom position rises (this applies in the case of single-jibcranes, for example), the limit switches at the sample interface must be exchanged because the controlspeed sign is the opposite of the boom speed sign. For example, if the luffing gear is at the forwards limitswitch, control speeds greater than or equal to zero are permitted, but not other control speeds.

3.7 Acceleration and deceleration behavior

Load swaying movements on slewing cranes are eliminated by controlling the acceleration and decelerationof the luffing and slewing gear.

The acceleration or deceleration behavior of the sway control system is set by means of three ramps or acceleration values.

The ramp applied in the case of acceleration without sway control/minimum acceleration (P2, P22) isgenerally the same as the ramp along which the boom or drive accelerates when the sway control system iscompletely deactivated. The minimum acceleration rate acts as a limit if one of the following conditions isfulfilled:

• Prelimit switches have been activated

• The crane is being operated by the sway control software, but the bit "Sway control ON" equals"0".

The operating principle of P2/P22 in the event of activation of prelimit switches is as follows (example): In thisexample, it is assumed that the slewing axis is moving in a positive direction and the forwards prelimit switchis activated at a given moment. The internal setpoint speed is then ramped down to the prelimit switch speedand the control speed is reduced accordingly with active sway control. However, an upper limit is applied by abraking ramp which starts at speed v_maxf and brakes according to the value of P22. In other words, if P22and P23 are set to similar values, the sway control function is impaired.

The minimum acceleration parameters have no effect in the normal traversing range. The sway controlsystem can then brake more slowly in order to compensate any load sway.

The maximum acceleration ramp (P4, P24) applies a limit in the opposite direction. The sway controlsystem will never accelerate or decelerate faster than the limits imposed by this ramp. It should ideally be setto the maximum possible physical value.





3.8 Hydraulic drive

The setpoint acceleration ramp (P3, P23) provides the basis for calculating the control speed of the swaycontrol system. However, in order to compensate for any load sway, the sway control system does not rigidlylimit acceleration/deceleration to this ramp.

The following settings are recommended:

• P4, P24: The maximum possible acceleration rate of the drive

• P3, P23: Approx. 75% of P4

• P2, P22: The following condition applies: P2 < P3 < P4 or P22 < P23 < P24. The specific value isdetermined by the position of the prelimit switches relative to the limit switches. At thisacceleration rate, it should be possible to brake the drive from full speed down to prelimit switchspeed between the prelimit switch and limit switch. The optimum values must then be determinedexperimentally on the crane. Compliance with the limit values always has priority over compensation of load sway.

Fig. 3-17: Acceleration and deceleration behavior of the sway control system

Note

Values below 20 (mm/s) cannot be set. When values < 20 are set, the acceleration value is interpreted asa ramp time and made available as a calculated acceleration value.

3.8 Hydraulic drive

If the luffing and/or slewing gear is equipped with a hydraulic drive, slewing and luffing operations must beperformed several times to warm up the drives prior to commissioning. This is especially important for calibrating the luffing speed.





3.9 Preparing the converters


3.9.1 Converter parameter sets

Two parameter sets should be available for the converters.

The first parameter set is used for the conventional crane control without sway control when damage occurs.The normal acceleration and deceleration ramps must be set there. The second parameter set is used for thesway control function. The setpoint is supplied continuously by the sway control system. The parameters areset as described in the following sections.

3.9.2 Acceleration and deceleration ramps

The acceleration and deceleration ramp times must be set to the lowest reasonably acceptable values for thedrives and mechanical components.

CAUTION

he ramps provide Emergency Stop functionality in the event of a fault.

NOTICE

cceleration and deceleration ramps that are too slow can cause swaying movements!

CAUTION

he sway control system can briefly calculate higher accelerations and decelerations than those thatoccur in normal travel operation – especially when neutralizing large swaying movements.

3.9.3 Initial and final rounding

As the speed characteristic is defined by the sway control system, initial and final rounding functions shouldbe deactivated.

NOTICE

Excessive roundings in the converter can cause swaying movements!

3.9.4 Minimum frequency of the converters

In order to be able to eliminate small swaying movements after stopping, the minimum frequency of theconverter must be set to 1 Hz or lower.

NOTICE

If the minimum frequency is too large, the residual swaying movements may be relatively large and thecrane will not or only rarely come to rest!







3.9.5 Speed controller of the converter

The internal speed control of the converter can be activated in order to achieve the best possible control

response. In addition to the proportional component, an adequate integral component should also beset. Good results have been achieved for the Simovert with kP = 3..5 and Tn ≤ 200.

3.9.6 Limitation of the speed control signal

Note

Configuring limits for the control signal in the converters can cause sway neutralization problems (residualsway), because the internal oscillation model does not represent the real movement of the load in suchcases. A following error can also develop in positioning mode. Limits applied in the converters must nottherefore be allowed to affect the control values of the sway control system.

As a general rule, speed limits in the sway control system must be implemented by means of the

corresponding parameters and/or the input variables from the PLC. A following error is the difference between the calculated and the actual position of the crane (deviationbetween setpoint and actual value).



Commissioning the sway control system 4

4.1 Brief guide

1. Connect up components, connect up PROFIBUS and the power supply

1.1 CeSAR slew

− Connect the camera cable to the RS-232 module, the hub and the power supply.

− Use the patch cable to connect the hub to the Ethernet-PROFIBUS gateway. Connect the hub tothe power supply.

− Connect the PROFIBUS cable and power supply to the Ethernet-PROFIBUS gateway.

1.2 CeSAR slew/blind

− Connect up the PROFIBUS cable and power supply to the wired module.

2. Set the PROFIBUS address

− Set the PROFIBUS address on the coding switch marked "Address" on the Ethernet-PROFIBUSgateway. Then switch the gateway power supply off and on again, because the address becomesoperative only when the power is switched on.

3. Connect the laptop/PC to the camera, start the diagnostic program− Use an Ethernet cable to connect the laptop/PC to the hub. The IP address of the laptop/PC must

be within the range 192.168.1.1 to 192.168.1.150.

− Launch the diagnostic program "CeCOMM.exe".

4. Check the image (CeSAR slew only)

− Check the camera alignment and focus of the image. Until the reflector has been detected, theimage might be too bright or too dark.

5. Perform the following commissioning steps

− Set the crane type and important parameters

− Define the reflector type

− Determine the minimum size− Set the alignment of the camera

− Calibrate the hoisting height

− Calibrate the camera measurement system

− Check positions and speeds

− Simulate errors/faults

− Store parameters

− Calibrate the hydraulic luffing drive

− Individual steps can be omitted depending on the configuration.

6. Test settings




Commissioning the sway control system

4.2 General information

− Switch power supply off and on again and perform a trial run

4.2 General information

The system is commissioned by setting parameters using the CeCOMM diagnostic program.

4.2.1 Parameters menu

For this purpose, the Parameters menu is called from the main menu or another display screen with the "P"key. The Parameters menu contains an overview of the parameter groups that can be displayed in shortform, page-by-page via the keys "1", "2", "3", etc.

An overview of all the functions which can be executed from the Parameters menu is also provided.

Parameters which are not set to their defaults are identified by a "+".

Only values in the range between the fixed minimum and maximum values can be entered for the parameter.If acceleration parameters are set to lower than 20, they will be interpreted as times and converted to thecorresponding parameter values.

Note

Each changed parameter takes effect immediately, but is not stored permanently. After confirmation with"OK", changes to parameter values should be permanently stored with "S" (Save all sets of parametersand fixed ranges). "S" always saves all parameter sets.

4.2.2 Parameter sets

Four parameter sets are provided. They are stored as a text file in directory /FlashFx/ on the flash EPROM.

The files are named Par0.txt, Par1.txt, Par2.txt and Par3.txt. If no parameter files are available at the start of the program or they are faulty, all parameters are set to their default values.

NOTICE

he parameter sets are numbered 1 to 4 in the CeCOMM diagnostic program. Therefore, file Par0.txtcontains parameter set 1 and Par3.txt parameter set 4.

If a parameter exceeds the specified limits when it is loaded, an error message is generated and the value of the relevant parameter is set to the default value.

The current parameter set is specified using the general command bits.

All parameter sets can be edited independently of the current command bits.

4.2.3 Switching parameter sets

NoteThe control response or system configurations can be changed by switching the parameter sets. Inconjunction with control elements, the crane operator can select a desired configuration.

The parameter "Parameter set locked during travel“ can be used to prevent the switching of parameter setsduring travel.

When the parameters of one set are copied to another set, it is possible to choose whether to copy allparameters or only the parameters from P60 onwards.





4.3 Preparations in CeSAR


4.3.1 Setting the access code

The access code sets the user level and determines the visibility of individual parameters. The access codeis stored in parameter P100.

Note

Only those parameters are displayed that correspond to the setting of parameter P100 (= access code).

Parameter P100 (= access code) must be set to "Service engineer" for commissioning.

The following settings are available:

• 0 = Any user

•1 = Commissioning engineer

• 2 = Service engineer or specially trained commissioning personnel

4.3.2 Setting the language

All screen displays in the diagnostic program are stored in language files on the camera.

The language is set in the diagnostic program "CeCOMM" via the menu "Options/Language" and saved inparameter P110. German and English are available.

Alternatively the language parameter P110 can be changed via the Parameters menu. The appropriatelanguage file is then automatically opened and read. The screen displays are updated.

4.3.3 Master and slave cameras for CeSAR slew

With the CeSAR slew variant of the system, the camera casing contains two cameras in order to increase thevertical field of vision for reflector detection. In this case, one camera is the master and the other camera theslave. The only task of the slave camera is to detect load sway and send the swing angle to the master if thereflector is outside the field of vision of the master.

The sections in Chapter 4 refer to the master camera and must be taken into account in relation to the master during commissioning. Nevertheless, certain commissioning steps still have to be performed for the slavecamera once the master camera has been commissioned. The commissioning engineer must first establisha connection to the slave camera via the terminal (CeCOMM) and set parameter P67 to "2".

The parameters P65, P72 and P73 must be set to the same values as the equivalent parameters of themaster camera.

The instructions from the chapter below must then be followed. Finally, commissioning step a (wippen.txt),two to four and six, must be performed.






4.3.4 Checking the interface

PLC - CeSAR slew

The communication link between the PLC and the sway control system must first be checked with theCeCOMM diagnostic program.

This includes checking whether data is being properly exchanged and whether the correct data formats andcontent are being used.

The display screen "Profibus Interface" (opened with key "2") shows the current input and output data of the sway control system. The data must first be checked for correctness.

Prerequisite for all other steps is correct incrementation of the send and receive counters in displayscreen 2. This means that the camera is receiving and sending data message frames.

Fig. 4-1: Monitor function, "PROFIBUS – Interface" display screen

The "CeSAR slew – Status of travel axes" display screen is opened with key "3" (Fig. 4-2). The command

and status signals are displayed here. They should also be checked for correct assignment before the nextcommissioning step is taken. The color differences in the display of the actual values show which values or states are OK or active (green).

Note

Red display indicates an error or stop in the system, "Not released", "Stop", "Off", etc.

No values should be displayed in red in Figures 4-1 and 4-2, as this would indicate an error or a stopcondition in the system ("Not released", "Stop" or "Off function" activated).






Fig. 4-2: Monitor function, "Status of travel axes" display screen

CeSAR slew - PLC

At the PLC end, it is possible to identify at the outputs of the two communication blocks FB84 and FB85whether the communication link is functioning properly. No error bit is displayed if the communication link iserror-free.

The values transmitted by CeSAR slew (under Output in screen 2 of CeCOMM) can be checked for plausibility with the values in DB86 of the PLC.

The values received by CeSAR (under Input in screen 2 of CeCOMM) can be checked for plausibility with thevalues in DB85 of the PLC.

4.3.5 Checking the camera image (CeSAR slew only)

The camera image is checked using the diagnostic tool. After activation of the "Camera image" function andselection of the "F5 - Update" button, the current camera image will be loaded.

Note

The "Checking the camera image" step must be performed for both the master camera and the slavecamera.






Fig. 4-3: Checking the camera image

The current camera image should have the following characteristics:

• The reflector must be correctly focused and well illuminated. (The image might still be too brightor dark before the system is commissioned – please refer to Chapter 4.6 (Camera operation) for

information on how to optimize the image)• With a slewing motion, the reflector moves horizontally through the image during hoisting. In

this case, it must be as close as possible to the vertical center of the image.

WARNING

Execution of this function causes very long cycle times in the camera and thus to a breakdown incommunication. For this reason, images should be read in (transferred) for diagnostic purposes only whenhe crane is stationary.

Proper functioning of the camera measurement system can be checked by means of diagnostic monitor four of the terminal. A screenshot of this monitor is shown below.






Fig. 4-4: Screen - camera

The + sign represents the current position of the reflector. An S instead of the + symbol indicates that thereflector has been detected by the slave camera.

Values displayed in this screen which are important to the user are described in the table below.Table 4-1 Screen - camera

RedNo.

Description RedNo.

Description

1 Ratio between errored measurementsand all measurements

12 Horizontal deviation from zero positionin pixels

2 P60 13 Vertical deviation from zero position inpixels

5 Rotation angle of reflector 14 Radial deviation from zero position

7 Amplitude camera measurement luffing

gear

15 Horizontal, tangential deviation from

zero position8 Amplitude oscillation model luffing gear 12 Reliability of detection

9 Amplitude camera measurementslewing gear

13 Number of error messages relating tocamera

10 Amplitude oscillation model slewinggear

14 Camera-to-reflector distance

15 Size of reflector in image (in pixels)





4.4 Overview of the commissioning steps to be performed

4.4 Overview of the commissioning steps to be performed

A number of calibration operations and value calculations need to be performed in order to calibrate thesystem. In order to avoid any misunderstandings, the terms used to describe these processes are explainedin the table below:

Table 4-2 Assignment between direction of motion and camera orientation

Term Meaning System Implementation

Cameraalignment

Assignment between cameracoordinate system and travel axes

CeSAR slew Commissioningstep 4

4.5.5

CeSAR slew Commissioningstep 5

4.5.6

Hoisting heightcalibration

Calculation of effective pendulum lengthreferred to hoisting height

CeSAR blind "Calibratehoisting height"function in theCeComm

Cameracalibration

Calculation of zero position of reflector from camera viewpoint

CeSAR slew Commissioningstep 7 or usingthe diagnosticmodule

4.5.8

The following steps must be performed in succession:

Commissioning steps in the Commissioning menu (4.5)

Checking and fine adjustment of the camera (4.6)

Checking and fine adjustment of the sway control system (4.7)

Commissioning of the positioning system (4.8)

4.5 Commissioning steps in the Commissioning menu

The commissioning steps in the Commissioning menu must be performed as the next step. This menu iscalled by means of the "I" key from the main menu or the display screens.

The commissioning process must be started with the first step and continued step-by-step. These steps

involve the setting or automatic calculation of important parameters. Parameter settings are displayed in color to indicate the successful completion of a commissioning step. After the commissioning steps have beenperformed successfully, it is not generally necessary to set these parameters manually.

Note

Individual steps can be omitted depending on the configuration.

It is important to note that any changes made will affect all four parameter sets! If only selected parameter sets are to be adapted to meet the requirements of a special application, the other parameter sets (par0.txtto par3.txt), which do not need to be changed, must be saved temporarily with the file manager in CeComm.






4.5.1 Commissioning step 1

In the first commissioning step, the system will request input of the settings for the following parameters:

P73 Double-jib (0) single-jib crane (1) with hydraulic drive (2)

The parameter must be set according to the crane type. On cranes with a hydraulic drive, a speed offset isactive for the hydraulic drive which is calibrated in commissioning step 9.

Default: 0

Single-jib crane

A single-jib crane is a light-weight crane andis thus ideal for use in areas with limited load-bearing capacity, e.g. narrow quays and andlight-weight craneways. The single-jib cranereveals its full potential when it is used tohandle bulk materials, especially heavy or extremely heavy loads.

Double-jib crane

Double-jib cranes are also used, for example, tohandle bulk materials. By virtue of its designprinciple, the double-jib crane offers the advantageof short load paths and pendulum lengths, but it alsooffers a second decisive benefit: The load handlingmovement is essentially controlled by the luffingmotion, i.e. the slewing motion is of secondaryimportance. The effects of braking and accelerationhave no impact on performance.

Hydraulic system:

The non-rotatory motion of the boom is controlled by a hydraulic luffing gear.

P67 Single (0)/Master (1)/Slave (2) cameraThis parameter must be set to 0 for the CeSAR blind variant. When the camera-based variant is used(CeSAR slew, system uses two cameras), the parameter must be set to 1 for the master camera and 2 for the slave camera.Default: 0

P109 Normalization setpoint and control speed

The parameter contains the normalizing factor for all speeds that are transferred via the fieldbus. If theparameter is set to 28,000, for example, then a setpoint speed of –14,000 corresponds to half the negativemaximum speed (P1 or P21) of the corresponding axis.






Default: 32.767

These parameters are specified by the crane manufacturer or derived from their specifications.

P1 Maximum control speed of luffing gear

Speed limit value in mm/s. Notice: The set value corresponds to the maximum attainable speed of the drive(hydraulic cylinder, toothed rack etc. ) and not the speed of the boom.

The maximum control speed corresponds to the maximum attainable speed of the drive axis. It influences theamplitude of the oscillation model and must therefore be set precisely.

Default: 500 mm/s

P2 Acceleration without sway control

When the sway control system is deactivated, the drive accelerates and decelerates with the set acceleration

value. The value is applied as a minimum deceleration rate when the prelimit switch range is reached. Theparameter is thus applied for two scenarios in the sway control system, i.e. travel without sway control andtravel in the prelimit switch range. If different acceleration rates need to be used for these two situations, thena parameter set switchover will be required.

Default: 150 mm/s²

P3 Setpoint acceleration of the boom

The setpoint acceleration is an internal acceleration variable in mm/s². It is operative in all basic operatingmodes, during acceleration and deceleration. Input values less than 20 are interpreted as a ramp time. Setmanually according to manufacturer or customer specifications. The value should correspond to approx. 75%of the maximum acceleration (P4).

Default: 150 mm/s²

P4 Maximum acceleration of boom

Acceleration limit in mm/s². The set value corresponds to the maximum boom acceleration/deceleration.Input values less than 20 are interpreted as a ramp time.

The maximum acceleration setting limits the rate of acceleration of the output signal of the sway controlsystem. It should be set to the same or a smaller value than the converter acceleration limit.

Default: 250 mm/s²

P0 Positioning speed luffing gear

This value (in mm/s) corresponds to the maximum speed of the boom in positioning mode. P0 is alwayslimited internally to 95% of the currently possible maximum boom speed. The boom speed is determined by

file Wippen.txt Geometry. The positioning speed is the maximum setpoint speed specified for automaticpositioning. Depending on control processes, the actual speed can be less or greater, but never greater thanthe maximum control speed.

Default: 450 mm/s






P10 Deceleration gain, luffing gear

Deceleration gain or reduction factor. The deceleration rate is calculated on the basis of P3*P10, or

P3*P10*P113 for plugging. These values are also limited by the maximum control value P4.P10 has no effect in positioning mode.

Default: 1

P20 Positioning speed slewing gear

This value (in cgr/s) corresponds to the maximum speed in positioning mode. In order to allow a slightovershoot, a value corresponding to 90% of the maximum control speed should be set.

Default: 450 cgr/s

P21 Maximum control speed, slewing gear

Speed limit in cgr/s. The set value corresponds to the maximum attainable speed.

Default: 500 cgr/s

Note

After the user has confirmed the setting for parameter P21, the system asks whether P20, P22, P23, P24and P32 should be updated. Updating is meaningful only if the speeds and acceleration rates dependentupon P21 have already been entered and only P21 needs to be adjusted again. With this "update"process, parameters P20, P22, P23, P24 and P32 are altered in equal proportion to P21.


When the sway control system is deactivated, the drive accelerates and decelerates with the set accelerationvalue. The value is applied as a minimum deceleration rate when the prelimit switch range is reached. The

parameter is thus applied for two scenarios in the sway control system, i.e. travel without sway control andtravel in the prelimit switch range. If different acceleration rates need to be used for these two situations, thena parameter set switchover will be required.

Default: 150 cgr/s²

P23 Setpoint acceleration rate, slewing gear (inner circle)

The setpoint acceleration is an internal acceleration quantity in cgr/s² for operation with active sway control(input bit "AS_ON").

In positioning mode, the value of P23 is always applied for the slewing gear. In speed control mode, thesetpoint acceleration rate depends on the current position of the luffing gear. (See Section 1.7.1 anddescription of P32 for details.)


P32 Setpoint acceleration rate, slewing gear (outer circle)

The setpoint acceleration is an internal acceleration quantity in cgr/s² for operation with active sway control(input bit "AS_ON").

P32 is relevant only in speed control mode. (See Section 1.7.1 and description of P23 for details.)

Default: 75 cgr/s²






P24 Maximum acceleration rate, slewing gear

Acceleration limit in cgr/s². The set value corresponds to the maximum drive acceleration/deceleration. The

value should be 50 to 100% higher than the setpoint acceleration.Default: 250 cgr/s²

P30 Deceleration gain, slewing gear

Deceleration gain or reduction factor. The deceleration rate is calculated from the product of P30 and theinterpolated slewing acceleration value (see description of P23 and P32). The second factor corresponds toP30*P114 for plugging. These values are also limited by the maximum control value P24. P10 has no effectin positioning mode.

Default: 1

P92 Luffing gear position for automatic inward luffing

This luffing gear position is approached first in automatic positioning mode. Outward luffing toward the targetposition of the luffing gear commences shortly before the slewing gear reaches its target position. Theparameter should be set to the last luffing gear position at which the slewing speed has not yet started todecrease.

Default: 50,000 mm






Fig. 4-5: Overview of speed control

Depending on the system configuration, further special parameters are subsequently called for setting.

4.5.2 Checking the file "wippen.txt" (commissioning step a)

Section 3.6 describes how the file "wippen.txt" (which must be set up by the user) should be structured. Incommissioning step a, the user should check whether the system has correctly identified the file. Thiscommissioning step should be carried out before the crane performs any movement. When the step isselected, the sway control system loads the "wippen.txt" file currently stored in folder FlashFx on the camera.There are three possible scenarios after selection of this step.






In the first scenario, a read-in error has occurred and a corresponding message is displayed when the step isselected. Furthermore, error signal E7 is set and the luffing gear cannot be moved.

In the second scenario, a table has been read in and the commissioning screen displays the table values. Inthis case, the user must check whether the numbers are correct.

In the third scenario, the "wippen.txt" file contains geometry parameters. These are displayed on the screenand the user must check whether they are correct. Another screen is displayed containing the tablecomputed internally from the geometry parameters and the content of this table must also be checked by theuser.

At the end of the step, "n" can be entered in order to return to the beginning of the step. When this is done,the "wippen.txt" file currently stored on the camera is loaded. If the user loads a new "wippen.txt" file to thecamera before entering "n", this new file will be read in. By pressing any of the other keys, it is possible toreturn to the commissioning menu.

4.5.3 Determining the reflector type (commissioning step 2)

From the viewpoint of the camera, the reflector can be aligned in two ways.

P62=1 P62=0

reflector 1 reflector 2

Fig. 4-6: Reflector alignment

The algorithm searches for the two alignments and shows the result.

Only one reflector alignment may be detected during this commissioning step.

Note

For the purpose of the alignment check, the distance between the reflector and the camera should lie inthe range 5 m to 10 m.

Precondition for accurate calculation of the value of P70: The reflector must be in the center of the image,it must be correctly focused, and must not move (it must be absolutely still). After completing thecommissioning step, the user should always check the "distance" display in Monitor 4 for the correctdistance. If there is a significant deviation, the commissioning step must be repeated.

When the reflector type is determined on a system with master and slave cameras, the reflector must be

situated exclusively in the field of vision of the relevant camera.

If both alignments are detected, this can have the following causes:

Two reflectors are present in the field of vision of the camera.

A light-dark combination in the field of vision has been incorrectly identified as a reflector. In this case, theparameter P62 must be varied manually and the measurement result in display 4 compared with the positionof the reflector.

The reflector is detected by both the master and slave cameras.

If no reflector is detected, this can have the following causes:

The camera is not aligned correctly. The reflector is not in the field of vision.






The ambient light is too bright or too weak. The parameters for gain and offset (P60 and P61) can betemporarily set to zero. The camera then automatically sets the gain and the offset to the brightness of theentire image. After successful completion of the commissioning step, the parameters must be reset to theoriginal or required values.

The window size (parameter P63) is set to values that are too large or too small. P63 should be set to "11" per default.

After completion of the commissioning step, the current distortion of the reflector is also stored (P70). Thisquantity is important for measuring the distance correctly.

Note

On completion of commissioning step 2, it is possible that the value calculated for P70 will not be storedcorrectly even though the save command was selected at the end of the step. The user can checkwhether the value has been stored by looking in the Parameters menu to see whether the value displayedfor P70 is the same as the value previously displayed on the screen.

4.5.4 Determining the minimum window size (commissioning step 3)

To obtain highly reliable measurements, the P63 parameter can be used to set the smallest size of thereflector in the image.

The image will then always be searched for a reflector with this minimum size and all similar smaller-sizedpatterns will be ignored.

Parameter P63 is set to values of between 1 and 10 to program a fixed minimum window size. A setting of 1means that the reflector is very small in the image and a setting of 10 that it is very large.

Automatic adaptation of the minimum window size is activated when P63 is set to a value of between 11 and20. This function works provided that the reflector has been detected. The setting values 11 to 20 (which

correspond to 1 to 10) are otherwise applied as the minimum window size.

Fig. 4-7: Determining the minimum window size

Note

For semi-automatic determination of the size, the reflector (the load carrying device) must be luffedoutward as far as possible.

The diagnostic system then checks the size of the detected reflector and suggests an appropriate factor.

4.5.5 Setting the alignment of the camera (commissioning step 4)

In this commissioning step, the assignment between the directions of motion and camera orientation iscalculated (P66).

Note

After the commissioning step has been started, the load hook must be lifted while the load is not swinging.

The diagnostic system detects the direction of motion of the reflector in the camera image and uses this todetermine the camera orientation in relation to the crane axes.






Table 4-3 Assignment between direction of motion and camera orientation

Lifting the load hook Binary Decimal

Up 000 0

Right 001 1

Down 010 2

Causes the reflector tomove in the cameraimage in direction

Left 101 5

Note

In the case of a slewing motion to the right (when looking down onto crane), the control values mustincrease.

4.5.6 Calibrating the hoisting height (commissioning step 5)

When the hoisting height is calibrated, the gain and offset are determined for the conversion of thetransmitted hoisting height to an effective pendulum length with correct sign and absolute value.

The calibration is performed with two sway measurements at different heights. The respective effective ropelengths and conversion parameters are determined from these movements.

4.5.7 Calibrating the camera measurement (commissioning step 6)

NOTICE

Calibration is possible only when no camera measuring error is present.

To calibrate the camera, the reflector must be moved to 4 specific positions. The commissioning engineer must confirm each position. The position sequence (P1 – P2 – P3 – P4) is illustrated in the following diagram:






P1

P2

P3

P4

Fig. 4-8: Calibrating the camera measurement system

Note

The positions must be confirmed when the load is stationary.

Note: The value for HOIST among the values displayed on the terminal screen is not the current hoistingheight, but an internally calculated auxiliary quantity.

Note

When the calibration process is complete, the measured radial and tangential deviation from zero in bothdirections must be close to zero (Display 4).

4.5.8 Checking positions and speeds (commissioning step 7)

It is possible to perform another check on the current speeds of the luffing and slewing gear while the crane isin operation.






4.5.9 Simulating errors (commissioning step 8)

All error bits of the sway control system can be simulated in this step in order to check the analysis of errorsin the PLC.

The corresponding bits can be found in the product manual.

4.5.10 Saving parameters (commissioning step 0)

All parameter sets are saved.

The commissioning parameters can be copied to the other parameter sets in the Parameters menu.

4.5.11 Calibrating the hydraulic luffing drive (commissioning step 9)

This step can be performed in order to determine the speed-dependent non-linear behavior of a hydraulicluffing drive. After successful completion of the step, the system will compensate the non-linear behavior.

The luffing gear must fulfill one important requirement in order to ensure successful completion of the step. Itmust be capable of reaching the speed specified by P1 in both directions (cylinder is retracted/extended bydrive). The commissioning engineer may need to adapt P1 for this purpose.

The commissioning step comprises two phases. During the first phase, the luffing gear of the crane must bemoved backward and forward by maximum deflection of the joy stick. During this process, the control speedof the luffing gear is incremented (in 2% steps) by the software and held for approximately 2 seconds in eachstep. The quotient of the actual speed at the end of each step and the currently applied control speed is thencalculated. The commissioning screen gradually displays the values as they are calculated. At the end of the

phase, a table containing the speed steps (-50 -> retract cylinder with 100% of P1, +49 -> extend cylinder with 98% of P1) and the quotients has been generated.

On the last line of the terminal monitor, the current values for normalized control speed (normalization P109),speed steps (between -100 and +100, 2% steps), control speed and actual speed are displayed in eachcase. If teach-in is aborted during the first phase of the commissioning step, any missing values are filledusing the corresponding data currently stored on the camera.

In the second phase, the user can modify individual values manually. It is thus possible, for example, tomodify any seemingly implausible anomalous values.

NOTICE

Unsuitable values in file Hydraulik.txt can result in false control speeds.

At the end of the step, the table of quotients can be stored in file "Hydraulik.txt". (NOTICE! The first column of the file Hydraulik.txt does not contain the indices -50 to 49, but numbers 0 to 99 instead.) Once the table hasbeen stored, the sway control system will apply its content in operation to compensate the non-linearities of the luffing gear hydraulic system.





4.6 Checking and fine adjustment of the camera

Note

To ensure correct hydraulic system calibration, the resolution of the luffing gear position must not exceed

1cm per increment.

Note

While commissioning step 9 is in progress, traces cannot be recorded with the CeCOMM tool.


The following parameters can be set manually from the Parameters menu of the diagnostic program:

Most of the parameters listed below will have been set during the preceding commissioning steps, or arepreset in the shipped state, and should only be changed where necessary.

Selecting passive or active reflector

The type of reflector (passive or active, P72) must be set. The different brightness conditions for activereflectors fitted with LEDs and passive reflectors means the camera uses two different optimizationalgorithms for the brightness control.

Reflector type

The reflector type is determined in commissioning step 2 (P62).

If no reflector is found even though it is situated within the field of vision, the set window size (P63) must alsobe checked.

LensIf the accuracy is not adequate, a lens with a longer focal length can be used. This, however, reduces themaximum measurable swing angle.

The focal length of the lens is preset, but the setting can be changed if necessary in parameter P78.

Brightness

The software controls the reflector brightness depending on the ambient light when parameters P60 – Videoinput gain and P61 – Video input offset are set accordingly.

The default values mean:

Gain = 64 The gain is adjusted proportional to the offset.

Offset = 256 The offset value is increased and decreased between 1 and 255 until a reflector is found. Thereflector brightness is then regulated to a constant value.

Note

The current offset and gain values are shown in Display 4 during camera diagnostics.

Window size

The camera searches for a reflector of a specific size (commissioning step 3 in Chapter 4.5.4). When awindow size of 1 is selected, the camera searches for a reflector of 12 x 12 pixels in size. When a windowsize of 10 is selected, the reflector must be 66 x 66 pixels in size in the image. By comparison: The entireimage is 640 x 480 pixels in size.






Note

To prevent incorrect measurements, the set window size should be as large as possible.

However, if the set window size is larger than the reflector image, the camera will not find the reflector at all.For this reason, changes to parameter settings should be checked at the maximum distance betweencamera and reflector.

Values larger than 10 activate the automatic window size control function. If no reflector is found, "windowsize = parameter value – 10" will be set. If the reflector has been found and it lies completely within thecamera image, the window size will be automatically adapted to the size of the reflector (1..10).

Note

The current window size is shown in Display 4.

Limitation of search area

If the camera incorrectly identifies a reflector in an incorrect image area, the search area for the global searchshould be limited.

The search area limits remain valid only while the camera is unable to find a reflector (global search). Oncethe reflector has been found, the camera searches only in the immediate vicinity of the last position (localsearch).

Using parameters (P76, P77) it is possible to reduce the size of the search area by up to 90%, starting fromthe outer boundaries.

Injection of camera measuring signal

The settings of parameters P19/39 "Gain of camera measuring signal for luffing/slewing gear" can beadjusted to determine the extent to which the internal oscillation model will be influenced by camerameasurements. The camera measurement has no effect when the setting is zero.

If internal drive delays of significant duration occur, it can be useful to deactivate injection of camerameasurements using P82 as of a certain hoisting height (see Description of Parameters for further details).

Note

The luffing gear and slewing gear are coupled in the internal oscillation model. For this reason, when thecamera is active and P39 equals 0 and P19 does not equal zero, the camera measurement of the luffinggear will also influence the sway neutralization motion of the slewing gear. When the assignments of P19and P39 are reversed, the response of the oscillation model is also reversed. Both these parametersshould normally be set either to zero or to a value other than zero.

Measuring reliability

Several parameters can be used to influence measuring reliability.

The algorithms first use fast search functions to find a reflector in the image and determine a recognitionreliability. Parameter P64 "Reflector recognition limit" is used to specify a minimum limit as of which areflector can be deemed to have been reliably recognized. When the reflector is situated in heavy shadow,this value should not exceed 650 (65%).

The subsequent size measurement then returns a high reliability for the presence of a reflector in the image.Up to 16 characteristics are checked for this purpose. Parameter P71 ("Measuring reliability of the camera")can be used to specify the number of characteristics to be used. If more than 10 characteristics are specifiedto be checked, a reflector will be used only when the reflector size was determined using the characteristics.This means P71 > 10 achieves a very high measuring reliability.





4.7 Checking and fine adjustment of the sway control system

Note

Setting very low values for P64 and P71 can cause reflector recognition errors. This can in turn result inabrupt speed changes in the oscillation model and have a negative impact on sway neutralization.


The following parameters can be set manually (if this has not already been done in commissioning step 1)from the Parameters menu in the diagnostic program:

Specifying the hoisting height range

In order to determine the limits for hoisting height parameters P85/P86 and P90/P91, proceed as follows:

Make sure that the hoisting height has been calibrated correctly

Move the hoisting gear across the entire traversing range and measure the minimum and maximum

pendulum lengths (values are displayed in screen 1 "Kinematics" in CeComm)

These limit values (plus a safety reserve in both directions) are entered in parameters P85/P86

If for any special reason you want the sway control system to be deactivated at a specific hoisting height, thisresponse can be set with parameters P90/P91, otherwise set P90 = P85 and P91 = P86.

The parameters "Upper and lower sway control limits" (P90, P91) are used to specify the hoisting heightrange in which the "Sway control" function is active.

Fig. 4-9: Specifying the hoisting height range






Note

The range for the permissible pendulum length P85 / P86 must always be larger or equal to the range for hoisting-height-dependent deactivation of the sway control system P90/P91, i.e. P85 <= P90 < P91 <=P86.

Parameters P85, P86, P90 and P91 are taken into account in error messages E4 and E5 (see Section 5.2.2).

Compensating load carrying devices

If different load carrying devices are used, this information must be passed to the control software as thecenter of gravity and/or the pendulum length changes.

The following parameters are used to adapt the system to load conditions:

a) Weight of load carrying device P89

b) Analog hoisting distance correction P88

c) Digital hoisting distance correction P87

Fig. 5-7 provides an overview of the internal processes used to determine the distances for the oscillationmodel and camera calibration.

Analoghoisting

distancecorrection

Digitalhoisting

distancecorrection

Hoistingdistance

HoistingdistanceLPforoscillationmodel

Load

Resolutionofhoistinggearsensor

Hoistinggearoffset

Minimum,maximum

hoistinggearpositions

HoistingdistanceLKforcameracalibration

+

+

10

++

Weightofload

carryingdevice

Fig. 4-10: Compensation of load carrying devices

With the analog hoisting distance correction, shifts in the center of gravity that result from the load weight, canbe taken into account.

Shifts in the center of gravity that result from the use of different load carrying devices are compensated withthe digital hoisting distance correction.





4.8 Commissioning the positioning system

Note

In certain constellations, the load offset might trigger error message E4, but not E5.

Setting the permissible residual sway

The parameters for residual sway (P103, P104) should not be set lower than required. Values that are toolow can result in swaying after stopping because of dead times.

Setting the sway control factor

A sway control factor (P15, P16, P35, P36) can be set for each travel axis for manual operation (separatevalues for acceleration and deceleration). Values greater than 1.4 result in aperiodic transient responses,values less than 1.4 to overshoot. Sway control factors in the range from 1 to 1.2 represent a compromise

between short rise time and slight overshoot. The difference between the sway control factors for acceleration and deceleration should not be too large, as the control signal can otherwise change abruptlyduring the transition to the deceleration phase.

Only the values of P15 and P35 are relevant in positioning mode. No distinction is made betweenacceleration and deceleration.

Defining the minimum speed and minimum time

The sway control system is not activated until the minimum speed (P105) and minimum time (P106) havebeen reached. It is recommended that both parameters be left at zero. If the activation conditions are nolonger fulfilled, the sway control system is deactivated after the deactivation delay time (P107) has expired.

Setting the starting delay of the drives

The starting delay of the frequency converter after opening of the brake can be set for each axis ( P120,P121).


4.8.1 Calibrating the position value

In order to commission an automatic positioning system, the position values must be calibrated.

The following values must be recorded at two different positions:

• x1 Position 1 in mm

• x2 Position 2 in mm

• s1 Distance value sent by the PLC at position 1

• s2 Distance value sent by the PLC at position 2This information can be used by the diagnostic program "CeCOMM" (menu "Calculations/Positionparameters") to compute the conversion parameters "resolution" (rise) and "offset".

Resolution and offset must be entered for specific axes in the corresponding parameters.

Resolution of position sensor (P5, P25)

The resolution or maximum control speed of the relevant drive axis must be set such that the displayedactual speed corresponds to the control speed in travel at constant speed in manual operation.







Offset of position sensor (P6, P26)

The offset should be set such that the internal position values are always positive.

4.8.2 Set position controllers and sway control factors

The position controllers must be set as shown in the following sequence:

Set position controllers (P14, P34) to zero and start positioning over a long distance

The setpoint and target positions must be virtually identical at the end. Slight differences result through thedeactivated position controller.

Greater deviations might be caused by a maximum control speed error or limits in the drive system. (In order to localize the error, the sway control system can be deactivated by setting the sway control factors to zero.)

Setting the position controllers and sway control factors to default valuesThe sway control factors must be set so as to obtain slight overshoot at the target position (default value).This setting produces short rise times in the sway control system.

The position controller outputs must be slowly increased in 0.1 increments and the behavior compared after each increase by means of a positioning movement (record chart).

The value should not normally exceed 0.5.

The value must be reduced if the speed curve exhibits oscillations or oscillations occur at the target positionas a result of the position controller.

Excessively high setting values can cause swaying movements!

Note

High position controller settings can result in residual sway after positioning.

The value must be reduced when connection of the speed controller causes an oscillating speed curve andan overshoot at the target position.

Note

An overshoot at the target position often results not from a large position controller value but rather froman incorrectly set limit speed. Before the position controller setting is reduced, therefore, another checkshould be performed in travel at constant speed and in controlled operation (position controller set to zeroor manual operation) whether the actual speed is approximately equal to the setpoint speed.

The position control function can be optimized by adaptation of parameters P118 and P119.

4.8.3 Other settings

The following parameters can be set manually:

Positioning accuracy (P9, P29)

The set positioning accuracy should be as small as necessary and only affects the "Positioning complete"message. Positioning continues while the mode and the travel signal remain set.

Following error (P122, P123)

The following error is the difference between the calculated position and actual position of the crane. An error message is triggered when the tolerance is exceeded.



Parameter and Error List 5

5.1 Parameter list

5.1.1 Parameters for luffing gear

P0 Positioning speed luffing gear This value (in mm/s) corresponds to the maximum speed of the boom in positioning mode. P0 is alwayslimited internally to 95% of the currently possible maximum boom speed. The boom speed is determined byfile Wippen.txt Geometry.

Default: 450 mm/s

P1 Maximum control speed of luffing gear

Speed limit value in mm/s. Notice: The set value corresponds to the maximum attainable speed of the drive(hydraulic cylinder, toothed rack etc. ) and not the speed of the boom.

Default: 500 mm/s

P2 Acceleration without sway controlWhen the sway control system is deactivated, the drive accelerates and decelerates with the set accelerationvalue. The value is applied as a minimum deceleration rate when the prelimit switch range is reached. Theparameter is thus applied for two scenarios in the sway control system, i.e. travel without sway control andtravel in the prelimit switch range. If different acceleration rates need to be used for these two situations, thena parameter set switchover will be required.

Default: 150 mm/s²

P3 Setpoint acceleration of boom

The setpoint acceleration is an internal acceleration variable in mm/s². It is operative in all basicoperating modes, during acceleration and deceleration. Input values less than 20 are interpreted as aramp time. Set manually according to manufacturer or customer specifications. The value should

correspond to approx. 75% of the maximum acceleration (P4). (see Chapter 3.7)Default: 150 mm/s²

P4 Maximum acceleration of boom

Acceleration limit in mm/s². The set value corresponds to the maximum boomacceleration/deceleration. Input values less than 20 are interpreted as a ramp time.

Set manually according to manufacturer or customer specifications.

Default: 250 mm/s²




Parameter and Error List

5.1 Parameter list

P5 Resolution of luffing gear position sensor

Calibration value for the luffing gear position.

The actual position of the boom is calculated in millimeters with P5 and P6, see Section 3.4.3.

Default: 1

P6 Luffing gear position sensor offset

Calibration value for the luffing gear position.

The actual position of the boom is calculated in millimeters with P5 and P6, see Section 3.4.3.

Default: 0 mm

P7 Minimum position for boom in positioning mode

Smaller target positions are ignored. Note that the limitation refers to calibrated target positions (after conversion with resolution and offset).

See also E3.Default: 0 mm

Note

The limit values should be a little below the possible setpoint position in order to allow slight overshoot.

Furthermore, the value must not be lower than the smallest boom position defined in the geometry table(see commissioning step a, Chapter 3.6.3).

P8 Maximum position for boom in positioning mode

Larger target positions are ignored. Note that the limitation refers to calibrated target positions (after conversion with resolution and offset).

See also E3.Default: 200,000 mm

Note

The limit values should be a little higher than the possible setpoint position in order to allow slightovershoot.

Furthermore, the value must not be higher than the largest boom position defined in the geometry table(see commissioning step a, Chapter 3.6.3).

P9 Positioning accuracy boom

Tolerance between actual and target positions within which the output bit "Pos_complete" is signaled. Inorder to achieve the requisite degree of positioning accuracy, the value for the position controller P14 mustbe greater than zero.

Default: 200 mm

P10 Deceleration gain luffing

Deceleration gain or reduction factor. The deceleration rate is calculated on the basis of P3*P10, or P3*P10*P113 for plugging. These values are also limited by the maximum control value P4. P10 has noeffect in positioning mode.

Default: 1





5.1 Parameter list

P11 Maximum load speed when luffing gear is operated

Oscillation speed tolerance during travel.

Default: 20 mm/s

P13 Prelimit switch speed luffing

Percentage speed value within the prelimit switch range.

Default: 10 %

P14 Position controller for luffing gear

P position controller for automatic positioning.

Default: 0,1

P15 Damping factor for luffing gear (deceleration)

Damping factor for conventional sway control during positioning and during deceleration in manual mode.Large values result in aperiodic transient responses and low values to overshoot and short rise times.

Default: 1,2

P16 Damping factor for luffing gear (acceleration)

Damping factor for conventional sway control in manual mode during acceleration. Large values result inaperiodic transient responses and low values to overshoot and short rise times. To achieve fast acceleration,the value should be lower than the damping factor for deceleration.

Default: 1

P17 Low-pass frequency factor luffing

This parameter can be used to set a low-pass filter for the camera measured values. The filter must beactivated if the load carrying device exhibits undesirable trim oscillations. The cutoff frequency of the filter iscalculated by multiplying it with the natural frequency of the swaying movement. A meaningful setting is 2 or higher. The filter is deactivated if this parameter is set to 0.

Default: 0

P18 Luffing speed for zero speed signal

Specifies a percentage of P1 (control speed) as of which "zero" speed is signaled internally. (See descriptionof status bits "Direction of travel".)

Default: 1%

P19 Camera measuring signal gain for direction luffingGain value for injecting the camera measuring signal into the internal oscillation model. The camerameasurement has no effect when this parameter is set to zero.

Default: 0,05

5.1.2 Parameters for slewing gear

The unit for the slewing gear position is 1/100 degrees (cgr) and for the slewing speed 1/100 degrees per second (cgr/s).

A full circle from 0 to 36,000 cgr is thus described.





5.1 Parameter list

P20 Positioning speed slewing gear

P20 is always set internally to 95% of the currently possible maximum slewing gear speed. This valuecorresponds to the maximum slewing speed in Positioning mode.

Default: 450 cgr/s

P21 Maximum control speed slewing gear

Speed limit in cgr/s. The set value corresponds to the maximum attainable speed.

Default: 500 cgr/s

Note

After the user has confirmed the setting for parameter P21, the system asks whether P20, P22, P23, P24and P32 should be updated. Updating is meaningful only if the speeds and acceleration rates dependentupon P21 have already been entered and only P21 needs to be adjusted again. With this "update"process, parameters P20, P22, P23, P24 and P32 are altered in equal proportion to P21.


When the sway control system is deactivated, the drive accelerates and decelerates with the set accelerationvalue. The value is applied as a minimum deceleration rate when the prelimit switch range is reached. Theparameter is thus applied for two scenarios in the sway control system, i.e. travel without sway control andtravel in the prelimit switch range. If different acceleration rates need to be used for these two situations, thena parameter set switchover will be required.


P23 Setpoint acceleration rate slewing gear (inner circle)

The setpoint acceleration is an internal acceleration quantity in cgr/s² for operation with active sway control

(input bit "AS_ON").In positioning mode, the value of P23 is always applied for the slewing gear. In speed control mode, thesetpoint acceleration rate depends on the current position of the luffing gear. (See Section 1.7.1 anddescription of P32 for details.)


P24 Maximum acceleration rate, slewing gear

Acceleration limit in cgr/s². The set value corresponds to the maximum drive acceleration/deceleration.Input values less than 20 are interpreted as a ramp time. Set manually according to manufacturer or customer specifications.


P25 Resolution of slewing angle sensor

Calibration value for the slewing gear position.

The actual position of the slewing gear in cgr is calculated by P25 and P26, see Section 3.4.3.

Default: 1





5.1 Parameter list

P26 Slew angle sensor offset

Calibration value for the slewing gear position.

The actual position of the slewing gear in cgr is calculated by P25 and P26, see Section 3.4.3.Default: 0 cgr

P29 Positioning accuracy slewing gear

Tolerance between actual and target positions within which the output bit "Pos_complete" is signaled. Inorder to achieve the requisite degree of positioning accuracy, the value for the position controller P14 mustbe greater than zero.

Default: 50 cgr

P30 Deceleration gain, slewing gear

Deceleration gain or reduction factor. The deceleration rate is calculated from the product of P30 and the

interpolated slewing acceleration value (see description of P23 and P32). In case of plugging the first factor isP30*P114. The results are also limited by the maximum control value P24. P10 has no effect in positioningmode.

Default: 1

P31 Maximum load speed when stopped (slewing gear)

Oscillation speed tolerance after stopping.

Default: 50 cgr/s

P32 Setpoint acceleration rate, slewing gear (outer circle)

The setpoint acceleration is an internal acceleration quantity in cgr/s² for operation with active sway control

(input bit "AS_ON").P32 is relevant only in speed control mode. (See Section 1.7.1 and description of P23 for details.)

Default: 75 cgr/s²

P33 Prelimit switch speed, slewing gear

Percentage speed value within the prelimit switch range.

Default: 10 %

P34 Position controller, slewing gear

P position controller for automatic positioning.

Default: 0,1

P35 Damping factor, slewing gear (deceleration)

Damping factor for conventional sway control during positioning and during deceleration in manual mode.Large values result in aperiodic transient responses and low values to overshoot and short rise times.

Default: 1,2

P36 Damping factor, slewing gear (acceleration)

Damping factor for conventional sway control in manual mode during acceleration. Large values result inaperiodic transient responses and low values to overshoot and short rise times. To achieve fast acceleration,the value should be lower than the damping factor for deceleration.





5.1 Parameter list

Default: 1

P37 Low-pass frequency factor, slewing gear This parameter can be used to set a low-pass filter for the camera measured values. The filter must beactivated if the load carrying device exhibits undesirable trim oscillations. The cutoff frequency of the filter iscalculated by multiplying it with the natural frequency of the swaying movement. A meaningful setting is 2 or higher. The filter is deactivated if this parameter is set to 0.

Default: 0

P38 Slewing speed for zero speed signal

Specifies a percentage of P1 (control speed) as of which "zero" speed is signaled internally. (See descriptionof status bits "Direction of travel".)

Default: 1%

P39 Camera measuring signal gain, direction slewing

Gain value for injecting the camera measuring signal into the internal oscillation model. The camerameasurement has no effect when this parameter is set to zero.

Default: 0,05

5.1.3 Camera calibration values

P40 Calibration radius 1

Calibration parameter which is set automatically during calibration.

Default: 1 mm

P41 Calibration radius 2


Default: 1 mm

NOTICE

The parameters P42 to P53 should not be changed manually. They are set automatically as part of commissioningstep 6.

P42 Calibration parameter X0

Calibration parameter which is set automatically during calibration.Default: 320



Default: 0



Default: 0





5.1 Parameter list



Default: 0

P46 Calibration parameter Y0


Default: 240



Default: 0


Calibration parameter which is set automatically during calibration.Default: 0



Default: 0

P50 Calibration parameter A0


Default: 0



Default: 0



Default: 0



Default: 0

P55 Camera measuring signal gain, slewing gear

Gain factor for the camera measuring signal before it is injected into the oscillation model.

Default: 1





5.1 Parameter list

P56 Camera measuring signal gain, slewing gear

Gain factor for the camera measuring signal before it is injected into the oscillation model.

Default: 1

5.1.4 Camera and reflector parameters

P60 Video input gain

Video signal gain. The automatic gain control is activated when the setting is zero. The maximum value is 64.

0 Automatic gain control (depending on the brightness of the entire image).

1 – 63 Fixed gain (bright environment => low values).

64 The gain is calculated from ¼ of the current offset of the video input. This means that the gain canalso be varied as a function of the reflector brightness.

Default: 64

P61 Video input offset

Exposure time of the camera. The exposure time can be set to a value between 1 and 255. Automatic settingof the exposure time must be selected either in conjunction with control of the brightness of the entire imageor control of the brightness of the reflector. The maximum value is 511.

0 Automatic exposure time (depending on the brightness of the entire image).

1 – 255 Fixed exposure time (bright environment => low values).

256 Automatic exposure time depending on the brightness of the reflector when the reflector has beenrecognized; otherwise automatic search for the optimum exposure time.

257 – 511 255+a: Automatic exposure time (depending on the brightness of the reflector) if the reflector has been recognized; if the reflector has not been recognized, the fixed exposure time a (1..255) will be set.

Default: 256

P62 Reflector alignment

This parameter defines the alignment of the white areas. Bottom right and top left (1) or top right and bottomleft (1).

Default: 0

P63 Minimum window size for reflector recognition

This parameter must be set to the highest possible value when the camera and reflector are located at thelargest possible distance from one another. (See also Sections 4.5.4 and 4.6 for further information.)

1-10 Fixed window size.

11-20 Automatic size control (depending on reflector), otherwise fixed.Default: 11

P64 Reflector recognition limit

The probability of recognition of the reflector determined by the correlation function is compared with thisfactor. Only when the calculated probability is more than or equal to this value will the reflector be deemed tobe recognized.

Default: 850 ‰





5.1 Parameter list

P65 Size of white reflector area

Width of the white reflector area in mm. This parameter is used to determine the distance between thecamera and the reflector.

Default: 300 mm

P66 Camera orientation

This parameter describes the orientation of the camera with reference to the reflector motion. It may be setonly to values 0, 1, 2 and 5. Other values may cause the crane to behave incorrectly. The meaning of thevalues is explained in Table 4-3. This parameter should be set during commissioning step 4 (see Chapter 4.5.5).

Default: 1

P67 Single (0)/Master (1)/Slave (2) camera

This parameter must be set to 0 for the CeSAR blind variant. When the camera-based variant is used

(CeSAR slew, system uses two cameras), the parameter must be set to 1 for the master camera and 2 for the slave camera.Default: 0

P68 Upper hoisting gear position for camera calibration

Internal value which is calculated automatically during camera calibration. It must not be changed manually.

Default: 1,000 mm

P69 Lower hoisting gear position for camera calibration

Internal value which is calculated automatically during camera calibration. It must not be changed manually.

Default: 10,000 mm

P70 Reflector distortion

Specifies the optical distortion of the reflector. This parameter is set automatically during commissioning.

Default: 0 mm

P71 Measuring reliability of camera

The value specifies the required degree of measuring reliability for determining the reflector size (0..7). If the3rd bit is also set, a swing angle measurement is valid only when the reflector size has been successfullymeasured (8..15).

Default: 12

P72 Passive (0) or active (1) reflector

When the appropriate reflector type is selected, the automatic brightness control takes account of theappropriate light conditions.

Default: 1

P73 Double-jib (0) single-jib crane (1) with hydraulic drive (2)

The parameter must be set according to the crane type. When a hydraulic system is used, a speedcorrection for the hydraulic drive is also active.

Default: 0





5.1 Parameter list

P74 Light/dark limit

This parameter can be used to specify the light-dark limit.

0 - Arithmetic mean of the reflector (default)1 - Suppress dark disturbances on white surfaces (shadows)2 - Suppress light disturbances on dark surfaces

Default: 0

P75 Minimum reflector contrast

For the image evaluation, the contrast between the bright and dark areas must have at least this value. Themeasured contrast can lie between 0 and 255. Normally, the contrast of a reflector lies within the range 40 to100. The contrast of an active reflector is higher than that of a passive reflector.

Default: 40

P76 Restriction of global search area (X)

If the reflector has not been found, the horizontal image area in which the reflector is searched can be limited.With a setting of 0%, all 640 image columns are searched for the presence of a reflector. With a setting of 90 %, the search will be restricted to only the middle 64 image columns.

Default: 0 %

P77 Restriction of global search area (Y)

If the reflector has not been found, the vertical image area in which the reflector is searched can be limited.With a setting of 0%, all 480 image rows are searched for the presence of a reflector. With a setting of 90 %,the search will be restricted to only the middle 48 image rows.

Default: 0 %

P78 Focal length of lensThe parameter specifies the focal length of the used lens in mm. Typical focal lengths are: 8 mm, 12 mm,16 mm, 25 mm, 50 mm.

Default: 16 mm

5.1.5 Hoisting height parameters

P80 Resolution of hoisting height sensor

P80*s_Hoist + P81 is the internally applied hoisting height (without load offset). For further details, seedescription of hoisting height calibration and Section 4.7 "Specifying the hoisting height range".

Default: 1

P81 Hoisting height offset

P80*s_Hoist + P81 is the internally applied hoisting height (without load offset). For further details, seedescription of hoisting height calibration and Section 4.7 "Specifying the hoisting height range".

Default: 0 mm





5.1 Parameter list

P82 Upper limit for camera measurement

The camera measurement is deactivated for pendulum lengths shorter than this value. This can be a useful

response in the following situations: If internal drive delays occur as a result of conversion of the controlvalues supplied by the CeSAR system, a difference can develop in the phase between the internal oscillationmodel and the camera measurement. The lower the hoisting height, the shorter the period of the oscillationand thus the greater the negative impact of the phase difference. It can therefore be useful to switch off thecamera when a certain hoisting height is reached.

Default: 0 mm

P84 Maximum slewing speed with Cartesian control

Limits the slewing speed in Cartesian control mode to a percentage of the maximum control speedcorresponding to P84 * P21.

Default: 100 %

P85 Maximum hoisting gear position

Upper limit value for hoisting gear position.

Default: 1,000 mm

P86 Minimum hoisting gear position

Lower limit value for hoisting gear position.

Default: 200,000 mm

P87 Digital hoisting distance correction

Shift in the center of gravity of the load when bit "Loadtyp" is set.

Default: 0 mm

P88 Analog hoisting distance correction

Relationship between load weight and shift in the center of gravity.

Default: 0 mm/kg

P89 Weight of load carrying device

Weight of the load carrying device to determine the shift in the center of gravity. If the weight of the load isequal to or less than the weight of the load carrying device, the shift in the center of gravity equals zero.

Default: 0 kg

P90 Upper limit for sway controlThe sway control system is deactivated above this hoisting height (internal value: P80*s_Hoist+P81). SeeSection 4.7 for details.

Default: 3,000 mm

P91 Lower limit for sway control

The sway control system is deactivated below this hoisting height (internal value: P80*s_Hoist+P81). SeeSection 4.7 for details.

Default: 100,000 mm





5.1 Parameter list

P92 Luffing gear position for automatic inward luffing

This luffing gear position is approached first in automatic positioning mode. Outward luffing toward the targetposition of the luffing gear commences shortly before the slewing gear reaches its target position. Theparameter should be set to the last luffing gear position at which the slewing speed has not yet started todecrease.

Default: 50,000 mm

P93 Correction time automatic outward luffing

Outward luffing after automatic inward luffing can be started in advance by this time period. Low or negativevalues delay outward luffing.

Default: 5 s

Note

Automatic outward luffing is executed at the latest (regardless of the setting in P93) when the internal

setpoint speed for the slewing gear has dropped to 0.

P94 Course offset controller

Offset controller to keep the boom moving along a specified straight line in Cartesian control mode. Thecorrection value is determined by the distance to the specified straight line and the controller factor.

Default: 8

P95 Course speed controller

Controller to keep the boom moving along a specified straight line in Cartesian control mode. The correctionvalue is determined according to the change in distance from the straight line and the controller factor.

Default: 1

P96 Course tolerance (relevant only in Cart. speed control mode)

If the prespecified course changes by an amount corresponding to at least this value, the course line iscalculated again. The previously specified course line otherwise remains valid as the setpoint.

Default: 10°

P97 Course change delay timer (relevant only in Cart. speed control mode)

When the boom changes course, the setpoint for the new course line is not issued until this timer has rundown in order to allow reorientation in the new direction without overshoot.

Default: 7.5 s

P98 Suppress opposite direction (slewing gear)

As long as the slewing gear does not reach this percentage value of maximum speed in polar speed controlmode, the slewing gear will move only in the direction specified by the crane operator.

Default: 75 %

P99 Permissible residual sway on luffing gear stop

Largest permissible swing angle in mm after completion of a crane movement.

Default: 500 mm





5.1 Parameter list

5.1.6 General parameters

P100 Access code

Access code for changing parameters.

0 – Any user 1 – Commissioning engineer 2 – Service engineer

Default: 2

P101 Parameter set locked during travel

The current parameter set cannot be switched over to another parameter set during travel if the value of P101 does not equal 0.

Default: 1

P102 Sampling time

This value corresponds to the current sampling time of the control process in milliseconds. A reduction ismeaningful only in the event that the calculations do not exceed the set sampling time.

Default: 75 ms

Note

Delays or fluctuations might occur in the display of actual values and setpoints. These are caused by thetime taken to measure and transfer data by different scanning systems (sensor, PLC, drive, sway controlsystem). The fluctuations have no effect on the mode of operation of the sway control function.

P103 Permissible residual sway on slewing gear stop

Largest permissible swing angle in mm after completion of a crane movement.Default: 200 mm

P104 Permissible residual sway during travel

If the load sway drops below this value during travel, the output bit Antsw_complete (see Table 3-6) is set.

Default: 150 mm

P105 Activation speed sway control system

If the absolute speed control value is greater than this setting, the sway control system is activated internallyafter expiry of the ON delay in P106. By the same principle, it is deactivated if the absolute control speed hasdropped below the setting in P105 and the timer set in P107 has then run down.

This functionality is available in speed control mode only.Default: 0 %

Note

If the ON delay P105 is programmed with a value other than zero and load sway must be neutralizedwhen the crane stops moving, the setting in P107 must be sufficiently high. If the setting is too low, theremight be insufficient time available to neutralize the sway before the sway control system is deactivatedinternally, resulting in a residual load sway.





5.1 Parameter list

P106 ON delay sway control system

The absolute speed control value must be higher than the activation speed programmed in P105 for

at least the period set in P106 in order to ensure activation of the sway control system.Default: 0 s

P107 OFF delay sway control system

The sway control function is deactivated after this period has expired if the ON conditions (P105, P106) areno longer satisfied.

Default: 0 s

P109 Normalization setpoint and control speed

The parameter contains the normalizing factor for all speeds that are transferred via the fieldbus. If theparameter is set to 28,000, for example, then a setpoint speed of –14,000 corresponds to half the negative

maximum speed (P1 or P21) of the corresponding axis.Default: 32.767

P110 Language

This parameter specifies the language used by the diagnostic software.

0 – German1 – English

Default: 1

P111 Diagnostic value

Depending on the set value, the diagnostic variable is assigned the value "10" and transmitted to

DiagHPCeSAR.0-2 Limit values 3-5 Setpoints 6-8 Actual values 9-11 Control values 12-14 Delayed control values 15-17Oscillation model 18-20 Camera measurements; in the order Position-Speed-Acceleration in each case

Default: 0

P112 Image sensor deactivated

0 - Image sensor of the camera is activated. Automatic monitoring active.1 - Image sensor of the camera is deactivated.

Default: 0

P113 Deceleration gain for luffing gear in case of plugging

Deceleration gain or reduction factor. The deceleration rate is calculated on the basis of P3*P10, or P3*P10*P113 for plugging. These values are also limited by the maximum control value P4.

Default: 1

P114 Deceleration gain for slewing gear in case of plugging

Deceleration gain or reduction factor. The deceleration rate is calculated from the product of P30 and theinterpolated slewing acceleration value (see description of P23 and P32). The second factor corresponds toP30*P114 for plugging. These values are also limited by the maximum control value P24.

Default: 1





5.1 Parameter list

P115 Acceleration reduction, short travel

If the speed setpoint and the actual speed equal less than 30% of the maximum speed, the set acceleration

is multiplied by this factor. The value applies for all drive axes.Default: 0.5

P116 Deceleration reduction, short travel

If the speed setpoint and the actual speed equal less than 30% of the maximum speed, the set accelerationis multiplied by this factor and used as deceleration setpoint. The value applies for all drive axes.

Default: 0,5

P117 Commissioning status

Information encoded bit-by-bit about which commissioning steps have been completed successfully.

Default: 0

P118 Time constant current rise luffing gear

The current rise and therefore the change in acceleration over time are often limited by the converter. In order to take this delay into account when activating the oscillation model and the position control, a first-order delay element has been provided, whose time constant is set with this parameter. If the value is less than 1,the delay element is deactivated.

Default: 0 ms

Note

This parameter can also be used to compensate runtime delays in the crane control system (PLC).

P119 Time constant current rise, slewing gear

The current rise and therefore the change in acceleration over time are often limited by the converter. In order to take this delay into account when activating the oscillation model and the position control, a first-order delay element has been provided, whose time constant is set with this parameter. If the value is less than 1,the delay element is deactivated.

Default: 0 ms

Note

This parameter can also be used to compensate runtime delays in the crane control system (PLC).

P120 ON delay, luffing gear drive

ON delay of the converter after opening of the brakes. If the value is less than 1 and greater or equal to 0, thedelay element is deactivated. With a single-jib crane with hydraulic system (P73>=1), a setting of -1 will mean

that the ON delay is automatically detected in travel according to polar coordinates on the basis of the luffingspeed.

P120 influences the following error in positioning mode. The larger the value (and real deceleration of thedrive), the higher the following error will be. In order to prevent the CeSAR system from issuing following error messages, P120 can either be reduced and the procedure described in Section 3.5.4 applied(recommended), or P122 (following error luffing gear) can be increased.

Default: 0 ms





5.1 Parameter list

P121 ON delay, slewing gear drive

ON delay of the converter after opening of the brakes. If the value is less than 1 and greater or equal to 0, the

delay element is deactivated. With a single-jib crane with hydraulic system (P73>=1), a setting of -1 will meanthat the ON delay is automatically detected in travel according to polar coordinates on the basis of the luffingspeed.

P121 influences the following error in positioning mode. The larger the value (and real deceleration of thedrive), the higher the following error will be. In order to prevent the CeSAR system from issuing following error messages, P121 can either be reduced and the procedure described in Section 3.5.4 applied(recommended), or P123 (following error slewing gear) can be increased.

Default: 0 ms

Note

When parameters P120 and P121 are set to values other than zero, deviations from the straight line mightoccur in Cartesian mode.

P122 Following error luffing gear

The deviation between the setpoint and actual positions must not exceed the value of this parameter duringpositioning. An error message is otherwise generated. If the value is zero, the following error monitoringfunction is deactivated.

Default: 0 mm

P123 Following error, slewing gear

The deviation between the setpoint and actual positions must not exceed the value of this parameter duringpositioning. An error message is otherwise generated. If the value is zero, the following error monitoringfunction is deactivated.

Default: 0 cgr

P124 Position controller manual mode luffing gear

P position controller for the operating mode "Manual control". High setting values can cause swayingmovements.

Default: 0

P125 Position controller manual mode slewing

P position controller for the operating mode "Manual control". High setting values can cause swayingmovements.

Default: 0

P126 Smoothing of torque setpoint luffing gear

In addition to the control speed, the control acceleration is fed back to the PLC for the torque feedforwardcontrol of a speed control loop. The smoothing of the torque setpoint can be set with this time constant. If thevalue is less than 1, the delay element is deactivated.

Default: 0 ms





5.2 Error messages

P127 Smoothing of torque setpoint slewing gear

In addition to the control speed, the control acceleration is fed back to the PLC for the torque feedforward

control of a speed control loop. The smoothing of the torque setpoint can be set with this time constant. If thevalue is less than 1, the delay element is deactivated.

Default: 0 ms

P130 Smoothing of actual speed luffing gear

Smoothing of the speed calculated from the current position can be set with this time constant. If the value isless than 1, the delay element is deactivated. Parameter 130 only influences the display in CeComm.

Default: 350 ms

P131 Smoothing of actual speed slewing gear

Smoothing of the speed calculated from the current position can be set with this time constant. If the value is

less than 1, the delay element is deactivated. Parameter 131 only influences the display in CeComm.Default: 350 ms

5.2 Error messages

5.2.1 General

WARNING

Situations can develop while the crane is moving which cause the control value issued by the CeSARsystem to be abruptly reset to zero. In this case, the braking ramps are determined by the set converter ramps (Chapter 3.9.2). The sway control system ceases to function.

This type of scenario can occur, for example, if the parameter settings for positioning accuracy, residualsway and zero speed signal are high and the sway control system generates the "Positioning complete"signal internally while the control speed is still high.

Another typical scenario is when the PLC resets the travel signal while the crane is moving.

WARNING

The PLC programmer is obliged to evaluate the error messages issued by the electronic sway control

system. The control values from the sway control system must not be utilized when an error is active. Thedrive control system must be controlled exclusively via the PLC.

Each error has a number, a title, an error description and remedy information.

The errors have one of three different characteristics:

Error ÆReaction needed, deactivate sway control system

Warning Conditional reaction, sway control system need not be deactivatedÆ

Note Æ Status and diagnostic function

Errors that are transferred to the PLC, are identified by an error bit.





5.2 Error messages

Table 5-1 Overview of error messages with error bit

Error no. Bit no. Meaning

E0 0 Invalid parameter file

E1 1 Invalid operating mode

E2 2 Fieldbus error

E3 3 Invalid target or actual position for positioning

E4 4 Invalid hoisting gear position

E5 5 Sway control Off (pendulum length)

E6 9 Camera measuring system not calibrated

E7 8 Errors in crane geometry description

E8 11 Camera measuring system impaired

E9 12 Camera measuring system faulted

E28 6 Following error luffing gear

E29 7 Following error slewing gear

E38 13 Course intersects inner slewing circle (Cartesian coordinates)

5.2.2 Error list

E0 Invalid parameter file

An error has occurred while loading the parameter files. One or more parameter files are missing or faulty.The relevant parameter set will be set to default values.

Error bit: 0Error type: Error

Reaction: Check parameters in the Parameters menu and save.

E1 Invalid operating mode

Multiple operating modes or no operating mode at all has been selected via the command bits, or no licenseis available for the selected mode.

Error bit: 1Error type: Error Reaction: Check PLC program Set only one operating mode bit per travel axis, or purchase license.

E2 Fieldbus error

The sway control system could not establish a communication link with the PLC or has not received any data

for at least two seconds.Error bit: 2Error type: Error Reaction: Check the cable, check the PLC.

E3 Invalid target or actual position for positioning

The target position or actual position of the boom is outside the range defined by P7 and P8. The cranecancels positioning of the boom.

Error bit: 3Error type: WarningReaction: Check P7 and P8, specify a valid target position (if target position is invalid) or

traverse to valid position in manual mode (if actual position is invalid).





5.2 Error messages

Note

If this error is not processed in the PLC and occurs while the crane is in motion, the slewing motion

towards the target position will continue. However, the luffing gear cancels the positioning operation, butcontinues to perform the compensating movements required to neutralize the radial swaying motionsgenerated by the slewing gear.

A different response can be obtained by entering the corresponding input bits of the sway control systeminto the PLC. For example, if it is desired that the luffing and slewing gear stop moving with active swaycontrol, the bit "Controlled stop" must be set for both of them.

E4 Invalid hoisting gear position

The position of the hoisting gear P80*s_Hoist+P81 (see Table 3-1) with or without consideration of the loadoffset is outside the programmed limits (P85, P86).

Error bit: 4Error type: Warning

Reaction: Check hoisting gear position and parameters

E5 Sway control OFF (hoisting height + P81)

The sway control function has been deactivated because the hoisting height is not within the specified limits(P90, P91).The error message is issued on the basis of hoisting height s_Hoist and the hoisting height offset (P81). It isnot influenced by shifts in center of gravity.

Error bit: 5Error type: NoteReaction: Check parameters.

E6 Camera measuring system not calibratedThe camera has not yet been calibrated. The camera measurement is not influencing the sway controlsystem.

Error bit: 9

Error type: Warning

Reaction: Perform commissioning step 6

E7 Error reading in file "wippen.txt"

Text file "wippen.txt" has not been read in successfully and the luffing gear cannot be moved.

Error bit: 8Error type: Warning

Reaction: See Chapter 3.6

E8 Camera measuring system impaired

Soiling or poor lighting and visibility conditions have caused a reduction in the quality of the camerameasuring system. The reflector, however, is still recognized sufficiently well.

Error bit: 11Error type: NoteReaction: Clean the reflector, improve the lighting and visibility conditions.





5.2 Error messages

E20 Sway control OFF (start luffing)

The sway control function has not been activated because the set starting speed (P105) has not yet beenreached or the start time (P106) has not yet elapsed.

Error bit: -Error type: NoteReaction: -

E21 Incorrect language file

Lines that are too long or cannot be displayed have been detected during loading of the language fileSprache0.txt.

Error values 0..199 – Parameter texts200..300 – Error texts

Error bit: -Error type: Note

Reaction: Correct language file

E22 Sway control Off (start slewing)

The sway control function has not been activated because the set starting speed (P105) has not yet beenreached or the start time (P106) has not yet elapsed.

Error bit: -Error type: NoteReaction: -

E23 Camera calibration active

The crane is currently being used to calibrate the camera.

Error bit: -Error type: NoteReaction: Terminate calibration. Check wiring.

E25 Controlled stop active

The command bit "Controlled stop" is set.

Error bit: -Error type: NoteReaction: Reset "Controlled stop" bit.

E26 Incorrect IP address

The entered or read IP address of the peer is incorrect, i.e. it is not in the format 192.168.1.140, its individualcomponents are not within the 0 to 255 range, or it is identical to the device's own IP address.

Error bit: -Error type: NoteReaction: Enter a valid IP address in the Parameters menu.





5.2 Error messages

E27 Load weight error

The load weight (Table 3-1) transferred by the PLC minus the value of P89 is either less than zero or greater

than 10,000 kg. Any displayed fault value corresponds to the calculated weight in kg. If no value is displayed,the weight equals 0 kg.

Error bit: -Error type: NoteReaction: Check load measurement.

E28 Following error luffing gear

The difference between the setpoint and actual positions is greater than the parameterized value.

Error bit: 6Error type: MessageReaction: Check the drive and position measurement system.

E29 Following error slewing gear

The difference between the setpoint and actual positions is greater than the parameterized value.

Error bit: 7Error type: MessageReaction: Check the drive and position measurement system.

E31 Speed limit value too low

The current limit speed for the luffing boom or slewing gear is less than 1mm/s or 1cgr/s respectively. In thiscase, the limit speed is calculated on the basis of P1* or P21 multiplied by v_act/P109. P1* is the speed valueof the boom which is calculated from P1, the current position of the luffing gear and the luffing gear geometry.The relevant axis is the displayed value.

Error values: 0 - Luffing gear, 1 - Slewing gear, 2 - Luffing and slewing gear Error bit: -Error type: NoteReaction: Check PLC limit values.

E33 Axis release in Cartesian control mode

The luffing and slewing gear axes must always be released for operation in Cartesian control mode. Thiserror message will appear if only one of the axes has been released.

Error bit: -Error type: MessageReaction Check the PLC program.

E34 Error hoisting height above ground

This error is set if A is outside the interval [0,150000m].

Applicable to double-jib crane:

A = (maximum pos. of the boom in Wippen.txt ) - (internal hoisting height)

Applicable to single-jib crane with Wippen.txt:

A = (maximum pos. of the boom in Wippen.txt ) - s_Hoist2

Applicable to single-jib crane with geometry data:

A = (L+E) - s_Hoist2





5.2 Error messages

Error bit: -Error type: MessageReaction: Check the hoisting height data.

E35 Cartesian control mode not permitted

The command bit "Cartesian Control" has been set, but the appropriate license is not available.

Error bit: -Error type: MessageReaction: Reset command bit or purchase license.

E36 Sway control not permitted

The command bit "Sway control system" has been set, but the appropriate license is not available. The copyprotection has been damaged.

Error bit: -

Error type: MessageReaction: Reset command bit or purchase license.

E37 Cycle time exceeded

The cycle time set with P102 is too short.

Error bit: -Error type: MessageReaction: Increase the setting in the sampling time parameter.

E38 Course intersects inner slewing circle (Cartesian coordinates)

The course for Cartesian control mode which is selected in manual operation or computed in automatic

operation is closer to the center of rotation than the minimum luffing gear position.

Error bit: 13Error type: Error Reaction: Check the course and minimum luffing gear position.





5.3 Troubleshooting


5.3 Troubleshooting

Table 5-2 Troubleshooting/FAQs

Symptom Possible causes and remedies

Camera is not receiving any message framesalthough the PLC is receiving data. Error message "Fieldbus error". The status LEDsof the gateway and camera connections areilluminated on the hub. However, only thetransmit LED of the camera is flashing.

Check the hardware configuration.

The data must not be transferred as consistent datato the peripheral output!

The counter in the send data message header mustbe incremented with each new cycle. Thisincrementation triggers the transmission of Ethernetmessage frames through the gateway.

Crane does not settle after completion of thetravel motion.

Check minimum frequency and ramp-up time of theconverter.

The actual pendulum length differs greatly from theinternally calculated effective pendulum length(display 1).

Calibrate the hoisting height (commissioning step 5)

Sway control system initiates swayingmovements.

Check acceleration and deceleration ramps of theconverter, delete any roundings and check thecontrol parameters of the converter.

Setting the alignment of the camera (commissioningstep 4)

Crane moves a short distance on its own for no reason.

Camera loses the reflector and for a short time findsobjects in the vicinity similar to reflectors. Determine

the minimum window size (commissioning step 3)Change low-pass frequency factor (1), restrict thesearch area of the camera, increase the contrast.

Trim oscillations occur with a higher frequency than the swaying movement.

Activation of the low-pass filter for the appropriatedrive axis (typical value: 1) and reduction of thecamera injection (typical value: 0.015)

Residual swaying movements are always or occasionally too large.

Check ramps and speed controller of the converter.



Maintenance 6

6.1 Reflector maintenance

The reflector must be cleaned regularly depending on the dust content of the environment. If the dust contentis low, it is sufficient to inspect/clean the reflector once per year. If the dust content is high, however, the

reflector must be cleaned at 4-6 weekly intervals. All dirt and paint residues must be removed.Solvents must not be used to clean the reflector.

The reflector must be checked for secure mounting as part of the regular crane inspection.

6.2 Camera maintenance

The glass screen on the front of the camera's protective casing must be checked at the same intervals as thereflector and cleaned if necessary. The camera must also be checked for secure mounting.




Appendix 7

7.1 Operation of CeCOMM menu

Table 7-1 CeCOMM menu tree

SPACE 1 Display kinematics

2 Display PROFIBUS-Interface

3 Display state of drive axis

4 Display state of camera calibration

5 Display auto check

B Edit Obstacles

E Fault

I Start up menu

H Fault HistoryP Parameters menu

S Shell

V Version Info

! Stop diagnosis

# Exit program

B Edit Obstacle 1 Display fixed obstacles

I Add obstacles

C Change obstacles

D Delete obstacles

S Save all sets of parameters

N New set of parameters

Y Copy set of parameters

L Show list of parameters

ESC Back to main screen

E Fault ESC Return to last selected display – page 1 to7




Appendix

7.1 Operation of CeCOMM menu

? Help for selected fault

H Fault History ESC Return to last selected display – page 1 to 7

I Commissioning menu 0 Set configuration and parameters

1 Determination of reflector orientation

2 Determination of minimum window size

3 Setting the alignment of camera

4 Calibrate hoist position for X camera direction

5 Calibrate hoist position for Y camera direction

6 Calibrate skew

7 Calibration of camera measurement

8 Fault simulation

9 Determination of limit speed

S Save all sets of parameters

? Help


P Parameters menu 1 Display trolley parameters

2 Display crane parameters

3 Display skew drives parameters

4 Display camera parameters

5 Display hoist position parameters

6 Display general parameters 1

7,8 Display parameters detour control

C Change parameters

D Set default values

F Search parameters

I Change IP address

L Show list of parameters

N New set of parameters

R Reload parameters

S Save all sets of parameters/areas

Y Copy set of parameters

T Title of set of parameters

? Help





Appendix

7.2 Order numbers

V Version Info Any key Return to last selected display

! Stop diagnosis Space Restart of diagnosis

7.2 Order numbers

Order number (MLFB) Description

6GA7200-2AA02-0AA0 CeSAR slewing crane basic control

6GA7200-2AA02-1AA0 CeSAR slewing crane advanced control

6GA7202-2AA20-0XX0

Camera for CeSAR slew swing anglemeasurement, 16 mm lens, aluminum casing, -25 to +60 °C

6GA7201-0AA04-0AA0 Reflector 700x640 mm, active, 1 to 40 m

simocrane cesar slewv0403 e

Documents