simocrane sc integrated - siemens...simocrane sc integrated 2 simatic s7 configuration 3...

Preface

System Description 1

Software Engineering for SIMOCRANE SC Integrated

2

SIMATIC S7 Configuration 3

Commissioning AddOn Software

4

General Information 5

SIMOCRANE

SC Integrated

Operating Instructions

Valid for Hardware: - SIMOTION D435 as of firmware V4.1.5.6 - SINAMICS as of firmware V2.5.1 - CenSOR M as of Board Revision V-MHPC-251D

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

Software: - SCOUT as of version V4.1.5.3 - SIMATIC CFC as of version V7.0.1.5 - SIMOCRANE Basic Technology: as of version V2.0 SP1 - JAVA as of version V1.0.0.11 - Sway Control as of version V5.2.4.39 - CenSOR M as of version V1.5.0.10 - CeCOMM as of version V4.4.1.16

04/2011 Edition V1.07-D

Safety information

These Operating Instructions contain information which you should observe to ensure your own personal safety as well as to protect the product and connected equipment. Notices referring to your personal safety are highlighted in the manual by a safety alert symbol; notices referring to property damage only have no 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 severe personal injury may result if proper precautions are not taken.

CAUTION

with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.

CAUTION

without safety alert symbol indicates that property damage may result if proper precautions are not taken.

NOTICE

indicates that an unwanted result or state may occur if the relevant instruction is not observed.

In the event of a number of levels of danger prevailing simultaneously, the warning corresponding to the highest level of danger is always used. A warning with a safety alert symbol indicating possible personal injury may also include a warning relating to material damage.

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

Qualified personnel

The relevant device/system may only be set up and operated in conjunction with this documentation. A device/system 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 to energize, ground, and tag device, systems, and circuits in accordance with established safety procedures. A further requirement is the successful completion of a commissioning training course of the Siemens AG.

Proper use

Note the following:

WARNING The device may only be used for the applications described in the catalog and the technical description, and only in conjunction with equipment or components from other manufacturers which have been approved or recommended by Siemens. Correct transport, storage, installation and assembly, as well as careful operation and maintenance, are required to ensure that the product operates safely and without faults.

Siemens AG Copyright © Siemens AG 2011 Automation and Drives Subject to change P.O. Box 48 48 80437 Nuremberg Germany

WARNING

The electronic Sway Control system is an aid during the transport of loads with almost complete elimination of swaying movements. The crane driver is still responsible for monitoring movements of the load on the crane 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 to persons or damage to objects. The functionality of the Sway Control system must be switched off and the crane operated manually without Sway Control until the fault has been corrected. If the fault cannot be corrected with the aid of the product manual, please contact the Siemens AG.

Trademarks

All designations with the trademark symbol ® are registered trademarks of Siemens AG. Other designations in this documentation may be trademarks whose use by third parties for their own purposes can violate the rights of the owner.

Disclaimer of liability

We have verified that the contents of this document correspond to the descriped hardware and software. However, since variance cannot be precluded entirely, we cannot guarantee full consistency. The information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Copyright © Siemens AG 2011 Automation and Drives Subject to change P.O. Box 48 48 80437 Nuremberg Germany

Preface Content

This document is part of the SIMOCRANE AddOnTechnology package. It describes the new "Sway Control", "2D-Trajectory" AddOn application solutions (basis: Sway Control) and "TLS Control" for cranes based on the SIMOCRANE Basic Technology.

Requirement (area of validity)

This manual is valid for the application with SIMOTION SCOUT in conjunction with technology package SIMOTION DCC as of version 4.1.4.1 and SINAMICS as of version 2.5.1, and SIMOCRANE Basic Technology as of version V2.0 SP1.

Additional information

Hotline and Internet addresses

If you have any technical questions, please contact our Hotline (worldwide):

A&D Technical Support:

Tel.: +49 (180) 50 50 222

Fax: +49 (180) 50 50 223

E–mail: [email protected]

Internet: http://www.siemens.de/automation/support-request

Siemens Internet address

The latest information about SIMOTION products, product support, and FAQs can be found on the Internet at:

http://www.siemens.de/simotion (German)

Product Support: http://support.automation.siemens.com/WW/view/de/10805436

The latest information about SINAMICS products, product support, and FAQs can be found on the Internet at:

http://www.siemens.de/sinamics (German)

Additional support

We also offer courses to help you familiarize yourself with the SIMOCRANE AddOnTechnology and its principle operation.

Please contact the Siemens AG in D-39104 Magdeburg, Listemannstrasse 10, Tel. +49 (391) 56871-10.

SIMOCRANE SC Integrated Operating Instructions, 04/2011 Edition, V1.06-D 5

mailto:[email protected]

http://www.siemens.de/automation/support-request

http://www.siemens.de/simotion

http://support.automation.siemens.com/WW/view/de/10805436

Table of contents

1 System Description.................................................................................................................................... 9 1.1 Introduction ....................................................................................................................................9 1.2 System Overview ...........................................................................................................................9 1.3 Scope of Delivery.........................................................................................................................14 1.4 Product Structure .........................................................................................................................15 1.5 Functional Scope .........................................................................................................................15

2 Software Engineering for SIMOCRANE SC Integrated............................................................................ 17 2.1 Software Structure .......................................................................................................................17 2.2 Sway Control Function Blocks .....................................................................................................29 2.3 Sway Control Applications ...........................................................................................................68 2.4 Configuration................................................................................................................................78

3 SIMATIC S7 Configuration..................................................................................................................... 121 3.1 Software Structure .....................................................................................................................121 3.2 Mode-independent Logic ...........................................................................................................123 3.3 Acceleration and Braking Behavior............................................................................................127 3.4 Basic Operating Modes..............................................................................................................128 3.5 Activation of the AddOn Technologies in the Basic Technology ...............................................138 3.6 Sway Control Configurations .....................................................................................................139 3.7 PROFIBUS Interface..................................................................................................................170

4 Commissioning AddOn Software ........................................................................................................... 197 4.1 Requirements.............................................................................................................................197 4.2 Ethernet communication ............................................................................................................197 4.3 Configuration of the AddOn Functions.......................................................................................202 4.4 CeCOMM commissioning software............................................................................................204 4.5 Camera Measuring System (only STS) .....................................................................................239 4.6 Commissioning Requirements for AddOn Systems...................................................................259 4.7 Sway Control Commissioning ....................................................................................................263 4.8 2D-Trajectory Commissioning....................................................................................................284 4.9 TLS Control Commissioning ......................................................................................................285 4.10 Alarm, Error and System Messages ..........................................................................................289


Table of contents

SIMOCRANE SC Integrated 8 Operating Instructions, 04/2011 Edition, V1.07-D

5 General Information ............................................................................................................................... 309 5.1 Maintenance and Service ..........................................................................................................309 5.2 Technical Data ...........................................................................................................................311 5.3 Parameters.................................................................................................................................321 5.4 Appendix ....................................................................................................................................360

System Description 1 1.1 Introduction

The technology module T300 with MASTERDRIVES drive for crane-specific technology was used in the previous crane application solution. Since mid-2007, the new sector solution SIMOCRANE Basic Technology in the IDT MC Cranes business area is available. The new platform based on a S7 + SIMOTION + SINAMICS hardware configuration contains the motion control of all main drives of a crane. The modular construction makes it possible to customize the system to the associated crane.

The AddOn technologies described in these operating instructions can be used with or without the SIMOCRANE Basic Technology:

Sway Control Eliminates load oscillations on container cranes and ship unloaders for the trolley through the specific influencing of the acceleration and braking actions.

2D-Trajectory Automatic or semi-automatic motion of the load on a path curve taking account of all blocked regions (e.g. container, crane design, etc.). The blocked regions can be transferred in various ways or learnt internally by "observing" the crane operator. Prerequisite is the "Sway Control" AddOn.

TLS Control Controls the so-called trim, list and skew positions of a spreader. The current positions of all four TLS cylinders can be saved as zero positions and approached again. An electronic Skew Control can also be activated.

Bay Profile Scanning Scans the container stacks during travel using a laser scanner and sends the collected data to the PLC.

1.2 System Overview

1.2.1 General Information

The AddOn functions are provided to augment new or extend existing crane controllers with or without Siemens drive technology.

Requirements

Use of a crane controller (PLC)

SIMOTION D435 for calculations and the control of the drives (/Ref. 3/ and /Ref. 4/)


System Description 1.2 System Overview

Sensors for the axes to be positioned when positioning is used, otherwise only for the hoisting gear

The AddOns are included as libraries in an existing SCOUT crane solution project. Depending on the AddOn and the variant, additional hardware may be required (e.g. camera, reflector, hoisting gear, laser, HMI, etc.) or various prerequisites must be satisfied.

Supplementary conditions

Each SIMOTION allows just one Sway Control system to be implemented (two independent trolleys are not possible). The AddOn technology uses parameter sets for the activation and control of the drives. Speeds, accelerations and limitations are stored permanently during the commissioning and can only be changed by switching the parameter set.

Note In the basic technology /Ref. 2/, in case of failure of a drive, e.g. Hoist_1 or Trolley_1, a continuation of the crane operation is possible only without 'Sway Control' AddOn technology.

System configuration

The following figure shows the communication paths between the individual components.

Fig. 1-1: Sway Control logical structure of the integrated (SIMOTION D) variant



Fig. 1-2: Component layout of the stand-alone (SIMOTION C) variant

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

The system receives the required process information via the PLC, the SIMOTION D (signals from the base technology and TO objects) and the camera (optional) as well as the HMI (optional) or operator controls. After processing, the calculated speed manipulated variables are forwarded to the drives via the TO objects.

1.2.2 Versions

Each movement of a crane with cable guides results in the load swaying and therefore a longer transport process. The task of the "Sway Control" and "TLS Control" AddOns is the prevention of these swaying motions. Together with "2D-Trajectory", they help relieve the crane operator and so optimize the transfer times.

Basically two different versions are possible for these AddOns:

Version with camera

Version without camera

1.2.2.1 Version with camera for container cranes

Swaying motions can be calculated and corrected using a mathematical oscillation mode. However, it is not possible to compensate swaying motions caused by external effects (e.g. wind or diagonal pull).

If a camera measuring system is used an optical contact-free measurement can also determine the hoisting height, swing angle and rotation angle parameters. The results are incorporated in the calculation model. The calculations are performed on the SIMOTION.



The resulting calculations are more accurate than for a system without camera and can also eliminate sway caused by external forces.

If the measuring signal of the camera fails, only the states of the model are used.

This is the preferred version for container cranes (STS).

The camera measuring system consists of:

Camera with lens and infra-red filter in protective housing with connection cable

Reflector with infra-red LEDs

that must be installed at various locations on the crane.

Fig. 1-3: Schematic representation of a container crane with Sway Control components when a camera

is used

Camera with lens system and infra-red filter

A camera with a 16 mm lens and an active reflector will be supplied for "seeing" systems as standard. If there are larger distances between the camera and the reflector, the 25 mm lens should be chosen. The camera is installed in a protective housing.

When an active infra-red reflector is used, the camera is also equipped with an IR filter. Therefore measuring errors caused by shadows and artificial lighting to be largely prevented.

Reflector

The reflector is a construction specially designed to handle vibrations that typically occur on cranes. The white areas of the active reflectors have an infra-red highlighted LED matrix. If necessary, the reflector can be fitted with heating to thaw snow or ice.

Application planning

A reflector will be detected very reliably the used lenses and reflector depend on the hoisting height of the crane. Up to the maximum recommended distance (Table 1-1) a reflector will be detected very reliable. When very good light conditions pertain, a reflector can be detected at 1.5 times the specified distance.

The relationship between the hoisting height, lens type and reflector size and the measuring accuracy of the measuring system is contained in the following Table 1-1:



Table 1-1 Measuring accuracy

Focal length of the lens 16 mm (standard) 25 mm Resolution (relative to the distance) 0,12 mm/m 0.08 mm/m Image length in the X direction 17° 11° Image length in the Y direction 13° 8° Measuring range in the X direction (relative to the distance)

292 mm/m 187 mm/m

Measuring range in the Y direction (relative to the distance)

216 mm/m 138 mm/m

Recommended maximum distance Reflector 500 x 500 up to 23 m up to 37 m Reflector 800 x 800 up to 35 m up to 55 m

Note When strong sunshine is prevailing, shadows can result on the reflector that cause restrictions of the TLS function. If the system is not able to stop the slewing motions within five periods, the crane operator should deactivate the TLS function because a safe functionality cannot be guaranteed.

Note When strong wind conditions are prevailing, the TLS function can act disruptively during the unloading action for the placement of containers. If the system is not able to stop the slewing motions within five periods, the crane operator should deactivate the TLS function because a safe functionality cannot be guaranteed.

1.2.2.2 Version without camera for ship unloader

In the version without camera, the Sway Control function is performed exclusively with the aid of an arithmetic model. Swaying caused by external forces cannot be corrected.

This is the preferred version for ship unloaders (GSU).


System Description 1.3 Scope of Delivery

1.3 Scope of Delivery The package for

"Sway Control" AddOn,

"2D-Trajectory" AddOn,

"TLS Control" AddOn, contains:

Hardware (optional for STS)

Camera - CenSOR M (Siemens AG, connection box) with Ethernet connection Lens: 16 mm or 25 mm Camera casing: Aluminum or stainless steel Current firmware version and operating system

Reflector 500x500 active or 800x800 active

Software

CD with: Commissioning software - CeCOMM (Siemens AG) Java Runtime AddOn DCC library and online help AddOn FB library and standard application Setup for installation of the DCC library CenSOR M Language files, para meter files Documentation

On the camera CenSOR M

License of the Siemens AG

oftware licenses

cope of delivery, two RT licenses are used for the AddOn technologies.

f the AddOn technologies, a

he license number and the delivery note number with which the Internet link

S

Depending on the s

SIMOCRANE SC integrated basic control for SIMOTION C and D

SIMOCRANE SC integrated AddOn control for SIMOTION C and D

Because the memory card (CF card) is not part of the scope of delivery olicense key must be created and transferred to the CF card. This is done using the supplied "Certificate of License".

This certificate contains twww.siemens.com/automation/license can be used to create a license key and copied to the CF card of the SIMOTION D. This enables the corresponding functionality of the AddOn technologies.


http://www.siemens.com/automation/license

System Description 1.4 Product Structure

1.4 Product Structure The software package contains an AddOn DCC library (e.g. DCC_SCHoist), an AddOn FB library (e.g. FB_HoistPLCToAddOn) and a complete standard application.

The AddOn DCC library comprises a collection of blocks that are implemented as "Drive Control Charts" (DCC) blocks. DCC is a representation which supports graphic configuring and interconnecting. The detailed functional scope of the AddOn DCC library is contained in Section 2.1.3. The blocks are already wired to each other and preconfigured in the standard application.

The AddOn FB library comprises a collection of blocks for the implementation of data exchange implemented as function blocks in "Structured Text" (ST). These blocks are called-up in the drive-oriented sequential control.

1.5 Functional Scope An overview of the AddOn modes and the dependencies on other systems and the associated functions is shown in the following tables.

Table 1-2 Overview of the AddOn modes

AddOn Contained functionality AddOn mode Requires license

Sway-controlled travel in manual mode

SC Speed Control Basic license

Sway Control Sway-controlled travel in automatic

and semi-automatic mode

Sway neutralization to load position

Sway neutralization to trolley position

SC Automatic

SC Semi Automatic

Advanced license

TLS Control TLS Control

Skew control

Basic license

2D-Trajectory

Sway-controlled travel in all AddOn modes

Hoist control with internal and external obstacle management

Internal target generator

SC Speed Control

SC Automatic

SC Semi Automatic

Advanced license

The following dependencies of the AddOns from other systems exist:


System Description 1.5 Functional Scope


Table 1-3 Dependency matrix

SIMATIC S7 Basic technology Commissioning tool

AddOn techn.

Sway Control X o X

2D-Trajectory X o X Sway Control

TLS Control X X

X - required, o - optional

Software Engineering for SIMOCRANE SC Integrated 2 2.1 Software Structure

2.1.1 Software structure

The software for the Sway Control consists of units that implement the sending and receiving of data between SIMATIC S7 and SIMOTION D (/Ref. 3/ and /Ref. 4/), and between SIMOTION D and the camera. The software also has a manipulated value channel for influencing the acceleration and speed change that was implemented with the DCC (Drive Control Chart) graphical programming language.

Table 2-1 Overview of the blocks in the AddOn DCC library

No. Function Brief description

1 General In the "DCC_SCCommon" block, all axis data and camera measured values are acquired concurrently. All data are grouped and the manipulated values are calculated. It also controls the communication to the CeCOMM commissioning tool. This block must be present.

2 Camera (only STS)

The "DCC_SCCamera" block makes data available for the communication with the camera and receives the camera measured values.

3 Trolley control The "DCC_SCTrolley" block controls the trolley in all basic modes. Creating the control signals influences the trolley behavior. The block then issues an actuator speed, etc.

4 Hoisting gear control

The "DCC_SCHoist" block controls the hoisting gear in all basic modes. Creating the control signals influences the hoisting gear behavior. The block then issues an actuator speed, etc.

5 Target generator

The "DCC_SCTargets" block is responsible for learning the target positions and their internal administration. Targets on the waterside are always learnt independently by observation. A parking, a lashing and several lane positions can also be learnt.

The correct function requires the use of the "DCC_SCTrolley" and "DCC_SCHoist" DCC blocks.

6 Obstacles The "DCC_SCObstacles" block can be used to transmit blocked regions considered in the "SC Automatic" AddOn mode.

Up to five blocked regions can be transferred simultaneously. When deleted, all previously transferred blocked regions will be removed.

7 TLS control The "DCC_SCTLS" block can be used to control the hydraulic cylinders


Software Engineering for SIMOCRANE SC Integrated 2.1 Software Structure

(only STS) of a container bridge. This allows travelling to the so-called trim, list and skew positions of a spreader. Sway Control functionality is integrated for the Skew Control.

8 Diagnostics The inputs and outputs for the CeCOMM diagnostic tool are controlled with the "DCC_SCDiag" block.



Fig. 2-1: Software structure (GSU without camera and TLS)

The "AddOn" MCC chart consists of the following receive blocks (see previous figure):



FB_CommonPLCToAddOn

FB_HoistPLCToAddOn

FB_TrolleyPLCToAddOn

FB_TLSPLCToAddOn (only STS)

FB_TargetsPLCToAddOn

FB_ObstaclePLCToAddOn and the send blocks:

FB_CommonAddOn ToPLC

FB_HoistAddOn ToPLC

FB_TrolleyAddOn ToPLC

FB_TLSAddOn ToPLC (only STS)

FB_TargetsAddOn ToPLC

FB_ObstacleAddOn ToPLC

The "Camera" MCC chart contains the following FB blocks (see previous figure):

FB_Receive_Analysis (only STS)

FB_Send_Preparation (only STS)

The "Sway Control" DCC chart consists of the following DCC blocks (see previous figure):

DCC_SCCommon

DCC_SCHoist

DCC_SCTrolley

DCC_SCTLS (only STS)

DCC_SCTargets

DCC_SCObstacle

DCC_SCCamera (only STS)

DCC_SCDiag

The following graphic shows how the "Sway Control" AddOn is generally activated and the "Sway Control" manipulated values are used.



Fig. 2-2: Sway Control for Hoist_1 structure



2.1.2 Structure of a function module

The structure of a function module consists of a unit with an MCC program. In cyclical operation, the receive blocks are performed first and then the send blocks. A separate unit with an MCC program is stored for the optional camera.

In the "AddOn" unit, the "AddOn MCC" program is executed according to the following sequence:

Processing in AddOn MCC

Fig. 2-3: Unit "AddOn", program sequence "AddOn MCC"



Fig. 2-4: Receive and send module (GSU without TLS)

The function blocks in the "Receive PLC" module read the PROFIBUS DP input area for the associated block and write it to the global variables.

The function blocks in the "Send PLC" module read the associated blocks from the global variables and write them to the PROFIBUS DP output area.

Only STS:

In the "Camera" unit, the "CameraMCC" program is executed:

Processing in CameraMCC

Fig. 2-5: Unit "Camera", program sequence "CameraMCC"

Fig. 2-6: Camera module

The "Receive" block prepares the data and analyses this once it has been received. The data is processed in the "DCC_SCCommon" DCC block. The "Send" block prepares the data before it is sent.

2.1.3 Control structure

The control structure is constructed so that the function blocks implement the communication between SIMATIC S7 ↔ SIMOTION and camera ↔ SIMOTION. The data received from the "Receive" blocks,



is prepared and forwarded to the appropriate DCC blocks. The data subsequently forwarded to the "Send" blocks is evaluated and calculated there.

Fig. 2-7: AddOn control structure in the new SIMOTION D / SINAMICS platform (GSU without TLS and

camera)



2.1.4 Global variables – Connection between the components

2.1.4.1 Overview

The function blocks are connected to the S7 using global variables in the I/O area.

The connection of the function blocks to the DCC blocks and from the basic technology to the DCC blocks is made using unit-global variables.

To achieve a high control quality and eliminate runtime loss, the manipulated values for the trolley and the hoisting gear are applied directly to the TO objects for the individual axes. The current position values are also fetched directly from the drive (see Sections 2.2.1.3 and 2.2.1.4).

The signals from the basic technology, and from and to the technology objects are described in Sections 2.1.4.4 and 2.1.4.5.

Note Although some signals that come from the basic technology or form the interface to the technology objects have data type LREAL, they are processed as DINT data format in the "Sway Control" AddOn. Consequently, these signals have only the value range of the DINT data format, i.e. -2**31 … +2**31-1.

Note If the "AddOn" and "Camera" (optional) MCC unit has been imported, the unit-global variables are already created and the connections pulled automatically once an AddOn DCC block is added to the "Sway Control" DCC chart.

Using an example, the following figure shows the signal flow from the hoist block of the S7 to the "DCC_SCHoist" (Release) DCC block and back (Ready = answer from Release).



Fig. 2-8: Example of the signal flow between the S7 and the DCC block

The detailed descriptions of the connections for function and DCC blocks are contained in Sections 2.2.1 and 2.2.2. This description makes it possible to track the connections from MCC programs to DCC blocks.

2.1.4.2 Normalizations

For SIMOCRANE SC Integrated, a normalization (P204) is only required for the TLS actuator speed. The reference value is P183.

2.1.4.3 Naming scheme for the global variables

The global variables serve as connection elements between the components and have the following structure:



Section Description Example

1 Specifies which DCC library block is involved. Trolley, Hoist, Common, TLS, Targets, Obstacle, Camera

2 Source of the variables. BT, SC, PLC, CAM

3 Meaning of the variables. This is identical with the name on the DCC blocks and on the function blocks.

e.g. Brake_Closed, Active

Example:

2.1.4.4 AddOn technology –basic technology

Basic technology AddOn technology

The following signals are forwarded via unit-global variables of the "AddOn" MCC unit from the basic technology /Ref. 2/ to the AddOn technology:

Table 2-2: Basic technology variables AddOn technology

Tag Format Meaning Unit Range of values

trolley_BT_S_Set_TR_Extern LREAL

External target position from the basic technology for the trolley

± mm -2**31..2**31-1

trolley_BT_V_Set_TR LREAL Set velocity for the trolley from the basic technology

mm/s

Normalized to the maximum actuator speed (P0) of the trolley from the parameter set

-2**31..2**31-1

hoist_BT_S_Set_HO_Extern LREAL

External target position from the basic technology for the hoisting gear

± mm -2**31..2**31-1

hoist_BT_V_Set_HO LREAL

Set velocity for the hoisting gear from the basic technology

mm/s

Normalized to the maximum actuator speed (P40) of the hoisting gear from the parameter set

-2**31..2**31-1

hoist_BT_Field_Weak REAL Limitation from the basic technology for field weakening

% 0..100% of the maximum actuator speed (P40) of the



Tag Format Meaning Unit Range of values hoisting gear from the parameter set

-2**31..2**31-1

2.1.4.5 AddOn technology - TO objects

TO object AddOn technology

Table 2-3: TO object variables AddOn technology


TO_Trolley_1. positioningstate.actualposition

LREAL Current position of the trolley

mm -2**31..2**31-1

TO_Hoist_1. positioningstate.actualposition

LREAL Current position of the hoisting gear

mm -2**31..2**31-1

TO_Trolley_1. motionstatedata.actualvelocity

LREAL Current velocity of the trolley

mm/s -2**31..2**31-1

TO_Hoist_1. motionstatedata.actualvelocity

LREAL Current velocity of the hoisting gear

mm/s -2**31..2**31-1

AddOn technology TO object

Table 2-4: AddOn technology variables TO object


TO_Trolley_1 Defaultmotionin.velocity

LREAL Actuator speed of the trolley

mm/s

Normalized to the maximum speed (P0) of the trolley from the parameter set

-2**31..2**31-1

TO_Hoist_1 Defaultmotionin.velocity

LREAL Actuator speed of the hoisting value

mm/s

Normalized to the maximum speed (P40) of the hoisting gear from the parameter set

-2**31..2**31-1

2.1.4.6 Polarity of speeds and position values

The following assignments are used for the polarities of speeds and position values for the individual axes:


Software Engineering for SIMOCRANE SC Integrated 2.2 Sway Control Function Blocks

Axis Direction of motion Polarities

Raise Positive speed Increasing position values

Hoist

Lower Negative speed Decreasing position values

Right Positive speed Increasing position values

Gantry

Left Negative speed Decreasing position values

Forwards (to the waterside)

Positive speed Increasing position values

Trolley Backwards (to the landside)

Negative speed Decreasing position values

Raise Positive speed Increasing position values

Boom

Lower Negative speed Decreasing position values

2.2 Sway Control Function Blocks

2.2.1 AddOn DCC library

2.2.1.1 General Information

Note The source code of every DCC block is closed. A license for the SIMOCRANE AddOn technology is required to use the AddOn DCC library. If an under-licensing is determined during the startup, only a manual operation without Sway Control is possible.

The naming scheme of the AddOn DCC blocks conforms to the naming scheme of the SIMOCRANE Basic Technology /R1/.

If not otherwise noted, then the following statements apply to all DCC blocks.

Firmware version

SIMOTION Drive Based (D4x5): Firmware V4.1.4.1 or higher

SINAMICS: Firmware V2.5.1 or higher

Configuration

The DCC blocks in "Sway Control" operate in the sampling time of the SIMOTION interpolator cycle (T2).



2.2.1.2 DCC_SCCommon

Icon

Brief description

The function block contains basic functions for the DCC blocks and the "Sway Control", "TLS" and "2D-Trajectory" functions. It must always be used.

Operating principle

All data is grouped and the manipulated values are calculated in this block. It also writes and reads the buffers for the communication to the "CeCOMM" commissioning tool.

The three last outputs of the block are hidden in the default setting. They specify memory locations and buffer sizes for the Java communication. Their comments must not be changed.

Connections

The DCC block inputs are connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "FB_CommonPLCToAddOn" block. The DCC block outputs are interconnected with the inputs of the "FB_CommonAddOn ToPLC" block using unit-global variables.

Table 2-5: DCC_SCCommon connections

Name Type DefaultData type

"AddOn" unit-global variables

Meaning

iParSet IN 1 SINT common_PLC_ ParSet

Request Parameter set

bNo_Wait_Pos IN 1 BOOL common_PLC_ No_Wait_Pos

Request Do not use wait position

bHoist_Man IN 0 BOOL common_PLC_ Hoist_Man

Hoisting gear manual

bLocked_Bit0 IN 0 BOOL common_PLC_ Locked_Bit0

Locking state of the spreader

bLocked_Bit1 IN 0 BOOL common_PLC_ Locked_Bit1

Locking state of the spreader

bSlackrope IN 0 BOOL common_PLC_ slackrope

Slack rope



Name Data "AddOn" unit-

Type Default Meaning type global variables

bBayscanner_Valid IN 0 BOOL common_PLC_ Bayscanner_Valid

Use Bay scanner

bLearn_Profile_On IN 0 BOOL common_PLC_ Learn_Profile_On

Request Learn height profile on the waterside

bLearn_Profile_Reset IN 0 BOOL common_PLC_ Learn_Profile_Reset

Request Initialize height profile on the waterside

bDig_Hoist_Dist_Corr IN 0 BOOL common_PLC_ Dig_Hoist_Dist_Corr

Digital center of gravity offset

bStart_2D_Calc IN 0 BOOL common_PLC_ Start_2D_Calc

Start of the 2D calculation

bSpreaders_Coupled IN 0 BOOL common_PLC_ Spreaders_Coupled

Spreaders coupled

iLoad IN 0 INT common_PLC_ Load

Load [10 kg]

iValue_Bayscanner IN 0 DINT common_PLC_ Value_Bayscanner

Bay scanner

iCount_Bayscanner IN 0 DINT common_PLC_ Count_Bayscanner

Numerator for Bay scanner

iDS_Width IN 5000 INT common_PLC_ DS_Width

Overall width of the double-spreader operation

iParSet_OUT OUT 1 SINT common_SC_ ParSet_OUT

Answer Parameter set

bNo_Wait_Pos_OK OUT 0 BOOL common_SC_ No_Wait_Pos_OK

Answer Do not use wait position

bLearn_Profile_On_OK

OUT 0 BOOL common_SC_ Learn_Profile_On_OK

Answer Learning curve active

bLearn_Profile_Reset_OK

OUT 0 BOOL common_SC_ Learn_Profile_Reset_OK

Answer Learning curve reset

bStart_Auto_OK OUT 0 BOOL common_SC_ Start_Auto_OK

Automatic must not be started

bHoist_TakeOver_OK OUT 0 BOOL common_SC_ Hoist_TakeOver_OK

Manual hoisting gear takeover is possible





bOpen_Grab OUT 0 BOOL common_SC_ open_Grab

Open grab

bChange_Target OUT 0 BOOL common_SC_Change_Target

Only GSU: Change target

bFault1 OUT 0 DWORD common_SC_error1 Fault word 1

bFault2 OUT 0 DWORD common_SC_error2 Fault word 2

bInfo_No_Auto_Start OUT 0 DWORD common_SC_ Info_No_Auto_Start

Data for user output

bError OUT 0 BOOL Error bit from the block

iErrorID OUT 0 DINT Error number from the block

Error messages

If an error occurs, output "boError" is set and the error number is displayed at output "iErrorID" (for description and help, refer to Section 4.10.5.3). If several errors are present, the oldest error will be displayed.

2.2.1.3 DCC_SCHoist

Icon



Brief description

The block controls the hoisting gear in all basic modes.

Operating principle

Creating the control signals allows the hoisting gear to be influenced. The block then issues an actuator speed, etc.

Connections

The DCC block inputs are connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "FB_HoistPLCToAddOn" block. The DCC block outputs are interconnected with the inputs of the "FB_HoistAddOn ToPLC" block using unit-global variables.

Table 2-6: DCC_SCHoist connections

Name Type Default Data type


Meaning

bRelease IN 0 BOOL hoist_PLC_ Release

Enable

bTravel IN 0 BOOL hoist_PLC_ Travel

Travel signal

bOM_Pos IN 0 BOOL hoist_PLC_ OM_Pos

Positioning basic mode

bOM_Speed IN 0 BOOL hoist_PLC_ OM_Speed

Speed control basic mode

bOM_Hoist_Control IN 0 BOOL hoist_PLC_ OM_Hoist_Control

Hoist control basic mode

bLS_UP IN 1 BOOL hoist_PLC_ LS_UP

Limit switch up

bLS_DN IN 1 BOOL hoist_PLC_ LS_DN

Limit switch down

bPreLS_UP IN 1 BOOL hoist_PLC_ PreLS_UP

Prelimit switch up

bPreLS_DN IN 1 BOOL hoist_PLC_ PreLS_DN

Prelimit switch down

bBrake_Closed IN 1 BOOL hoist_PLC_ Brake_Closed

Brake closed

iOverride IN 100 INT Hoist_PLC_Override Override

rField_Weak IN 100 REAL Hoist_BT_ Field_Weak

Field weakening

rS_Act_HO IN 0 LREALTO_Hoist_1 positioningstate. actualposition

Current hoisting position

rS_Set_HO_Extern IN 0 LREALhoist_BT_ S_Set_HO_Extern

Target position



Name Type Data "AddOn" unit-

Default Meaning type global variables

rV_Act_HO IN 0 LREALTO_Hoist_1 motionstatedata. actualvelocity

Current hoisting gear velocity

rV_Set_HO IN 0 LREALhoist_BT_ V_Set_HO

Set velocity

bReady OUT 0 BOOL hoist_SC_ Ready

Enable

bActive OUT 0 BOOL hoist_SC_ Active

Active

bPos_Completed OUT 0 BOOL hoist_SC_ Pos_Completed

Positioning

bTravel_UP OUT 0 BOOL hoist_SC_ Travel_UP

Raise

bTravel_DN OUT 0 BOOL hoist_SC_ Travel_DN

Lower

rV_Pos_HO OUT 0 LREALTO_Hoist1 Defaultmotionin. velocity

Actuator speed

rA_Pos_HO OUT 0 LREAL - Actuator acceleration



Error messages




2.2.1.4 DCC_SCTrolley

Icon

Brief description

The block controls the trolley in all basic modes.

Operating principle

Creating the control signals allows the trolley to be influenced. The block then issues an actuator speed, etc.

Connections

The DCC block inputs are connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "FB_TrolleyPLCToAddOn" block. The DCC block outputs are interconnected with the inputs of the "FB_TrolleyAddOn ToPLC" block using unit-global variables.

Table 2-7: DCC_SCTrolley connections



Meaning

bRelease IN 0 BOOL trolley_PLC_ Release

Request release

bTravel IN 0 BOOL trolley_PLC_ Travel

Travel signal

bOM_Pos IN 0 BOOL trolley_PLC_ OM_Pos

Positioning basic mode

bOM_Speed IN 0 BOOL trolley_PLC_ OM_Speed

Speed control basic mode

bOM_Load_Pos IN 0 BOOL trolley_PLC_ OM_Load_Pos

Sway-neutralization to load position basic mode

bOM_Trolley_Pos IN 0 BOOL trolley_PLC_ OM_Trolley_Pos

Sway-neutralization to trolley position basic mode





bOM_Hoist_Control IN 0 BOOL trolley_PLC_ OM_Hoist_Control

Hoist control basic mode

bSC_ON IN 0 BOOL trolley_PLC_ SC_ON

Sway Control On

bLS_FW IN 1 BOOL trolley_PLC_ LS_FW

Limit switch forward

bLS_BW IN 1 BOOL trolley_PLC_ LS_BW

Limit switch backward

bPreLS_FW IN 1 BOOL trolley_PLC_ PreLS_FW

Prelimit switch forward

bPreLS_BW IN 1 BOOL trolley_PLC_ PreLS_BW

Prelimit switch backward

bBrake_Closed IN 1 BOOL trolley_PLC_ Brake_Closed

Brake closed

bSC_When_Stop IN 0 BOOL trolley_PLC_ SC_When_Stop

Sway Control only when stopping

bControlled_Stop IN 0 BOOL trolley_PLC_ Controlled_Stop

Controlled stop

bFlying IN 0 BOOL trolley_PLC_ Flying

On-the-fly unloading

iOverride IN 100 INT trolley_PLC_ Override

Override

rS_Act_TR IN 0 LREALTO_Trolley_1 positioningstate. actualposition

Current trolley position

rS_Set_TR_Extern IN 0 LREALtrolley_BT_ S_Set_TR_Extern

Target position

rV_Act_TR IN 0 LREALTO_Trolley_1 motionstatedata. actualvelocity

Current trolley velocity

rV_Set_TR IN 0 LREALtrolley_BT_ V_Set_TR

Set velocity

bReady OUT 0 BOOL trolley_SC_ Ready

Answer release

bActive OUT 0 BOOL trolley_SC_ Active

Active

bPos_Completed OUT 0 BOOL trolley_SC_ Pos_Completed

Positioning

bSC_Completed OUT 0 BOOL trolley_SC_ SC_Completed

Sway-neutralized

bTravel_FW OUT 0 BOOL trolley_SC_ Forwards





Travel_FW

bTravel_BW OUT 0 BOOL trolley_SC_ Travel_BW

Backwards

bSC_State OUT 0 BOOL trolley_SC_ SC_State

0 = Sway Control is active

1 = Sway Control is not active

iLoad_Defl_TR OUT 0 INT trolley_SC_ Load_Defl_TR

Load deflection

rV_Pos_TR OUT 0 LREALTO_Trolley_1 Defaultmotionin. velocity

Actuator speed

rA_Pos_TR OUT 0 LREAL - Actuator acceleration



Error messages


2.2.1.5 DCC_SCTLS (only STS)

Icon



Brief description

This block can be used to control the TLS hydraulic cylinders of a container bridge.

Operating principle

It is possible to control the trim, list and skew, and to activate an automatic Skew Control. A required rotational position (skew) can be specified here as angle. A current TLS position can also be saved and traveled to again.

Connections

The DCC block inputs are connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "FB_TLSPLCToAddOn" block. The DCC block outputs are interconnected with the inputs of the "FB_TLSAddOn ToPLC" block using unit-global variables.

Table 2-8: DCC_SCTLS connections

Name Type De-fault

Data type


Meaning

bTrim_RH IN 0 BOOL tls_PLC_ Trim_RH

Trim right

bTrim_LH IN 0 BOOL tls_PLC_ Trim_LH

Trim left

bList_WS IN 0 BOOL tls_PLC_ List_WS

List waterside

bList_LS IN 0 BOOL tls_PLC_ List_LS

List landside

bSkew_CW IN 0 BOOL tls_PLC_ Skew_CW

Skew right

bSkew_CCW IN 0 BOOL tls_PLC_ Skew_CCW

Skew left

bMove_To_Zero IN 0 BOOL tls_PLC_ Move_To_Zero

Travel to zero position

bSave_Pos_As_Zero IN 0 BOOL tls_PLC_ Save_Pos_As_Zero

Define current position as zero position

bNo_Skew IN 0 BOOL tls_PLC_ No_Skew

Correct skew

bSkew_Control IN 0 BOOL tls_PLC_ Skew_Control

Automatic Skew Control

bUse_Ext_Skew IN 0 BOOL tls_PLC_ Use_Ext_Skew

Use external rotation

iSpreader_Width IN 0 SINT tls_PLC_ Spreader_Width

Spreader width

iS_Skew_Extern IN 0 DINT tls_PLC_ S_Skew_Extern

Required skew

rS_Act_TR IN 0 LREALTO Trolley_1 positioningstate.

Trolley position



Name De- Data "AddOn" unit-

Type Meaning fault type global variables

actualposition

rS_Act_HO IN 0 LREALTO Hoist_1 positioningstate. actualposition

Hoisting position

iPos_Cyl_A IN 0 DINT tls_PLC_Pos_Cyl_A Cylinder A position

iPos_Cyl_B IN 0 DINT tls_PLC_Pos_Cyl_B Cylinder B position

iPos_Cyl_C IN 0 DINT tls_PLC_Pos_Cyl_C Cylinder C position

iPos_Cyl_D IN 0 DINT tls_PLC_Pos_Cyl_D Cylinder D position

bMove_Out_Cyl_A OUT 0 BOOL tls_SC_ Move_Out_Cyl_A

Move cylinder A out

bMove_Out_Cyl_B OUT 0 BOOL tls_SC_ Move_Out_Cyl_B

Move cylinder B out

bMove_Out_Cyl_C OUT 0 BOOL tls_SC_ Move_Out_Cyl_C

Move cylinder C out

bMove_Out_Cyl_D OUT 0 BOOL tls_SC_ Move_Out_Cyl_D

Move cylinder D out

bMove_In_Cyl_A OUT 0 BOOL tls_SC_ Move_In_Cyl_A

Move cylinder A in

bMove_In_Cyl_B OUT 0 BOOL tls_SC_ Move_In_Cyl_B

Move cylinder B in

bMove_In_Cyl_C OUT 0 BOOL tls_SC_ Move_In_Cyl_C

Move cylinder C in

bMove_In_Cyl_D OUT 0 BOOL tls_SC_ Move_In_Cyl_D

Move cylinder D in

bOil_Pressure1 OUT 0 BOOL tls_SC_ Oil_Pressure1

Oil pressure 1

bOil_Pressure2 OUT 0 BOOL tls_SC_ Oil_Pressure2

Oil pressure 2

bZero_Reached OUT 0 BOOL tls_SC_ Zero_Reached

Zero position reached

bSkew_Removed OUT 0 BOOL tls_SC_ Skew_Removed

Skew eliminated

iSpeed_Cyl_A OUT 0 INT tls_SC_ Speed_Cyl_A

Cylinder A speed

iSpeed_Cyl_B OUT 0 INT tls_SC_ Speed_Cyl_B

Cylinder B speed

iSpeed_Cyl_C OUT 0 INT tls_SC_ Speed_Cyl_C

Cylinder C speed

iSpeed_Cyl_D OUT 0 INT tls_SC_ Cylinder D speed





Speed_Cyl_D



Error messages


2.2.1.6 DCC_SCTargets

Icon

Brief description

The block is responsible for the internal administration of the target positions. If it is omitted, although automatic travel is also possible, the targets must then be specified by the PLC.

Operating principle

The correct function also requires the use of the "DCC_SCTrolley" and "DCC_SCHoist" AddOn DCC blocks. The block can also be used to learn a parking, a lashing and several lane positions.

It also controls the administration of the learnt target positions integrated in the Sway Control system. Targets on the waterside are always learnt independently by observation.

Connections

The DCC block inputs are connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "FB_TargetsPLCToAddOn" block. The DCC block outputs are interconnected with the inputs of the "FB_TargetsAddOn ToPLC" block using unit-global variables.



Table 2-9: DCC_SCTargets connections

Name Type De-fault

Data type


Meaning

bUse_Lash_Platf IN 0 BOOL targets_PLC_ Use_Lash_Plat

Use lash platform

bStack_Form_Bit0 IN 1 BOOL targets_PLC_ Stack_Form_Bit0

Control bit 0

bStack_Form_Bit1 IN 1 BOOL targets_PLC_ Stack_Form_Bit1

Control bit 1

iLane_Ship_Load IN 0 SINT targets_PLC_ Lane_Ship_Load

Load lane to the ship

iLane_Ship_Unload IN 0 SINT targets_PLC_ Lane_Ship_Unload

Unload lane to the ship

bNo_Ship_Load IN 0 BOOL - No further loading of the ship

bNo_Ship_Unload IN 0 BOOL - No further unloading of the ship

bCycling IN 0 BOOL targets_PLC_ Cycling

Cyclic operation

bOffset_To_Land IN 0 BOOL targets_PLC_ Offset_To_Land

Direction offset in the land direction

bOffset_To_Water IN 0 BOOL targets_PLC_ Offset_To_Water

Direction offset in the water direction

bLearn_Lash_Platf IN 0 BOOL targets_PLC_ Learn_Lash_Platf

Learn current position as lashing platform

bLearn_Park_Pos IN 0 BOOL targets_PLC_ Learn_Park_Pos

Learn current position as parking position

iLearn_Pos_Lane IN 0 SINT targets_PLC_ Learn_Pos_Lane

Assign current position to a truck lane

bUse_Extern_Targets IN 0 BOOL targets_PLC_ Use_Extern_Targets

Use target position from PLC

bDirection_Land OUT 0 BOOL targets_SC_ Direction_Land

Target lies in the land direction

bDirection_Water OUT 0 BOOL targets_SC_ Direction_Water

Target lies in the water direction

iTarget_Trolley OUT 0 DINT - Target coordinates for the trolley

iTarget_Hoist OUT 0 DINT - Target coordinates for the hoisting gear

iLane_Load_OK OUT 0 SINT targets_SC_ Lane_Load_OK

Load lane to the ship

iLane_Unload_OK OUT 0 SINT targets_SC_ Unload lane to the ship





Lane_Unload_OK

bPos_Saved OUT 0 BOOL targets_SC_ Pos_Saved

Saving the positions was successful



Error messages


2.2.1.7 DCC_SCObstacles

Icon

Brief description

This block can be used to transfer as many as 200 external variable blocked regions to the Sway Control block. The functionality of the blocked regions is described in Section 2.3.3.

Operating principle

Five blocked regions can be transferred simultaneously. When deleted, all previously transferred blocked regions will be removed.

Connections

The DCC block inputs are connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "FB_ObstaclesPLCToAddOn" block. The DCC block outputs are interconnected with the inputs of the "FB_ObstaclesAddOn ToPLC" block using unit-global variables.



Table 2-10: DCC_SCObstacles connections

Name Type De-fault

Data type


Meaning

iSet1_Tr1 IN 0 DINT

obstacle_PLC_ Set1_Tr1

Trolley position 1 - blocked region 1

iSet1_Tr2 IN 0 DINT



iSet1_Hoist IN 0 DINT

obstacle_PLC_ Set1_Hoist

Hoisting position - blocked region 1

iSet2_Tr1 IN 0 DINT



iSet2_Tr2 IN 0 DINT






iSet3_Tr1 IN 0 DINT



iSet3_Tr2 IN 0 DINT






iSet4_Tr1 IN 0 DINT



iSet4_Tr2 IN 0 DINT






iSet5_Tr1 IN 0 DINT



iSet5_Tr2 IN 0 DINT






bPrg_Obst IN 0 BOOL obstacle_PLC_ Pgr_Obst

Request Accept blocked regions

bDel_Obst IN 0 BOOL obstacle_PLC_ Del_Obst

Request Delete blocked regions

iRet1_Tr1 OUT 0 DINT - Trolley position 1 - blocked region 1


iRet1_Hoist OUT 0 DINT - Hoisting position - blocked





region 1



iRet2_Hoist OUT 0 DINT - Hoisting position - blocked region 2










bPrg_Obst_OK OUT 0 BOOL obstacle_SC_ Prg_Obst_OK

Answer Blocked regions transferred

bObst_Deleted OUT 0 BOOL obstacle_SC_ Obst_Deleted

Answer Blocked regions deleted

iNumber_Obst OUT 0 INT obstacle_SC_ Number_Obst

Number of blocked regions



Error messages




2.2.1.8 DCC_SCCamera (only STS)

Icon

Brief description

The block makes data available for the communication with the camera and accepts the camera measured values.

Operating principle

The block does not communicate directly with the camera. The "FB_Receive_Analysis" and "FB_Send_Preparation" FB blocks are required for this in the ST program. The implementation of the communication to the camera and the integration in the execution system are described in Sections 4.2.2 and 2.1.2.

Connections

The DCC block inputs are connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "FB_Receive_Analysis" block. The "iHoist_Height_PLC" DCC block output is interconnected with the "FB_Send_Preparation" block input using a unit-global variable. This signal is transferred to the camera with a UDP message frame via Ethernet. The other DCC block outputs are connected with the inputs of the DCC block using retentive unit-global variables.

Table 2-11: DCC_SCCamera connections

Name Type De-fault

Data type

"Camera" unit-global variables

Meaning

bCamera_OK IN 0 BOOL camera_CAM_ Camera_OK

Camera OK

iX_Pos IN 0 DINT camera_CAM_X_Pos Deflection in X direction

iV_X IN 0 DINT camera_CAM_V_X Swaying speed in X direction

iY_Pos IN 0 DINT camera_CAM_Y_Pos Deflection in Y direction

iV_Y IN 0 DINT camera_CAM_V_Y Swaying speed in Y direction

iSkew IN 0 DINT camera_CAM_Skew Reflector skew

iV_Skew IN 0 DINT camera_CAM_V_Skew Skew speed



Name De- Data "Camera" unit-global

Type Meaning fault type variables

iHoist_Height IN 0 DINT camera_CAM_Hoist_ Height

Hoisting position (measured by the camera)

uIn_Addr_1 IN 192 USINT camera_SC_Addr [0] IP address of the camera (part 1)




uIn_Port IN 8500 UINT camera_SC_Port Camera port

iHoist_Height_PLC OUT 0 DINT camera_SC_ Hoist_Height_PLC

Transfer hoisting position from the PLC

Name Type De-fault

Data type

"Camera" retentive unit-global variables

Meaning

uOut_Addr_1 OUT 192 USINT camera_SC_Addr [0] IP address of the camera (part 1)




uOut_Port OUT 8500 UINT camera_SC_Port Camera port

bCamera_Valid OUT Camera signal valid



Error messages




2.2.1.9 DCC_SCDiag

Icon

Brief description

The block controls the inputs and outputs for the CeCOMM diagnostic tool.

Operating principle

WARNING This block must be called after the "DCC_SCCommon" block!

This block may not operate in the T1 execution level. The task runtime must be at least 5 ms. The block can require up to 4 ms computation time.

Connections

The inputs and outputs of the DCC block do not have to be connected. They are connected internally with the "DCC_SCCommon" block.

Table 2-12: DCC_SCDiag connections

Name Type De-fault

Data type


Meaning

bDiag_ON IN 1 BOOL Diagnostics ON

iStatus OUT 0 INT

Diagnostic status see below

Diagnostic status

1 – Diagnostics are being performed 2 – Waiting for the controller 3 – Block switched off 4 – Move diagnostics to slower task 5 – Move diagnostics to execution system behind the controller 6 – The controller has required too much computation time



2.2.2 AddOn FB library


The source code of each FB block is open for customer-specific adaptations.

The naming scheme of the AddOn function blocks conforms to the naming scheme of the SIMOCRANE Basic Technology /Ref 2/.

If not otherwise explained, the following statements apply to all ST function blocks.

Firmware version

SIMOTION Drive Based (D4x5): Firmware V4.1.4.1 or higher

SINAMICS: Firmware V2.5.1 or higher

Call

The function blocks must be called in a cyclical task.

2.2.2.2 FB_CommonPLCToAddOn

Icon (FBD representation)

Task

The "FB_CommonPLCToAddOn" block reads the input area from the PROFIBUS DP for the Common block and separates the provided array into words and bits.

Connections

The outputs must be connected using unit-global variables of the "AddOn" MCC unit with the inputs of the "DCC_SCCommon" DCC block.



Table 2-13: FB_CommonPLCToAddOn connections

Name Type De-fault

Data type


Meaning

Common_IO_PIW IN - ARRAY [0..11] OF word

AddOn _common_ receive (I/O-Global)

Input array for the Common block (see Fig. 2-24)

b16_STW1 OUT 0 WORD - Control word 1 not separated into individual bits

bo_STW1_No_Wait_Pos OUT 1 BOOL common_PLC_ No_Wait_Pos

Bit 2 of control word 1

bo_STW1_Hoist_Man OUT 0 BOOL common_PLC_ Hoist_Man


bo_STW1_Locked_Bit0 OUT 0 BOOL common_PLC_ Locked_Bit0


bo_STW1_Locked_Bit1 OUT 0 BOOL common_PLC_ Locked_Bit1


bo_STW1_Slackrope OUT 0 BOOL common_PLC_ slackrope


bo_STW1_Bayscanner_Valid OUT 0 BOOL common_PLC_ Bayscanner_Valid


bo_STW1_Learn_Profile_On OUT 0 BOOL common_PLC_ Learn_Profile_On


bo_STW1_Learn_Profile_Reset OUT 0 BOOL common_PLC_ Learn_Profile_ Reset


bo_STW1_Dig_Hoist_Dist_Corr OUT 0 BOOL common_PLC_ Dig_Hoist_Dist_ Corr


bo_STW1_Start_2D_Calc OUT 0 BOOL common_PLC_ Start_2D_Calc


bo_STW1_Spreaders_Coupled OUT 0 BOOL common_PLC_ Spreaders_Coupled


i16Load OUT 0 INT common_PLC_ Load

Weight of the load

i32Value_Bayscanner OUT 0 DINT common_PLC_ Value_Bayscanner

Bay scanner value

i32Count_Bayscanner OUT 0 DINT common_PLC_ Count_Bayscan

Bay scanner counter



Name Type De-fault

Data type


Meaning

ner

i8ParSet OUT 1 SINT common_PLC_ ParSet

Parameter set

i16DS_Width OUT 5000 INT common_PLC_ DS_Width

Overall width of the double-spreader operation

Error messages

None

2.2.2.3 FB_CommonAddOn ToPLC


Task

The "FB_CommonAddOn ToPLC" writes the Common block to the PROFIBUS DP output area.

Connections

The inputs must be connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "DCC_SCCommon" DCC block.

Table 2-14: FB_CommonAddOn ToPLC connections

Name Type De-fault

Data type "AddOn" unit-global variables

Meaning

bo_ZSW1_No_Wait_Pos_OK IN 0 BOOL common_SC_ No_Wait_Pos_OK

Bit 2 of status word 1

bo_ZSW1_Learn_Profile_On_OK

IN 0 BOOL common_SC_ Learn_Profile_ On_OK


bo_ZSW1_Learn_Profile_Reset_OK

IN 0 BOOL common_SC_ Learn_Profile_




Name Type "AddOn" unit-

De-Data type Meaning global

fault variables Reset_OK

bo_ZSW1_Start_Auto_OK IN 0 BOOL common_SC_ Start_Auto_OK


bo_ZSW1_Hoist_TakeOver_OK IN 0 BOOL common_SC_ Hoist_TakeOver_OK


bo_ZSW1_Open_Grab IN 0 BOOL common_SC_ Open_Grab


bo_ZSW1_Change_Target IN 0 BOOL Common_SC_Change_Target


b32Fault1 IN 0 DWORD common_SC_ Fault1

Fault area 1

b32Fault2 IN 0 DWORD common_SC_ Fault2

Fault area 2

b32Info_No_Auto_Start IN 0 DWORD common_SC_ Info_No_Auto_ Start

Information area for automatic start

i8ParSet_OUT IN 0 SINT common_SC_ ParSet_OUT

Return value for parameter set

Common_IO_PQW OUT - ARRAY [0..11] OF word

AddOn _common_ send (I/O-Global)

Output array for the Common block (see Fig. 2-24)

Error messages

None



2.2.2.4 FB_HoistPLCToAddOn


FB_HoistPLCToAddOn

Hoist_IO_PIW b16_STW1bo_STW1_Release

bo_STW1_Travelbo_STW1_OM_Pos

bo_STW1_OM_Speedbo_STW1_OM_Hoist_Control

bo_STW1_LS_UPbo_STW1_LS_DN

bo_STW1_PreLS_UPbo_STW1_PreLS_DN

ARRAY

i16Override

WORDBOOL

BOOLBOOLBOOLBOOLBOOLBOOL

BOOLBOOL

INT

bo_STW1_Brake_Closed BOOL

Task

The "FB_HoistPLCToAddOn" block reads the input area from the PROFIBUS DP for the Hoist block and separates the provided array into words and bits.

Connections

The outputs must be connected using unit-global variables of the "AddOn" MCC unit with the inputs of the "DCC_SCHoist" DCC block.

Table 2-15: FB_HoistPLCToAddOn connections

Name Type De-fault

Data type


Meaning

Hoist_IO_PIW IN - ARRAY [0..5] OF word

AddOn _hoist_ receive (I/O-Global)

Input array for the Hoist block (see Fig. 2-24)

b16_STW1 OUT 0 WORD - Control word 1 not separated into individual bits

bo_STW1_Release OUT 0 BOOL hoist_PLC_ Release


bo_STW1_Travel OUT 0 BOOL hoist_PLC_ Travel


bo_STW1_OM_Pos OUT 0 BOOL hoist_PLC_ OM_Pos


bo_STW1_OM_Speed OUT 0 BOOL hoist_PLC_ OM_Speed


bo_STW1_OM_Hoist_Control OUT 0 BOOL hoist_PLC_ OM_Hoist_Control


bo_STW1_LS_UP OUT 1 BOOL hoist_PLC_ LS_UP


bo_STW1_LS_DN OUT 1 BOOL hoist_PLC_ LS_DN


bo_STW1_PreLS_UP OUT 1 BOOL hoist_PLC_ Bit 10 of control





PreLS_UP word 1

bo_STW1_PreLS_DN OUT 1 BOOL hoist_PLC_ PreLS_DN


bo_STW1_Brake_Closed OUT 1 BOOL hoist_PLC_ Brake_Closed


i16Override OUT 100 INT hoist_PLC_override PLC override

Error messages

None

2.2.2.5 FB_HoistAddOn ToPLC


Task

The "FB_HoistAddOn ToPLC" writes the Hoist block to the PROFIBUS DP output area.

Connections

The inputs must be connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "DCC_SCHoist" DCC block.

Table 2-16: FB_HoistAddOn ToPLC connections

Name Type De-fault

Data type


Meaning

bo_ZSW1_Ready IN 0 BOOL hoist_SC_ Ready


bo_ZSW1_Active IN 0 BOOL hoist_SC_ Active


bo_ZSW1_Pos_Completed IN 0 BOOL hoist_SC_ Pos_Completed


bo_ZSW1_Travel_UP IN 0 BOOL hoist_SC_ Travel_UP


bo_ZSW1_Travel_DN IN 0 BOOL hoist_SC_ Travel_DN


Hoist_IO_PQW OUT - ARRAY [0..5]

AddOn _hoist_ send

Output array for the Hoist block (see Fig. 2-





OF word

(I/O-Global) 24)

Error messages

None

2.2.2.6 FB_TrolleyPLCToAddOn


Task

The "FB_TrolleyPLCToAddOn" block reads the input area from the PROFIBUS DP for the Trolley block and separates the provided array into words and bits.

Connections

The outputs must be connected using unit-global variables of the "AddOn" MCC unit with the inputs of the "DCC_SCTrolley" DCC block.



Table 2-17: FB_TrolleyPLCToAddOn connections

Name Type De-fault

Data type


Meaning

Trolley_IO_PIW IN -

ARRAY [0..5] OF word

AddOn _trolley_ receive (I/O-Global)

Input array for the Trolley block (see Fig. 2-24)

b16_STW1 OUT 0 WORD Control word 1 not separated into individual bits

bo_STW1_Release OUT 0 BOOL trolley_PLC_ Release


bo_STW1_Travel OUT 0 BOOL trolley_PLC_ Travel


bo_STW1_OM_Pos OUT 0 BOOL trolley_PLC_ OM_Pos


bo_STW1_OM_Speed OUT 0 BOOL trolley_PLC_ OM_Speed


bo_STW1_OM_Load_Pos OUT 0 BOOL trolley_PLC_ OM_Load_Pos


bo_STW1_OM_Trolley_Pos OUT 0 BOOL trolley_PLC_ OM_Trolley_Pos


bo_STW1_OM_Hoist_Control OUT 0 BOOL trolley_PLC_ OM_Hoist_Control


bo_STW1_SC_ON OUT 0 BOOL trolley_PLC_ SC_ON


bo_STW1_LS_FW OUT 1 BOOL trolley_PLC_ LS_FW


bo_STW1_LS_BW OUT 1 BOOL trolley_PLC_ LS_BW


bo_STW1_PreLS_FW OUT 1 BOOL trolley_PLC_ PreLS_FW


bo_STW1_PreLS_BW OUT 1 BOOL trolley_PLC_ PreLS_BW


bo_STW1_Brake_Closed OUT 1 BOOL trolley_PLC_ Brake_Closed


bo_STW1_SC_When_Stop OUT 0 BOOL trolley_PLC_ SC_When_Stop


bo_STW1_Controlled_Stop OUT 0 BOOL trolley_PLC_ Controlled_Stop


bo_STW1_Flying OUT 0 BOOL trolley_PLC_ Flying


i16Override OUT 100 INT Trolley_PLC_ PLC override





Override

Error messages

None

2.2.2.7 FB_TrolleyAddOn ToPLC


Task

The "FB_TrolleyAddOn ToPLC" writes the Trolley block to the PROFIBUS DP output area.

Connections

The inputs must be connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "DCC_SCTrolley" DCC block.

Table 2-18: FB_TrolleyAddOn ToPLC connections



Meaning

bo_ZSW1_Ready IN 0 BOOL trolley_SC_ Ready


bo_ZSW1_Active IN 0 BOOL trolley_SC_ Active


bo_ZSW1_Pos_Completed IN 0 BOOL trolley_SC_ Pos_Completed


bo_ZSW1_SC_Completed IN 0 BOOL trolley_SC_ SC_Completed


bo_ZSW1_Travel_FW IN 0 BOOL trolley_SC_ Travel_FW


bo_ZSW1_Travel_BW IN 0 BOOL trolley_SC_ Travel_BW


bo_ZSW1_SC_State IN 0 BOOL trolley_SC_ SC_State


i16Load_Defl_TR IN 0 INT trolley_SC_ Current load deflection



Name Type "AddOn" unit-

Data Default Meaning global

type variables Load_Defl_TR

Trolley_IO_PQW OUT -


AddOn _trolley_ send (I/O-Global)

Output array for the Trolley block (see Fig. 2-24)

Error messages

None

2.2.2.8 FB_TLSPLCToAddOn (only STS)


Task

The "FB_TLSPLCToAddOn" block reads the input area from the PROFIBUS DP for the TLS block and separates the provided array into words and bits.

Connections

The outputs must be connected using unit-global variables of the "AddOn" MCC unit with the inputs of the "DCC_SCTLS" DCC block.

Table 2-19: FB_TLSPLCToAddOn connections

Name Type De-fault

Data type


Meaning

TLS_IO_PIW IN - ARRAY [0..15] OF word

AddOn _tls_receive (I/O-Global)

Input array for the TLS block (see Fig. 2-24)

b16_STW1 OUT 0 WORD -

Control word 1 not separated into individual bits





bo_STW1_Trim_RH OUT 0 BOOL tls_PLC_ Trim_RH


bo_STW1_Trim_LH OUT 0 BOOL tls_PLC_ Trim_LH


bo_STW1_List_WS OUT 0 BOOL tls_PLC_ List_WS


bo_STW1_List_LS OUT 0 BOOL tls_PLC_ List_LS


bo_STW1_Skew_CW OUT 0 BOOL tls_PLC_ Skew_CW


bo_STW1_Skew_CCW OUT 0 BOOL tls_PLC_ Skew_CCW


bo_STW1_Move_To_Zero OUT 0 BOOL tls_PLC_ Move_To_Zero


bo_STW1_Save_Pos_As_Zero OUT 0 BOOL tls_PLC_ Save_Pos_ As_Zero


bo_STW1_No_Skew OUT 0 BOOL tls_PLC_ No_Skew


bo_STW1_Skew_Control OUT 0 BOOL tls_PLC_ Skew_Control


bo_STW1_Use_Ext_Skew OUT 0 BOOL tls_PLC_ Use_Ext_Skew


i32Pos_Cyl_A OUT 0 DINT tls_PLC_ Pos_Cyl_A

Cylinder A position

i32Pos_Cyl_B OUT 0 DINT tls_PLC_ Pos_Cyl_B

Cylinder B position

i32Pos_Cyl_C OUT 0 DINT tls_PLC_ Pos_Cyl_C

Cylinder C position

i32Pos_Cyl_D OUT 0 DINT tls_PLC_ Pos_Cyl_D

Cylinder D position

i32S_Skew_Extern OUT 0 DINT tls_PLC_ S_Skew_Extern

PLC skew

i8Spreader_Width OUT 0 SINT tls_PLC_ Spreader_Width

Spreader width

Error messages

None



2.2.2.9 FB_TLSAddOn ToPLC (only STS)


Task

The "FB_TLSAddOn ToPLC" writes the TLS block to the PROFIBUS DP output area.

Connections

The inputs must be connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "DCC_SCTLS" DCC block.

Table 2-20: FB_TLSAddOn ToPLC connections



Meaning

bo_ZSW1_Move_Out_Cyl_A IN 0 BOOL tls_SC_ Move_Out_Cyl_A


bo_ZSW1_Move_Out_Cyl_B IN 0 BOOL tls_SC_ Move_Out_Cyl_B


bo_ZSW1_Move_Out_Cyl_C IN 0 BOOL tls_SC_ Move_Out_Cyl_C


bo_ZSW1_Move_Out_Cyl_D IN 0 BOOL tls_SC_ Move_Out_Cyl_D


bo_ZSW1_Move_In_Cyl_A IN 0 BOOL tls_SC_ Move_In_Cyl_A


bo_ZSW1_Move_In_Cyl_B IN 0 BOOL tls_SC_ Move_In_Cyl_B


bo_ZSW1_Move_In_Cyl_C IN 0 BOOL tls_SC_ Move_In_Cyl_C


bo_ZSW1_Move_In_Cyl_D IN 0 BOOL tls_SC_ Move_In_Cyl_D


bo_ZSW1_Oil_Pressure1 IN 0 BOOL tls_SC_ Oil_Pressure1


bo_ZSW1_Oil_Pressure2 IN 0 BOOL tls_SC_ Oil_Pressure2






bo_ZSW1_Zero_Reached IN 0 BOOL tls_SC_ Zero_Reached


bo_ZSW1_Skew_Removed IN 0 BOOL tls_SC_ Skew_Removed


i16Speed_Cyl_A IN 0 INT tls_SC_ Speed_Cyl_A

Cylinder A speed

i16Speed_Cyl_B IN 0 INT tls_SC_ Speed_Cyl_B

Cylinder B speed

i16Speed_Cyl_C IN 0 INT tls_SC_ Speed_Cyl_C

Cylinder C speed

i16Speed_Cyl_D IN 0 INT tls_SC_ Speed_Cyl_D

Cylinder D speed

TLS_IO_PQW OUT -


AddOn _TLS_ send (I/O-Global)

Output array for the TLS block (see Fig. 2-24)

Error messages

None



2.2.2.10 FB_TargetsPLCToAddOn


Task

The "FB_TargetsPLCToAddOn" block reads the input area from the PROFIBUS DP for the Targets block and separates the provided array into words and bits.

Connections

The outputs must be connected using unit-global variables of the "AddOn" MCC unit with the inputs of the "DCC_SCTargets" DCC block.

Table 2-21: FB_TargetsPLCToAddOn connections

Name Type Default

Data type


Meaning

Targets_IO_PIW IN -


AddOn _targets_ receive (I/O-Global)

Input array for the Targets block (see Fig. 2-24)

b16_STW1 OUT 0 WORD

Control word 1 not separated into individual bits

bo_STW1_Learn_Park_Pos OUT 0 BOOL targets_PLC_ Learn_Park_Pos


bo_STW1_Learn_Lash_Platf OUT 0 BOOL targets_PLC_ Learn_Lash_Platf


bo_STW1_Use_Lash_Platf OUT 0 BOOL targets_PLC_ Use_Lash_Plat


bo_STW1_Stack_Form_Bit0 OUT 1 BOOL targets_PLC_ Stack_Form_Bit0


bo_STW1_Stack_Form_Bit1 OUT 1 BOOL targets_PLC_ Stack_Form_Bit1


bo_STW1_Cycling OUT 0 BOOL targets_PLC_ Cycling




Name Defau Data "AddOn" unit-

Type Meaning lt type global variables

bo_STW1_Offset_To_Land OUT 0 BOOL targets_PLC_ Offset_To_Land


bo_STW1_Offset_To_Water OUT 0 BOOL targets_PLC_ Offset_To_Water


bo_STW1_Use_Extern_Targets OUT 0 BOOL targets_PLC_ Use_Extern_ Targets


i8Lane_Ship_Load OUT 0 SINT targets_PLC_ Lane_Ship_Load

Number of the lane from which the ship will be loaded

i8Lane_Ship_Unload OUT 0 SINT targets_PLC_ Lane_Ship_Unload

Number of the lane from which the ship will be unloaded

i8Learn_Pos_Lane OUT 0 SINT targets_PLC_ Learn_Pos_Lane

Store current position with this lane number

Error messages

None

2.2.2.11 FB_TargetsAddOn ToPLC


Task

The "FB_TargetsAddOn ToPLC" writes the Targets block to the PROFIBUS DP output area.

Connections

The inputs must be connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "DCC_SCTargets" DCC block.



Table 2-22: FB_TargetsAddOn ToPLC connections

Name Type Default

Data type


Meaning

bo_ZSW1_Pos_Saved IN 0 BOOL targets_SC_ Pos_Saved


bo_ZSW1_Direction_Land IN 0 BOOL targets_SC_ Direction_Land


bo_ZSW1_Direction_Water IN 0 BOOL targets_SC_ Direction_Water


i8Lane_Load_OK IN 0 SINT targets_SC_ Lane_Load_OK

Return the lane number from which the ship will be loaded

i8Lane_Unload_OK IN 0 SINT targets_SC_ Lane_Unload_OK

Return the lane number from which the ship will be unloaded

Targets_IO_PQW OUT - ARRAY [0..5] OF word

AddOn _targets_ send (I/O-Global)

Output array for the Targets block (see Fig. 2-24)

Error messages

None

2.2.2.12 FB_ObstaclesPLCToAddOn


Task

The "FB_ObstaclesPLCToAddOn" block reads the input area from the PROFIBUS DP for the Obstacles block and separates the provided array into words and bits.



Connections

The outputs must be connected using unit-global variables of the "AddOn" MCC unit with the inputs of the "DCC_SCObstacles" DCC block.

Table 2-23: FB_ObstaclesPLCToAddOn connections

Name Type De-fault

Data type


Meaning

Obstacle1_IO_PIW IN - ARRAY [0..15] OF word

AddOn _obstacle1_ receive (I/O-Global)

Input array for the Obstacle block 1 (see Fig. 2-24)

Obstacle2_IO_PIW IN - ARRAY [0..15] OF word

AddOn _obstacle2_ receive (I/O-Global)

Input array for the Obstacle block 2 (see Fig. 2-24)

b16_STW1 OUT 0 WORD - Control word 1 not sepa-rated into individual bits

bo_STW1_Pgr_Obst OUT 0 BOOL obstacle_PLC_ Pgr_Obst


bo_STW1_Del_Obst OUT 0 BOOL obstacle_PLC_ Del_Obst


i32Set1_Tr1 OUT 0 DINT obstacle_PLC_Set1_Tr1

Blocked region 1 trolley position 1

i32Set1_Tr2 OUT 0 DINT obstacle_PLC_ Set1_Tr2


i32Set1_Hoist OUT 0 DINT obstacle_PLC_ Set1_Hoist

Blocked region 1 hoisting position





























Error messages

None

2.2.2.13 FB_ObstaclesAddOn ToPLC


Task

The "FB_ObstaclesAddOn ToPLC" writes the Obstacles block to the PROFIBUS DP output area.

Connections

The inputs must be connected using unit-global variables of the "AddOn" MCC unit with the outputs of the "DCC_SCObstacles" DCC block.

Table 2-24: FB_ObstaclesAddOn ToPLC connections

Name Type De-fault

Data type


Meaning

bo_ZSW1_Prg_Obst_OK IN 0 BOOL obstacle_SC_ Prg_Obst_OK


bo_ZSW1_Obst_Deleted IN 0 BOOL obstacle_SC_ Obst_Deleted


i16Number_Obst IN 0 INT obstacle_SC_ Number_Obst

Number of blocked regions

Obstacle1_IO_PQW OUT - ARRAY [0..15] OF word

AddOn _obstacle1_ send (I/O-Global)

Output array for the Obstacle block (see Fig. 2-24)

Obstacle2_IO_PQW OUT - ARRAY [0..15] OF word

AddOn _obstacle2_ send (I/O-Global)

Output array for the Obstacle block (see Fig. 2-24)



Error messages

None

2.2.2.14 FB_Send_Preparation (only STS)


Task

The block prepares the data for the camera before it is sent as UDP message frame.

Connections

The block input is connected with the output of the "DCC_SCCamera" DCC block using a unit-global variable. The output signal is transferred to the camera with a UDP message frame via Ethernet.

Table 2-25: FB_Send_Preparation connections



Meaning

i32Hoist_Height_PLC IN 0 DINT camera_SC_ Hoist_Height_PLC

Transfer external hoisting position from the PLC


"Camera" unit variables

Meaning

aSenddata OUT 0 ARRAY [0..7] OF BYTE

SendData The data sent to the camera

Error messages

None

2.2.2.15 FB_Receive_Analysis (only STS)




Task

This block analyzes and processes the data received as UDP message frame.

Connections

At the input of the "FB_Receive_Analysis" function block, the data received as UDP message frame is separated and interconnected to the associated output variables of the block. The outputs must be connected using unit-global variables of the "Camera" MCC unit with the inputs of the "DCC_SCCamera" DCC block.

Table 2-26: FB_Receive_Analysis connections


"Camera" unit variables Meaning

aReceivedata IN 0 ARRAY [0..169] OF BYTE

ReceiveData Data received from the camera via Ethernet

u32Datalength IN 0 UDINT udp_back_receive.dataLength Data length



Meaning

bo_Camera_OK OUT 0 BOOL camera_CAM_Camera_OK Camera OK

i32X_Pos OUT 0 DINT camera_CAM_X_Pos Deflection in X direction

i32Y_Pos OUT 0 DINT camera_CAM_Y_Pos Deflection in Y direction

i32Skew OUT 0 DINT camera_CAM_Skew Reflector skew

i32Hoist_Height OUT 0 DINT camera_CAM_Hoist_Height Hoisting position (measured by the camera)

i32V_X OUT 0 DINT camera_CAM_V_X Swaying speed in X direction

i32V_Y OUT 0 DINT camera_CAM_V_Y Swaying speed in Y direction

i32V_Skew OUT 0 DINT camera_CAM_V_Skew Skew speed

Error messages

None


Software Engineering for SIMOCRANE SC Integrated 2.3 Sway Control Applications

2.3 Sway Control Applications This section describes the various SIMOCRANE Sway Control applications. Each application consists of a "Sway Control" DCC chart. This chart contains a wide range of Sway Control options. An "AddOn" MCC unit is also present. This unit manages the communication between the controller (S7) basic technology and the SIMOTION Sway Control. A camera application also has an additional "Camera" MCC unit. This unit fetches and processes the camera data. The application with a camera is only possible for an STS crane.

In addition, the connection between the basic and advanced technology has been simplified in order to minimize the configuration work. Global variables have been introduced have been for this purpose that replace the manual integration of variables in the project and the connection of the units (see Sections 2.4.12 / 2.4.13).

The simplified projects from Sway Control all end with _SC as well as the associated basic technology projects. If the old projects are still to be used, ensure that the basic technology project matched the Sway Control project.

In the figure below, the simplified projects are in the right-hand columns (extension _SC):

STS GSU

Basic technology project

Sway Control project

STS_Crane_V2_0_SP2

STS_Crane_V2_0_SP2_SC

SwayControl_SimoD_STS_SC



STS_TandemDP_V2_0_SP2

STS_TandemDP _V2_0_SP2_SC

SwayControl_SimoD_STS

Single spreader Double spreader

SwayControl_SimoD_GSU



GSU_Crane_V2_0_SP2

GSU_Crane_V2_0_SP2_SC

Which projects do I need and where can I find them?

The projects with a light gray background are on the Basic Technology CD. The projects with a dark gray background are on the Sway Control CD. Note: In the basic technology, the double spreader is called tandem spreader.

SwayControl_SimoD_STS_SC

SwayControl_SimoD_GSU_SC

SwayControl_SimoD_GSU

SwayControl_SimoD_STS

Fig. 2-9: Project selection

When using the simplified projects (extension _SC), the Sections: "Connection between the basic technology and AddOn for old projects without the extension _SC" 2.4.12 and "Connection between the TO objects and AddOn for old projects without the extension _SC" 2.4.13 can be skipped.



When using the other projects (without extension _SC), the Section "Establishing a connection between the basic technology and AddOn for new projects with the extension _SC" 2.4.11 can be omitted.

2.3.1 Simple Sway Control for ship unloaders


The application is a simple configuration example for a ship unloader (GSU= Grab Ship Unloader). Trolleys and hoisting gear can be controlled manually and automatically. When automatic control is used, the targets must be specified and managed by the PLC. Fixed blocked regions can be considered during the automatic travel (see Section 2.3.3.2).

The Sway Control system operates only with an internal oscillation model. A camera is not used.

The controller possesses appropriate functions for ship unloaders, such as pre-limit and limit shutdown, the consideration of reduced speeds for large loads or a grab emptying during the motion (on-the-fly unloading).

2.3.1.2 Required blocks, signals and connections

Required FB blocks

FB_CommonPLCToAddOn


FB_HoistPLCToAddOn

FB_HoistAddOn ToPLC



Required DCC blocks

DCC_SCCommon

DCC_SCHoist

DCC_SCTrolley

DCC_SCDiag

Inclusion of the blocks in execution levels

The blocks are calculated in the following execution groups:

The DCC blocks in "Sway Control" operate in the sampling time of the SIMOTION interpolator cycle. The function blocks in the "AddOn" MCC unit operate in a cyclical execution level.



Required signals from the drive line for SIMOCRANE Sway Control

Load-dependent field weakening

Speed setpoints (trolley and hoisting gear)

Actual position values (trolley and hoisting gear)

Actual speed values (trolley and hoisting gear)

Required connections

The required connections are contained in the tables for the connections of the required DCC and FB blocks ("Variables" column) in Sections 2.2.1 and 2.2.2.

2.3.2 Simple Sway Control for container cranes


The application is a simple configuration example for a container crane. Trolleys and hoisting gear can be controlled manually and automatically. The Sway Control system operates with an internal oscillation model. A camera that records the load oscillation is also used. This allows oscillations caused by external forces also to be corrected.

The controller possesses appropriate functions for container bridges, such as pre-limit and limit shutdown or the consideration of reduced speeds for large loads.

When automatic control is used, the targets must be specified and managed by the PLC. Fixed blocked regions can be considered during the automatic travel (see Section 2.3.3.2).


Required FB blocks

FB_CommonPLCToAddOn


FB_HoistPLCToAddOn

FB_HoistAddOn ToPLC



FB_Receive_Analysis

FB_Send_Preparation

Required DCC blocks

DCC_SCCommon

DCC_SCHoist

DCC_SCTrolley



DCC_SCCamera

DCC_SCDiag



The DCC blocks in "Sway Control" operate in the sampling time of the SIMOTION interpolator cycle. The function blocks in the "AddOn" "Camera" MCC units operate in a cyclical execution level.








2.3.3 Sway Control with 2D-Trajectory and Bay Scanning


The application is an extended configuration example for a container crane. Trolleys and hoisting gear can be controlled manually and automatically. The Sway Control system operates with an internal oscillation model. A camera that records the load oscillation is also used. This allows oscillations caused by external forces also to be corrected.

The "2D-Trajectory" AddOn permits the automatic motion of the load on the path curve. The path curve is determined here so that the spreader or the grab does not collide with the crane construction, the containers or any other obstacles.

The basis is a layout of the working area in which blocked regions are defined. Blocked regions can be defined during the commissioning, transferred from the PLC or learnt internally during the travel. Travel is permitted only outside these blocked regions. Depending on the starting point and the target position, the fastest possible travel path is generated from the data about the blocked regions. The target position is determined automatically. A parking position, a lashing position and several lane positions can also be learnt and used to calculate the path curve.

If a Bay Scanner is used, the signal of the measured hoisting height is also evaluated and also used to calculate the path curve (see Section 2.3.3.3).


2.3.3.2 Definitions

Obstacles

An obstacle is a physical object that must be avoided in order to prevent collisions. Such examples are, on the waterside, containers, structures in the form of cell guides, frames for container



attachments, etc., and on the landside, crane constructions (e.g. Silbeam), the lashing platform or trucks.

Blocked regions

Blocked regions are individual or several combined obstacles or also areas, which the crane should not enter for safety reasons. A blocked region is described by two trolley positions and one hoisting position. Up to 20 fixed and 200 variable blocked regions can be defined.

Fixed blocked regions

Fixed blocked regions are primarily defined on the landside. They are entered from the "CeCOMM" commissioning tool in the "B" region menu (set blocked regions) during the commissioning and stored in the "Par0.txt" to "Par3.txt" parameter files. During loading, the values are taken from "Par0.txt".

Variable blocked regions

Note Variable blocked regions are used only in conjunction with the "2D-Trajectory" AddOn.

Variable blocked regions are created dynamically and principally on the waterside for transfer of the container stack. Depending on the type of the transfer, variable blocked regions are divided into external variable blocked regions and internally-learnt variable blocked regions.

External variable blocked regions are designated as those blocked regions transferred from the PLC to the Sway Control system. This is necessary when the container management should be realized in a higher-level control system. The blocked regions are transferred to the Sway Control system prior to the automatic start.

External variable blocked regions can also be used for other purposes, such as the blocking of all heights below the trucks.

Internally-learnt variable blocked regions are created from the height profile by

Monitoring the spreader movements in all basic modes, and also optionally by

Acquiring the laser values of the Bay Scanner

External variable blocked regions and internally-learnt variable blocked regions are stored internally in different data storage areas, but linked before the automatic start.

Container stack

The container stack is the two-dimensional location description of all containers in a row on the ship.



Height profile

If the container stacks are learnt internally, all spreader positions are recorded as a height profile irrespective of the basic operating mode. The laser values of the Bay Scanner can also be used. The learnt height profile extends from the start to the end of the waterside. The internal learnt variable blocked regions are created continually from the height profile.

If the measured values of the Bay Scanner are not used, the height profile during the unloading at the beginning of the learning process does not correspond to the real container stack, although it approaches this after each unloading action.

Limit curve

With the initialization and calculation of the automatic travel, all fixed and variable blocked regions are combined in a limit curve.

List of switchover points

The fastest possible travel path is generated from the limit curve data, taking account of not only the start point and the target position, but also the maximum speed of the hoisting gear and trolley. The result is a switchover point.

Fig. 2-10: Relationship between blocked regions, limit curves and switchover point list

Path curve

The path curve is the calculated optimum travel curve of the spreader. The switchover point list forms the basis.

Fig. 2-11: Sequence for determining the optimum path curve



2.3.3.3 Bay scanning

If a Bay Scanner is also used, this signal of the obstacle height is evaluated in addition to the traveled curve. If the Bay Scanner signal is valid, it takes priority over the learnt travel curve. This allows more exact values of the container stack to be determined.

See Section 3.2.3

2.3.3.4 Double spreader

The "Sway Control" AddOn technology can also be used on cranes with double spreaders in "single mode" and in coupled mode. The following must be observed:

NOTICE

The camera must be attached via the landside spreader.

Single mode

NOTICE

In single mode, the waterside spreader must be pulled up to the upper limit switch. Otherwise the "Sway Control" AddOn technology must be deactivated. This is a safety function and must be implemented in the S7.

No additional signals are required and there are no changes in the behavior compared to operation with a single spreader.

Coupled mode

In "coupled mode", the landside spreader is the master. This is monitored by a camera. The "master" is always positioned. Its position (middle of the landside spreader) must be transferred to the Sway Control via the interface.

The current total width of the double spreader is taken into account during learning and when avoiding obstacles. The double spreader is treated as a large spreader, with regards to the learning behavior. The width of the blocked regions is increased in the landside direction.

The current total width and the signal for coupled mode must be specified via the interface.


Required FB blocks

FB_CommonPLCToAddOn


FB_HoistPLCToAddOn

FB_HoistAddOn ToPLC



FB_TargetsPLCToAddOn (optional)

FB_TargetsAddOn ToPLC (optional)



FB_ObstaclesPLCToAddOn (optional)

FB_ObstaclesAddOn ToPLC (optional)

Required DCC blocks

DCC_SCCommon

DCC_SCHoist

DCC_SCTrolley

DCC_SCDiag

DCC_SCObstacles (optional)

DCC_SCTargets (optional)

The use of the "DCC_SCTargets" and "DCC_SCObstacles" blocks, and the associated FB blocks for receiving and sending data depends on the transfer mode of the blocked regions.

Table 2-27: Transfer modes of blocked regions

Fetching from the parameter file

External via PLC

Internal learning

Acquisition by Bay Scanner

Fixed blocked regions

Variable blocked regions

Required FB blocks

FB_ObstaclesPLCToAddOn FB_ObstaclesAddOn ToPLC

FB_TargetsPLCToAddOn FB_TargetsAddOn ToPLC

Required DCC blocks

No further blocks required

DCC_SCObstacles DCC_SCTargets

A combination of all transfer modes is possible. In this case, all blocks marked as optional must be present and configured.



The DCC blocks in "Sway Control" operate in the sampling time of the SIMOTION interpolator cycle. The function blocks in the "AddOn" MCC unit operate in a cyclical execution level.










2.3.4 TLS Control (only STS)


"TLS Control" controls the so-called trim, list and skew positions of a spreader.

The TLS Control assumes that

the lengths or

the pivot points

of the four carrying cables of a spreader can be adjusted by hydraulic cylinders with the aid of the camera.

Through actuation of these hydraulic cylinders in pairs, the spreader can be tilted to the left or right (trim), inclined towards the waterside or landside (list) or rotated in a clockwise or counterclockwise direction (skew). All of these movements can be carried out simultaneously.

The current positions of all four cylinders can be saved as zero positions and approached again. The command to approach the zero positions has priority over the trim, list and skew commands.

The Skew Control function, the electronic Sway Control function, can also be activated. With this function, the skewing motion of the spreader is measured with the camera and eliminated through control of the hydraulic cylinders. Optionally, travel is made to the last TLS setting on the landside and waterside or an externally specified rotational position (e.g. from Truck Positioning). This command will not be performed when the "Move zero" or a TLS command is present.


Required FB blocks

FB_CommonPLCToAddOn


FB_TLSPLCToAddOn

FB_TLSAddOn ToPLC

FB_Receive_Analysis

FB_Send_Preparation

Required DCC blocks

DCC_SCCommon

DCC_SCTLS

DCC_SCCamera

DCC_SCDiag








2.3.5 Sway Control with TLS Control (only STS)


The application is a simple configuration example for a container crane with Trim, List and Skew Control. Trolleys and hoisting gear can be controlled manually and automatically. When automatic control is used, the targets must be specified and managed by the PLC. Fixed blocked regions can be considered during the automatic travel (see Section 2.3.3.2).

The Sway Control system operates with an internal oscillation model. A camera that records the load oscillation is also used. This allows oscillations caused by external forces also to be corrected.


In addition, the trim, list and skew control and a Skew Control is used. Further information is contained in Section 2.3.4.1.


Required FB blocks

FB_CommonPLCToAddOn


FB_HoistPLCToAddOn

FB_HoistAddOn ToPLC



FB_TLSPLCToAddOn

FB_TLSAddOn ToPLC

FB_Receive_Analysis

FB_Send_Preparation


Software Engineering for SIMOCRANE SC Integrated 2.4 Configuration

Required DCC blocks

DCC_SCCommon

DCC_SCHoist

DCC_SCTrolley

DCC_SCTLS

DCC_SCCamera

DCC_SCDiag











2.4 Configuration

2.4.1 Requirement

Functional project

Requirement for the installation of the AddOn technology is a functional project of the basic technology /Ref 2/, because at least one specific version of the basic technology belongs to each AddOn Sway Control (SIMOTION SCOUT in conjunction with SIMOTION DCC technology package as of Version 4.1.4.1 and SINAMICS as of Version 2.5.1 as well as SIMOCRANE basic technology as of Version 2.0).

See: Sway Control Applications 2.3

This can be checked as follows:

Save and compile project with the "Save Project and compile all" icon

Consistency check from the "D435" context menu, "Check consistency" entry



Setting the system cycle clocks

The task run time settings must also be checked. This requires that the SIMOTION container in SCOUT is selected. The "Target System/Expert/Set System Cycle Clock" menu is used to set the system cycle clocks as shown in the following screenshot.

Fig. 2-12: Setting the task run times

2.4.2 Overview of the configuring steps to be performed

The following steps should be performed in succession:

1. Perform setup (installation of the DCC library) (Section 2.4.3)

2. Import the SCOUT project of the AddOn technology (Section 2.4.4)

3. PROFIBUS configuration (Section 2.4.5)

4. Copy I/O variables (Section 2.4.6)

5. Copy AddOn FB library (Section 2.4.7)

6. Copy MCC charts (Section 2.4.8)

7. Add DCC blocks (Section 2.4.9)

8. Save, compile and check consistency (Section 2.4.10)

9. Only new projects with the extension _SC: Establish connection between the basic technology and AddOn for GSU (Section 2.4.11)

10. Only old projects without the extension _SC: Establish connection between the basic technology and AddOn for STS (Section 2.4.12)

11. Customize the AddOn to the company's conditions (Section 2.4.16)

12. Include the "AddOn" and "Camera" programs in the execution system (Section 2.4.14)



13. Transfer the project to the SIMOTION D (Section 2.4.17)

14. Communications test (Section 2.4.18)

2.4.3 Perform setup

NOTICE

To install the AddOn DCC library, SCOUT must be closed.

To install the required DCC library, the supplied "Setup.exe" must be executed. Follow the instructions displayed during the installation. This installation adds the current DCC blocks to the DCC library.

Fig. 2-13: Installation of the AddOn DCC library

2.4.4 Import of the SCOUT project of the AddOn technology

The SCOUT project of the AddOn technology must be imported next.

NOTICE To import a project in the "XML-Format", the SCOUT must be open, although all projects must be closed.

Click the icon to start the import of a SCOUT project. To import the project, the "SwayControl_SimoD.xml" file on the CD must be selected. After clicking "OK" to confirm, enter an arbitrary project name in the following window and select a target folder for the project.



Note The project example is available in zipped form on the CD. The ZIP file must be unzipped outside the project using Winzip.Only then the data are present and can be imported with the SCOUT. Then the resulting project can also be opened with the SIMATIC Manager in order to get access to the sample blocks.

Fig. 2-14: Import of the SCOUT project of the AddOn Technology

After clicking "OK" to confirm, the project will be imported and compiled.

Note After the import, it is essential to check whether the compilation was successful.

2.4.5 PROFIBUS configuration

Open the SCOUT projects of the basic technology /Ref. 2/ and the AddOn technology. After ROFIBUS has been configured, you can copy the programs from one project into another project.


Communication between the higher-level SIMATIC S7 control and the drive-related control SIMOTION D435 is established via PROFIBUS DP (up to max. 12 process data items per axis). The SINAMICS control unit is integrated in the drive-based SIMOTION D (/Ref. 3/ and /Ref. 4/). The communication between these has the same character as PROFIBUS DP, but with motion control extension with up to a maximum of 25 process data items (in accordance with PROFIdrive - Profile Drive technology /Ref. 1/) for Vector Control and is called DP-Integrated.

SIMOTION D435 has three PROFIBUS DP interfaces (two DP interfaces and one DP integrated interface).

The communication between SIMATIC S7 and SIMOTION basic technology /Ref. 2/ is configured on DP1, whereas DP2 is used for the complete AddOn technology. The connection between SIMOTION and SINAMICS is permanently configured on the internal DP interface.

The following PROFIBUS addresses have been defined for the PROFIBUS DP interface on the SIMOTION D:



Table 2-28: PROFIBUS DP interfaces on the SIMOTION D for AddOn technologies

PROFIBUS DP interface

Communication to the ...

PROFIBUS address

DP1 Basic Technology 44

DP2 AddOn technology 45

DP Integrated SINAMICS Internal

2.4.5.2 Configuring the connection

Communication between SIMATIC S7 and SIMOTION D is established via PROFIBUS DP. The S7 module is master and the SIMOTION is an intelligent slave.

SIMOTION hardware configuration

The DP2/MPI line must be opened in the hardware configuration of the SIMOTION.

Fig. 2-15: Hardware configuration SIMOTION

The PROFIBUS address of the DP2/MPI line of the SIMOTION is defined as "45".



Fig. 2-16: Object properties of DP1

The DP2/MPI line must now be configured as intelligent DP-SLAVE. This is done under Properties - DP2/MPI in the "Operating Mode" tab. The checkbox for Programming, status/modify or other PG functions and unconfigured communication connections possible MUST be set.

Fig. 2-17: Setting up an intelligent DP slave



Note The DP2/MPI line can no longer be seen in the hardware configuration after this was configured as intelligent slave.

SIMATIC S7 hardware configuration

The DP line is set up in the hardware configuration of the SIMATIC S7 as PROFIBUS with a transmission rate of 6 Mbit/s. Then, the SIMOTION is inserted from the catalog under "already configured stations":

Fig. 2-18: Overview of the SIMATIC S7 hardware configuration

When inserting the already configured SIMOTION station, a coupling is listed, refer to the diagram below. Click the "Connect" button to establish the coupling between SIMATIC S7 and SIMOTION.

Note Communication between SIMATIC S7 and SIMOTION can only be configured after the coupling has been established.



Fig. 2-19: Object properties of the DP line

After the coupling has been established, data transfer between SIMATIC S7 and SIMOTION must be configured. The appropriate process data must be configured for each block.

Note For the AddOn technology, identical I/O address ranges are used in the SIMATIC S7 and the SIMOTION D. The address ranges of 2000-2043 are reserved.

The addresses 2000-2167 of this range are used for "Sway Control", "TLS Control" and "2D-Trajectory".

Table 2-29: I/O address ranges for the AddOn technologies

Module Functions PROFIBUS address

Length (words)

I/O address range

DCC_SCCommon General 45 12 2000-2023

DCC_SCHoist Hoisting gear 45 6 2024-2035

DCC_SCTrolley Trolley 45 6 2036-2047

- Slewing gear (not yet specified)

45 6 2048-2059

DCC_SCTLS (only STS)

TLS (only STS) 45 16 2060-2091

DCC_SCTargets Targets 45 6 2092-2103

DCC_SCObstacles Blocked regions 45 16 2104-2135



Module PROFIBUS Length

Functions I/O address range address (words)

Block1

Blocked regions Block2

45 16 2136-2167

- Further AddOn functions

45 38 2168-2243

For each function, these addresses must be created under "DP slave properties" in the "Configuration" tab.

Fig. 2-20: I/O peripherals definition in the S7 hardware configuration (1st part)



Fig. 2-21: I/O peripherals definition in the S7 hardware configuration (2nd part)

The send and receive direction must be configured for each function. For example, the trolley with start address 2036 is configured once as output for the master and once as input for the slave.

The following settings in the DP slave properties window are very important:

Properties of the output words Properties of the input words

Fig. 2-22: Properties of the input and output words to be created (trolley example)



Once all functions of the AddOn technology have been configured, the hardware configurations must be compiled in the SIMATIC S7 and SIMOTION.

The complete SIMATIC S7 and SIMOTION hardware is displayed in the "NETPRO" screen. The PG/PC should be connected at the DP1 line. An active connection must be configured at the PC/PC, otherwise routing to SINAMICS_Integrated and the CX32 modules is not possible.

Fig. 2-23: Netpro overview

2.4.5.3 Definition of the message frame

The PROFIBUS module used for the standard application can exchange 244 bytes of data between SIMATIC S7 and SIMOTION. The standard message frame in accordance with PROFIdrive profile V4.1 /Ref. 1/ is used as message frame.

Twelve function blocks (e.g. FB_CommonPLCToAddOn, FB_CommonAddOn ToPLC) are programmed in the AddOn technology to process communication message frames (or interconnect and convert signals) between SIMATIC S7 and SIMOTION.



In addition, the corresponding function blocks and data blocks on the SIMATIC S7 side for defined communication are made available to users on the Software CD.

2.4.6 Copying I/O variables

In SIMOTION, the complete communication with the I/O or with the master is performed using the I/O variables. An I/O array with process data must be created for receiving and sending for each function module participating in communication.

The required I/O arrays are preferably copied from the AddOn project to the project with the basic technology. The I/O variables of the AddOn project are shown below.

Fig. 2-24: Overview of the I/O variables in SCOUT (communication between SIMATIC S7 and

SIMOTION)

To copy, the "I/O" container is activated in the AddOn project, the arrays selected in the symbol browser and copied with the context menu. The I/O arrays are inserted in the project with the basic technology by activating the "I/O" container, selecting the first free cell in the symbol browser and then with the Enter key.



Fig. 2-25: Copying the I/O variables

Basic technology AddOn

2.4.7 Copying the AddOn FB library

The library is preferably copied from the AddOn project to the project with the basic technology. To do this, select in the AddOn and copy it from the context menu. In the project with the basic technology, it is added by selecting the "LIBRARIES" container and clicking Paste. The prompt for the objects to be copied should be answered with "Yes".

Fig. 2-26: Import of the AddOn FB library




Fig. 2-27: Inserting an AddOn library

Fig. 2-28: Also copying objects

The newly added library must now be compiled.

Fig. 2-29: Accept and compile library

2.4.8 Copying MCC charts

After the successful compilation, the "AddOn" and "Camera" MCC programs (only STS) can be copied into the project with the basic technology.



Fig. 2-30: Copying MCC programs in the AddOn

Fig. 2-31: Insert MCC programs in Basic Technology



2.4.9 Inserting DCC blocks

Before the "SwayControl" DCC chart is copied, the newly-installed DCC block library is checked. To do this, an arbitrary DCC chart, such as "Gantd_1", is opened in the project with the basic technology. "Options / Block Types…" is selected from the menu item.

Fig. 2-32: Update block types

The following pop-up should be answered with "OK".



Fig. 2-33: Pop-up for updating the DCC library

The available libraries are now shown on the left-hand side with the previously-imported libraries shown on the right-hand side. Only import the most-recent available library. You must now click the arrow pointing to the right.

Fig. 2-34: Available and installed libraries

You see that the library appears on the right-hand side.



Fig. 2-35: Available and installed libraries are identical

You can now copy the "Sway Control" DCC chart from the AddOn project to the basic technology project. To do this, select with the right mouse button the chart in the AddOn project and copy it.

Fig. 2-36: Copy DCC chart from the AddOn

In the basic technology, the chart can be inserted by selecting the "PROGRAMS" container and pressing the right mouse button.

AddOnBasic technology



Fig. 2-37: Insert the DCC chart in the basic technology

Note The DCC chart can be inserted in a SCOUT project only by copying.

2.4.10 Saving, compiling and checking consistency

The project is compiled and saved ( ). Then press the "Ctrl + Alt + K" key combination to perform a consistency check. The project should now be free from any errors.

2.4.11 Connection between the basic technology and AddOn for new projects with the extension _SC

The connections for speed and position must be established for the communication between the basic technology and AddOn. This is performed automatically in the GSU project. Only the hidden communications elements have to be displayed.

To do this, the MCC chart AddOn must be opened:



Fig. 2-38: Addonmcc

The Receive TO and Send TO must then be opened and the deactivated blocks selected.

The following list is now displayed by right-clicking:



Fig. 2-39: Displaying the addonmcc

The blocks are now activated with "Mask in".

Continue at Section 2.4.14 for projects with the extension _SC.

2.4.12 Connection between the basic technology and AddOn for old projects without the extension _SC

For the communication between the basic technology and AddOn, the connections for the speed, position and load-dependent field weakening must be established if this has not been done automatically.

To do this, the connection to the AddOn must first be established in the "Hoistp_1" and "Trollp_1" interface from the "Connections" tab.



Fig. 2-40: Connection from "Hoistp_1" and "Trollp_1" to the AddOn

The following variables must now be interconnected for the AddOn:

Velocity setpoint

The velocity setpoint is interconnected for the individual axes in the associated MCC charts of the basic technology in the "Receive S7" module (see following figure).

Table 2-30: Interconnection of the velocity setpoints

Hoistp_1

Trollp_1

Axis MCC program

MCC chart Basic technology variables

AddOn unit-global variables

Hoisting gear

hoistp_1 hoistmcc_1_s my_Hoist_1_receive. r64comvelocity

hoist_BT_V_Set_HO

Trolley trollp_1 trollmcc_1_s my_Trolley_1_receive. r64comvelocity

trolley_BT_V_Set_TR



Fig. 2-41: Example for the interconnection of the velocity setpoint for the hoisting gear

Position setpoint

The position setpoint is interconnected for the individual axes in the associated MCC charts of the basic technology in the "Receive S7" module (see following figure).

Table 2-31: Interconnection of the position setpoints

Axis MCC program



Hoisting gear

hoistp_1 hoistmcc_1_s r64targetposition hoist_BT_S_Set_HO_Extern

Trolley trollp_1 trollmcc_1_s r64targetposition trolley_BT_S_Set_TR_Extern



Fig. 2-42: Example of the interconnection of the position setpoint for the hoisting gear

Field weakening

For the "Load-dependent field weakening override“ signal, the corresponding output for the "LoadDependingFieldWeak" in the "Hoistd_1" is interconnected with the corresponding input in the AddOn.

Table 2-32: Interconnection of the signal for the field weakening

Basic technology DCC program

Basic technology DCC block

Connection AddOn unit-global variables

Hoistd_1 LoadDependingFieldWeak rSetPointVelAfterRampGen Hoist_BT_Field_Weak



Fig. 2-43: Interconnection between Hoistd_1 and AddOn

"Positioning complete" signal

The "Positioning complete" signal is interconnected for the individual axes (on the master drive when several axes are used) in the associated MCC charts of the basic technology in the "Operation Mode" module (see following figure).

Table 2-33: Interconnection on the Mode block

Axis MCC program



Hoisting gear

hoistp_1 hoistmcc_1_s boswaycontrolpositioncompleted

Hoist_SC_Pos_Completed

Trolley trollp_1 trollmcc_1_s boswaycontrolpositioncompleted

Trolley_SC_Pos_Completed



Fig. 2-44: Example of the interconnection on the Mode block for the trolley

2.4.13 Connection between the TO objects and AddOn for old projects without the extension _SC

The connections for velocity and position must be established for the communication between the TO objects and AddOn. The "SwayControl" DCC chart must be opened first.

Actual position value

Table 2-34: Interconnection of the actual position values

Axis TO objects DCC block Connection

Hoisting gear

Hoist_1.positioningstate.actualposition DCC_SCHoist rS_Act_HO

Trolley Trolley_1.positioningstate.actualposition DCC_SCTrolley rS_Act_TR

TLS (only STS)

Hoist_1.positioningstate.actualposition DCC_SCTLS rS_Act_HO

TLS (only STS)

Trolley_1.positioningstate.actualposition DCC_SCTLS rS_Act_TR



Fig. 2-45: Example of the interconnection of the actual position value for the hoisting gear

Actual speed

Table 2-35: Interconnection of the actual speed

Axis TO objects DCC block Connection

Hoisting gear

Hoist_1.motionstatedata.actualvelocity DCC_SCHoist rV_Act_HO

Trolley Trolley_1.motionstatedata.actualvelocity DCC_SCTrolley rV_Act_TR

Actuator speed

The following block entries are interconnected with the TO variables.



Table 2-36: Interconnection of the actuator speed

Axis SwayControl DCC block

Connection TO objects

Hoisting gear

DCC_SCHoist rV_Pos_HO Hoist_1.defaultmotionin.velocity

Trolley DCC_SCTrolley rV_Pos_TR Trolley_1.defaultmotionin.velocity

2.4.14 Execution system

The newly-inserted "AddOn" (GSU and STS) and "Camera" (only STS) programs must still be integrated in the execution system. They supply the PLC ("AddOn") and camera ("Camera") values to the Sway Control system.

Both programs must be integrated in the background task.

Note Under no circumstances may the "Camera" program be called in the TimerInterruptTask, because the program uses system functions not permissible in this task.

2.4.15 Required AddOn DCC blocks

The following table shows which AddOn DCC blocks are required for the respective AddOn.



Table 2-37 Required and optional DCC blocks for the various AddOns

AddOn DCC block Sway Control 2D-Trajectory TLS Control

DCC_SCCommon X X X

DCC_SCCamera o o o

DCC_SCTrolley X X -

DCC_SCHoist o X -

DCC_SCTargets - X -

DCC_SCObstacles - X -

DCC_SCTLS - - X

DCC_SCDiag X X X

X – required o – optional

2.4.16 Customization of the AddOn for old projects without the extension _SC

Example of a customization of the AddOn for the case without TLS

The TLS should be removed for a project that contains all features (maximum expansion). The following explains which blocks and variables must be removed.

Note Everything concerning Camera and TLS has already been removed in the GSU projects.

Step 1: Remove the superfluous functions blocks

The "AddOn MCC" MCC program is opened.



Fig. 2-46: "AddOn MCC" MCC program

The "Receive PLC" and "Send PLC" modules are then opened successively and the subroutine call for the TLS block removed (see following figures).

Fig. 2-47: The subroutine call for TLS in the Receive module is deleted



Fig. 2-48: The subroutine call for TLS in the Send module is deleted

Step 2: The global variables for TLS are removed

Double-clicking the "AddOn" MCC source opens the window with the global variables on the right-hand side. All variables that belong to the TLS are removed here.



Fig. 2-49: Superfluous global variables

Step 3: The DCC block for TLS is removed

Fig. 2-50: Superfluous TLS DCC_Block



Then click to recompile the project.

Fig. 2-51: Recompiling a DCC chart



Step 4: The I/O variables for TLS are removed

Fig. 2-52: Superfluous I/O variables

Step 5: Compile project

As last step, the project is compiled ( ). Then press the "Ctrl + Alt + K" key combination to perform a consistency check. The project should now be free from any errors.

2.4.17 Transferring the Project to the SIMOTION D

After completion of the configuring with "SCOUT", the following files must be transferred to the CF card of the SIMOTION D.



Copying language files and online helps for the AddOn system from the CD

The "SWAYCONTROL" directory must be created on the CF card. Into this directory, the following

"Sprache0.txt" and "Sprache1.txt" language files, and the

"Help_D.chm" and "Help_E.chm" online helps

must be copied from the CD.

Copying JAVA Runtime from the CD

From the "CD_1/Software/JAVA" directory on the CD, copy the files

"buffer.jar"

"jinvoke.xml"

"Simotion.jar"

"VMconfig.ini"

to the main directory of the CF card.

Transferring a SCOUT project

The successfully compiled SCOUT project must be transferred to the CF card. This requires that an online connection with the SIMOTION exists. Alternatively, a card reader can also be used.

Note After writing the CF card, a reboot must be performed.



Fig. 2-53: Transferring the SCOUT project

Creating and transferring a license key

At least one license key for the "SIMOTION Crane Sway Control Technology" on the SIMOTION D CF card is required. This must be created first.

Enter the license number and delivery note number (on your Certificate of License) on the Internet link www.siemens.com/automation/license

Create a license key and copy it to the CF card of the SIMOTION D

This enables the corresponding functionality of the AddOn technology.

2.4.18 Communication test

The communication between the PLC and the Sway Control system can be checked by issuing a signal and tracking the signal characteristic.

This path starts at the higher-level SIMATIC S7 controller. The signal must reach the SIMOTION using the I/O variables. From here, the signal from the MCC sources is queried and processed in the appropriate function blocks. Then the signal is forwarded to the DCC chart and from there to the MCC sources and technology objects. The signal returns to the S7 from the MCC sources; it goes from the technology object to the drive object (see following overview figure).


http://www.siemens.com/automation/license


Fig. 2-54: Signal characteristic overview figure

A signal characteristic in accordance with the above principle is observed step-by-step to improve understanding in the following section.

Signal characteristics

Step 1: Check execution system and SIMOTION in Run

Prior to the actual observing, a check must be made whether the programs in the execution system are assigned to the appropriate tasks, because otherwise the programs cannot be processed.

The "AddOn" and "Camera" MCC execution programs must be integrated in a cyclical task that should not be called more often than the DCC chart assigned in the default settings of the IPO task.

To activate the tasks, the SIMOTION must be switched to Run.

Step 2: Create value on the S7 and check on the I/O variables

The S7 writes a value (500 decimal = 0000.0001.1111.0100 binary) for the "DCC_SCTargets" block to the first word of the array. The I/O address range of 2092-2103 is reserved for the "DCC_SCTargets" DCC block.

When this value reaches the SIMOTION, it must be available in the I/O area. To do this, the "I/O" is selected and the symbol browser observed (see following figure).



Fig. 2-55: I/O area

The value specified by the S7 is present in the I/O area.

Note To prevent misunderstandings, the display format should be identical with that of the S7.

Step 3: Check the value at the inputs of the FB block

The "AddOn" MCC source or the "AddOn MCC" MCC program calls the "FB_TargetsPLCToAddOn" function block and accesses the array in the I/O area for which it was parameterized.



Fig. 2-56: Array assignment

Fig. 2-57: Signal in the function block



The "FB_TargetsPLCToAddOn" function block copies word 1 (targets_io_piw[0]) to the "b16_STW1" output and also separates it into bits. These are applied to the block outputs. The bit separation has the following form.

bo_STW1_Learn_Park_Pos = 0 (control word 1, bit 0)

bo_STW1_Learn_Lash_Platf = 0 (control word 1, bit 1)

bo_STW1_Use_Lash_Platf = 1 (control word 1, bit 2)

bo_STW1_Stack_Form_Bit0 = 0 (control word 1, bit 3)

bo_STW1_Stack_Form_Bit1 = 1 (control word 1, bit 4)

bo_STW1_Cycling = 1 (control word 1, bit 5)

bo_STW1_Offset_To_Land = 1 (control word 1, bit 6)

bo_STW1_Offset_To_Water = 1 (control word 1, bit 7)

bo_STW1_Use_Extern_Targets= 1 (control word 1, bit 8)

Because the "b16_STW1" word at the block output is no longer further interconnected, the following bit variables are set

bo_STW1_Use_lash_Platf

bo_STW1_Stack_Form_Bit0

bo_STW1_Stack_Form_Bit1

for tracking the signal.

Step 4: Check the value at the inputs of the DCC block

The outputs of the function block are interconnected with unit-global variables. The inputs and outputs of the DCC blocks from the DCC charts are interconnected with the unit-global variables. The three bit variables to be tracked are connected with the Targets block.



Fig. 2-58: DCC blocks

The three variables arrive at the block exactly as specified by the S7. Because the signals in the DCC block are further processed, they cannot be further tracked.

To track the path back to the S7, you can select a variable at the block output and track it back in the same manner.

The technology object has only the following variables supplied by the AddOn technology or sent back from the technology object.

AddOn technology TO object

TO_Trolley_1.Defaultmotionin.velocity

TO_Hoist_1.Defaultmotionin.velocity

TO object AddOn technology

TO_Trolley_1.positioningstate.actualposition

TO_Hoist_1.positioningstate.actualposition

TO_Trolley_1.motionstatedata.actualvelocity

TO_Hoist_1.motionstatedata.actualvelocity



2.4.19 Brief summary for various AddOn configurations

Simple Sway Control for ship unloader (minimum configuration)

Components to be removed:

MCC 'AddOn' DCC block in 'SwayControl'

I/O variables

- Blocks for receiving PLC data (Targets, Obstacles)

- Blocks for sending PLC data (Targets, Obstacles)

- Global variables for Targets, Obstacles

- DCC_SCTargets - DCC_SCObstacles

- AddOn _targets_receive - AddOn _targets_send - AddOn _obstacle1_receive - AddOn _obstacle1_send - AddOn _obstacle2_receive - AddOn _obstacle2_send

Simple Sway Control for container cranes



I/O variables

- Blocks for receiving PLC data (Targets, Obstacles)

- Blocks for sending PLC data (Targets, Obstacles)

- Global variables for TargetsObstacles

- DCC_SCTargets - DCC_SCObstacles

- AddOn _targets_receive - AddOn _targets_send - AddOn _obstacle1_receive - AddOn _obstacle1_send - AddOn _obstacle2_receive - AddOn _obstacle2_send

Sway Control‚ 2D-Trajectory and Bay Scanning with camera



I/O variables

- Blocks for receiving PLC data (Obstacles)

- Blocks for sending PLC data (Obstacles)

- Global variables for Targets, Obstacles

- DCC_SCObstacles

- AddOn _obstacle1_receive - AddOn _obstacle1_send - AddOn _obstacle2_receive - AddOn _obstacle2_send

TLS Control with camera






I/O variables

- Blocks for receiving PLC data (Trolley, Hoist, Targets, Obstacles)

- Blocks for sending PLC data (Trolley, Hoist, Targets, Obstacles)

- Global variables for Trolley, Hoist, Targets, Obstacle

- DCC_SCTrolley - DCC_SCHoist - DCC_SCTargets - DCC_SCObstacles

- AddOn _hoist_receive - AddOn _hoist_send - AddOn _trolley_receive - AddOn _trolley_send - AddOn _targets_receive - AddOn _targets_send - AddOn _obstacle1_receive - AddOn _obstacle1_send - AddOn _obstacle2_receive - AddOn _obstacle2_send - AddOn _slew_receive - AddOn _slew_send

Sway Control, TLS Control with camera



I/O variables

- Blocks for receiving PLC data (Trolley, Hoist, Targets, Obstacles)

- Blocks for sending PLC data (Trolley, Hoist, Targets, Obstacles)

- Global variables for Trolley, Hoist, Targets, Obstacle

- DCC_SCTrolley - DCC_SCHoist - DCC_SCTargets - DCC_SCObstacles

- AddOn _hoist_receive - AddOn _hoist_send - AddOn _trolley_receive - AddOn _trolley_send - AddOn _targets_receive - AddOn _targets_send - AddOn _obstacle1_receive - AddOn _obstacle1_send - AddOn _obstacle2_receive - AddOn _obstacle2_send - AddOn _slew_receive - AddOn _slew_send

SIMATIC S7 Configuration 3 3.1 Software Structure

3.1.1 Structure of the S7 blocks

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 is stored in the DB990 and DB995 data blocks. The SFC14 and SCF15 functions are responsible for receiving and sending data.

The blocks have the following specific tasks:

1. SFC15 Sends current data to the SIMOTION D via PROFIBUS

Sends the processed data from the provided data area (DB995) to the I/O output area.


SIMATIC S7 Configuration 3.1 Software Structure

Warning All data should not be transferred as consistent data.

2. SFC14 Receives current data from the SIMOTION D via PROFIBUS

Loads the received data from the I/O input area into the provided data area (DB990).

3. FB990 Processes the received data

Processes and links the received data.

4. FB995 Prepares all data

Prepares the transferred data for sending.

5. DB995 Send data for the SIMOTION D

6. DB990 Receive data from the SIMOTION D

3.1.2 Brief description of the S7 blocks

Table 3-1: Brief description of the data and function blocks

Function Name Description

FB990 AddOn _Recv_data Calls the instance blocks for the state signals

FB1831 AddOn _Recv_Common Relocates the state signals from the Common block from the I/O to an internal flag area

FB1832 AddOn _Recv_Hoist Relocates the state signals from the Hoist block from the I/O to an internal flag area

FB1833 AddOn _Recv_Trolley Relocates the state signals from the Trolley block from the I/O to an internal flag area

FB1834 AddOn _Recv_Slew Relocates the state signals from the Slew block from the I/O to an internal flag area

FB1835 AddOn _Recv_TLS Relocates the state signals from the TLS block from the I/O to an internal flag area

FB1836 AddOn _Recv_Targets Relocates the state signals from the Targets block from the I/O to an internal flag area

FB1837 AddOn _Recv_Obstacle Relocates the state signals from the Obstacle block from the I/O to an internal flag area

FB995 AddOn _Send_data Calls the instance blocks for the control signals Evaluation of the state signals and form the control signals for the Sway Control taking account of the crane signals

FB1841 AddOn _Send_Common Relocates the control signals from the Common block from the internal flag area to the I/O

FB1842 AddOn _Send_Hoist Relocates the control signals from the Hoist block from the internal flag area to the I/O

FB1843 AddOn _Send_Trolley Relocates the control signals from the Trolley block from the internal flag area to the I/O


SIMATIC S7 Configuration 3.2 Mode-independent Logic

Function Name Description

FB1844 AddOn _Send_Slew Relocates the control signals from the Hoist block from the internal flag area to the I/O

FB1845 AddOn _Send_TLS Relocates the control signals from the Slew block from the internal flag area to the I/O

FB1846 AddOn _Send_Targets Relocates the control signals from the Targets block from the internal flag area to the I/O

FB1847 AddOn _Send_Obstacle Relocates the control signals from the Obstacle block from the internal flag area to the I/O

DB990 AddOn _Receive_interface

Data block with state signals from the Sway Control system fetched from the I/O via SFC14 (FC1810)

DB995 AddOn _Send_interface Data block with state signals from the Sway Control system written to the I/O via SFC15 (FC1810)

FC1810 AddOn _Communication Calls SFC14 and 15 for reading and writing the I/O data

3.2 Mode-independent Logic

3.2.1 Formation of the “bTravel” travel signal

Note The travel signal must be set while the travel request exists and the "bPos_Completed" signal has not yet been set. Otherwise, the compensation of the swaying motion will be aborted and the target position not reached.

Fig. 3-1: Formation of the travel signal

3.2.2 Formation of the signal for opening and closing the brake

The signal for opening and closing the brake must be formed in the PLC with the following logic from the direction signals output from the Sway Control system.



Trolley Hoist

Fig. 3-2: Formation of the signal for closing the brake

Note The brake must be closed when no further direction signals are output; the brake must be opened in the opposite situation. The real mechanical brake opening times (0.5 -1.0 seconds) mean a time delay occurs between the "brake open" and "brake closed" signal. For this reason, the "brake closed" signal should always be applied to the "Brake_Closed" bit for trolley and hoisting gear. This means a dead time behavior for the control can be avoided.

3.2.3 Conversion of the Bay Scanner values

If a Bay Scanner is also used, this signal of the obstacle height is evaluated in addition to the traveled curve. If the Bay Scanner signal is valid, it takes priority over the learnt travel curve. This allows more exact values of the container stack to be determined.

Note Depending on the installation position of the laser, the system is able to travel to the next position in automatic loading operation.

The distance (hm) from the scanner to the surface of the container stack is measured (dashed lines). The PLC must convert this value into a laser value (hVB) that represents the distance between the hoisting height ZERO (h0) to the upper edge of the container stack at this position (Bay Scanner value, see following figure). The height between two valid measuring points is direction-dependent and is set to the height of the upper measuring point.

Fig. 3-3: Measurement of the height of the container stack with the laser scanner

Formula for calculating the obstacle height:

hVB=hs-hm



The conversion can be performed as follows in the PLC software for the evaluation of the Bay Scanner data (FC84 SIMO_Bayscanner):

1. Lower the spreader to the quay, and record the actual position of the hoisting gear (Actualposition hoistQuay) and the bay scanner value (Measured laser valueQuay).

Measured laser valueQuay= 45000 mm

h0 (Quay)Actualposition hoistQuay= 1000 mm

2. The measured laser value (Measured laser valueQuay) and the actual position of the hoisting gear (Hoist actualpositionQuay) at a defined position produce the installation height of the scanner (Scanner height hs) that can be calculated manually: hs = Measured laser valueQuay + Actualposition hoistQuay hs = 45000 mm + 1000 mm hs = 46000 mm



3. The converted laser value (Value Bay Scanner hVB) is then calculated using the Scanner height hs equation transferred with the "ValueBayscan" signal to the Sway Control computer: hVB = hs - hm

hVB = 46000 mm – 31000 mm hVB = 15000 mm

Fig. 3-4: Example of the conversion in S7 FC84 "SIMO_Bayscanner"

This converted laser value (Value Bay Scanner hVB) is also displayed in the "Hoist control [6]" display screen (Section 4.4.6.1).

4. Checking of the adjustment of the bay scanner values and the hoisting height in the "Hoist control [6]" display screen. These must be approximately the same (±100 mm) if the spreader is placed onto the quay.


SIMATIC S7 Configuration 3.3 Acceleration and Braking Behavior

Fig. 3-5: Checking of the adjustment of the bay scanner values and the hoisting height

3.3 Acceleration and Braking Behavior Load oscillations on container cranes and ship unloaders are eliminated by the specific manipulation of the acceleration and braking actions of the trolley.

The acceleration and braking behavior of the Sway Control is set using three ramps respectively acceleration values.

The acceleration without Sway Control / minimum acceleration (P7) generally corresponds to the same ramp that the drive also travels when the Sway Control is deactivated completely. The minimum acceleration acts as limitation when one of the following requirements is satisfied:

Prelimit switches act

Speed reduction caused by a change of the external override

The Sway Control software is used for the travel, although the "SC_ON" bit (= Sway Control on) is "0".

The minimum acceleration does not act In the normal travel range and when the override does not change. Then the Sway Control can also brake slower to catch the sway.

The maximum acceleration (P5) represents a limitation in the other direction. Under no circumstances the Sway Control will accelerate or decelerate greater than this ramp. Ideally, it should be set to maximum possible physical value.


SIMATIC S7 Configuration 3.4 Basic Operating Modes

The set acceleration (P6) forms the calculation basis for the actuator speed of the Sway Control. However, to ensure the catching of the sway, travel does not strictly follow this ramp.

The following settings are recommended:

P5: The maximum acceleration the drive can achieve

P6: Approx. 75% of P5

P7: The following condition applies: P7 < P6 < P5. The concrete value results from the position of the prelimit switches for the limit switches. The optimum values must be determined subsequently experimentally on the crane.

The observance of the limit values has always priority over catching the sway.

Fig. 3-6: Acceleration and deceleration behavior of the Sway Control

Note The brake must be closed when no further direction signals are output; the brake must be opened in the opposite situation. The real mechanical brake opening times mean a time delay occurs between the "brake open" and "brake closed" signal. For this reason, the "brake closed" signal should always be applied to the "Brake_Closed" bit for trolley and hoisting gear. This means a dead time behavior for the control can be avoided.

3.4 Basic Operating Modes The following basic operating modes are available for the trolley and hoist axes:

Speed control

Positioning

Hoist control



Sway-neutralization to load position (trolley only)

Sway-neutralization to trolley position (trolley only)

Only one basic operating mode can be selected for each axis at any time. The basic operating mode is selected by the PLC by setting the appropriate operating mode bit.

The AddOn operating modes listed in the following table result from the linking of various basic operating modes for trolley and hoisting gear in the PLC. AddOn operating modes are virtual operating modes as used by the crane operator.

Table 3-2: AddOn operating modes - basic operating modes relationship

AddOn mode Axis Basic operating mode Operating mode bit

Trolley Speed control OM_SPEED (Table 3-15) SC Speed Control

Hoist Speed control OM_SPEED (Table 3-15)

Trolley Hoist control OM_HOIST_CONTROL (Table 3-15) SC Automatic

Hoist Hoist control OM_HOIST_CONTROL (Table 3-15)

Trolley Positioning OM_POS (Table 3-15)

Hoist Speed control OM_SPEED (Table 3-15)

Trolley Sway neutralization to load position

OM_LOAD_POS (Table 3-15) SC Semi Automatic

Trolley Sway neutralization to trolley position

OM_TROLLEY_POS (Table 3-13)

Note The limit switches are direction-dependent and only the "Speed control" basic operating mode is permitted in the limit switch for which deceleration is made on the maximum ramp in the limit switch area. (See E7: "Invalid basic operating mode at the limit switch, trolley")

3.4.1 Speed control

In the "speed control" basic operating mode the speed is specified manually from a higher-level controller. This operating mode is also called manual mode in the rest of the documentation. The trolley is accelerated or decelerated to the set speed in such a way that the load sway has been eliminated when the set speed is reached. If the crane is to be operated in manual mode without Sway Control, this must be specified explicitly.

The possibilities of the different activation in this basic operating mode are described in section 3.6.1.2, "Possible settings".

Activation of the basic operating mode

The "speed control" basic operating mode is activated by setting the appropriate operating mode bit "OM_Speed" on the axes (see Table 3-15, Table 3-13, control bits for trolley and hoisting gear).

This basic operating mode can be started from all other basic operating modes without having to stop the drives.

Movements of the hoisting gear are possible during the speed control and have very little effect on the quality of the Sway Control.



Internal deactivation of the Sway Control system

The Sway Control system is internally disabled under the following conditions (although the axes can still be moved by the system):

The control bit "SC_ON" (= "Sway Control ON", see Table 3-15, trolley control bits) is reset.

The activation speed (P146) has not been reached.

The Sway Control activation delay (P147) has not yet expired.

When the Sway Control deactivation delay (P148) has expired after falling below the activation speed (P146).

The "SC_When_Stop" control bit (= Sway Control only for stopping, see Table 3-15, trolley control bits) is set. The Sway Control function is only active when stopping. This bit is only effective in the speed control mode.

The hoisting gear is located above the upper or below the lower Sway Control limit (P83, P84).

The license is damaged or missing.

Suppress opposite direction (P141)

Fig. 3-7: Conventional control, P141 = 75%, master switch 50%

Red curve represents the master switch. This is only actuated briefly in one direction. The blue line indicates the actuator speed, the pink line shows the oscillation model curve.

With P141 = 0, travel is briefly forward and then relatively long back to catch the sway. For very precise positioning, the crane operator often has problems with this behavior.

It is easier for the user if in this case the crane does not traverse back, but waits until the sway is forwards again and then always only traverses in one direction.

There are two ways to enable the other direction:

a) Travel is faster than the parameter

b) The other direction is enabled with the master switch

3.4.2 Positioning

The higher-level controller or the internal target generator can specify a target position for each individual axis in the "positioning" basic operating mode. This position is approached automatically



after enabling. The trolley is controlled in such a way that the load sway is eliminated not only when the maximum speed is reached, but also at the target position.

Both axes do not need to be in this basic operating mode at the same time.

CAUTION Blocked regions are not considered for the calculation of the course.

The possibilities of the different options in this basic operating mode are described in section 3.6.1.4, "Possible settings".


The "positioning" basic operating mode is activated by setting the appropriate operating mode bit "OM_Pos" (see Table 3-15, Table 3-13, control bits for trolley and hoisting gear).

Abort of the positioning

The positioning can be aborted at any time, by

Setting the "Controlled_Stop" control bit (see Table 3-15, trolley control bits), or

Resetting the "bTravel" travel signal (see Table 3-15, Table 3-13, trolley and hoisting gear control bits)

Resetting the "BRelease" signal (see Table 2-6: DCC_SCHoist connections)

Or resetting the "BOM_POS" signal (see Table 2-6: DCC_SCHoist connections)

Causes

The positioning should be aborted in the PLC for all errors where travel is no longer possible or in higher-level errors, e.g.

Overload

Specification of a new target from an external source (PLC)

When bit "bStart_2D_Calc" is no longer present

Drive faults

Emergency stop

Error in the position sensing

Loss of homing

If a limit switch has been overtraveled, the software internally aborts the positioning.



Response to overtraveling a limit switch

The crane stops with maximum deceleration and does not travel any further

The Sway Control function is deactivated

The automatic mode is not possible (see E7: "Invalid basic operating mode at the limit switch, trolley")

The crane can only be traversed in manual operation without Sway Control


The positioning with on-the-fly unloading utilizes the swinging of a grab when unloading bulk goods and saves turnover time in this way. The trolley is decelerated before the target position is reached while the grab sways to the target (e.g. funnel).

Note The on-the-fly unloading with constant angle can only be used with time-optimized control. On-the-fly unloading is only possible with an approximate constant angle in conventional mode.

CAUTION

Because of the rapid acceleration changes, the crane operator cabin should not be linked to the trolley in time-optimized operation.

The following figure shows an example of such a travel operation.

Fig. 3-8: Travel operation over time (in seconds) for on-the-fly unloading



The trolley initially decelerates from the 60 m position with time-optimized control to -1.7 m/s (travel from the waterside to land). The target position at 20 m is reached with a load deflection of approx. 0.8 m. The return travel is restarted shortly after the "Open_Grab" state bit (see Table 3-23, Common state bits) has been reset. The grab remains for approximately two seconds in the target area of 20 m … 21 m. The duration which the grab is present within a target area results mainly from the braking acceleration. The smaller the braking acceleration, the longer is the duration.

The following figure illustrates the unloading:

Fig. 3-9: Unloading operation for the on-the-fly unloading

Section 1:

Travel is started with time-optimized control. The "FLYING" control bit must be set.

Section 2:

In the acceleration phase, the load remains behind the accelerating trolley due to the mass inertia. The control reduces this offset as quickly as possible.

Section 3:

Because the trolley is in the braking phase, the grab sways forward. The signal to "open grab" (OPEN_GRAB status bit) is set because the "distance before opening the grab" (P31) has been undershot. The unloading begins (the loading good is dispatched in the funnel).

Section 4:

Once the trolley speed is less than the "on-the-fly unloading abort speed" (P30), the "OPEN_GRAB" state bit will be reset. A new target (ship) must be specified if the bit "CHANGE_TARGET" is set. The "FLYING" control bit must be reset.To save cycle time, the grab can remain open.



Activation of the on-the-fly unloading

To be able to use the on-the-fly unloading, the following conditions must be satisfied:

The specified target must be on the landside.

The "positioning" basic operating mode (command bit "OM_POS") must be set for the trolley and either the "positioning" or the "speed control" basic operating mode (command bit "OM_SPEED") for the hoisting gear or the "hoist control" basic operating mode (command bit "OM_HOIST_CONTROL") for both axes.

The time-optimized control must be activated in P152.

The "FLYING" control bit (= "on-the-fly unloading", see Table 3-15, trolley control bits) must also be set.

The actuator speed > "on-the-fly unloading abort speed" (P30).

The signal to "open grab" is set when the "distance before opening the grab" (P31) is undershot.

The best results are achieved with time-optimized control and on-the-fly unloading with a constant angle.

P30 and P31 must be set correctly o The "Open grab" signal (OPEN_GRAB status bit) must first be received via P31 o The time for resetting the "Open grab" signal (OPEN_GRAB status bit) is set with P30 and

therefore the setting time for "Change target" (CHANGE_TARGET status bit).

Note With the on-the-fly unloading, the prelimit switch bits must remain set if they are used.

On-the-fly unloading with the aid of a PT1 element (P38)

If the automatic mode with time-optimized control is selected, short deceleration ramps are inserted in the ramp-up operation and short acceleration ramps in the braking operation. This is the fastest possible way to suppress a swaying motion.

The grab is subject to trim oscillations especially in this mode. To reduce this, a PT1 element can be interposed to round off or delay the actuating signal.

The PT1 filter must be set so that its characteristic frequency is significantly below the frequency of the grab oscillation, but still significantly above the load oscillation.

Example: For a cable length of 20 m, the resulting frequency of the load oscillation is 0.11 Hz. With a grab oscillation frequency of approx. 0.4 Hz, the time constant of the PT1 must be set to approx. 4 s (corresponds to 0.25 Hz).

The grab oscillation frequency must be determined experimentally.

The larger the selected time constant, the greater the effect of the PT1 element; at the same time however, this has an adverse effect on the Sway Control.

If the parameter is set to zero, the effect of the PT1 is deactivated.

On-the-fly unloading with the aid of an input shaper (P39)

An input shaper can also be used for the elimination of the trim oscillation (see: On-the-fly unloading with the aid of a PT1 element).

The input shaper must be matched exactly to the grab oscillation frequency. The

grab oscillation frequency must be determined experimentally.

The grab frequency must not correspond to the load sway frequency for the input shaper to function correctly. The load sway frequency can be calculated from



. With g = acceleration due to gravity and l = effective pendulum length. Example:

Frequencies for typical grab oscillations on GSU cranes are between 0.3 Hz and 0.5 Hz. The effective pendulum lengths vary typically between 5 m and 30 m. This results in load sway frequencies between 0.22 Hz and 0.091 Hz. Therefore the input shaper functions correctly because this does not correspond to the grab frequency.

If contrary to expectation, both frequencies are nevertheless the same, the input shaper should not be used.

The effect on the Sway Control system is significantly less than with the PT1 element.

If the parameter is set to zero, the effect of the input shaper is deactivated.

Note Only one of two filters can be activated. The input shaper has priority, i.e. if it is active, the PT1 parameter is not taken into account.

3.4.3 Hoist control

Obstacles are taken into consideration during the automatic target approach in the "hoist control" basic operating mode. The load is moved along an optimum path curve. The swaying of the load has been eliminated when the stationary speed or standstill is reached. The hoist control enables collisions with obstacles located in blocked regions to be avoided.

The travel behavior with hoist control exhibits the following characteristics:

Advanced calculation of the travel course from the starting position to the target position taking account of the blocked regions.

It is possible to disable the automatic target approach on the waterside (automatic mode - P109). Automatic journeys are only possible in the land direction. This only applies when no external targets are specified (bUse_Extern_Targets = 0 bit).

To give the crane operator trust in the automatic target approach, the spreader is lowered after a specific trolley position for each travel from the waterside to the landside. At the earliest, this position is two spreader widths before the water/land boundary.

Both axes (hoist, trolley) must be in this basic operating mode and are controlled concurrently. The transition to the "speed control" basic operating mode always effects the trolley travel and the hoisting gear.

The hoist control is configured via parameters.

The possibilities of the different activation in this basic operating mode are described in Section 3.6.1.3, "Possible settings".


The "hoist control" basic operating mode is activated by setting the appropriate operating mode bit "OM_Hoist_Control" on both axes (see Table 3-15, Table 3-13, control bits for trolley and hoisting gear).



Taking account of blocked regions

The principles for blocked regions are described in Section 2.3.3. Notes for considering blocked regions are contained in Section 3.6.2.5.

Target generator

The Target generator function monitors the activities of the crane operator and "remembers" where containers are picked up or put down. Once the "DCC_SCTargets" block is contained in the "SwayControl" DCC plan, the "memory" for all travel movements in all basic operating modes will be activated.

The "memory" on the waterside is cleared when the "Learn_Profile_Reset" (see Table 3-11, Common control word) is set and consequently the internally learnt variable blocked regions deleted. This must be done, at least, when the gantry travels. The land position is retained, as it is assumed that the truck track does not change.

If the target generator knows useful positions, the automatic approaches these independently at the start of a travel operation. If, for example, a container has just been fetched from a truck, the next logical position is the place where the previous container was put down (on the ship). The crane recognizes whether the crane operator wants to load or unload.

The S7 interface (bits 2-4, Targets control word, Table 3-19) can be used to specify

Stacking type

Approach of the parking position

Use of the lashing platform

The stacking type is the method of operation with which the automatic stacks the containers on the ship. The options are column-by-column, row-by-row towards the land or row-by-row away from the land.

Note For the "row-by-row towards land" stacking type, the automatic does not go beyond the water-land boundary; a subsequent manual travel must follow.

Note If the stacking type is changed, a manual travel is necessary because the next internal target is unknown. The current travel is terminated.

If a lashing platform is used, it will be integrated in the sequences.

WARNING The lashing position should normally always be approached from above. This means that a fixed blocked region must be defined below this position and two others that are higher, in front and behind. The automatic mode then always lowers from above down to the lashing platform.


The on-the-fly unloading can also be used in the "hoist control" basic operating mode. The trolley and the hoisting gear must be in this basic operating mode for this. Further information on the activation can be found in Section 3.4.2, at On-the-fly unloading.



Horizontal trolley travel over the hopper (P75/P76)

The parameters specify the minimum length which the trolley is to travel over the hopper (unloading funnel) without executing a hoisting motion. The calculation of the travel curve can be influenced with these parameters independent of blocked regions; in effect, a horizontal distance is inserted. The parameters act in both directions, ship to hopper travel (P75) and hopper to ship travel (P76). They have no effect when the value is zero.

P75/P76 are optimized for the special requirements of the on-the-fly unloading for GSUs. The following supplementary conditions therefore apply for their use: The obstacle around the hopper is significantly higher than all other obstacles between start and

target (usually this is the case) this is the only way to ensure a sufficiently long straight travel path.

The target above the hopper must be higher than the obstacle + safety and travel clearance. Non-compliance with the parameters P75/P76, i.e. the starting point of the automatic travel is the minimum clearance (value of parameter 75/76), also reduces the horizontal travel over the hopper. This can result angular looking travel curves. However, compliance with the supplementary conditions listed is still required. If the target is changed during travel, make sure that the system reacts immediately. This means that when switching over during on-the-fly unloading, the HW target must never come before the trolley target, as otherwise the target position is in the hopper obstacle for a brief moment. The Sway Control then correctly triggers an error. The S7 programmer must therefore always change the trolley target first because a consistent transmission via PB not possible via the entire interface.

3.4.4 Sway neutralization to load position (trolley)

The "sway neutralization to load position" basic operating mode (only for the version with camera) is used to eliminate swaying movements of the load from standstill. The sway neutralization is linked to a positioning, whereby the target position is the load position in basic operating mode at the time the travel signal is switched on.

The load position is calculated from the actual position of the trolley + the load deflection.

The sway neutralization results in slight travel movements to both sides of the target position.

The signal sequence corresponds to that of the positioning.

3.4.5 Sway neutralization to trolley position (trolley)

The "sway neutralization to trolley position" basic operating mode (only for the version with camera) is used to eliminate swaying movements of the load from standstill. The sway neutralization is linked to a positioning, whereby the target position is the trolley position in basic operating mode at the time the travel signal is switched on.

The sway neutralization results in slight travel movements to both sides of the target position.

The signal sequence corresponds to that of the positioning.


SIMATIC S7 Configuration 3.5 Activation of the AddOn Technologies in the Basic Technology

3.5 Activation of the AddOn Technologies in the Basic Technology In the basic technology /Ref. 2, Sections 4.3.4 and 4.3.5/, there is an axis-related "Sway Control" basic technology operating mode, with which the AddOn technologies (Section 1.1) are activated.

When the "Sway Control" basic technology operating mode is active, the entire motion control is specified by the AddOn technologies (Fig. 2-2). Neither the motion control nor the monitoring is then performed by the basic technology.

When the "Sway Control" basic technology operating mode is not active and consequently one of the basic technology modes is active, the entire motion control and the monitoring are performed by the basic technology. To prevent jerky movements when switching from an arbitrary basic technology operating mode to the "Sway Control" basic technology operating mode, it is useful to run the used AddOn technology/technologies in parallel despite inactivity.

The "Sway Control" basic technology operating mode is selected by the S7 controller in application control word 1, bit 15. The basic technology returns the state of the "Sway Control" basic technology operating mode axis related in application status word 1, bit 15. The other basic technology modes may not be selected (application control word1, bit 9 to bit 14). Switchover to the "Sway Control" basic technology operating mode is made only when all the conditions mentioned below are satisfied:

Requirements for the associated axis:

1. Selection of the "Sway Control" basic technology operating mode

2. No error is present

3. The drive is not in closed-loop control

4. Axis homed

In SIMOTION D, the Motion-In interface will be activated when the "Sway Control" basic technology operating mode is selected. This means the speed setpoints are not transferred by the travel commands to the technology object, but rather the speed setpoint is transferred directly from the AddOn technology to the technology object.

Note Irrespective of whether the "Sway Control" basic technology operating mode is active or not, an additional speed setpoint is available from the basic technology (DCC block "DCC_StartPulse") in mm/s for the hoisting gear. This prevents or reduces the "load sag" when starting the hoisting gear with a suspended load.

Note In master-slave operation or synchronous operation, the "Sway Control" basic technology operating mode must be selected for both the master and the slave.

Note The PLC must contain a logic for the selection of the basic technology operating mode that does not select any basic technology operating mode in a fault situation.

The feedback "Sway Control active" (via HOIST1_APPL_ZSW1_BIT15 and TROLLEY1_APPL_ZSW1_BIT15) sets the release for the "Trolley" and "Hoist" blocks in the "Sway Control" AddOn technology.


SIMATIC S7 Configuration 3.6 Sway Control Configurations

Fig. 3-10: "Sway Control" release sequence

Section 1:

Activate the "Sway Control" basic technology operating mode via the basic technology. If a successful activation is confirmed, the individual axes of the AddOn technology (trolley, hoist) can be released.

Section 2:

Normal operation with AddOn technology.

Section 3:

Deselect the "Sway Control" basic technology operating mode via the basic technology.

3.6 Sway Control Configurations The Sway Control system is configured using parameters (Section 4.3) and can be controlled by the PLC by setting various control bits.



3.6.1 Sway Control (manual mode)

3.6.1.1 Required blocks



Length (byte)

I/O address range




3.6.1.2 Control in the "SC Speed Control" AddOn mode

In the "SC Speed Control" mode, the travel signal is set by actuating the master switch. If all input signals are fault-free, the Sway Control system issues an actuator speed to the drives.

If one of the two direction signals is active, the brake must be opened. As long as the brake is closed, an actuator speed is not output.

The travel signal can be reset when "bPos_Completed" (positioning complete) is signaled.

CAUTION As soon as a drive axis of the Sway Control system receives valid travel signals, the actuating signals should also be used for the drives. In the reverse case, if control is not requested by the Sway Control system, the travel signals have to be reset. Otherwise there may be sudden travel movements.

Stopping through the demand of a speed setpoint of zero is recommended.



S

R

≠0.0

bBrake_Closed

rV_Set_HO

bTravel

MC-Hoisting gear

&

rV_Pos_HO

bTravel_UPbTravel_DN

bPos_Completed

HoistDrive Hoisting gear

Travel signals Brake control

Actuating signalsSway Control

bRelease (1)

BT

TO

PLC PLCSIMOTION D

bOM_Speed (1)

Fig. 3-11: Control in the "SC Speed Control" AddOn mode, hoisting gear

S

R

≠0.0

bBrake_Closed

rV_Set_TR

bTravel

MC-Trolley

&

rV_Pos_TR

bTravel_FWbTravel_BW

bPos_Completed

TrolleyDrive Trolley

Travel signals Brake control

Actuating signalsSway Control

bRelease (1)

BT

TO

PLC PLCSIMOTION D

bOM_Speed (1)

Fig. 3-12: Control in the "SC Speed Control" AddOn mode, trolley



Start of a travel motion

Requirements

The following is true for the "DCC_SCHoist" and "DCC_SCTrolley" blocks. The set velocity (rV_Set_HO, rV_Set_TR) is ZERO before travel starts. All other signals should have a value within the value range (i.VR).

In this AddOn mode, only the following signals are taken into account on the "DCC_SCCommon" block:

The "iParSet" signal that transfers the number of the associated parameter set, and

"bDig_Hoist_Dist_Corr" signal (see Sections 3.7.1.1 and 4.7.2.2).

Table 3-4: Assignment of the input signals for Sway Control

DCC_SCHoist DCC_SCTrolley DCC_SCCommon

Name Default

Name

Default

Name

Default

bRelease 1 bRelease 1 iParSet i.VR

bTravel 0 bTravel 0 bNo_Wait_Pos 1

bOM_Pos 0 bOM_Pos 0 bHoist_Man 0

bOM_Speed 1 bOM_Speed 1 bLocked_Bit0 0

bOM_Hoist_Control 0 bOM_Load_Pos 0 bLocked_Bit1 0

bLS_UP 1 bOM_Trolley_Pos 0 bSlackrope 0

bLS_DN 1 bOM_Hoist_Control 0 bBayscanner_Valid 0

bPreLS_UP 1 bSC_ON 1 bLearn_Profile_On 0

bPreLS_DN 1 bLS_FW 1 bLearn_Profile_Reset 0

bBrake_Closed 1 bLS_BW 1 bDig_Hoist_Dist_Corr 0

iOverride i.VR bPreLS_FW 1 bStart_2D_Calc 0

rField_Weak i.VR bPreLS_BW 1 bSpreader_LS 0

rS_Act_HO i.VR bBrake_Closed 1 iLoad 0

rS_Set_HO_Extern i.VR bSC_When_Stop 0 iDS_Width 5000

rV_Act_HO i.VR bControlled_Stop 0 iValue_Bayscanner 0

rV_Set_HO 0 bFlying 0 iCount_Bayscanner 0

iOverride i.VR

rS_Act_TR i.VR

rS_Set_TR_Extern i.VR

rV_Act_TR i.VR

rV_Set_TR 0



A travel motion is triggered by setting the "bTravel" travel signal with the master controller and by resetting the "bBrake_Closed" signal.

The following signal sequence is performed:

Fig. 3-13: Signal sequence at the start of a travel motion

Section 1:

The Sway Control system is activated and the "speed control" basic operating mode selected with help of the "bOM_Speed" bit for all used axes.

Section 2:

The master switch is deflected. The travel signal must be set (see Section 3.2.1). If this is the case and no fault is present, the direction signals, and thus the signals for opening the brake, are output (see Section 3.2.2).

Section 3:

The brake is opened. The actuator signals are transferred to the drives.

End of a travel motion

The travel motion is complete when the actuator speed is small and the "bPos_Completed" positioning status bit is set by the Sway Control system.

This requires that the set velocity (rV_Set_HO, rV_Set_TR) is set to zero.


Fig. 3-14: Signal sequence at the end of a travel motion for the "SC Speed Control" AddOn mode



Section 1:

Sway-controlled travel.

Section 2:

The travel has been terminated by the master switch; the actuator speed becomes smaller.

Section 3:

Actuator speed is ZERO which causes the "bPos_Completed" signal to be set.

Section 4:

The travel signal must be reset (see Section 3.2.1). This causes no direction signals to be output and so the signal to close the brake initiated (see Section 3.2.2).

Section 5:

The brake has been applied.

Possible settings

Mode

Two different operating modes are possible for the trolley in the speed control:

Mode 1: Sway Control is active permanently. The Sway Control function is already active when accelerating to a specified constant speed. In this way, the load sway is suppressed during travel and has been eliminated when the constant speed is reached.

Mode 2: Sway Control is only active when stopping. In this mode the load sway is only eliminated when stopping. As with mode 1, the load sway has been eliminated after stopping. The load sway is not corrected when starting.

The changeover is made with the command bit "bSC_When_Stop" (= "Sway Control only when stopping", Table 3-15, trolley control bits) from the crane PLC.

Activating/deactivating the Sway Control function

The Sway Control function can be activated or deactivated by the "bSC_ON" command bit (= "Sway Control ON", see Table 3-15, trolley control bits). When the function is switched off, the controller generates standard ramps corresponding to the set accelerations.

The internal activation of the Sway Control function is indicated by the "bSC_State" status bit (= "Sway Control ON", see Table 3-30, trolley status bits).

3.6.1.3 Control in the "SC Automatic" AddOn mode

The entire loading and unloading operation is performed in this mode. When the loading or unloading is completed, a new operation is started by the crane driver again.

For the "SC Automatic" AddOn mode, the "hoist control" mode is activated. In this AddOn mode, the travel signal is triggered by the "Start Automatic" signal (e.g. by foot-operated pushbutton). The system checks whether the automatic can be started. The reasons why an automatic start is unsuccessful can be obtained from the "INFO_NO_AUTO_START" status word, Table 3-26. If one of these conditions is not satisfied, the "bStart_Auto_OK" status bit will not be set. An automatic start should be made only when this bit is set.

CAUTION If the "bStart_Auto_OK" status bit is not used for the automatic start, the PLC programmer must ensure an appropriate monitoring of the conditions listed in Table 3-26.



If all input signals are without error and the "Start_2D_Calc" signal is set in the PLC, the travel curve can be calculated and a positioning speed issued to the trolley and the hoisting gear. The positioning speed of the trolley and the hoisting gear is determined by the P1 and the P41 parameter, respectively.

If one of the two direction signals is active, the brake must be opened. As long as the brake is closed, no positioning speed will be output.

The travel signal can be reset when "bPos_Completed" (positioning complete) is signaled.

CAUTION If the automatic travel is interrupted by signals (e.g. bRelease = 0), but the travel signal is not present, the crane continues with automatic travel when the signal returns. Uncontrolled travel motion can result. It is recommended that the travel signals are reset when automatic travel is interrupted.

CAUTION

If the "Start_2D_Calc" signal is removed during automatic travel, the crane stops with Sway Control. The "Start_2D_Calc" bit is a signal for the acceptance of variable external obstacles, etc. This is prohibited during travel. External variable obstacles must be transferred prior to the automatic travel.

Various setpoints and actual values can be checked during travel with the "Hoist control [6]" display (see Section 4.4.6.1).

Fig. 3-15: Control in the "SC Automatic" AddOn mode, hoisting gear



Fig. 3-16: Control in the "SC Automatic" AddOn mode, trolley

Start of a travel motion

Requirements

The following is true for the "DCC_SCHoist" and "DCC_SCTrolley" blocks: All Boolean input signals should be set or reset for a simple positioning as described. For at least one axis, the target position must differ from the actual position (rS_Set_HO_Extern ≠ rS_Act_HO or rS_Set_TR_Extern ≠ rS_Act_TR). All other signals should have a value within the value range (i.VR).

In this AddOn mode, all signals are used on the "DCC_SCCommon" block and many combinations are possible. When the specified values are created, only those fixed blocked regions saved during the commissioning in the parameter file are considered during the travel.

The "DCC_SCTargets" block must be available for the use of internal targets (only STS).

When the "DCC_SCTargets" block is used, the target positions are used depending on the "bUse_Extern_Targets" bit. If this is not present, the external targets are always used as target positions:

"bUse_Extern_Targets" = 1: Targets from the PLC

"bUse_Extern_Targets" = 0: Targets from the target generator



Table 3-5: Assignment of the input signals for Sway Control with 2D-Trajectory

DCC_SCHoist DCC_SCTrolley DCC_SCCommon

Name Default

Name

Default

Name

Default

bRelease 1 bRelease 1 iParSet i.VR

bTravel 0 bTravel 0 bNo_Wait_Pos 1

bOM_Pos 0 bOM_Pos 0 bHoist_Man 0

bOM_Speed 0 bOM_Speed 0 bLocked_Bit0 0

bOM_Hoist_Control 1 bOM_Load_Pos 0 bLocked_Bit1 0

bLS_UP 1 bOM_Trolley_Pos 0 bSlackrope 0

bLS_DN 1 bOM_Hoist_Control 1 bBayscanner_Valid 0

bPreLS_UP 1 bSC_ON 1 bLearn_Profile_On 0

bPreLS_DN 1 bLS_FW 1 bLearn_Profile_Reset 0

bBrake_Closed 1 bLS_BW 1 bDS_ON 0

iOverride i.VR bPreLS_FW 1 bDig_Hoist_Dist_Corr i.VR

rField_Weak i.VR bPreLS_BW 1 bStart_2D_Calc 0

rS_Act_HO i.VR bBrake_Closed 1 bSpreader_LS 0

rS_Set_HO_Extern i.VR bSC_When_Stop 0 iLoad i.VR

rV_Act_HO i.VR bControlled_Stop 0 iDS_Width 5000

rV_Set_HO i.VR bFlying 0 iValue_Bayscanner 0

iOverride i.VR iCount_Bayscanner 0

rS_Act_TR i.VR

rS_Set_TR_Extern i.VR

rV_Act_TR i.VR

rV_Set_TR i.VR

A travel motion of the hoisting gear and trolley gear are triggered by setting the "bTravel" travel signal with "Start Automatic" (e.g. foot-operated button). The "bStart_2D_Calc" bit on the "DCC_SCCommon" must also be set. This starts the calculation of the travel curve. The "bBrake_Closed" signal must be reset once direction signals have been issued. The travel motion begins.

The travel signals must remain set throughout the entire travel motion as in the other AddOn modes. The following signal sequence is performed:



Fig. 3-17: Signal sequence at the start of "SC Automatic" AddOn mode

Section 1:

The Sway Control system is activated and the "hoist control" ("bOM_Hoist_Control" bit) basic operating mode selected for the hoisting gear and the trolley. A target position has been specified.

Section 2:

The "automatic start" (e.g. with foot-operated pushbutton) has been triggered. If no fault has occurred that blocks this AddOn mode ("bStart_Auto_OK" bit set), the travel signal must be set. The "bStart_2D_Calc" control bit (common block) should be set only when all external variable blocked regions have been transferred. This starts the calculation of the travel curve. When the calculation has finished, direction signals and thus the signals for opening the brake will be issued.

Section 3:

The brake is opened. The actuating signals are issued to the trolley and the hoisting gear, and the positioning of the two axes commenced.

During the raising, the field weakening is determined and the speed during the travel corrected.

End of a travel motion

The travel motion in the "SC Automatic" AddOn mode is complete when the "bPos_Completed" positioning status bit is set by the Sway Control system.

Requirements

The actual position in the tolerance of the target position has been reached (rS_Act_TR=rS_Set_TR_Extern ± tolerance, rS_Act_HO=rS_Set_HO_Extern ± tolerance).

The "bSC_Completed" (sway-neutralized) bit at the "DCC_SCTrolley" trolley block is set. This is achieved with a residual load deflection.




Fig. 3-18: Signal sequence at the end of positioning in the "SC Automatic" AddOn mode

Section 1:

Sway-controlled travel of both axes to the target position.

Section 2:

Actual position (rS_Act_HO, rS_Act_TR) comes near the target position; actuator speed becomes smaller.

Section 3:

Target position is reached, actuator speed is ZERO, which causes the "bPos_Completed" signal to be set.

Section 4:

The travel signal must be reset (see Section 3.2.1). This causes no direction signals to be output and so the signal to close the brake initiated (see Section 3.2.2).

Section 5:

The brake has been applied.

Possible settings

Manual hoisting motion during the "SC Automatic" AddOn mode

During an automatic positioning operation in the "SC Automatic" AddOn mode, the hoisting motion can be diverted from the intended path by an external control.

The relevant monitoring functions and error messages are deactivated by setting the "Hoist_man" control bit (= "Manual actuation of hoisting gear", see Table 3-11, Common control bits). The specified target position is still approached by the trolley. The set "hoist control" basic operating mode does not need to be switched here.

The Sway Control must be informed of the actuating signal via the "rV_Set_HO" hoisting gear speed setpoint (see Table 3-13, hoist control bits) by the basic technology.

After resetting the "Hoist_man" control bit, the spreader is guided back to the calculated path with the aid of the position controller.



Interruption of the "SC Automatic" AddOn mode

In this AddOn mode, the travel motions can be interrupted at one of the positions specified with parameters (P25, P65), if the command bit "NO_WAIT_POS" (= "Wait position not approached", see Table 3-11, Common control bits) is not set.

If a waiting position is to head for, approach is first made to the trolley position (P25) located on the travel curve. Shortly before reaching this position, the hoisting gear will be lowered or raising to the parameterized value (P65). If the "NO_WAIT_POS" command bit is set before the waiting position is reached, travel will be continued to the target position without interruption.

Start of the "SC Automatic" AddOn mode during a manual hoist operation with Sway Control

General It is possible to start the "SC Automatic" AddOn mode during a manual hoist operation. In this way, the crane operator can first lift the spreader out of the hazardous area and then switch to automatic control without stopping.

Note Protection must be provided in the PLC against an unintentional operator error, so that the "SC Automatic" AddOn mode is stopped when the master switch is not released within two seconds after the automatic start.

Start on the landside The following steps are performed when starting on the landside:

Raising until the "Slack rope" signal (see Table 3-11, Common control word) is no longer set

Slow hoisting to determine the field weakening coefficient (if supported by the crane control)

Rapid hoisting

Alternatively, the start can be programmed exclusively from a hoisting movement through operating mode control.

Start on the waterside If the "bStart_Auto_OK" status bit is used for the automatic start, a start on the waterside is only possible when no "Slack rope" (see Table 3-11, Common control word) is detected and the hoisting gear is located above the immersion point (see Section 3.6.2.3). If these conditions are fulfilled, the following steps are performed:

Slow hoisting to determine the field weakening coefficient

Rapid hoisting

Start of the "SC Automatic" AddOn mode with slack rope

If the "SC Automatic" AddOn mode should be started even though the "Slack rope" bit is still set, the "bSTART_AUTO_OK" bit must not be evaluated.

If P47 > 0 is set, the automatic starts at reduced speed until the "Slack rope" bit is no longer set. If, because of a defect (e.g. defective force transducer), the "Slack rope" bit remains set during the lifting action, lifting continues until the maximum travel range or limit switch is reached; the trolley, however, does not travel.



CAUTION

The monitoring of the load cell must be implemented in the PLC. The PLC decides when the automatic is terminated if the "Slack rope" signal is present continually.

Override

The travel speed can be reduced in all basic operating modes using an externally definable "Override" (see Table 3-12, hoist control bits) between 0% and 100%. This speed reduction is useful for commissioning purposes (test with reduced speed).

The external override may change in steps. The effect is delayed as internal acceleration limits are maintained.

A superimposed internal override takes effect when prelimit switches are triggered.

During automatic travel, deviations from the spatial trajectory calculated at the start time can occur when the override has too many sudden changes or changes >10%.

This may also result in the hoisting gear traversing to the range limit and then stopping with an E35 error message (e.g. when the override is switched back and forth between 10% and 100% in the 100 ms cycle).

Note Too frequent changes of the override are technologically unnecessarily and result in increased system wear.



Fig. 3-19: Field weakening flow chart

The speed setpoint is specified in the "SC Speed Control" AddOn mode by the master switch and in the "SC Automatic" AddOn mode by the internally calculated speed setpoint.

Use of the "bOpen_Grab" (open grab) status bit

The time after when the opening of the grab is possible is specified with parameter P31 (distance for opening the grab) and triggers the setting of the "Open_Grab" status bit (see Table 3-23, Common status bits). This bit can be used to open the grab.

If the bit “Change_target” is set the grab can be closed again. The positioning control expects at this time a new target (position over the ship) for the start of a new travel. The reset is triggered by parameter P30 (on-the-fly unloading abort speed).



3.6.1.4 Control in the "SC Semi Automatic" AddOn mode

Under this operating mode, not all the loading and unloading take is performed automatically, only a part. Another part is performed manually by the operator.

This AddOn mode is therefore a combination of automatic and manual operation. One axis is in the "Positioning" ("bOM_Pos" bit) basic operating mode and the other axis in the "speed control" ("bOM_Speed" bit) mode. The axis in the "positioning" basic operating mode continues to travel automatically to the assigned target. Note that blocked regions are not considered. The crane operator controls the other axis with the master switch in the "Speed control" basic operating mode. An application example for this AddOn mode is the so-called hoisting gear acceptance.

Hoisting gear acceptance

For this operation, the Sway Control system is in the "SC Automatic" AddOn mode and travel has started. The crane operator accepts the hoisting gear with the master switch, for example, to lower faster.

When the trolley and the hoisting gear is in the "hoist control" ("bOM_Hoist_Control" bit) basic operating mode, an operating mode switchover can be performed through actuating the master switch with the following logic (Fig. 3-20).

The basic operating mode of the hoisting gear is immediately switched to "speed control" ("bOM_Speed" bit).

The basic operating mode of the trolley is switched to "positioning" ("bOM_Pos" bit) when the "bHoist_TakeOver_OK" confirmation bit (bit 6 in the "ZSW1_Common_PLC" status word, Table 3-23) is set. The trolley continues to travel automatically to the target.

If the "bHoist_TakeOver_OK" bit is not set, the trolley will also be switched to the "speed control" basic operating mode.

The "bHoist_TakeOver_OK" bit is set when a safe height is reached and consequently no blocked region exists between the current position and the target position of the trolley.

CAUTION If the "Hoist_TakeOver_OK" bit is set, a collision check is no longer possible. Consideration of any obstacles is the responsibility of the crane operator.



Fig. 3-20: Hoisting gear acceptance

Fig. 3-21: Hoisting gear acceptance status diagram



Case A

Section 1:

Hoisting gear and trolley are in the "Hoist control" basic operating mode ("bOM_Hoist_Control" bit). The hoisting gear is not yet at a safe height, i.e. the "bHoist_TakeOver_OK" confirmation bit is not yet set.

Section 2:

The crane operator deflects the master switch and so requests a hoisting gear acceptance. Because the danger of a collision still exists, this action must cause termination of the trolley motion. The trolley and the hoisting gear are switched to the "speed control" basic operating mode ("bOM_Speed" bit).

Section 3:

Trolley and hoisting gear are in the "speed control" basic operating mode ("bOM_Speed" bit), the crane operator has complete control over both axes with the master switches.

Case B

Section 1:

Trolley and hoisting gear are in the "hoist control" basic operating mode ("bOM_Hoist_Control" bit). The hoisting gear is at a safe height, i.e. the "Hoist_TakeOver_OK" confirmation bit is set.

Section 2:

The crane operator deflects the master switch and so requests a hoisting gear acceptance. Because no danger of a collision exists, the trolley and the hoisting gear can be switched to the "positioning" basic operating mode ("bOM_Pos" bit) and the "speed control" basic operating mode ("bOM_Speed" bit) respectively.

Section 3:

The trolley is in the "positioning" basic operating mode ("bOM_Pos" bit), i.e. it moves further in the direction of the specified target without, however, taking account of any obstacles. The crane operator is responsible for the safe height of the load. The crane operator has complete control over the hoisting gear with the master switch.

Note

An acceptance of the hoisting gear from the automatic into the manual mode should be prevented by the PLC when the master switch is actuated only very briefly (unintentional operator error). This delays the acceptance of the hoisting gear into manual mode by the wait time.

Note The conditions when the "SC Semi Automatic" AddOn mode should be cancelled are described in Section 3.4.2.

3.6.1.5 Taking account of blocked regions

The principles for the blocked regions are contained in Section 2.3.3 and the notes for the behavior of the system in Section 3.6.2.5.



DANGER

The blocked regions are only taken into account in the "Hoist control" basic operating mode. In all other basic operating modes, also the "Positioning" basic operating mode, collisions can occur if the crane operator is inattentive.

Note The PLC requires the position of the lower edge of the spreader as the position to the hoisting gear (concerns hoist (TO) actual position) for the calculation of the path curve

3.6.2 Sway Control with 2D-Trajectory and Bay Scanning




Length (byte)

I/O address range




DCC_SCTargets (optional; for use of the learning mode and the Bay Scanner)

Targets 45 12 2092-2103

Blocked regions Block1

45 32 2104-2135 DCC_SCObstacles (optional; for transfer by PLC) Blocked

regions Block2 45 32 2136-2167


The control in the "SC Speed Control" AddOn mode is made in this configuration in the same method of operation as for Sway Control (see Section 3.6.1.2). The statements concerning the parameter sets also apply here (see Section 4.3).

3.6.2.3 Control in the "SC Automatic" AddOn mode

The control in the "SC Automatic" AddOn mode is made in this configuration in the same method of operation as for Sway Control (see Section 3.6.1.3). The statements concerning the parameter sets also apply here (see Section 4.3). In addition to the settings specified in Section 3.6.1.3, the following functions can be controlled:



Possible settings

Target generator

The blocked regions on the waterside can be learnt by observing the spreader motions in this configuration. The learning process is started by setting the "Learn_Profile_ON" bit (bit 8 in the "STW1_PLC_Common" control word, Table 3-11). In addition to learning the height profile, the function "notes" where containers can be picked up or placed down. If the automatic control knows useful positions, it approaches these independently at the automatic start. Further information for the execution and for the target generator are contained in Section 3.4.3.

Position offset

An offset can be given to the trolley position automatically for the automatic target approach to simplify the loading and unloading tasks above deck. A stop is made shortly before or after a calculated target.

The most recently approached target position is saved internally at the load change when loading or unloading (logic combination of the interlock state change, the slack rope signal, load change cycle) and an offset is added for the next target approach of the trolley.

Two different offset values can be saved in the P35 (position offset for unloading) and P36 (position offset for loading) parameters. Depending on the locking state of the spreader, the corresponding value in the target generator is used.

Selection possibility for the direction of the position offset The "Offset_To_Land" and "Offset_To_Water" control bits (see Table 3-19, Targets control word) can be used to select the offset increment in the water- or landside direction. The control can be made, for example, from a Crane Operator Panel or a control element. A negative or a positive offset is added for the next target position approach (trolley only). If none of the control bits is set, the trolley positions again at the last target position.

Fig. 3-22: Normal path for container pick-up in automatic mode



Fig. 3-23: Changed stopping point in automatic mode with Offset_To_Land

Fig. 3-24: Changed stopping point in automatic mode with Offset_To_Water

Immersion point

The immersion point is active for the STS crane. The immersion point is deactivated for the GSU crane.

The immersion point is a conservative estimate of the hoisting height learnt by observing the manual travel above which the trolley can be freely positioned above the ship. This means, no superstructure (cell guides, frames for container fastening, etc.) is present above this height.

No automatic travel is possible here because the bit is not set and it is assumed that the spreader is located in the cell guides or between two container stacks.

The following figure shows the principle of the immersion point. At point A, the immersion point is set to a value that lies above the "real" deck height because the spreader immerses between two container stacks. Point B lies approximately in the height of the ship deck and corresponds to the beginning of the cell guides.



Fig. 3-25: Principle of the immersion point

The "Learn_Profile_Reset" bit (bit 9 in the "STW1_PLC_Common" control word, Table 3-11) resets both the immersion point and the height profile to their initialization values. The initialization value for the immersion point results from P69 (maximum position for hoisting gear positioning) – 3*P108 (maximum container height).

The immersion point is set dynamically to the current hoisting height when one of the following two conditions is satisfied:

The trolley moves on the waterside above the speed limit P46 + 10%, the hoisting gear, however, is located below the current immersion point.

For the transition of the trolley speed from 10% above to 10% below the speed in parameter P46, the current immersion point is set on the waterside. The value refers to the maximum speed of the trolley.

Example (following figure):

P46: 20% (upper limit value: 30%; lower limit value: 10% of the maximum speed of the trolley) P0: 3500 mm/s (upper limit value: 1050 mm/s (lower limit value: 350 mm/s) Immersion point at the begin (before overtraveling the waterside): 31000 mm



Fig. 3-26: Setting the immersion point

The first condition is satisfied in the A area. The immersion point is rematched to the current hoisting height in each cycle.

A traversal of the band between the upper and lower limit value for the velocity is then made in which the immersion point is not updated.

The second condition takes effect at point B. The lower speed setpoint is undershot and the current hoisting height is assigned as new immersion point. The new value for the immersion point is located at approx. 18600 m.

3.6.2.4 Control in the "SC Semi Automatic" AddOn mode

The control in the "SC Semi Automatic" AddOn mode is made in this configuration in the same method of operation as for Sway Control (see Section 3.6.1.4). The statements concerning the parameter sets also apply here (see Section 4.3).

3.6.2.5 Taking account of blocked regions

The principles for blocked regions are described in section 2.3.3.

DANGER The blocked regions are only taken into account in the "Hoist control" basic operating mode. In all other basic operating modes, also the "Positioning" basic operating mode, collisions can occur if the crane operator is inattentive.



Note For the calculation of the path curve, the PLC requires the position of the lower edge of the spreader as the position to the hoisting gear (concerns hoist (TO) actual position).

General features

Table 3-7: General features of the blocked regions

Fixed blocked regions Variable blocked regions

External Internally learnt

Input, edit and save

Region menu in the CeCOMM diagnostic program, "B" key

Deletion and transfer via PLC before automatic start

By monitoring the movements of the trolley and the hoisting gear in manual operation

By acquisition of the laser values from the Bay Scanner

Default values for the activation

Saved regions in the parameter files

None

Maximum height of the hoisting gear if obstacles are to be learnt (bLearn_Profile_On = 1), otherwise none

Start position in the blocked region

Automatic does not start Although automatic starts, only the hoisting gear is controlled until the blocked region is exited

Target in the blocked region

Automatic does not start The blocked region causes the trolley to be stopped at the target position

List display of the blocked regions

"Region menu" for CeCOMM (with the "B" key) (Section 4.4.6.2)

"Variable blocked regions" screen page in CeCOMM (with the "G" key) (Section 4.4.6.2)

Graphical display of the blocked regions

CeCOMM diagnostic program; Diagram function in the X/Y representation (Section 4.4.9.4).

3.6.2.6 External variable blocked regions

Transfer sequence for external variable blocked regions:

1. First delete all external variable blocked regions of the previous travel job.

2. Unsorted transfer of the current container stack via the PLC. The blocked regions are written with the data field in the obstacles block (see Section 3.7.1.6) consist of an array comprising five elements each with three int32 values.

It is recommended that the transfer of the external variable blocked regions be checked thoroughly before the commissioning.

Transfer

The transfer of a data set containing up to five blocked regions is performed with the following signal assignment:



Fig. 3-27: Transfer of external variable blocked regions

Sequential transfer

If more than five blocked regions have to be transferred, the transfer must be sequential, i.e. over several cycles. A special control bit and confirmation bit are provided for this.

The rising edge of the "Prg_Obst" control bit (bit 0 in the "STW1_PLC_Obstacles" control word, Table 3-21) transfers the blocked regions present on the Obstacles block.

The "PrgBlock" confirmation bit (bit 0 in the "ZSW1_Obstacles_PLC" status word, Table 3-36) is set as acknowledgment and the next block transfer can now begin.

The current total number of blocked regions in the Sway Control system is returned in the "Number_Obst" data field (SIMOTION → SIMATIC S7, Obstacles, see Table 3-35).

If zero values have been assigned to blocked regions, these are not transferred and therefore less than five blocked regions can be transferred. The current list of transferred blocked regions can be displayed in the diagnostic program on the screen page "Variable blocked regions" (with <G> key) (Section 4.4.6.2).

Fig. 3-28: Sequential transfer of external variable blocked regions

Delete

The deletion of external variable blocked regions is made with the following signal assignment:



Fig. 3-29: Deletion of all external variable blocked regions

The deletion of external variable blocked regions is performed according to the same principle as the transfer, with two bits in the interface section "Obstacles".

The list of external variable blocked regions is deleted in the Sway Control system by setting the control bit "Del_Obst" (bit 1 in the "STW1_PLC_Obstacles" control word, Table 3-21).

The "Obst_Deleted" confirmation bit (bit 1 in the "ZSW1_Obstacles_PLC" status word, Table 3-36) signals the successful execution to the PLC.

At the same time, the current total number of internal variable blocked regions in the Sway Control system is returned in the "Number_Obst" data field (SIMOTION → SIMATIC S7, Obstacles, see Table 3-35).

NUMBER_OBST = number of external learnt variable blocked regions + number of internal learnt blocked regions. The deletion deletes only the external learnt variable blocked regions. The internally learnt variable blocked regions are retained. This means the exact number of learnt variable blocked regions must be known beforehand in order that the total number of 200 is not exceeded. The following must be true for the maximum number of external variable blocked regions: Maximum value = 200 - maximum internal learnt blocked regions

Fig. 3-30: Deletion of external variable blocked regions (sequence)

3.6.2.7 Internally learnt variable blocked regions

The height profile can also be learnt internally. It extends from the waterside start to end (parameters P26 and P29). The following sequence must be followed:

3. First delete all internally learnt variable blocked regions.

4. Start the learning process by setting the "Learn_Profile_ON" bit in the Common block control word. This sets the blocked region for the waterside to the maximum position of the hoisting gear. However, only if the Bit"Learn_Profile_Reset" is zero.

Reset (delete) the internally learnt variable blocked regions (height profile)

The internally-learnt variable blocked regions (height profile) can be reset by setting the "Learn_Profile_Reset" bit (bit 9 in the "STW1_PLC_Common" control word, Table 3-11).

At the same time, the "Learn_Profile_ON" bit must be reset. The heights are set to the maximum position of the hoisting gear when this bit is not reset



The "Learn_Profile_Reset_OK" confirmation bit (bit 4 in the "ZSW1_Common_PLC" status word, Table 3-23) signals the successful execution to the PLC.

Fig. 3-31: Resetting all internally learnt variable blocked regions

The "Learn_Profile_Reset" bit must be reset after the deletion.

3.6.2.8 Reset conditions for learnt height profile

Note The internally learnt height profile must always be reset at least when the crane traverses to a new row of containers and starts with the loading or unloading.

A reset can also be performed when

The "Crane OFF" signal has been pending for more than two minutes

The boom is not down

Errors occur in the trolley, hoisting gear and travelling gear (PLC) position sensors

The variations of the redundancies are too large in the position mapping of the trolley and hoisting gear

A container has not been locked or unlocked for 15 minutes

Note The automatic mode cannot be started after a reset. Travel must first be performed in manual operation. But a travel is possible if targets exist (e.g. external targets , parking position)

3.6.2.9 Starting the learning process

Deletion of the blocked regions has priority over learning. Therefore, the "Learn_Profile_Reset" bit must be reset for a learning process.

The learning process is started by setting the "Learn_Profile_ON" command bit (bit 8 in the "STW1_PLC_Common" control word, Table 3-11). If the trolley gear is in manual mode or without an operation mode all motions of the spreader position independent of the associated basic operating mode are logged as height profile and dynamically combined in internally-learnt variable blocked regions. All blocked regions above the spreader at the current trolley position are cut off because no obstacle can occur there.

If the "Slack rope" bit is set, the hoisting height profile is not learnt.



Note An automatic start is not possible after the learning process has been started: Travel must first be performed in manual operation. But a travel is possible if targets exist (e.g. external targets , parking position)

During the learning process, the "Learn_Profile_ON" command bit must remain set in all basic operating modes.

Fig. 3-32: Learning internal variable blocked regions

3.6.2.10 Double spreader in coupled mode

The operation of double spreaders is described in section 2.3.3.4.

Note For the calculation of the path curve, the PLC requires the position of the lower edge of the spreader as the position to the hoisting gear (relevant for hoist actual position (TO)). The middle of the landside spreader is required for the position of the trolley (relevant for trolley actual position (TO)).

The operation of coupled double spreaders is activated by setting the "Spreaders_Coupled" control bit (bit 12 in the "STW1_PLC_Common" control word, Table 3-11).

The current total of the double spreader "DS_Width" is required as further value (see



Table 3-10). The total width is taken into account in the calculation of the path curve and is displayed on the "PROFIBUS-Interface [2]" display screen in the CeCOMM.

3.6.3 TLS Control

"TLS Control" controls the so-called trim, list and skew positions of a spreader. Basic information is contained in Section 2.3.4.1.

Activation of the "TLS Control" AddOn

This AddOn is activated in parameter P197 ("Trim/List/Skew Control") by enabling "Trim/List/Skew Control on".

The AddOn can be used independently of all other basic operating modes, AddOn modes and AddOns.




Length (byte)

I/O address range


DCC_SCTLS TLS 45 32 2060-2091

3.6.3.2 Control of the "TLS Control" AddOn

Activation and deactivation of the TLS commands

The "Trim", "List", "Skew" and "Approach zero position" TLS functions are activated by setting the associated command bit on the "DCC_SCTLS" DCC block. The command bit serves as basis for determining the set positions for each cylinder. The cylinder remains controlled until each cylinder has reached its set position – even when the command bits have already been reset.

With the help of the status bits, the cylinder states are returned to the PLC and the hydraulic cylinders controlled (binary move in/out bits).

Note If, for technical reasons with one of the TLS commands the target is not reached within 30 seconds after resetting the command bits, the control of the affected cylinder will be terminated.

Activation and deactivation of the Skew Control function

The Skew Control function is activated by setting the "Skew_Control" command (see Table 3-17, TLS control word, bit 9). All other TLS command bits (Trim, List, Skew, "Approach zero position") are not set.

A deactivation of the Skew Control function is possible by resetting the "Skew_Control" command bit or setting another TLS command bit.

The control of the Skew Control cylinder is terminated when



The swaying of the internal skew model is less than the set residual sway and the target is reached, or

The determined cylinder speed is less than the "TLS speed for zero signal" parameter (P186).

The following signal sequence is performed with activated Skew Control function during skew in clockwise direction and the correction of the skew:

bSkew_Control

bSkew_Removed

bNo_Skew

IN

IN

OUT

OUT0 cgr0 cgrSkew (CeCOMM, Screen 7)

INbSkew_CW300 cgr

Fig. 3-33: Signal sequence with activated Skew Control function

Section 1:

Skew Control function is switched on. There is no skew.

Section 2:

Skew in clockwise direction starts. This resets the "Skew_Removed" status bit.

Section 3:

Skew is finished.

Section 4:

"Correct skew" is requested with the "No_Skew" control bit.

Section 5:

The "Skew_Removed" status bit is set when the skew is corrected. This signal can be used to reset the "No_Skew" control bit.

Designation of the cylinders

The hydraulic cylinders are designated as follows:

Cylinder designation Carrying cable

A Landside, left

B Waterside, left

C Waterside, right

D Landside, right

Priorities

If several commands are present concurrently, the following priorities apply:

1. "Move_To_Zero" (highest priority),

2. Trim, list and skew commands and

3. "Automatic Skew Control".



Internal setpoints are calculated for each cylinder with all commands. Position controllers ensure that each cylinder reaches the calculated target position. If, for example, one cylinder moves in or out slower than the others, then it runs on for a certain time until it has also reached the target position.

The limit values that can be set for the trim, list and skew with the P194, P195, P196 parameters are relative to the position saved with "Save_Pos_As_Zero" (= "Save zero position", see Table 3-17, TLS control word). The limits are monitored in all directions. When the end positions are reached, further movement in or out is prevented.

TLS commands

Trim

The inclination of the container is set left/right with the aid of the binary control commands "Trim_LH" and "Trim_RH" (= "Trim left/right", see Table 3-17, TLS control word).

List

The inclination of the container to the landside/waterside with the aid of the binary control commands "List_WS" and "List_LS" (= "List waterside/landside", see Table 3-17, TLS control word).

Skew

The skew is set with the aid of the binary control commands "Skew_CW" and "Skew_CCW" (= "Turn clockwise/counterclockwise", see Table 3-17, TLS control word).

Approach/save zero position

The current cylinder positions can be saved with "Save_Pos_As_Zero" (= "Save zero position", see Table 3-17, TLS control word) and automatically approached with "Move_To_Zero" (= "Approach zero position", see Table 3-17, TLS control word).

Skew Control

The "Skew_Control" command (= "Automatic Skew Control", see Table 3-17, TLS control word) activates the automatic travel to the zero point with Skew Control. This command is preferred for the automatic positioning operation of the trolley.

In this case, the target point is the last position set with the TLS or "Move_To_Zero" commands (and not the position saved with "Save_Pos_As_Zero"). One last position is used for the waterside and one for the landside. These two target points can only be learnt, not parameterized.

By setting the command "Use_Ext_Skew" (= "External rotational position", see Table 3-17, TLS control word), the rotational position specified as "S_Skew_Extern" (= "Set angle", see Table 3-16) converted into cylinder positions is used as target point rather than the internally saved last position on the landside or waterside. The set angle must be specified in 1/100 degrees.

When the Skew Control is switched on, the "NO_SKEW" command (= "Correct skew", see Table 3-17, TLS control word) can be used to correct the skew, without the list and trim being affected.

Camera_OK

When strong sunshine is prevailing, shadows can result on the reflector that can cause restrictions of the TLS function (Skew Control). With the output bit "Camera_OK", an error (E4) can be signaled to the PLC after a parameterizable time. The delay time can be set by the user via parameter P127.

Note It is recommended that the Skew Control is deactivated via the PLC when error E4 occurs.



Hydraulic control

The hydraulic control uses the position data of the individual cylinders for

The automatic travel to the target point and

The switch-off at limit.

It calculates the cylinder speeds and the associated binary move in/out bits (see Table 3-32, TLS status bits) that are used for the control of the hydraulics.

If at least one of the speeds is not equal to zero, one of the oil pressure signals is set according to the following principle: If the set speed of at least one hydraulic cylinder exceeds the set speed limit, the output signal "bOil_Pressure2" (oil pressure 2) is activated, otherwise "bOil_Pressure1" (oil pressure 1) (see Table 3-32, TLS status bits). The oil pressure signals can be switched off with a settable delay.

Confirmation that the zero position has been reached is signaled with the "bZero_Reached" bit (see Table 3-32, TLS status bits).

The control bits for the skew are generated automatically internally based on the TLS commands. As for the trolley and hoisting gear, status bits of the slewing gear ("bReady", "bActive", "bPos_Completed", etc.) can be used for the monitoring of the TLS motions.

Permissible residual sway (P198), initial sway (P199)

The TLS function may have a disruptive effect when lowering containers under certain circumstances with small rotations, e.g. during the unloading operation,. Two parameters are available for this that permit a small residual sway (P198) or initial sway (P199) and can be set by the user.

3.6.4 Sway Control with TLS Control




Length (byte)

I/O address range




DCC_SCTLS TLS 45 32 2060-2091


The control in the "SC Speed Control" AddOn mode is made in this configuration in the same method of operation as for Sway Control (see Section 3.6.1.2). The statements concerning the parameter sets also apply here (see Section 4.3).


SIMATIC S7 Configuration 3.7 PROFIBUS Interface

3.6.4.3 Control of the "TLS Control" AddOn

The control in the "TLS Control" AddOn is made in this configuration in the same method of operation as for TLS Control (see Section 3.6.3.2). The statements concerning the parameter sets also apply here (see Section 4.3).

3.7 PROFIBUS Interface

3.7.1 SIMATIC S7 SIMOTION D for AddOn

3.7.1.1 Common



Table 3-10: SIMATIC S7 → SIMOTION, Common

PZD Signal name Unit Format Remark

1 STW1_PLC_Common - WORD Control word see below, Table 3-11

2 LOAD 10 kg INT Load see below

3 PARSET 1..99 SINT

Parameter set Number for the selection of the four different parameter sets for "Sway Control". For example, various speeds or accelerations can be set in the respective sets

1: parameter set 1

2: parameter set 2

3: parameter set 3

4: parameter set 4 NOTE

If the upper or lower limit is violated, the value is limited to the upper or lower limit.

4

5 VALUE_BAYSCANNER mm DINT

Bay scanner value see below

6

7 COUNT_BAYSCANNER - DINT

Bay scanner counter see below

8 DS_WIDTH mm INT Total width for double-spreader operation see below

9-12 Not used

VALUE_BAYSCANNER

Absolute height of the obstacle determined at the current trolley position. If the value is valid (see STW1_PLC_Common, bit 7), this has priority over the curve calculated from the learnt blocked regions (target generator).

COUNT_BAYSCANNER

Counter for the new value of the bay scanner. This counter checks whether the transferred bay scanner value is a currently determined value or an old one. Because each scanner has its own counter value, they are prepared by the PLC so that only one value is transferred to the Sway Control system.

LOAD

The current load is determined by the load measuring system and transferred by the PLC to the Sway Control system.



DS_WIDTH

In double-spreader operation, this value informs the Sway Control system how wide the two containers are, incl. the spacing of the cylinders. The current total width (dynamic value) is expected, from the outside edge of the container on the first spreader to the outside edge of the container on the second spreader. The current total width is taken into account in the calculation of the path curve.

Table 3-11: STW1_PLC_Common

Bit Signal name Remark

0 Reserved

1 Reserved

2 NO_WAIT_POS

Do not approach wait position This bit specifies whether a waiting position, defined from the trolley and the hoisting position, is to be approached. The positions are defined in the P25 (trolley) and P65 (hoisting gear) parameters.

0: Inactive 1: Active

3 HOIST_MAN

Manual hoisting gear If this bit is set, the hoisting gear can be raised manually without having to change the basic operating mode. The specified target position is still approached by the trolley.


4 LOCKED_BIT0

5 LOCKED_BIT1

Locking state of the spreader 00: No spreader locked

01/10: Spreaders are partly locked.

when only one spreader of a double spreader in coupled mode has been locked or

a 20-foot container has been locked on a spreader at maximum width.

The travel curves are calculated as required with loaded spreader. The automatic learning does not take account of the height of the locked container.

11: Spreaders are completely locked. The travel curves are calculated as required with loaded spreader. The lower edge of the container(s) is used to learn the blocked regions.

6 SLACKROPE

Slack rope 0: No slack rope 1: Slack rope available

If the "Slack rope" bit is set, no learning is possible, i.e. the internally learnt variable obstacles are not affected. NOTE

This bit has an affect in the "SC Speed Control" AddOn mode.




7 BAYSCANNER_VALID Bay scanner value valid 0: Bay scanner values not valid 1: Bay scanner values valid

8 LEARN_PROFILE_ON

Learn height profile If this bit is active, the permissible height profile is measured or recorded during the spreader motion in manual operation based on the position values of the trolley / hoisting gear in the waterside area (parameterizable) and combined in internally learnt variable blocked regions. No obstacle can exist at those positions where the spreader is located.

These internally learnt variable blocked regions are then taken into account in the "hoist control" basic operating mode when calculating the travel curve as superimposed motion of the trolley and hoisting gear. At the same time, the external variable and the fixed blocked regions are also included.

If the height profile has first been deleted and then the learning bit set, a large blocked region is initialized first, which stretches from the start of the waterside to the end of the waterside and which is set to maximum hoisting height.

If the "Slack rope" bit is set, the hoisting height profile is not learnt.

0: Do not learn 1: Learn NOTE

The height profile will only be learnt when the ROFILE_RESET" signal for deleting is set to "0". "LEARN_P

9 LEARN_PROFILE_RESET

Delete height profile This bit deletes a height profile that has been recorded up to that point in time.

0: Do not delete height profile 1: Delete height profile NOTE Conditions that require the learnt height profile to be deleted are described in Section 3.6.2.8. A deletion of the memory results a reset of the next target

ns saved on the waterside at the same time. positio

10 DIG_HOIST_DIST_CORR

Digital "correction of the effective pendulum length" This bit displaces the weight center of gravity by a specified amount (parameter P80). This is used to define two different types of load carrying devices with different weight centers of gravity. The digital offset acts parallel to the analog weight center of gravity taking account of the load weight.


11 START_2D_CALC Start 2D calculation The bit informs the "Sway Control" that the calculation of the 2D



Bit Signal name Remark travel curve can be started. It should be set when all blocked regions have been transferred completely. The automatic mode performs the path calculation and starts travel after release travelling signal and unlocking the brakes.

0: Inactive 1: Active NOTICE As soon as this bit changes from active to inactive, the crane

s with Sway Control. stop

12 SPREADERS_COUPLED

Spreaders coupled Bit indicates whether the two spreaders are coupled when using a double spreader. This has an effect on the calculation of the path curve.

0: Spreaders not coupled 1: Spreaders coupled

13 Not used

14 Not used

15 Not used

3.7.1.2 Hoist

Table 3-12: SIMATIC S7 → SIMOTION, Hoist


1 STW1_PLC_Hoist - WORD Control word see below, Table 3-13

2 OVERRIDE 0..100% INT Speed limitation see below

3-6 Not used



OVERRIDE

This value can be used to limit the speed. With a value of 100, the path speed is not reduced, with 0, the control stops the axis. This value can be used for the field weakening (see special functions).


Table 3-13: STW1_PLC_Hoist


0 RELEASE

Release request Hoisting release. The values are processed and actuator values issued. Can be used for disabling "Sway Control".

0: Stop with maximum deceleration (P50), without Sway Control 1: Basic operating modes and travel signal are evaluated

1 TRAVEL

Travel signal A direction signal, with which the brake can be opened is not output until this signal is present. The current basic operating mode is taken over.

0: Stop with maximum deceleration (P50), without Sway Control 1: Activation of the specified basic operating mode

2 OM_POS

"Positioning" basic operating mode A set position is specified by the higher-level controller or the internal setpoint encoder. In this basic operating mode, the hoisting gear travels to this position.


3 OM_SPEED

"Speed control" basic operating mode The higher-level controller specifies a set speed.


4 Reserved

5 Reserved

6 OM_HOIST_CONTROL

"Hoist control" basic operating mode If the trolley and the hoisting gear are in this basic operating mode and target positions are specified for both axes, a calculated path curve will be travelled.


7 Reserved

8 LS_UP Limit switch up 0: Actuated 1: Not actuated




9 LS_DN Limit switch down 0: Actuated 1: Not actuated

10 PRELS_UP

Prelimit switch up This bit is active only when P115 < 1. Otherwise the dynamic prelimit switch will be used. 0: Actuated 1: Not actuated

11 PRELS_DN

Prelimit switch down This bit is active only when P115 < 1. Otherwise the dynamic prelimit switch will be used. 0: Actuated 1: Not actuated

12 BRAKE_CLOSED

Brake closed Braking signal for hoisting gear. 0: Brake is open 1: Brake is closed, no motion possible

13 Not used

14 Not used

15 Not used

3.7.1.3 Trolley

Table 3-14: SIMATIC S7 → SIMOTION, Trolley


1 STW1_PLC_Trolley - WORD Control word see below, Table 3-15

2 OVERRIDE 0-100% INT Speed limitation see below

3-6 Not used

OVERRIDE

This value can be used to limit the trolley speed. With a value of 100, the path speed is not reduced, with 0, the control stops the axis. This value can be used for the field weakening (see special functions).




Table 3-15: STW1_PLC_Trolley


0 RELEASE

Release request Release request for the trolley. The values are processed and actuator values issued. Can be used for disabling "Sway Control".

0: Stop with maximum deceleration (P50), without Sway Control 1: Basic operating modes and travel signal are evaluated

1 TRAVEL

Travel signal A direction signal, with which the brake can be opened, is not output until this signal is present. The current basic operating mode is taken over.

0: Stop with maximum deceleration (P5), without Sway Control 1: Activation of the specified basic operating mode

2 OM_POS

"Positioning" basic operating mode A set position is specified by the higher-level controller or the internal setpoint encoder. In this basic operating mode, the trolley travels to this position.

0: Not active 1: Active

3 OM_SPEED

"Speed control" basic operating mode The higher-level controller specifies a set speed.


4 OM_LOAD_POS "Sway-neutralization to load position" basic operating mode 0: Not active 1: Active

5 OM_TROLLEY_POS "Sway-neutralization to trolley position" basic operating mode 0: Not active 1: Active

6 OM_HOIST_CONTROL

"Hoist control" basic operating mode If the trolley and the hoisting gear are in this basic operating mode and target positions are specified for both axes, a calculated path curve will be travelled.


7 SC_ON Sway Control On 0: Sway Control not active 1: Sway Control active

8 LS_FW Limit switch forward 0: Actuated 1: Not actuated

9 LS_BW Limit switch backward 0: Actuated 1: Not actuated

10 PRELS_FW Prelimit switch forward



Bit Signal name Remark This bit is active only when P115 < 1. Otherwise the dynamic prelimit switch will be used. 0: Actuated 1: Not actuated

11 PRELS_BW

Prelimit switch backward This bit is active only when P115 < 1. Otherwise the dynamic prelimit switch will be used. 0: Actuated 1: Not actuated

12 BRAKE_CLOSED

Brake closed Braking signal for the trolley. 0: Brake is open 1: Brake is closed, no motion possible

13 SC_WHEN_STOP

Sway Control only when stopping 0: Sway Control is active for starting and stopping 1: Sway Control is only active when stopping

NOTE

This bit acts only when bit 7 (SC_ON) has been set and the speed e selected. control mod

14 CONTROLLED_STOP

Controlled stop Stop of the trolley with normal deceleration and Sway Control in all basic operating modes. This bit also affects the hoisting gear in the "hoist control" basic operating mode.


15 FLYING

On-the-fly unloading With set bit and activated time-optimized control (parameter P152 = 34, P152 = 123, P152 = 124 or P152 = 1234), the target position is approached in "Positioning" and "Hoist control" basic operating modes so that the trolley stops before the target and the load sways to the target position. The bit has no significance in all other basic operating modes or when the time-optimized control is deactivated.

0: No on-the-fly unloading 1: Positioning with on-the-fly unloading

3.7.1.4 TLS

Table 3-16: SIMATIC S7 → SIMOTION, TLS


1 STW1_PLC_TLS - WORD Control word see below, Table 3-17

2

3 POS_CYL_A mm DINT

Position cylinder A see below




4

5 POS_CYL_B mm DINT

Position cylinder B see below

6

7 POS_CYL_C mm DINT

Position cylinder C see below

8

9 POS_CYL_D mm DINT

Position cylinder D see below

10

11 S_SKEW_EXTERN 1/100° DINT

Set angle see below

SPREADER_WIDTH 1..99 SINT

Spreader width Depending on the spreader state, the following values must be specified.

1: 20 ft 2: 30 ft 3: 40 ft 4: 45 ft NOTE

In twin-operation, the value "4" must be pecified for a width of 45 ft. s

12

Reserved USINT

13-16

Not used

POS_CYL_A/B/C/D

Position data from four hydraulic cylinders, which is used for the trim, list, skew and Skew Control. The application is specified with the aid of parameters.

S_SKEW_EXTERN

External value for the set skew of the spreader by a specified angle.

Table 3-17: STW1_PLC_TLS


0 TRIM_RH Trim right 0: No command 1: Incline to the right command

1 TRIM_LH Trim left 0: No command 1: Incline to the left command

2 LIST_WS List waterside 0: No command 1: Incline to the waterside command




3 LIST_LS List landside 0: No command 1: Incline to the landside command

4 SKEW_CW Skew in clockwise direction 0: No command 1: Rotate in clockwise direction command

5 SKEW_CCW Skew in counterclockwise direction 0: No command 1: Rotate in counterclockwise direction command

6 MOVE_TO_ZERO Approach to zero position 0: No command 1: Move all cylinders to zero position command

7 SAVE_POS_AS_ZERO Save zero position 0: No command 1: Save current cylinder positions as zero positions command

8 NO_SKEW

Correct skew 0: No command 1: Skew is corrected to zero in the "automatic Skew Control" mode. Trim and list remain unchanged.

9 SKEW_CONTROL Automatic Skew Control 0: No command 1: Suppress skewing motion automatically command

10 USE_EXT_SKEW

External rotational position The internally learnt values are always used as target for trim and list.

0: The internal rotational position is used separately according to water- or landside as target in the "automatic skew control" mode

1: The "S_SKEW_EXTERN" input value (set angle) is used as target in the "automatic skew control" mode

11-15 Not used

3.7.1.5 Targets

Table 3-18: SIMATIC S7 → SIMOTION, Targets


1 STW1_PLC_Targets - WORD Control word see below, Table 3-19

LANE_SHIP_LOAD 1..99 SINT Lane number for loading see below

2 LANE_SHIP_UNLOAD 1..99 SINT

Lane number for unloading see below




LEARN_POS_LANE - SINT Save position see below 3

Reserved

4 Not used

5 Not used

6 Not used

LANE_SHIP_LOAD/ UNLOAD

These values specify the numbers of the lanes on which the trucks are loaded or unloaded.

If only one lane number is specified for the loading/unloading (e.g. LANE_SHIP_LOAD = 0 (no lane) and LANE_SHIP_UNLOAD = 2 (lane 2)), the specified lane applies for all unloading and loading operations (here lane 2).

The information, for example, is generated by the crane operator panel or a control element and is transferred to the Sway Control system.

LEARN_POS_LANE

This value specifies which lane number is to be assigned to the current position (0 None; 1 Lane1; 2 Lane2, etc.). It is mainly used during the commissioning, but can also be used for later corrections. This value, for example, can be generated by the crane operator panel or a control element and transferred to the Sway Control system.

The value must remain present until the "POS_SAVED" status bit (Section 3.7.2.5) provides the confirmation that the position has been learnt. The brake must be applied during the learning process. After being learnt, the value must be set back to "0".

Table 3-19: STW1_PLC_Targets


0 LEARN_PARK_POS

Save parking position This bit is used for saving the current position as parking position.

0: Do not save parking position 1: Save parking position

For more information, see below.

1 LEARN_LASH_PLATF

Save lashing position This bit is used for saving the current position as lashing platform.

0: Do not save lashing platform 1: Save lashing platform

For more information, see below.

2 USE_LASH_PLATF

Include lashing position This bit must be set if the lashing platform is to be approached during loading or unloading. This signal, for example, is generated by the crane operator panel or a control element and is transferred to the Sway Control system.




0: Do not approach lashing platform 1: Lashing platform should be approached

If the corresponding bit is set the lashing platform represents a target position that is approached under the following conditions:

One of the "Column", "Line LS" or "Line WS" stacking forms is selected.

The container is locked.

The lashing platform is not approached if:

Travel is automatically to the parking position.

It has already been crossed in manual mode. (The crane does not turn back.)

After the lashing platform has been reached, the automatic travel command must be reset and set again in order to travel to the final position.

3 STACK_FORM_BIT0

4 STACK_FORM_BIT1

Stacking form This signal, for example, is generated by the crane operator panel or a control element and is transferred to the Sway Control system.

00 Parking position is approached 01 Loading or unloading is performed line-by-line in the waterside direction (next trolley position is one spreader width in the landside direction) 10 Loading or unloading is performed line-by-line in the landside direction (next trolley position is one spreader width in the waterside direction) 11 Ship is unloaded or loaded column-by-column

Note: Left bit = STACK_FORM_BIT1 Right bit = STACK_FORM_BIT0

5 CYCLING Cycling This is a function that permits the concurrent loading and unloading of a ship in a single cycle.

6 OFFSET_TO_LAND

Offset landside When positioning the trolley, an offset is added to the target position of the landside. This signal, for example, is generated by the crane operator panel or a control element and is transferred to the Sway Control system.

0: Offset landside is not active 1: Offset landside is active




7 OFFSET_TO_WATER

Offset waterside When positioning the trolley, an offset is added to the target position of the waterside. This signal, for example, is generated by the crane operator panel or a control element and is transferred to the Sway Control system.

0: Offset waterside is not active 1: Offset waterside is active

8 USE_EXTERN_TARGETS

Targets from PLC This bit specifies whether the targets are specified by the PLC or the internal target generator.

0: Targets from the target generator 1: Targets from the PLC

NOTE

This bit is only effective if P102 = 1 (STS). With P102 = 0 (ship unloader), the targets from the PLC are always used

spective of the signal state of this bit. irre

9-15 Not used

LEARN_PARK_POS / LEARN_LASH_PLATF

Although the control bits are used mainly for the commissioning, they can also be used for subsequent corrections. The associated signal, for example, is generated by the crane operator panel or a control element and is transferred to the Sway Control system.

The associated control bit must remain present until the "POS_SAVED" status bit (Section 3.7.2.5) provides the confirmation that the position has been learnt. The brake must be applied during the learning process. After the learning, the control bit must be reset.

3.7.1.6 Obstacles

Obstacles can be taken into consideration by the transfer of external variable blocked regions. The functionality of the blocked regions is described in Section 2.3.3.

Table 3-20: SIMATIC S7 → SIMOTION, Obstacles


1 STW1_PLC_Obstacles - WORD Control word see below, Table 3-21

2

3 SET1_TR1 mm DINT

BlockedRegion1_TrolleyPosition1 First trolley position for blocked region 1

4

5 SET1_TR2 mm DINT

BlockedRegion1_TrolleyPosition2 Second trolley position for blocked region 1

6

7 SET1_HOIST mm DINT

BlockedRegion1_HoistPosition Hoisting position for blocked region 1




8

9 SET2_TR1 mm DINT


10

11 SET2_TR2 mm DINT


12



14

15 SET3_TR1 mm DINT


16

17 SET3_TR2 mm DINT


18



20

21 SET4_TR1 mm DINT


22

23 SET4_TR2 mm DINT


24



26

27 SET5_TR1 mm DINT


28

29 SET5_TR2 mm DINT


30



32 Reserved

Blocked region data sets

The interface allows for each transfer a data set with up to five blocked regions. Not only a start and an end position of the trolley, but also the associated hoisting position, can be specified for each blocked region. An unused blocked region contains the value zero for all three entries. The transfer of the blocked regions to the Sway Control system is described in section 3.6.2.5.



Table 3-21: STW1_PLC_Obstacles


0 PRG_OBST

Programming blocked regions Bit for acceptance of the external variable blocked regions used to calculate the path curve. Zero data sets are ignored.

0: Do not accept 1: Accept (see section 3.6.2.5)

1 DEL_OBST

Delete blocked regions Bit to delete the variable blocked regions.

0: Do not delete 1: Delete

2-15 Not used

3.7.2 SIMOTION D for AddOn SIMATIC S7

3.7.2.1 Common

Table 3-22: SIMOTION → SIMATIC S7, Common


1 ZSW1_Common_PLC - WORD Status word see below, Table 3-23

2

3 FAULT1 - DWORD

Fault message 1 from AddOn technology, see below Table 3-24

4

5 FAULT2 - DWORD

Fault message 2 from AddOn technology, see below Table 3-25

6

7

INFO_NO_AUTO_START - DWORD

Automatic start information Contains information for the visualization for which reason an automatic start is not possible. (Bit 5‚ "START_AUTO_OK" is not set) see below, Table 3-26

PARSET_OUT 1..99 SINT

Parameter set confirmation Confirmation of the number of the parameter set used for "Sway Control".

1: Parameter set 1 2: Parameter set 2 3: Parameter set 3 4: Parameter set 4

8

Reserved

9-12 Not used



Table 3-23: ZSW1_Common_PLC


0 Reserved

1 CHANGE_TARGET

Only GSU: Change target 0 - Target is the hopper 1 - Target is the ship For on-the-fly unloading: Once the trolley speed is less than the "on-the-fly unloading abort speed" (P30), the "OPEN_GRAB" state bit will be reset. A new target (ship) must be specified. The bit "CHANGE_TARGET" should be used for this. The bit is always set via the landside target, independent of the on-the-fly unloading.

2 NO_WAIT_POS_OK Waiting position is not approached Confirmation of the general "NO_WAIT_POS" command bit. The hoist control does not stop.

3 LEARN_PROFILE_ON_OK Height profile learnt Response bit for "Learn height profile" mode is activated. The height profile is being learnt.




4 LEARN_PROFILE_RESET_OKHeight profile deleted Response bit for the deletion of the internally learnt variable blocked regions. The height profile has been deleted.

5 START_AUTO_OK

Automatic start permitted Bit for releases of the automatic without an error message being issued. An exact explanation why a start is not possible can be seen in Table 3-26. The PLC can also form a group bit from the individual messages. This allows specific functions to be permitted for the automatic (e.g. start from slack rope on the waterside).

6 HOIST_TAKEOVER_OK

Hoisting gear acceptance allowed This bit is set at the height above which the trolley positioning motion starts. A manual acceptance of the hoisting gear is possible as of this time. If this bit is not set, no manual control for the hoisting gear may be permitted during the automatic trolley travel. A collision with obstacles could occur. In this case, the automatic must be aborted for the trolley and the hoisting gear. CAUTION

If the "Hoist_TakeOver_OK" bit is set, the hoisting height is greater than all obstacles height. Consideration of any

bstacles is the responsibility of the crane operator. o

7 OPEN_GRAB

Open grab 0: Grab can be closed 1: Grab can be opened The bit has to be resetted if target swich over is requested.

This bit serves as control signal for opening and closing the grab. The time of opening is specified by parameter P31; the time of closing is specified by parameter P30. The bit itself is not for closing the grab. The grab must remain open on the way to the ship and only closed when material has been picked up. OPEN_GRAB is only set when the on-the-fly unloading (input bit FLYING) is activated and when parameter 152 has the following values: P152 = 34 P152 = 123 P152 = 124 P152 = 1234

8-15

Not used



Table 3-24: FAULT1


0 Invalid parameter file An error has occurred while loading the parameter files. Parameter files are missing or are faulty. The relevant parameter set will be set to default values.

1 Invalid basic operating mode

An unavailable basic operating mode or at the same time several basic operating modes cannot be selected. The error message also appears when the "Hoist control" basic operating mode has been selected for only one axis.

2 Reserved

3 Under-licensing A basic operating mode has been selected, but there is no license for this.

4 Invalid target position The target position of the trolley is outside the set limits.

5 Reserved

6 Start of positioning with too much swaying

The positioning motion was started when there was too much swaying.

7 Sway Control Off (pendulum length)The Sway Control function has been switched off as the hoisting height is not within the specified limits.

8 Reserved

9 Invalid basic operating mode at the limit switch

Only the "Speed control" basic operating mode is permitted in the limit switch for which deceleration is made on the maximum ramp in the limit switch area.

10 Sway Control temporarily reduced Because of large swaying movements, the damping factor for the trolley or the slewing gear has been temporarily significantly reduced for stability reasons.

11 Speed error The trolley, the hoisting gear or the slewing gear are not moving, are moving too fast or in the wrong direction.

12 Camera measuring system faulted The camera does not identify a reflector any more.

13 Fault in the DCC chart The DCC chart is faulty. At least one DCC block is missing for the selected application.

14 Copy protection damaged The software copy protection is damaged. The Sway Control function is deactivated.

15 Load stuck The load has stuck when starting to move.

16 Too many variable blocked regions An attempt has been made to transfer more than 200 variable blocked regions.

17 Starting point in fixed blocked region

The load is in a fixed blocked region at the time a travel operation is started with hoist control. The travel job is not executed.

18 Starting point in variable blocked region

The load is in a variable blocked region at the time a travel operation is started with hoist control. This warning does not result in a cancellation and remains pending until the region is exited.

19 Sway Control temporarily reduced

Because of large swaying movements, the damping factor for skewing has been temporarily significantly reduced for stability reasons in the cause of slewing sway control.

20-23

Reserved



Signal name Remark Bit

24 Group error abort, hoist control A travel job in the "Hoist control" basic operating mode has been aborted. Refer to other error messages for the exact cause of the error.

25 Target in fixed blocked region The target position is in a fixed blocked region. A travel job is not generated.

26 Reserved

27 Position setpoint in fixed blocked region

The position setpoint calculated during a travel operation has violated a blocked region.

28 Actual position in blocked region The actual position has violated a fixed or variable blocked region. The course has deviated too far from the setpoint.

29 Following error, trolley The difference between the actual and the set position is greater than the set permissible following error.

30 Following error, hoisting gear The difference between the actual and the set position is greater than the set permissible following error.

31 No path found The hoist control could not find a path between the starting position and the target position.

Table 3-25: FAULT2


0-31 Reserved

Each fault is represented by a bit. The "FAULT2" fault word has been added as reserve. Several faults can be present concurrently in both error messages. Both doublewords are always evaluated.

The messages described below are used primarily to detect why an automatic start is not possible. The messages can be forwarded to a crane operator panel or a display element in the crane operator cabin.

An assignment of the individual bits to the error numbers and recommended categories is made in a subsequent section.



Table 3-26: INFO_NO_AUTO_START


0 Target position not in permitted limits

Target position not in permitted limits Target position is not within the set limits for the positioning.

1 Starting position not in permitted limits

Starting position not in permitted limits Starting position is not within the set limits for the positioning.

2 Starting position in a fixed blocked region

Starting position in a fixed blocked region Current starting position is in a fixed blocked region.

3 Target position in a fixed blocked region

Target position in a fixed blocked region Target position is in a fixed blocked region.

4 No path found No path found A travel curve cannot be calculated for the starting and target point by the target generator.

5 Starting position is same as target position

Starting position is same as target position The starting position is the same as target position. The bit is output if the trolley position at the time of starting the automatic mode is less than double the positioning accuracy of the target position. The Auto-Start bit is not set.

6 Initial sway (only STS)

Initial sway As long as the initial sway is greater than the permissible initial sway specified by P156, this bit is set. If the initial sway is too large, error message E62 is issued when starting the automatic travel. Travel is then not possible, irrespective of what happens in the PLC. This affects the waterside and the landside.

7 Slack rope on the waterside

Slack rope on the waterside If the "AUTO_START_OK" bit is used in the PLC for locking the automatic, a start of the automatic is not possible because of slack rope. This affects the waterside and the landside.

8 Hoisting gear below immersion point (only STS crane)

Hoisting gear below immersion point If the "AUTO_START_OK" bit is used in the PLC for locking the automatic, a start of the automatic is not possible. The hoisting gear is located below the immersion point. This affects only the waterside.

9 Target repositioned Target repositioned The automatic mode starts, but is stopped before/over the variable blocked region.

10 Target too low

Target too low Only GSU: The target during on-the-fly unloading must not be no lower than the highest obstacle. Otherwise the automatic mode does not start.

11-31 Not used



3.7.2.2 Hoist

Table 3-27: SIMOTION → SIMATIC S7, Hoist


1 ZSW1_Hoist_PLC - WORD Status word see below, Table 3-28

2 Not used

3 Not used

4 Not used

5 Not used

6 Not used

Table 3-28: ZSW1_Hoist_PLC


0 READY

Ready 0: Response to release bit 1: The drive axis is ready for operation and is activated by setting a basic operating mode and the travel signal

1 ACTIVE

Active 0: The actuator speed is zero 1: The drive axis is active and outputs the currently required actuator speed

2 POS_COMPLETED

Positioning complete 0: The target position has not been reached yet, the actuator speed is not equal to zero in all operation modes 1: The target position has been reached (positioning, hoist control) or setpoint and actuator speed are zero (speed control) in all operation modes

3 Reserved

4 TRAVEL_UP Raise travel direction (path values become larger) 0: Actuating signal is negative or zero 1: Actuating signal is positive

5 TRAVEL_DN Lower travel direction (path values become smaller) 0: Actuating signal is positive or zero 1: Actuating signal is negative

6-15 Not used



3.7.2.3 Trolley

Table 3-29: SIMOTION → SIMATIC S7, Trolley


1 ZSW1_Trolley_PLC - WORD Status word see below, Table 3-30

2 LOAD_DEFL_TR ± mm INT Load deflection, see below

3 Not used

4 Not used

5 Not used

6 Not used

LOAD_DEFL_TR

Current load deflection. Relative position difference between the trolley and load.

STS (with camera) The value corresponds to the load deflection measured by the camera.

The following applies: LOAD_DEFL_TR = IY_POS (or IX_POS)

If the camera fails, the duration of the "Delay time for camera fault" (P127) is the deflection zero. If the tripping time (P127) has elapsed and the error E4 is present, then the deflection corresponds to the value of the model.

GSU (without camera) The value corresponds to a calculated value. With travel command = 0,

this value also becomes zero.

Table 3-30: ZSW1_Trolley_PLC


0 READY

Ready 0: Response to release bit 1: The drive axis is ready for operation and is activated by setting a basic operating mode and the travel signal activated

1 ACTIVE

Active 0: The actuator speed is zero 1: The drive axis is active and outputs the currently required actuator speed

2 POS_COMPLETED

Positioning complete 0: The target position has not been reached yet, the actuator speed is not equal to zero in all operation modes 1: The target position has been reached (positioning, sway neutralization, hoist control) or setpoint and actuator speed are zero (speed control) in all operation modes

3 SC_COMPLETED

Sway neutralization complete 0: The swaying motion of the load is greater than the specified tolerance 1: The swaying motion has been eliminated within the specified



Bit Signal name Remark tolerance

4 TRAVEL_FW Travel direction forwards (path values become larger) 0: Actuating signal is negative or zero 1: Actuating signal is positive

5 TRAVEL_BW Travel direction backwards (path values become smaller) 0: Actuating signal is positive or zero 1: Actuating signal is negative

6 Reserved

7 bSC_STATE Sway Control On 0: The Sway Control function is active 1: The Sway Control function is not active

8-15 Not used

3.7.2.4 TLS

Table 3-31: SIMOTION → SIMATIC S7, TLS


1 ZSW1_TLS_PLC - WORD Status word see below, Table 3-32

2 SPEED_CYL_A mm/s INT Speed cylinder A see below

3 SPEED_CYL_B mm/s INT Speed cylinder B see below

4 SPEED_CYL_C mm/s INT Speed cylinder C see below

5 SPEED_CYL_D mm/s INT Speed cylinder D see below

6-16 Not used

SPEED_CYL_A/B/C/D

Actuator speed for all four TLS hydraulic cylinders relative to the TLS cylinder maximum speed (P183 in the parameter file). The output actuator speed of the cylinders is always positive. The direction is determined by the signals for extending or retracting the cylinders (see Table 3-32).

Table 3-32: ZSW1_TLS_PLC


0 MOVE_OUT_CYL_A Move cylinder A out Control signal for extending cylinder A

1 MOVE_OUT_CYL_B Move cylinder B out Control signal for extending cylinder B

2 MOVE_OUT_CYL_C Move cylinder C out Control signal for extending cylinder C




3 MOVE_OUT_CYL_D Move cylinder D out Control signal for extending cylinder D

4 MOVE_IN_CYL_A Move cylinder A in Control signal for retracting cylinder A

5 MOVE_IN_CYL_B Move cylinder B in Control signal for retracting cylinder B

6 MOVE_IN_CYL_C Move cylinder C in Control signal for retracting cylinder C

7 MOVE_IN_CYL_D Move cylinder D in Control signal for retracting cylinder D

8 OIL_PRESSURE1 Oil pressure 1 Select pressure 1 (cylinder speed 1)

9 OIL_PRESSURE2 Oil pressure 2 Select pressure 2 (cylinder speed 2)

10 ZERO_REACHED Zero position reached All cylinders are in the tolerance range around the zero position.

11 Reserved

12 SKEW_REMOVED

Skew eliminated The skew has been eliminated. Trim and list have not been changed. The bit is already set approx. 20 s before the end of the cylinder motion. The traversing motion is stopped when the actual skew value reaches the set tolerance value P190.

13 Not used 14 Not used 15 Not used

3.7.2.5 Targets

Table 3-33: SIMOTION → SIMATIC S7, Targets


1 ZSW1_Targets_PLC - WORD Status word see below, Table 3-34

LANE_LOAD_OK 1..99 SINT Loading the lane number confirmation see below

2

LANE_UNLOAD_OK 1..99 SINT Unloading the lane number confirmation see below

3-6 Not used

LANE_LOAD_OK/UNLOAD_OK

Confirmation of the lane number for loading/unloading for the values present at "LANE_SHIP_LOAD"/"LANE_SHIP_UNLOAD" (Table 3-18). This signal can, for example, be forwarded to the crane operator panel or used by the PLC to release the automatic. Automatic may be permitted only when the signaled value and the confirmed value are identical.



Table 3-34: ZSW1_Targets_PLC


0 POS_SAVED

Position learning successful 0 Position learning unsuccessful 1 Position learning successful

This bit is used for the confirmation of the successful learning of the positions for parking, lashing platform and lane.

1 DIRECTION_LAND

Next target in the landside direction If a target position has been entered for the trolley or determined by the target generator, which, compared to the current position, lies in the land direction, this bit is set.

2 DIRECTION_WATER

Next target in the waterside direction If a target position has been entered for the trolley or determined by the target generator, which, compared to the current position, lies in the water direction, this bit is set.

3-15 Not used

3.7.2.6 Obstacles

Table 3-35: SIMOTION → SIMATIC S7, Obstacles


1 ZSW1_Obstacles_PLC - WORD Status word see below, Table 3-36

2 NUMBER_OBST - INT Number of blocked regions see below

3-32 Not used

NUMBER_OBST

NUMBER_OBST = number of external learnt variable blocked regions + number of internal learnt blocked regions.

Only the external learnt variable blocked regions are deleted. The internally learnt variable blocked regions are retained. This means the exact number of learnt variable blocked regions must be known beforehand in order that the total number of 200 is not exceeded. The following applies for the maximum number of transferrable, external, variable blocked regions:

Maximum value = 200 - maximum internal learnt blocked regions

Table 3-36: ZSW1_Obstacles_PLC


0 PRG_OBST_OK Blocked regions programmed Confirmation of the general command bit "Program blocked regions". The blocked regions are saved.

1 OBST_DELETED Blocked regions deleted Confirmation of the general command bit "Delete blocked




Bit Signal name Remark regions". The blocked regions have been deleted.

2-15 Not used

Commissioning AddOn Software 4 4.1 Requirements

The following requirements for the commissioning of the AddOn software must be satisfied:

1. All components of the system must be installed, attached, operational and connected with each other.

2. Installation and start of the CeCOMM diagnostic program (Section 4.4.2) on the commissioning PC.

3. Setting of the IP address of the commissioning PC in accordance with the SIMOTION (same subnet).

4. When a camera is used, the camera measuring system must be operational (Section 4.5.10).

4.2 Ethernet communication

4.2.1 General Information

The connection between the following components is implemented with Ethernet using the TCP/IP network protocol (Bild 4-1):

Camera and the AddOn technology in the SIMOTION (1) (only STS)

Camera and the CeCOMM diagnostic tool (2) (only STS)

AddOn function in the SIMOTION and the CeCOMM diagnostic tool (3)


Commissioning Software 4.2 Communication via Ethernet

SIMOTION C variant SIMOTION D variant

Fig. 4-1: Ethernet communication

SIMOTION C

Fig. 4-2: Ethernet communication

SIMOTION D

Whereas dashed connections ((2) and (3)) are only present during the diagnosis or commissioning, solid connections are always present.

The Ethernet connection between the SIMOTION D variant and the CeCOMM diagnostic tool (3) requires a JAVA application. This JAVA application (Buffer.jar) and the "DCC_SCCommon" block on the SIMOTION D control both the communication and the data flow.

Note SIMOTION D The JAVA application is not part of the SCOUT project, but is contained on the supplied CD. The customer must copy this application to the CF card of the SIMOTION D.

The continuous communication between the AddOn functions on the SIMOTION D and the camera (1) is not performed directly but using FB blocks. The interface is described in more detail in the next section.

4.2.2 SIMOTION for AddOn - CenSOR M

The signal flow between the camera, commissioning tool and SIMOTION components is shown in schematic form in Fig. 4-1 and Fig. 4-2.

Fig. 4-2 also shows that the "FB_Receive_Analysis" and "FB_Send_Preparation" ST programs perform the communication between the "DCC_SCCamera" DCC block and the camera.

The IP address and the port of the camera are stored in retentive variables. This information is available when the SIMOTION D is restarted and forwarded to the "DCC_SCCamera" block.



Note If the IP address of the camera is changed, this new address must be notified to both the SIMOTION and the camera via CeCOMM.

4.2.2.1 SIMOTION CenSOR M (only STS)

The SIMOTION data on the CenSOR M camera measurement system has the following structure:

Table 4-1: SIMOTION→ CenSOR M

BYTE Signal name Unit Format Remark

1 - 4 Reserved

5 - 8 iHoist_Height_PLC ± mm DINT Ext_Dist External distance

Hoist_Height_PLC:

Encoder value which is converted with the aid of the camera parameters P20 and P21 to produce the distance between the camera and the reflector. This value from the encoder goes to the drive and is forwarded to the SIMOTION. Then the value is supplied to both the PLC via the PROFIBUS DP as well as the camera.

4.2.2.2 CenSOR M SIMOTION (only STS)

Table 4-2: CenSOR M → SIMOTION


1

2 ZSW1_SC_CAM - WORD

Status word see below, Tabelle 4-3

3

4 EW1_SC_CAM - WORD

Error message 1 see below, Tabelle 4-4

5-8 X_POS ± mm DINT Deflection in the X direction Deviation of the reflector position from the zero position in the X direction

9-12 Y_POS ± mm DINT Deflection in the Y direction Deviation of the reflector position from the zero position in the Y direction

13-16 ROTATION ± cgr (1/100°)

DINT Skew Deviation of the reflector position from the zero position with regard to skew

17-20 DISTANCE_CAM + mm DINT Distance between camera and reflector Relative position difference between camera and reflector

21-24 V_X ± mm/s DINT Velocity in the X direction

25-28 V_Y ± mm/s DINT Velocity in the Y direction




29-32 V_ROTATION ± cgr/s DINT Speed of rotation

33-36 V_DISTANCE ± mm/s DINT Distance change

37-40 Message frame counter

- DINT

Message frame counter The SIMOTION uses the unsigned counter to detect whether a new message frame has been received

The signals ZSW1_SC_CAM, EW1_SC_CAM and the message frame counter are evaluated in the SIMOTION and when the camera is connected are visible for users in the CeCOMM but not in SIMOTION.

The following figure illustrates the CenSOR M measured values for the distance values.

Fig. 4-3: Graphical representation of the CenSOR M measured values

Table 4-3: ZSW1_SC_CAM


0 Reserved

1 Reserved

2 Calibration status 1

3 Calibration status 2

The signals report the calibration status of the camera measurement system (commissioning step 4). Two calibration steps exist. The calibration is complete when both signals are set. The signals are normally linked with lamps. 0: Calibration step not completed 1: Calibration step completed Flashing: Calibration currently being performed

4 Watchdog The signal is negated cyclically after 200 ms. It confirms that the endless loop of the controller is being processed

5-15 Not used




Table 4-4: EW1_SC_CAM


0 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.

1 Reserved

2 Camera measuring system not calibrated

A calibration was started by pressing the rotary switch on the connection box or in the commissioning menu of the diagnostic program and has not yet completed. The camera measuring is deactivated until the calibration has completed.

3 Camera measuring system impaired

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

4 Camera measuring system faulted

The camera does not identify a reflector any more.

5 Invalid distance The externally specified distance lies outside the set limits.

6-15 Not used

4.2.3 Parameterizing/addressing

For the communication between the components, the SIMOTION must make the IP address available to the camera. The camera is delivered with a predefined IP address.

The CeCOMM diagnostic software (see Section 4.3) is used for this purpose. After calling the Parameters menu with the "P" key and calling the "I" function, follow the instructions.

Default settings

IP address of the camera 192.168.1.155 Camera port 8500

Commissioning Software 4.3 Configuration of the AddOn Functions

4.3 Configuration of the AddOn Functions The AddOn functions are configured during the commissioning using the CeCOMM diagnostic program (Section 4.4) by setting parameters. These parameters are values and settings that do not change continually during crane travel (such as maximum speed, accelerations, maximum positions, etc.). The parameters are stored in parameter sets. They are loaded at each restart and can be used for the calculations.

Parameter sets

Four parameter sets are provided. They are stored as text files in the /SWAYCONTROL/ directory on the SIMOTION D CF card. The files are named Par0.txt, Par1.txt, Par2.txt and Par3.txt files. If no parameter sets are available at the start of the program or if they are faulty, all parameters are set to their default values.

NOTICE

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

If a parameter exceeds the specified limits while loading, an error message is generated and the value of the relevant parameter is set to the default value. The error is only reset after all parameter sets have been loaded successfully.

The current parameter set is defined by control bits in the Common block. All parameter sets can be edited irrespective of which parameter set is switched active by the control bits.

Switching the parameter sets Note The control response or the configuration can be changed by switching the parameter sets. In conjunction with control elements, the crane operator can select a desired configuration.

Different parameter sets can be used, for example, when different speeds and/or accelerations should be used.

The parameter P101 "Parameter set locked during travel“ can be used to prevent the switching of parameter sets during travel.

Input and editing of parameters

To input and edit parameters, the Parameters menu is called from the main menu or another display screen with the "P" key (Section 4.4.6.2). The Parameters menu contains an overview of the parameter groups that can be displayed in short form, page-by-page via the keys "1", "2", etc.

Parameters that differ from the default values are identified by a "+". When "?" and the parameter number is entered, a detailed explanation of the parameter is displayed together with the current, default, minimum and maximum values.

The parameter can be changed with "C" and the parameter number. Only values in the range between the fixed minimum and maximum values can be entered for the parameter.


Commissioning Software 4.3 Configuration of the AddOn Functions


If acceleration parameters less than 20 are entered, these values are interpreted as times and converted to the corresponding parameter values.

NOTICE

Always use the parameter menu of the "CeCOMM" diagnostic program to edit the parameter sets. The files can be destroyed when an editor is used.

Note Detailed information about the parameters is contained in Section 5 and the online help.

Saving parameters, effect

Note Each changed parameter takes effect immediately, but is not stored permanently. Changed parameters should be confirmed and then saved permanently with "S" (saving of all parameter sets and fixed ranges). All parameter sets are always saved.

Note Changes to parameters P100 – P104, P106 and P110 take effect in all parameter sets, otherwise only in the respective, active parameter set.

NOTICE

The semiautomatic commissioning sets parameters only in the current parameter set.

Note A documentation of all set values can be created best with the functions Parameter listing ("L"), History call ("F2"), Select (e.g. CTRL+A) and Save ("F4").

Note All parameters, whose settings during the commissioning are not absolutely necessary and therefore not described explicitly in the appropriate sections, should be left with their default settings and only changed when problems occur.

Commissioning Software 4.4 CeCOMM Commissioning Software

4.4 CeCOMM commissioning software

4.4.1 Introduction

The diagnostic program is used for the commissioning, parameterization and diagnosis of the Sway Control systems.

This program can be used for the following tasks:

Check and change the current parameter settings

Check the current camera image

Record curves

Transfer updates

Save and load parameter sets

Requirement for the diagnosis and commissioning is the Ethernet connection of the laptop/PC with the Sway Control system. Note The following sections describe the principle of the structure and the operation of the diagnostic program. For the diagnosis or commissioning, the shown menus, functions and dialogs in the function section can vary greatly depending on the connected Sway Control system.

4.4.2 Installing software

The CD contains a commissioning and diagnostic program. The installation that can be made on any PC or laptop is started from the CD drive by executing the "Setup CeComm.exe" file.

Note The program can run under the WINDOWS 2000 or WINDOWS XP operating systems. This requires that the user is logged on to the PC as administrator.

The installation program leads you step by step through the whole installation process. After the installation, the diagnostic program is available below "Windows Start Programs".


For the commissioning and diagnosis, the IP address of the commissioning laptop/PC must provide in the same subnet as the connected Sway Control system.



Note Any 'personal firewalls' (e.g. Windows Firewall for Microsoft XP) should be deactivated or exceptions permitted. The correct operation of the "CeCOMM" diagnostic program requires unrestricted access to specific ports (FTP, Telnet).

4.4.4 Operation

General

The diagnostic program consists essentially of four parts (Bild 4-4):

Windows menu (Section 4.4.5)

Icons for establishing the communication

Functions (Section 4.4.6 to 4.4.12)

Status bars

Fig. 4-4: General Layout

The Windows menu functions are located in the upper area. The icons for establishing the

communication are located below.

After the successful connection to the devices, the following Functions are available on the tabs:

Monitor: Device-dependent display of all diagnostic information, change



parameters, display error messages, etc.

Camera picture (image): Load the current camera image

File manager (Explorer): User interface for copying, renaming, editing, etc. files

Diagram: User interface for recording, saving and loading curves

Web server: Use the Web server available on the target system

Telnet: Establish connection to the Sway Control system with Telnet

Calibrate hoisting height: Tool for calibrating the hoisting height

Note Most of the available functions can be operated using a button (e.g. "F2 - History") and also the key (e.g. "F2") shown on the button. The following description only describes the button.

Note The displayed menus, functions and dialogs in the function part depend on the connected device or system and so can vary greatly.

The Windows status line contains the IP address of the connected device, the interface version and

the version of the Sway Control system and the loaded *.ini file. The icon can also be used to keep the window in foreground, even when it is not active. Pressing the icon again deactivates this function.

Establishing the communication

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

The IP addresses of the connected devices can be set via the "Interface" Windows function . See Section 4.5.5.

The connection is established in four successive phases:

Phase 1

The application attempts to reach the SIMOTION or the CenSOR M using the set IP address.

Phase 2

The node can be reached in the network and a connection established.

Phase 3

The current version of the application will be loaded.



Phase 4

The language files will be loaded appropriately for the current configuration.

Note After a restart of the Sway Control system (switch-on process, general reset) phases 1, 2 and 3 can take as long as one minute. In this case the communication should not be disconnected to allow the connection to be established correctly. If a connection cannot be established, check the interface settings on the diagnostic PC and in the CeCOMM commissioning tool. The "CeCOMM" commissioning tool and the Sway Control system may need to be restarted.

4.4.5 Windows menu functions

4.4.5.1 Windows menu function “File”

Open

When the connection is established, the software detects automatically the connected hardware (SIMOTION, CenSOR M, etc.) and loads the associated *.ini file from the program directory.

The "INI" file contains all settings and properties for the diagram (such as data selection, colors, line thicknesses).

If these settings are to be saved and reused with a different name, this can be realized using the "File / Save as" and "File / Load" Windows menu items.

If these *.ini files are deleted unintentionally, new files will be created using the default settings.

Save as

The settings for the diagram can be saved in an *.ini file.

Note For all changed properties (F8), the properties of the diagram will be saved automatically in the DiagXXX.ini or DiagXXX_engl.ini file in the program directory or the currently set directory and file name.

ReLoad last chart

This function loads the last recorded chart.

Connect/disconnect network drive

These are the usual Windows Explorer functions for the connection and disconnection of drives.

Properties

This function is only active in the "Explorer" tab and opens the Windows properties window when a file or a folder is selected.



4.4.5.2 Windows menu function View

The "View" Windows menu function can be used to call all functions provided on tabs.

4.4.5.3 Windows menu function Options

Note The Windows "Send text file", "Save image content" and "Start cemgr" menu functions are available only when the "Monitor" function (tab) is active.

Send text file

Note This Windows menu function is available only for the commissioning and diagnosis of the camera.

This function sends a prepared text file similar to the batch file to the Shell, a part of the operating system on the camera. This text file is used for the simple execution of saved MS-DOS commands and command sequences.

Save image content

This function is used to save the content of the current screen (e.g. display screen 1 = kinematics) in a text file (*.txt) that can be opened with a simple editor.

Start cemgr

This function is provided for service purposes and serves to start the program in debug mode.

Ping

This function can be used to quickly test whether a connection from the diagnostic tool to the camera or to the SIMOTION D exists. The following screenshot shows a successful connection request.

Fig. 4-5: Ping to the camera

Interface

The IP address of the connected device can be supplied via this function. It is also possible to configure the connection type and the associated required interfaces.



Fig. 4-6: Configuration of the IP address

Language

German and English are currently available. It is possible to switch from one language to the other at any time. The current language of the diagnostic program will also be set on the target system when the the target system is connected.

Auto configuration

When this function is activated, the program detects automatically the connected hardware (SIMOTION, CenSOR M, etc.) and loads the associated *.ini file.

Configuration file

The DiagHPC.ini configuration file will be loaded and can be edited.

Choose root directory

This function is active only in the "Explorer" tab and opens the root directory of the camera.

Set system time

The clock time cannot be stored permanently on the camera. The clock time is set to zero when the camera is restarted. When the connection is established with the diagnostic tool, the system time of the commissioning PC will be transferred automatically to the camera. The "Set system time" function can be used to manually transfer the system time. This option is particularly important for the time stamp used for saving parameter files (Par0.txt…Par3.txt)

4.4.5.4 Windows menu function Calculations

Position parameters

This tool can be used to calibrate the sensor data. The associated measurement data and the required position data are entered. The required conversion factors for measurement data to position data are displayed. This requires that a travel axis is used to approach two positions. The positions displayed in the controller are entered at the right-hand side as "Position values" and the internal positions displayed in the camera are entered at the left-hand side as "Measured values" in accordance with the approached position. "Calculate" provides the two conversion factors. These conversion factors must be entered manually in the parameter list.



Fig. 4-7: Calculations position parameters

Speed parameters

The crane manufacturers frequently specify the crane-specific P1 – P5 parameters in units that cannot be used directly in the parameters. This function is used for the simple conversion of the specified crane data into mm/s and mm/s².

Fig. 4-8: Calculations speed parameters

4.4.5.5 Windows menu function Help

INFO

The version number of the program is displayed below Info.

Help for CeCOMM Note This function is available only for the commissioning and diagnosis of the camera.

This menu entry provides help for using the CeCOMM diagnostic program.



Load online help

The commissioning help will be uploaded from the associated connected device or system and displayed in HTML format.

4.4.6 Monitors

General Information

When the space bar is pressed, all available keyboard commands will be displayed. Note The displayed menus, functions and dialogs in the function part depend on the connected Sway Control system and so can vary greatly.

Fig. 4-9: Monitor - Main menu

To trace the performed diagnostic steps, for copying or for the improved view of scrolling windows (e.g. display parameter listing), the "F2 - History" button can be used to display all previous steps. When this history function is called, the display screen will have a gray-colored background. After marking the required text using <CTRL>-<A> or <CTRL>-<C>, the "F4 - Save as…" button will be enabled and this selection can be saved with an entered name (see next figure).



Fig. 4-10: Marked text section from the parameter list

The "F3 - Return to monitor" button returns to the monitor function.

The functionality of the monitor function can be divided into three groups:

Display screens

Parameterization menus

Special functions

4.4.6.1 Monitor display screens

Depending on the target system, different display screens are available.

The display screens are called from the main menu using the appropriate keys (e.g. "1" for "Kinematics", Bild 4-11).

The "Monitor" function and its subfunctions have a monitor status line in the last line used to display information and enter values.



Fig. 4-11: Monitor - Kinematics display screen, Sway Control system

The "1" to "7" keys can be used to change arbitrarily between the display screens. Pressing the space bar causes the main menu to be displayed.

In general, the values displayed in the individual screens are self-explanatory because of their labeling and layout.

Some of the values are explained in greater detail below.

Load deflection/angle - "Kinematics [1]" display screen

The load deflection is the deviation of the load from the rest position. It is displayed in the "Kinematics [1]" display screen below the acceleration value (previous figure). The load deflection in the trolley direction is on the left-hand side and is specified in mm. The deviation of the load from the rest position during skew (Skew Control) is an angle and is specified in cgr (centi-degrees) on the right-hand side.

Effective pendulum length - "Kinematics [1]" display screen

The effective pendulum length is the basis for the calculation model for the prevention of swaying. It is displayed in the "Kinematics [1]" display screen for swaying in the trolley direction and the swaying during the skew (Skew Control) below the laser value (previous figure).

The effective pendulum length for the swaying in the trolley direction is the distance between the suspension point and the load center of gravity. For the slewing gear or the skew for the TLS (second value), the effective pendulum length is a virtual pendulum length. It is the length with which the skewing motion is eliminated when the same swaying duration as for the swaying movement is assumed. The swaying duration of the skewing motion is also independent of the load length.

Laser and Lanes - "Hoist control [6]" display screen



Fig. 4-12: "Hoist control" display screen, Sway Control system

The following displays are available for the laser scanner

Laser Measured height above zero.

Count Used for control: Will be increased continually when a new valid value comes from the PLC. Because only the last two places are displayed, it starts at zero again at overflow.

Distance The distance is the position difference of the trolley between two valid heights from the laser scanner. At this distance, the height of the obstacles is set to the higher value.

Laser Freq. Displays the frequency of how many cycles of the SIMOTION a valid value comes from the laser scanner. Notes for the validity of the laser values are described in Section 4.7.4.

The selected Lanes for loading and unloading are displayed for the laser values. If only one lane is specified, the other lane receives the same number.

Monitor – logger listing

For a fault analysis, it is important to know under what conditions the phenomenon or unwanted behavior occurs. To receive an indication when which input signal changes, the signal sequence of selected input signals is recorded. Such examples are the setting of the basic operating mode, target positions and override.

The "L" key in the "Monitor" function can be used to display the logged signals. The maximum number of entries is 9999. If this number is reached, the first entries will be overwritten.



Fig. 4-13: Monitor - logger listing

Content

1. Column: Sequential number of the entry

2. Column: Time of the event in the format "hh-mm-ss.ms"

3. Column: Name and content of the changed signal

Particularly important signals, such as the basic operating modes, are color-highlighted.

The following functions are available for operating this screen:

H – Home Display the first page

E – Endpos Display the last page

B – Backw Scroll back one page

F – Forw Scroll forward one page

S – Save Save the logged signal sequences in the "Logger.txt" file in the /SWAYCONTROL/ directory

RETURN – Refresh Update this page



ESC – Escape Exit this display screen

4.4.6.2 Monitor menus and special functions

General Information

The target systems offer various parameterization menus.

The functions described below are examples implemented in this or similar form on all target systems.

The menus and special functions can be called from the main menu and from the display screens. The menus contain various subitems documented in the menu tree (see Appendix) and whose use is largely self-explanatory. The current menu will be displayed after the subitem has been completed. The menus are closed with the ESC key and with the last-called screen displayed.

Parameters menu

The Parameters menu can be called from the main menu and all display screens with the "P" key (Bild 4-14). All parameters can be displayed, changed, saved and copied in this menu.

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

The following access codes are available:

Access code 0 – crane operators, maintenance personnel

Access code 1 – commissioning engineers

Access code 2 – service technicians and specially trained commissioning personnel

Access code 3 – developers



Fig. 4-14: Monitor – Parameters menu

The digits "1" to "12" can be used to display the parameters as groups. The "1" to "12" keys can be used to change arbitrarily between the display screens of the parameters. From these display pages it is also possible to execute the functions of the parameter menus.

Note Whereas the "C – Change parameters" and "F – Search parameters" functions refer to individual parameters, all others apply to the complete parameter set.

C – Change parameters After pressing the "C" key, the parameter number must be entered (e.g. "1" for parameter P1) and closed with <ENTER>. The new value is then entered and confirmed twice with <ENTER>.

Changed parameters are marked with a "+" and a different font color in the displays ("1" … "12").

Note Each changed parameter takes effect immediately, but is not stored permanently. Changed parameters should be confirmed with "OK" and then saved permanently with "S" (saving of all parameter sets and fixed ranges). All parameter sets are always saved.

D – Set default values The "D" key can be used to delete all previous settings and to load the initial settings.

I – Communication addresses All communication addresses can be set in this menu item.



S – Save all parameter sets and fixed areas This function saves and accepts all changed settings.

N – New parameter/area set This loads a different parameter set. The required number must be entered and confirmed with <ENTER>.

Y – Copy parameter/area set This function can be used to copy all ("A") or only a part (<ENTER>) of the parameters from the loaded parameter set into one of the three other parameter sets. The number of the target parameter set must be entered.

L – Parameters/area listing List all parameters. "F2 - History" can be used to view the list.

R – Reload parameters Load all parameters of the current parameter set. This is useful when a parameter has been changed and the previous version should be restored. If a parameter set is copied into the directory, the parameters must also be reloaded for updating.

F – Search parameters A search term can be entered. All parameters that contain this search term will be listed.

Commissioning menu

The commissioning menu can be called from the main menu and all display screens with the "I" key. All commissioning steps are performed in this menu.

The commissioning steps depend on the associated attached device. A detailed description for the commissioning steps for Sway Control on the SIMOTION is contained in Section 4.7.2.1. The commissioning steps for the camera are described in Section 4.5.10.2.

Monitor special functions

The special functions

E Faults

G Display variable blocked regions

H Faults history

S Shell

V Version information

! Stop diagnosis

X Simulation of the loading

are called from the main menu and from the display screens.

The "Faults" special function lists all currently pending faults. The "?" key and input of the fault number (e.g. "12") can be used to display a more detailed description of the fault.

Faults marked red are forwarded to the PLC. The faults marked green have the status of a warning and are not forwarded to the PLC.

The "Faults history" special function lists all faults that have occurred previously. All faults marked with an asterisk * are still active.



Note All faults are listed just once in the "Faults history" screen with the system time of the last occurrence, even if they have occurred several times.

The appropriate letter (E, H) can be used to switch between the "Faults" and "Faults History" functions.

The "Display Variable Blocked Regions (G)" function displays the external variables and internally learnt blocked regions (only SIMOTION or container crane).

The "Version information (V)" function displays information about the current version.

The "Shell" function is available only for the diagnosis of the camera and is used to monitor the boot process and to change special settings. The function can be called only when a connection to the camera using the serial interface has been established.

The "Stop diagnosis (!)" special function is provided for service purposes.

All special functions should preferably be closed using the "ESC" key. The last-called display screen is then displayed.

The "Simulation of the loading (X)" special function is used during the commissioning of the hoisting gear to test the correct functioning of the automatic mode. Pressing the "x" key in all display screens simulates the locking of a container, and when pressed again the unlocking. The current state is shown in the status line.

NOTICE

Only an empty spreader can be simulated as being loaded. Consequently, in simulation mode, the internally learnt obstacles are corrected as if a container were locked to the spreader. In such a state, travel must be performed at an adequate height (> max. container height P108) above the actually existing obstacles. Otherwise collisions can occur during automatic operation.

4.4.7 Image - checking the camera image (only STS)

Note This function is available only for the commissioning and diagnosis of the camera.

This function provides support during the commissioning, checks the calibration and determines the height in which the reflector will no longer be recognized.

NOTICE

If this function is used during crane travel, errors can occur with the calculation of the control algorithm and a correct travel can no longer be guaranteed.

After activation of the "Camera image" function and pressing the "F5 - Update" button, the current camera image will be loaded (only CenSOR M).



Fig. 4-15: Image function

The "Camera image" function contains the following additional functionality:

Display a fast image sequence The display of a fast image sequence is started with the "F2 - Multi-Burst" button. The number of images to be recorded is set in the side listbox and decremented after the start. "F3 - Stop" can be used to cancel this display prematurely.

Display a live image The "F4 - Live" button is used to continually display live images.

Save image The "F6 - Save image" button is used to save the current image in "*.JPG" format.

Display a crosshair To improve orientation, the "F7 - Crosshair" button displays a crosshair.



4.4.8 File manager

The file manager can be used to edit, copy, rename and delete files. Directories can be created. Note The displayed directories in the function part depend on the Sway Control system and so can vary greatly.

Fig. 4-16: Explorer function

Requirement for the correct function is the correct assignment of the IP address and the connected device in the "Options/interface" Windows menu function.

4.4.9 Diagram – user interface for recording curves


The "Diagram" function is a user interface for recording, loading and saving characteristic and signal curves.

Basically there are two diagram types:

Path/speed time diagram This diagram displays the signal characteristics (speed, path, degree) over time. All curve characteristics of the calculated and actual speeds and paths (upper area) as well as all states of




the input/output bits from and to the PLC on the Sway Control system (lower area) can be tracked (Bild 4-17, left-hand side).

X/Y diagram The path characteristics for two axes in the X/Y plane with displayed blocked regions can be monitored (Bild 4-17, right-hand side).

The recorded measured values are used for both diagram types. F11 or F12 can be used to switch between the diagram types.

Path/speed time diagram X/Y diagram Fig. 4-17: Diagram function

4.4.9.2 Procedure for recording diagrams

The "F2-Start" button is used to select which axes are affected, and which axes and parameters are to be recorded. The "Diagram view" window with the "Axes", "Main values", "Input bits" and "Output bits" tabs appears.


Fig. 4-18: Diagram function, F2-Start, Axes tab

The following settings can be made in the "Axes" tab:

Axes – Trolley, Hoist, Skew The required axes will be activated.

Recording cycle If the recording takes a long time, the number of values to be recorded per time unit can be reduced. For a "1" setting, a value will be recorded for each sampling time (camera = 70 ms); for a "10" setting, a value will be recorded only every tenth sampling time (camera = 700 ms).

Delete diagram The diagram will be removed.

Long-term recording This is a supporting function. This function can perform a long-term recording for diagnostic purposes, e.g. over several hours or several days. A new file is stored in the automatically created directory "LongTraces" every half hour (see also Section 4.4.9.3).

X/Y display This function is not supported. To display the X/Y diagram, the "position setpoints" and "actual position values" must be recorded. They will be selected automatically when the checkbox is activated.

The recording task is started with the "F2-Start" or "F4-Start Trigger" button. When started with the "F4-Start Trigger" button, the recording is performed only when the crane moves, otherwise immediately and permanently. The "Diagram view" window will be closed automatically.

The crane can now be operated so that the interesting states are visible. The recording phase can be monitored online on the screen and starts displaying the signal characteristics over time. It is, however, possible to switch to the X/Y diagram at any time. The recording is terminated with the "F3 - Stop" button (next figure).



Fig. 4-19: Diagram function, terminating the recording with F3

The following window then appears with the "Resolution" and "Time window" tabs:

Fig. 4-20: Recording dialog window – "Resolution" and "Time window"

The values recorded with a sampling rate of about 100 ms during the "Live recording" are displayed as a diagram; the digital signals are displayed at the precise time independently of this. In the background, all isochronously received data is buffered in a temporary file for the recording.

After completing a trace, a dialog window is displayed with selectable options in order to be able to reload the diagram subsequently. The user can now select the required clock-pulse rate or, if required, define a specific period of time.

The menu item <File>+<Load> last diagram…> contains the same option; the dialog window also is also displayed here. The temporary file is retained until a new recording has been started. Therefore, it is also possible to load the last recording to the diagram after CeCOMM is restarted.

With the option "Do not display this window any longer", the display of the dialog window is suppressed every time a recording is stopped. This option can be reactivated at any time by selecting it via the above menu function. The option is always deselected after a CeCOMM restart.

To improve clarity, the number of parameters to be recorded can be restricted. This is done using the "Main values", "Input bits" and "Output bits" tabs of the "Diagram view" window.



Note The "Reloading var-traces" button must be clicked before using the variables for the first time.

The following settings can be made in the "Main values" tab (next figure):

Values to be transferred Activate all interesting parameters to be displayed as curves in the upper half.

All ON Select all parameters.

All OFF Select no parameters.

Fig. 4-21: Diagram function, F2-Start, Main values tab



The following settings can be made in the "Input bits" and "Output bits" tabs:

Fig. 4-22: Diagram function, F2-Start, Input bits tab

Fig. 4-23: Diagram function, F2-Start, Output bits tab

Bit signals from/to PLC Selection of the bits from and to the PLC displayed in the diagram (lower area).

All ON Select all parameters.



All OFF Select no parameters.

Recording ON If this checkbox is deactivated, the recording of the bits can be completed without losing the settings of the parameters to be selected.

However, it is also possible to record all parameters first and then restrict the recording using the "F7 - View" button.

4.4.9.3 Elements and functionality of the diagram user interface

General Information

The user interface displays the signal characteristics with a legend on the right-hand side in which individual or all parameters can be selected. If the user moves the mouse cursor over the curves, the current X- and Y-values will be displayed dynamically in the corners, as shown in the following figure.

Fig. 4-24: Diagram function, display elements

Because of the size relationships, the speed values and the load deflection and the curves for the path are located on the left-hand axis and right-hand axis, respectively, in the path/speed time diagram. The signals are displayed only as numeric values without unit so that the user can arbitrarily assign the curves to the axes. The default assignment of the signals to the axes and the associated unit are described in the following table.



Table 4-5 Description of the analog signals

Short designation Meaning Axis Unit

Trolley VSet ext. trolley Trolley set speed specified from the master switch Right mm/s VSet int. trolley Trolley set speed using the set ramps Left mm/s VActuator trolley Trolley speed calculated by the oscillation model Left mm/s VActual trolley Trolley actual speed Left mm/s Trolley model Load deflection calculated by the model (deviation of

the load from the rest position) Left mm

Trolley camera Load deflection recorded by the camera (deviation of the load from the rest position)

Left mm

SSet trolley Position setpoint, trolley Right mm SActual trolley Actual position, trolley Right mm SDelay trolley Position after the set delays Right mm VDelay trolley Actuator speed after the set delays Left mm/s P104 Trolley Variable value that depends on the setting in the

Parameters menu Right Variable

Hoisting gear

VSet ext. hoisting gear

Hoisting gear set speed specified from the master switch

Right mm/s

VSet int. hoisting gear

Hoisting gear set speed using the set ramps Left mm/s

VActuator hoisting gear

Hoisting gear speed calculated by the oscillation model Left mm/s

VActual hoisting gear

Hoisting gear actual speed Left mm/s

SSet hoisting gear Hoisting gear set position Right mm SActual hoisting gear

Hoisting gear actual position Right mm

SDelay hoisting gear

Position after the set delays Right mm

VDelay hoisting gear

Actuator speed after the set delays Left mm/s

P104 Hoist Variable value that depends on the setting in the Parameters menu

Right Variable

Slewing gear VSet ext. slewing gear

Slewing gear set speed specified from the master switch

Right cgr/s

VSet int. slewing gear

Slewing gear set speed using the set ramps Left cgr/s

VActuator slewing gear

Slewing gear speed calculated by the oscillation model Left cgr/s

VActual slewing gear

Slewing gear actual speed Left cgr/s

Slewing gear model Rotation angle calculated by the model (deviation of the load from the zero point)

Left cgr

Slewing gear angle Skewing angle recorded by the camera (deviation of the load from the zero point)

Left cgr

SSet slewing gear Position setpoint, slewing gear Right cgr SActual slewing Actual position, slewing gear Right cgr



Short designation Meaning Axis Unit gear SDelay slewing gear

Position after the set delays Right cgr

VDelay slewing gear

Actuator speed after the set delays Left cgr/s

P104 Slewing gear Variable value that depends on the setting in the Parameters menu

Right Variable

In the the lower area of the diagram user interface, the states of the input and output bits in the PLC are displayed with a legend on the right-hand side in the path/speed time diagram; this diagram also allows the selection of a single parameter or all parameters.

Zoom

To provide a detailed display, areas of the diagram can be increased in size. This is done by clicking and dragging with the mouse pointer (from the top left to the bottom right - rectangular form) over the area of interest. If the original state should be restored, drag the rectangle in the opposite direction. The axes can be scrolled and zoomed.

The zoom function for the detailed view can also be used during the recording. Press the space bar to leave the zoom again. The monitoring of the recording continues.

The Zoom In and Zoom Out function is also active in the lower diagram area for displaying the states of the bits.

Ruler

The ruler can be used for more accurate tracking of signals (Specific bit was set How does a specific variable behave at this time?) and for determining specific points.

It is activated by placing the cursor on the left-hand side of the diagram, keeping the left mouse button pressed and dragging the ruler to the right.

Fig. 4-25: Ruler function – activating the ruler



The x value of the ruler is now displayed on the left below the diagram (1.61sec in the example).

The ruler is fixed by pressing the spacebar. The first ruler is now fixed and a second ruler appears and can be moved to the required position with the cursor.

When you press the key combination Ctrl + left-click, the x value of the second point appears and the difference between the first and the second points (see following figure).

Fig. 4-26: Ruler function – second ruler

To deactivate the ruler function, move the cursor back to the left-hand edge and left-click.

Long-term recording

This function can perform a long-term recording for diagnostic purposes, e.g. over several hours or several days. The function is activated by activating the "Long-term recording" checkbox on the Axes tab (F2 Start Axes Long-term recording).

When all settings have been made, the recording can be started (F2-Start). The following is displayed:

Fig. 4-27: Long-term recording active



The laptop screen can be closed. Screen savers do not interrupt the recording.

A file with date and time is now stored in the automatically created "LongTraces" directory every half hour.

These files can now be loaded and evaluated. To do this, select "File" "Load long-term recording".

Fig. 4-28: Loading long-term recording

The following window opens and the required file can be selected and displayed.

Fig. 4-29: Loading long-term recording file

Icons



Icon Short designation Description

Grid lines

A new window appears in which the axes for which the grid lines are to be drawn can be selected (default: time axis).

Measuring points

In the analog curves, all actual measuring points are indicated with a small icon. This makes it possible to check which measuring points produced the curve.

Delete curves

Delete the diagram. If individual elements of the display are to be removed again, this can be realized by deactivating the appropriate checkbox in the legend on the right-hand side.

Start Select which axes and parameters should be recorded and

start the recording task.

Stop Stop the recording.

Load file

Load existing "*.dgr" diagram file.

Saving the file

Save the diagram content (data) in a "*.dgr file".

Print

Print the diagram after selecting the printer and the print preview.

View

Select the displayed parameters and change the characteristics.

Properties

Change the characteristics of the diagram, such as the designation of all parameters and axes, limits and colors.

Help

Function description of the keys for scrolling and zooming in the diagram display.

The icons for operating the X/Y diagram are explained in Section 4.4.9.4.

The functions of selected icons are described in detail in the following sections.

Print, print preview – F6

The diagram can be printed using the "F6 - print" button. After selecting the printer and the printer settings, a print preview appears when the "OK" button is pressed to confirm (following figure). Various details (e.g. print with/without legend) can be set in this print preview. Zooming with the mouse is also possible.



Fig. 4-30: Print function, print preview

View – F7

Pressing the "F7 - View" button opens the "Display measurement series" window (following figure) with the "General" and "Bit signals" tabs that are used to select the displayed parameters and to change the characteristics (color, name, line type and line thickness). A selected parameter can be placed on the left-hand axis or on the right-hand axis. The direction arrow keys (up or down) can be used to change the order of the display.



Fig. 4-31: Diagram function, F7 - View, General tab

Properties – F8

The "F8 - Properties" button can be used to set and change the designation of all parameters and the axes. The limits and the colors can be specified for the background and for individual elements of the diagram.

Fig. 4-32: Diagram function, F8 - Properties, Analog values tab



Note For all changed properties (F8), the properties of the diagram will be saved automatically in the DiagXXX.ini or DiagXXX_engl.ini file in the program directory or the currently set directory and file name.

Help – F1

Pressing the "F1 - Help" button opens another window that contains all keyboard commands for scrolling and zooming in the diagram display.

Fig. 4-33: Diagram function, Help

4.4.9.4 X/Y diagram

One of the two buttons can be used to change to the X/Y diagram (next figure). This diagram shows the travel curve for two axes in the X/Y plane, where one axis represents the movement of the trolley and the other axis the path of the hoisting gear. When one of the other buttons (F11 or F12) is pressed, the axes will be interchanged. Activating the same button again changes to the path/speed time diagram.



Fig. 4-34: Diagram function, X/Y representation with blocked regions

The calculated and the actually travelled curve are displayed. The following icons can be used to display additional information.

Icons

Icon Short designation Description

Interpolation points

Add the curve with the interpolation points used as basis for calculating the travel curve. Note

The interpolation points are only relevant in the "Hoist control" basic operating mode.

Blocked regions

Display all blocked regions (fixed and variable). If the "Cyclical refresh" option is selected, the internally learnt variable blocked regions on the waterside will be updated continually during the crane travel.

Note The curves drawn in the diagram are always relative to the lower edge of the spreader.

Note When the spreader is locked to a container, all fixed and variable blocked regions are increased by a fixed amount (parameter P108, maximum container height in mm). If a container is removed, i.e. if both bits "Container locked bit 0 and bit 1" are reset (also applies if only one bit is reset), the blocked region is reduced by the minimum container height of exactly 2000 mm.



Note The zero line is drawn at the minimum position for the hoisting gear positioning (P63).

4.4.10 Web server

An integrated Web server can be used to display camera images (only CenSOR M). In addition, the system time can be set and the diagnostic buffer read.

4.4.11 Telnet

The connection to the camera (only CenSOR M) can also be established using Telnet. In this case, a connection to the Shell will be established using the Ethernet connection. The Shell is part of the operating system on the camera and permits the interpretation of the entered commands, such as display directories. The Shell is always started automatically.

4.4.12 Calibrate hoisting height

The "Calibrate hoisting height" function corresponds to commissioning step 2 of the Sway Control system. The values for the hoisting height, the number of swayings and the duration of these swayings, however, must be determined and entered by the user.

The individual steps are self-explanatory and closed with "F5 - Send values" (see figure below). The P60 and P61 parameters are set during the calibration of the hoisting height – trolley. During the calibration of the hoisting height – skew, depending on the spreader width, the P89, P90 (20 ft), P91, P92 (30 ft) or P93, P94 (40 ft) parameters are changed.

The integrated stopwatch can also be used individually with "F2 - Start" and "F2 - Stop".




Fig. 4-35: Calibrate hoisting height function

Commissioning Software 4.5 Camera Measuring System

4.5 Camera Measuring System (only STS)

4.5.1 Camera measuring system operating principle

The camera measuring system determines the offset and skew of the reflector, initially in pixels and then converts them into millimeters. Various algorithms are used to check and correct the reliability of the measuring signals.

The mounting parameters can be set with an automatic calibration. In this case, the reflector is dimensioned in the zero position for various distances.

The measuring system can additionally be configured using parameters.

4.5.2 Functions

4.5.2.1 Measurement of the deflection

The camera measuring system records the offset in two axes.

The absolute measuring accuracy of the camera measuring system depends on the distance of the camera to the reflector. When a lens with a 16 mm focal length is used, the absolute measuring accuracy is 5 mm at 10 m distance.

If a larger accuracy is required, a lens with longer focal length can be used. This, however, reduces the measuring range because of the smaller aperture angle.

The distance between the camera and the reflector can exist within the range 1 to 50 m. The larger the maximum distance, also the reflector must be the larger.

4.5.2.2 Measuring the rotation angle

The camera uses the reflector skew to determine the rotation angle. The resolution depends on the reflector size and the distance.

The maximum measurable angle of rotation is 15°. A larger skew would cause the pattern of the reflector no longer to be recognized by the camera.

4.5.2.3 Measurement of the distance

The camera measuring system uses the size of the reflector to determine the distance between the camera and the reflector. The measuring accuracy is approx. 2% relative to the distance.

4.5.3 CenSOR M camera interfaces

The CenSOR M camera possesses an Ethernet interface, a serial interface and a video interface.



Table 4-6 Camera interfaces

Connectors Connector type Signals

Serial I/O 15-pin 3-row D 2x RS232 serial

Video out, digital I/O 15-pin 3-row D (VGA) Video out, Hsync out, Vsync out, 2 in, 2 out

Ethernet RJ45 10BaseT

Ethernet is used for both the communication with the controller and the communication to the diagnostic software.

4.5.4 Installing/mounting, connection, operation

4.5.4.1 Installing/mounting

Camera Note Ensure that the camera protection housing is installed to the load carrying device (L) largely vertical over the reflector (R). The glass window of the housing must point down. The camera must have a free view of the reflector (R).

The camera should be easily accessible by the maintenance personnel later.

Fig. 4-36: Camera installation drawing

As shown in the above figure, fasten the camera unit (C) with the mounting plate (P) to the trolley (T).



Note The mounting plate (P) of the housing must be located at the left or right when viewed in the trolley direction (A–B).

The mounting plate (P) provides four holes with internal thread. The trolley is connected to the camera unit with four M8 screws.

Reflector

Attach the reflector (R) to the load carrying device (L) as shown in the following figure.

10

Fig. 4-37: Reflector installation drawing

CAUTION

Improper installation can damage the reflector.

Note The reflector must be well visible vertically from above and may not be covered by other constructions. The rotation of the reflector (R) relative to the camera unit (C) must not exceed 10°.

First attach the four supplied rubber cushions (M) to reflector (R) with four M10 screws as shown in X606HBild 4-31X. The reflector with the rubber cushion (M) is then attached at the provided installation points of the load carrying device (L) using four additional M10 screws.

Ethernet hub (optional)

The Ethernet hub (optional) must be clipped on to a DIN rail in a switchgear cabinet.

4.5.4.2 Connecting

The individual components must be connected as shown in the following schematic diagram.



Fig. 4-38: Connection schematic diagram of the individual components

Dashed lines represent a temporary connection for the commissioning and diagnostics. Solid connection lines represent a permanent communication. The use of a hub is optional and is not included in the scope of delivery.

If a hub is used, the commissioning and diagnostics of the camera can be implemented via an Ethernet connection.

If the hub does not exist, the camera can be directly connected to the gateway via an Ethernet cable (cross over). For commissioning and diagnostic purposes, the communication of the camera with the diagnostic PC is established via a serial cable.

WARNING A regulated switched-mode power supply must be used.

WARNING

If a serial cable is used is used for the diagnostics or commissioning, it must be removed from the camera after completing these tasks.

The heating system is self-regulating. If the ambient temperature does not fall below 0 C, a heating system is not required.



Camera

The camera is supplied with a pre-fabricated cable attached on one side. The camera must be connected to the 24 VDC supply and connected to the hub with the Ethernet cable. CAUTION

A regulated switched-mode power supply must be used (see camera technical data).

Reflector

The reflector is connected at the terminal socket to the 110 … 230 VAC power supply.

Hub (optional)

The Ethernet hub is connected to the 24 VDC power supply. An Ethernet cable is used to connect to the SIMOTION.

Diagnostics PC (during commissioning)

The diagnostics PC is connected to the computing unit via an Ethernet cable either directly or via a hub.

4.5.4.3 Operator control (hardware)

Camera lens settings

Fine focus

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

The hoisting gear must be lowered to the lowest point so that the distance between the camera and the reflector is largest. The distance setting on the lens must be changed so that this position produces a focused image.

Brightness

The camera aperture has the following factory settings:

1.4 - with IR filter

2 - for indoor applications

7 - for outdoor applications

These values are appropriate for most application scenarios. For particularly dark conditions, the aperture can be reduced; for very bright ambient light, the aperture can be increased. In addition to this setting, an automatic gain and offset control ensures the optimum picture brightness.


Each device must have its own IP address for communication in the Ethernet network.



NOTICE

The IP address for a device may only be used once within a network.

For the communication between the components, the SIMOTION must make the IP address available to the camera. The CeCOMM diagnostic software (see Section 4.4) is used for this purpose. After calling the Parameters menu with the "P" key and calling the "I" (communication addresses) function, follow the instructions.

The camera is delivered with a predefined IP address. The address of the camera can be changed via the diagnostic software "CeCOMM" "P" "I". The following screen is displayed:

Fig. 4-39: Connection schematic diagram of the individual components

The IP address of the camera can be physically changed here. The camera must be restarted after the address change.

Camera default settings

Setting the own IP address IP address of the camera: 192.168.1.155 Subnet mask: 255.255.255.0

Setting the IP address of the peer IP address of the peer (SIMOTION): 192.168.1.158 Port of the peer (SIMOTION): 8500



4.5.6 Calibration of the camera measuring system

The camera calibration can be performed via the calibration switch on the diagnostics module.

NOTICE The camera calibration must be performed during the commissioning or later after a reorientation/replacement of the camera or reflector.

It is recommended that the camera calibration be performed with the automatic commissioning step 4. Only when a diagnosis is not possible (no cable or computer available), should the calibration be performed with the diagnostics module.

Camera calibration with a diagnostics module:

The calibration switch on the diagnostic tool has three positions "Near position 1", "Calibration ready" (middle position) and "Far position 2". In normal operation, the switch must be in the middle position, otherwise errors E10 and E2 are output.

The LEDs are used to display the current status of the calibration process.

The hoisting gear must be traversed to two positions for the calibration.

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

Which hoisting position applies for position 1 or position 2 is specified via parameters. When executing commissioning step 4, the positions are taken over automatically after completion and stored in the parameters.

If the position for the calibration is already reached when setting the switch, the corresponding LED immediately starts to flash and then turns into steady light.

After execution of the camera calibration via the calibration switch, parameter changes are saved automatically in the parameter lists.

The following figure shows the calibration process.



Fig. 4-40: Camera calibration process



4.5.7 Parameterization cable

A shielded twisted-pair cable should be used as a connecting cable between the PC and CenSOR M (e.g. LIYCY 2 x 2 x 0.22).

During normal operation, the terminating resistor is activated on the diagnostics module (DIP switch "terminating resistor" = ON). If the diagnostics module is connected to a PC for the diagnostics and parameterization, this resistor must be switched off (DIP switch "terminating resistor" = OFF).

WARNING After completion of work and removal of the cable, the DIP switch "terminating resistor" must be returned to the position ON (older version: Plug in connector with built-in terminating resistor).

Fig. 4-41: Pin assignment for parameterization cable

4.5.8 Camera measuring system configuration

The camera measuring system is configured during the commissioning using the CeCOMM diagnostic program (Section 4.4) by setting parameters. The parameters are stored in parameter sets. They are loaded at each restart and can be used for the calculations.

The specifications made in the sections "Parameter sets", "Input and editing of parameters" and "Saving parameters, effect" in Section 4.3 apply. Deviations from these specifications are listed below.

NOTICE Four parameter sets are provided, but for this configuration only parameter set 1 has been permanently set. No other parameter sets can be used.

Storage is in the /FlashFx/ directory on the camera. NOTICE

The semiautomatic commissioning sets the parameters in all parameter sets.

Note Detailed information on the parameters is contained in Section 5.



4.5.9 Commissioning requirements

4.5.9.1 General requirements, overview

The following requirements for the commissioning of the camera measuring system must be satisfied:

1. All components of the system (camera, reflector, hub, SIMOTION) must be installed, connected, functional and interconnected (see Section 4.5.4.1)

2. Setting of the IP addresses of the camera and the SIMOTION peer (Sections 4.5.5 and 4.4.3)

3. Start of the diagnostic program and establishment of the connection between the commissioning PC and the camera (Section 4.4.4)

4. Setting of the access code (Section 4.5.9.2) and the language of the diagnostic program (Section 4.5.9.3)

5. Checking of the communication between SIMOTION and the camera measuring system (Section 4.5.9.4)

6. Checking the camera image (Section 4.5.9.5)

4.5.9.2 Setting the access code

The access code sets the user level. This determines the visibility of the individual parameters. The access code is saved under parameter P100.


Parameter P100 (= access code) should be set to 2 for the commissioning.

The following settings are available:

Access code 0 – crane operators, maintenance staff




The message "No authorization!" appears when an attempt is made to change a parameter that does not correspond to the access code. In order to be able to edit all parameters, parameter P100 should be set to 3.

4.5.9.3 Setting the language

The language of the diagnostic program is set via the menu "Options/Language" and saved under parameter P110. German and English are available.

Alternatively the language parameter P110 can be changed via the Parameters menu. The appropriate language file is then automatically opened and read. The screen displays are updated. However, only the function area of the screen display in the changed language is shown.



4.5.9.4 Checking the SIMOTION – CenSOR M interface

Initially the communication between the SIMOTION and the camera measuring system must be checked with the CeCOMM diagnostic program.

This includes the principle data exchange and the use of the correct data formats and contents.

The "CenSOR Interface" display screen (called with the "1" key ) shows the current input and output data of the camera measuring system. They should first be checked for correctness.

Requirement for other steps is that the send and receive counters increase in display screen 1. This means that the camera receives and sends data message frames.

Fig. 4-42: Monitor function, "CenSOR interface" display screen



4.5.9.5 Checking the camera image

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

The current camera image should have the following characteristics:

The reflector must be correctly focused and well illuminated. (Prior to the commissioning, it is possible that the image is still too light or dark – correction possibilities are described in Section 4.5.4.3).

For all hoisting heights, the reflector is located almost in the center of the image.

If the camera measuring system is provided only for one axis, the travel direction and thus the swaying direction should lie in the horizontal image direction.

Fig. 4-43: Checking the camera image

4.5.10 Camera measuring system commissioning

4.5.10.1 Overview of the commissioning steps to be performed

The following steps should be performed in succession:

1. Commissioning steps in the Commissioning menu

2. Checking and fine adjustment of the camera



4.5.10.2 Commissioning steps in the Commissioning menu

The commissioning steps in the Commissioning menu of the CeCOMM diagnostic tool must be performed next. This menu is called via the "I" key from the main menu or the display screens.

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

The parameters of the active parameter set are set (notes, see Section 4.3).

DANGER

For this reason, the active parameter set may not be changed during the commissioning.

Some parameters are set automatically in these steps. The successful completion of a commissioning step is identified by a "+". After the commissioning steps have been performed successfully, it is no longer necessary to set these parameters manually.

Note Depending on the configuration, individual steps can be hidden.

Setting the configuration and important parameters (commissioning step 1)

In this commissioning step, all required parameters are successively called automatically and must be set correctly.

Semiautomatic commissioning of the camera measurement (commissioning steps 2 to 4)

The commissioning steps 2 to 4 run semiautomatically. The result of these steps is set automatically in some parameters.

Determine the reflector type (commissioning step 2)

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

The algorithm searches for the two alignments and shows the result. The result is saved in camera parameter P2.

Normally, the reflector is correct in one alignment and not recognized in the other alignment.



Note While checking the alignment, the distance between the reflector and the camera should lie in the range 5 m to 10 m.

If both alignments are detected, this can have the following causes: a) Two reflectors are present in the field of vision of the camera.

b) A light-dark combination in the field of vision was incorrectly identified as a reflector. In this case,

the parameter P2 must be varied manually and the measurement result in display 4 compared with the position of the reflector.

If no reflector is detected, this can have the following causes: c) The camera is not aligned correctly. The reflector is not in the field of vision.

d) The ambient light is too bright or too weak. The parameters for gain and offset (P0 and P1) can be

temporarily set to zero. The camera then automatically sets the gain and the offset to the brightness of the complete image. After the successful commissioning step, the parameters must be reset to the original or required values.

e) The window size (parameter P3) is set to values that are too large or too small. By default, P3=11 should be set.

After completion of the commissioning step, the current distortion of the reflector is also saved. This size is important for the correct distance measurement.

Determine the reflector position (commissioning step 2.1)

If in commissioning step 1 it was specified that the reflector position is to be supplied from an external source (P102 = 0), a relation must be established between the transferred position and the measured distance via a linear equation y=mx+n (where m = P20 and n = P21).

The correct position determination is checked in the Monitor function, "CenSOR Interface" display screen.



Fig. 4-44: Monitor function, "CenSOR interface" display screen

The values signify:

(1) – External distance, read in via the PLC

(2) – Internal value, dependent on P102

P102 = 0 (reflector position from external source): The value converted with P20 and P21 from the PLC P102 = 1 (reflector position from internal source): Value from the camera

(3) – Distance measured by the camera

Prerequisite for this step is that the measured distance (3) displayed in Bild 4-37 corresponds to the real distance between the camera and reflector.

Procedure

1. The external distance (1) and the measured distance (3) must be read and recorded in two different hoisting heights (distance > 10 m).

2. In the "Calculations" window of the "CeCOMM" diagnostic program, the two measured distances (3) must be entered at "Measured value" and the two associated position values (1) in the "Position value" column.



Fig. 4-45: Calibration of the position values for the hoisting gear

3. "Calculate" determines the resolution (factor) and the offset for the distance sensor; these values must be entered in the P20 and P21 parameters.

4. The correct determination of the reflector position must be checked by traveling various distances. Whereby the internal distance (2) and the measured distance (3) must be identical.

The external transfer of the reflector position via the PLC is recommended for all STS cranes. This enables the reflector pattern to be identified more quickly which increases the measuring reliability.

Determine minimum window size (commissioning step 3)

To achieve a high measuring reliability, the smallest size of the reflector in the image must be set in parameter P3.

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

Note For the semiautomatic determination of the size, lower the reflector as far as possible.

The result of the commissioning step is an integer value between 1 and 10. 1 means that the reflector is very small in the image, 10 very large. The following appears at the end of the commissioning step (example):

"The factor for the window size is: 9 19". This means that the diagnostics have identified the factor 9 as suitable and stored the value 19 (factor + 10) in parameter P3.

Factors > 10 mean that the window size is automatically varied after the commissioning depending on the distance.

Calibrate the camera measurement (commissioning step 4) NOTICE

The calibration is possible only when no camera measuring fault is present. All TLS cylinders must be in the zero position, i.e. trim, list and skew are 0°.

The zero position of the reflector is determined during this commissioning step.

The reflector is measured in two different hoisting heights.



The result of the calibration is saved in the camera parameters P7 – P13.

After the automatic calibration, P27 must be adjusted so that any existing rotation (skew through mechanical mounting) is compensated.

Example:

If the rotation in display 2 is 1.20°, then the value -120 must be entered in parameter P27.

NOTICE

After completion of the calibration, the determined load deflection in both directions and the rotation must be almost zero. (display 2).

Simulate errors (commissioning step 5)

All error bits of the controller can be simulated in this step to check the error analysis on the SIMOTION side.

The corresponding bits are described in Section 4.10.5.2.

Save parameters (commissioning step 6)

All parameter sets are saved.

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

4.5.10.3 Checking and fine adjustment of the camera

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

Reflector type

The reflector type is determined in commissioning step 2.

If no reflector is found, even though it lies in the field of vision, the set window size (P3) must also be checked.

Distance measurement

If no external path sensor for measuring the distance between the camera and the reflector is present, this must be entered in the P102 parameter. The distance is then determined using the size of the reflector, the set focal length of the lens and the size of the white reflector area.

The accuracy of the internal distance measurement decreases with the distance between the camera and the reflector. It is approximately 2% of the distance.

Lens

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

The focal length of the set lens must be set in the P17 parameter.

Brightness

The camera is adjusted as described in Section 4.5.4.3.

The software controls the reflector brightness depending on the ambient light when the P0 – Video input gain and P1 – Offset of the video input parameters are set appropriately.

The default values mean:

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



Offset = 256 The offset is changed increasing and decreasing from 1-255 until a reflector is found. The regulating is then made to constant reflector brightness.

Note The current offset and gain values are displayed for the camera diagnosis in Display 2.

Window size

The camera searches for a reflector that has a specific size. For a window size of 1, a search is made in a 12 x 12 pixel field. For a window size of 10, the reflector in the image must have a size of 66 x 66 pixels. As comparison: The complete image has a size of 640 x 480 pixels.

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

If, however, the set window size is larger than the reflector image, a reflector is not found (see figure). For this reason, the parameter (P3) for setting the window size should be checked at the largest distance between the camera and the reflector.

Values between 1 and 10 mean that the reflector is always sought with a fixed window size in the image, irrespective of how far the reflector is from the camera. This is only recommended when the distance remains constant.

Values larger than 10 activate the automatic control of the window size. This means that the window size is varied automatically depending on the distance.

Note The current window size is shown in Display 2.

Limitation of the search area

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

The limiting of the search area acts only while no reflector is found (global search). Once the reflector has been found, the search is made only in the immediate vicinity of the last position (local search).

The P15 and P16 parameters can be used to reduce the search area beginning from the edges by up to 90%.

Measuring reliability

Several parameters can be used to influence the measuring reliability.

The algorithms first use fast search functions to find a reflector in the image and determine a recognition reliability. The P4 ("Reflector recognition limit") parameter is used to specify the starting reliability for recognizing a reflector as such. If the reflector has dark shadows, this value should not exceed 650 (65%).



If the reflector has been detected, only a search near the reflector is required. The recognition limit in the direct environment can be reduced with the parameter P19 "Reflector recognition limit (reflector environment)", i.e. P19 should be less than P4.

The subsequent size measurement then returns a high reliability for the presence of a reflector in the image. Up to 16 characteristics are checked here. The P6 ("Measuring reliability of the camera") parameter can be used to specify the number of characteristics to be used. If more than ten characteristics are specified to be checked, a reflector will be used only when the reflector size was determined using the characteristics. This means P6 > 10 achieves a very high measuring reliability.

Reflector identification

The reflector identification can be checked in the Monitor function, "CenSOR– Camera [2]" display screen.

Fig. 4-46: Checking the reflector identification

The following must be observed:

The reflector is located almost in the picture center (represented as a cross).

The contrast between the white and black areas of the reflector should be adequately large. This is the case when the histogram contains two different values for the environment (number of pixels per gray value, shown bold) that have an adequate separation from each other. In the example, 76 pixels and 77 pixels were recognized for the black area and for the white area, respectively.

The determined "Distance" should match the actual distance.

A sufficiently good reflector detection can be read at the values "Safety" (should lie near 100%) and "Fault" (should be 0).

The following information values are displayed displayed:

Fault rate: Fault rate as %




Gain: Video input gain (P0)

Offset: Exposure time of the camera (P1)

Size: Pixel size of the reflector in the picture

Average: Determined average gray value of the reflector

Rotation: Rotation of the reflector

Black-White-Gray value: Monochrome limit (P18)

Commissioning Software 4.6 Commissioning Requirements for AddOn Systems

4.6 Commissioning Requirements for AddOn Systems

4.6.1 General requirements, overview

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

DANGER The commissioning and testing of the Sway Control functions may only be performed by trained personnel who are familiar with the operation of the crane. The regulations of the crane operating company must be observed. A further requirement is the successful completion of a commissioning training course of the Siemens AG.

DANGER

All safety functions of the crane must be implemented independently of the Sway Control system. Measures must be taken to ensure that the crane stops without any adverse affects on persons or goods when a fault occurs.

WARNING

The PLC programmer is required to evaluate the error messages of the Sway Control system. In a fault situation, the manipulated values of the Sway Control system may no longer be used. Only the higher-level controller may implement the control of the drives.

The following requirements for the commissioning of the Sway Control system must be satisfied:

1. All the drives to be controlled and the hoisting gear must be functional

2. All components of the system must be installed and connected

3. Preparation of the PLC program (Section 4.6.2)

4. Preparation of the converters (Section 4.6.3)

5. Start of the diagnostic program and establishment of the connection between the commissioning PC and the Sway Control system (Section 4.4.4)

6. Setting of the language of the diagnostic program (section 4.6.4) and the access code (Section 4.6.5)

7. Checking of the communication between the PLC and the Sway Control system (section 4.6.6)

4.6.2 Preparation of the PLC program

The PLC program must be prepared so that all signals are provided for the Sway Control system and all output data is processed further (Section 3).



Note The error bits must be evaluated in all circumstances in order to detect malfunctions and to be able to respond appropriately.

4.6.3 Preparation of the converters

Parameter sets of the converters

The converters should have their own parameter set for the Sway Control function.

The setpoint comes continuously from the Sway Control computer. The parameters are set as described in the following sections.

Acceleration and deceleration ramps

The internal converter acceleration and deceleration ramps should be set to the maximal allowed ramps.

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

WARNING The Sway Control system can calculate higher accelerations and decelerations than those that occur in normal travel operation – especially when neutralizing large swaying movements.

Initial and final rounding

As the speed characteristic is defined by the Sway Control, an initial and final rounding should be deactivated.

WARNING Roundings in the converter that are too large can cause swaying movements!

Minimum frequency of the converters

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

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

Speed controller of the converter



The internal speed control of the converter can be activated in order to achieve a control response that is as good as possible. In addition to the proportional component, an adequate integral component should also be set. Good results have been achieved for the SIMOVERT MASTERDRIVES with kP = 3..5 and Tn 200.

Limitation of the speed actuating signal

Note Limitations of the actuating signal (e.g. in the converter) can result in the tripping of the following error and therefore should only be intended for safety reasons.

The following error is the path difference between the calculated curve and the curve actually travelled (= set-actual deviation).

4.6.4 Setting the access code

The access code sets the user level and determines the visibility of the individual parameters. The access code is saved below parameter P100.


Parameter P100 (= access code) should be set to 2 for the commissioning.

The following settings are available:

Access code 0 – crane operators, maintenance staff




The message "No authorization!" appears when an attempt is made to change a parameter that does not correspond to the access code.

4.6.5 Setting the language

The language of the diagnostic program is set via the menu "Options/Language" and saved under parameter P110. German and English are available.

Alternatively the language parameter P110 can be changed via the Parameters menu. The appropriate language file is then automatically opened and read. Although the screen displays are updated, only the function area will be displayed in the newly selected language.



4.6.6 Checking the communication between the PLC and SIMOTION

The communication between the PLC and SIMOTION must be checked first. This includes the principle data exchange and the use of the correct data formats and contents.

The CeCOMM program can display various diagnostics screens that allow the communication to be checked. The "PROFIBUS interface" display screen is called from the main menu or another display screen with the "2" key.

Fig. 4-47: Monitor function, "PROFIBUS – Interface" display screen

The current input and output data of the Sway Control system are shown on this display screen. They should first be checked for correctness.

Note The values of the Trolley and Hoist axes are output in mm and the skew in cgr (centi-degrees).

The "State of drive axis" display screen is called with the "3" key. The command and status bits are displayed here. They should also be checked for correct assignment before the commissioning. 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 case or stop in the system, "Not enabled", "Stop", "Off", etc.

Fig. 4-48: Monitor function, "Status of the travel axes" display screen

4.7 Sway Control Commissioning When all the requirements (Section 4.6) have been satisfied, you can start with the commissioning.

The commissioning of the camera measuring system is performed by setting parameters with the CeCOMM diagnostic program (notes, see Section 4.3).

4.7.1 Operation of Sway Control

Operation and characteristics

The Sway Control system determines the swing angle with the aid of a camera measuring system. The pendulum angle and the distance are used to calculate the load deflection. The reliability of the measuring signal is checked with various algorithms and, if required, corrected. If the measuring signal fails, a mathematical oscillation model is used for the current states.

Commissioning Software 4.7 Sway Control Commissioning

CAUTION

The acceleration and deceleration ramps can vary greatly. They depend on the initial swaying and the pendulum length.

Generally, the Sway Control system has the following characteristics:

The swaying of the load has been eliminated when the stationary speed or standstill is reached

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

The Sway Control system is configured using parameters (Section 4.3) and can be controlled by the PLC by setting various control bits.

The Sway Control system calculates the setpoint speed that are forwarded to the drives using TO objects.

Sway Control algorithms

As Sway Control algorithm, the parameter P152 (trolley) can be used either for

conventional state feedback or the

time-optimized control.

Use of the conventional state feedback produces an aperiodic characteristic for the swing angle. The acceleration ramp is smoothed. The acceleration times are approx 1.1 times the natural oscillation duration of the load oscillation. The travel operations are performed with low stressing of the entire crane structure.

The time-optimized control is based on the "Theory of the optimal control". Short deceleration ramps are inserted in the acceleration operation and short acceleration ramps inserted in the deceleration operation. This achieves the quickest possible suppression of a swaying movement. The acceleration and deceleration times depend on the available drive power. The time restrictions of the conventional state feedback do not apply.

Note The time-optimized control is not appropriate for STS cranes.

Dynamic prelimit switch

Dynamic prelimit switches improve the travel behavior of the crane at the outer position areas.

In contrast to fixed prelimit switches, the axes are braked at various positions. This position depends on the current axis speed. This means an axis traveling at low speed can be braked much later in order to reach the prelimit switch speed at the positions (P24, P27, P64, P68) specified by parameters.

The following figures use two different speeds to illustrate the operation of the dynamic prelimit switches:

P115: 1 (dynamic limit switches active) P24: 95000 mm (position for trolley VES speed backwards) P27: 6000 mm (position for trolley VES speed forwards) P0: 3500 mm/s (maximum actuator speed of the trolley



Fig. 4-49: Trolley behavior with dynamic prelimit switches at full speed

Fig. 4-50: Trolley behavior with dynamic prelimit switches at half-speed

The figures show clearly the different braking points depending on the speed. For fixed prelimit switches, this point is always at the same trolley position (P115<1).

Although the behavior is similar for hoisting gear (P64, P68), the behavior on the landside and the waterside differ. On the waterside, the lower dynamic prelimit switch does not act in order to allow the immersion in the ship's hold. In this case, the higher-level controller must ensure that no damage can occur to the crane or the ship.

CAUTION

If P115 < 1, ensure that the correct operation of the prelimit switches is guaranteed.

To provide an explanation, the behavior of the dynamic prelimit switch in the following figures is described compared with the behavior of fixed prelimit switches:

Behavior for P6 (trolley acceleration setpoint) < P7 (acceleration without Sway Control / minimum acceleration) and



P115=0

Fig. 4-51: Behavior when P6 < P7 for P115 = 0

The crane moves with 50% of the maximum speed in the prelimit switch. The maximum speed and respectively the actuator speed are shown white and blue. Two things occur when the prelimit switch is reached:

The trolley decelerates to the VES speed. P6 (green curve) serves as calculation basis. The Sway Control is active.

The maximum permitted speed is reduced with P7.

If the blue curve (actuator speed) intersects the white curve, it will be limited to its value. It may, however, be lower. If to catch the sway it is desirable to reverse the travel direction (the blue curve undershoots the pink curve), the full maximum speed is permitted briefly.

(Notice: The diagrams are accurate to only approx. 100 ms)



Behavior when P6>P7 and P115=0

Fig. 4-52: Behavior when P6 > P7 for P115 = 0

The case shown here does not impair the limitation because the ramp is very flat. This allows the Sway Control effect to be seen exactly. If the VES speed is undershot once by the actuator speed, the limit value must be reduced immediately because an acceleration above the VES speed is not permitted.

The fixed prelimit switches are fully independent of the path measuring system and function even when the encoders do not operate reliably or are not present. This procedure is standard for all industrial cranes.



Behavior when P115=1

Fig. 4-53: Behavior when P115 = 1

The trolley can continue with the speed setpoint. The maximum speed is limited depending on the distance to a parameterized position; this is the reason for the root function.

The positions for the prelimit switch speed (P24, P27) must be set so that these are located before the limit switch position or exactly on the limit switch position. This ensures that the trolley has been braked to the prelimit switch speed when the limit switch is reached.

Because a crane operator does normally not travel to the limit switch without reason, but in the extreme case approaches a position near the limit switch, as in the normal travel range, the crane operator will release or reduce the master switch before reaching the destination. This means that the crane operator does not observe anything about the dynamic VES other than the destination is very near the limit switch and the operator misses the correct moment. The travel is limited only when the last possible point is reached. However, one knows that even in this case the Sway Control remains active and the sway is caught when the required movement does not violate the limitation (at approx. 28-29 s).

Note If the delay to prelimit speed should occur with Sway Control, the setpoint must be reduced in the crane controller.



4.7.2 Commissioning of the Sway Control system

4.7.2.1 Commissioning steps in the Commissioning menu

Next, the commissioning steps in the Commissioning menu must be performed. This menu is called via the "I" key from the main menu or the display screens.

Fig. 4-54: Monitor function, Commissioning menu

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

Some parameters of the active parameter set are set automatically in these steps.

WARNING For this reason, the active parameter set may not be changed during the commissioning.

The successful completion of a commissioning step is identified by a "+". After the commissioning steps have been performed successfully, it is no longer necessary to set these parameters manually.

Note Depending on the configuration, individual steps can be hidden.



Note The Sway Control must be switched off during commissioning steps 1 to 3. This is implemented internally and temporarily triggers error E61.

Setting the configuration and important parameters (commissioning step 0)

In this commissioning step, all required parameters are successively called automatically and must be set correctly.

The request begins with the parameter for the configuration of the system (P102).

In the subsequent processing, the parameters:

Maximum actuator speed

Positioning speed

Set acceleration

Maximum acceleration

Prelimit switch speed

Minimum and maximum position

should be set for each axis. These parameters are specified by the crane manufacturer or derived from these specifications.

The maximum actuator speed (P0, P40) is the maximum speed that can be attained by the drive axis. It has an effect on the amplitude of the oscillation model and therefore must be set precisely.

With SIMOTION D, it is an adjustable parameter.

With SIMOTION C, it is an optimization parameter.

The positioning speed (P1, P41) is the maximum specified set speed for an automatic positioning. Depending on the control process, the actual speed can be less or greater, but never greater than the maximum actuator speed.

The set acceleration (P6, P51) is the acceleration with which the set speed rises or falls at the input of the Sway Control. As the Sway Control causes an additional deceleration, it should be set larger than the acceleration and deceleration actually wanted.

With a deceleration gain (P8, P52) greater than one, the set deceleration is greater than the set acceleration.

The maximum acceleration (P5, P50) limits the acceleration of the output signal of the Sway Control. It should be set to the same or a smaller value than the converter acceleration limit.

When the prelimit switch signal is active, the prelimit switch speed (P2, P43) in the relevant direction of travel is not exceeded – also not by the Sway Control processes. For this reason, the elimination of swaying movements in the prelimit switch range often takes longer.

The minimum (P23, P63) and maximum position (P28, P69) is only checked at the start of an automatic positioning.

In positioning mode, the error E35 "Starting point in an invalid area" is only considered in relation to the traversing motion of the respective axis. If the error is present in the hoist control mode, no travel job is generated for the hoisting gear and trolley axes. In positioning mode, a travel job is generated for the axis that does not have this error.

The parameters "Upper and lower Sway Control limits" (P83, P84) specify the hoisting height range in which the "Sway Control" function is active.



When the Sway Control is deactivated, the drive accelerates and decelerates with the set acceleration value P7 acceleration without Sway Control / minimum acceleration.

The following figure provides an overview of the use of the speed and acceleration parameters.

Fig. 4-55: Overview of the speed control

Set alignment of the camera (commissioning step 1)

In this commissioning step, the assignment of the directions of motion to the camera orientation is determined and the result saved in parameter P120.



Before the commissioning step, the following basic requirements must be satisfied:

- Eliminate the initial swaying

- Reflector must always remain in the field of vision

Note After starting the commissioning step, the trolley should then be moved when the load is steady. If the Sway Control causes swaying movements, this step must be checked.

The diagnostics record the main direction of sway and the sign of the beginning deflection. From this information, the assignment of the trolley direction to the camera x or y direction and its sign are determined.

The result can be saved when the Sway Control is only to be activated for the trolley direction. Otherwise the crane has to be moved so that the sign of the deflection in the crane direction can be determined.



Calibrate hoisting height – TROLLEY (commissioning step 2) Note Only systems with a camera can perform this automatic commissioning step. For systems without a camera, this step must be performed manually with the tool on the "Calibrate hoisting height" tab.

Fig. 4-56: Calibrate hoisting height – TROLLEY (commissioning step 2)

The following options can be selected for this commissioning step:

0 – Reset P80, P81 Parameters P80 and P81 are set to 0 and therefore have no effect.

1 – Basic Calibration It is essential that this basic calibration step is performed. Swaying movements are initiated at two different heights. From the swaying measurements, the gain and offset are determined for the conversion of the transmitted hoisting height to an effective pendulum length with correct sign and absolute value. The result is entered in parameters P60 and P61.

This automatic commissioning step was successful when the swaying duration displayed in the tool is roughly identical in each cycle. If this is not the case, the step can be performed manually with the tool on the "Calibrate hoisting height" tab.

Not the calibrated hoisting height, but the hoisting height taken from the interface is used for the control and positioning of the hoisting gear. This must have increasing values with the increasing height of the load carrying device above the ground.

2 – Dig. hoisting dist. corr. This step is optional. Shifts in the center of gravity that result from the use of different load carrying devices are compensated with the digital "correction of the effective pendulum length". Parameter P80 is written.



3 – Anal. hoisting dist. corr. Note Before performing step 3, the weight of the load carrying device must be determined and stored in parameter P82.

This step is optional. With the analog "correction of the effective pendulum length", shifts in the center of gravity that result from the load mass, can be taken into account. Parameter P81 is written.

Note In most cases it is sufficient to perform the basic calibration. After being performed successfully, this commissioning step is displayed in green, although the digital and the analog "corrections of the effective pendulum length" have not yet been performed. These steps are optional.

Calibrate hoisting height - SKEW (commissioning step 3) Note Only systems with a camera (P102) and activated TLS (P197) can perform this automatic commissioning step.

In the calibration of the hoisting height, the gain and offset are determined for the conversion of the transmitted hoisting height to an effective pendulum length with correct sign and absolute value.

The calibration is performed with two sway measurements at different heights.

A swaying movement must be induced at different heights. The respective effective pendulum lengths and conversion parameters are determined from these movements. Depending on the used spreader width, the result is entered in the P89, P90 (20 ft), P91, P92 (30 ft) or P93, P94 (40 ft) parameters.

This commissioning.step must be performed separately for each existing spreader width.

1) Retract spreader to 20 ft. The controller must return the value 1 as spreader width. Perform commissioning step 3. Parameters P89 and P90 are determined.

2) Extend spreader to 30 ft. The controller must return the value 2 as spreader width. Perform commissioning step 3. Parameters P91 and P92 are determined.

3) Extend spreader to 40 ft or 45 ft. The controller must return the value 3 or 4 as spreader width. Perform commissioning step 3. Parameters P93 and P94 are determined (separate parameters are not available for 40 ft or 45 ft).

This automatic commissioning step was successful when the swaying duration displayed in the tool is roughly identical in each cycle. If this is not the case, the step can be performed manually with the tool on the "Calibrate hoisting height" tab.

Simulate errors (commissioning step 4)

All error bits of the Sway Control system can be simulated in this step to check the error analysis on the PLC side.

The corresponding bits are described in Section 4.10.5.2.

Determine speed limit (commissioning step 5)

The speed limit can be set automatically in this step when the current actual position value is transferred with the PLC data.



The axes should be moved singly and steadily with constant speed in the "speed control" basic operating mode. If the axis moves with constant speed, this should be confirmed by pressing <ENTER> twice. The maximum actual speed, i.e. the speed limit, produced at the maximum actuating signal is determined from the maximum actuator speed output on the converter and the measured actual speed value.

The determined speed limit can be taken over in the respective parameter (P0 for the trolley or P40 for the hoisting gear) as well as the resulting positioning speed (P1 (trolley) and P41 (hoisting gear)).

Communication addresses (commissioning step 6)

NOTICE

The IP address for a device may only be used once within a network.

For the communication between the components, the SIMOTION must make the IP address available to the camera. The camera is delivered with a predefined IP address.

In commissioning step 6 "communication addresses", the following selection can be made depending on the used hardware and use of a camera:

UDP (IP address and port of the camera)

PROFINET (camera system supports this protocol)

SIMOTION (IP address, subnet mask, PB address)

The following table shows the respective possibilities for hardware – camera combinations and the associated selection option.

Table 4-7 Selection options for communication addresses

SIMOTION C SIMOTION D

With camera Without camera With camera Without camera

1 – UDP

2 – PROFINET

3 – SIMOTION

1 – SIMOTION

1 – UDP

2 – PROFINET

No commissioning step 6 "communication addresses" available

If the addresses are to be changed again at a later point in time, this can be performed after calling the Parameters menu with the "P" key and by calling the "I" function (communication addresses).

Save parameters (commissioning step 7)

All parameter sets are saved.

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

4.7.2.2 Checking and fine adjustment of the Sway Control

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

Selection of the control method

The control method (conventional or time-optimized control) is selected via parameter P152.

The time-optimized algorithm calculates the ramps so that swaying has been eliminated when the required speed setpoint is reached. External influences that cause deviations (especially when stopping), are eliminated conventionally.

With the conventional control, the travel behavior is smooth and comfortable for the crane operator. Precise positioning is possible. There is a noticeable counter-response (greater deceleration when the opposite direction is specified) with different values for set and maximum acceleration.

If time-optimized control is selected, the drive accelerates and decelerates with the set acceleration to the set speed. The deceleration sections integrated in the acceleration operations can be



uncomfortable for the crane operator. The time-optimized control algorithms use search algorithms that require a lot of computation time.

Note The time-optimized control is not appropriate for STS cranes.

"Correction of the effective pendulum length"

If different load carrying devices are used, this must be incorporated in the program as the center of gravity and the pendulum length changes.

If not already performed semi-automatically in commissioning step 2, the adaptation to the load conditions is performed with the following parameters:

P80 Digital "correction of the effective pendulum length" Shifts in the center of gravity that result from the use of different load carrying devices are compensated

P81 Analog "correction of the effective pendulum length" Shifts in the center of gravity that result from the load mass are taken into account

P82 LAM weight

The effective pendulum length is corrected. It is calculated as follows:

Correction eff. pendulum length = analog correction eff. pendulum length+ digital correction eff. pendulum length

Analog "correction of the effective pendulum length"

The value in parameter P81 for the analog "correction of the effective pendulum length" acts only when the load (iLoad on DCC_SCCommon) is greater than the weight of the load carrying device (P82). In this case, the value for the load in screen 2 (PROFIBUS interface) of the diagnostic tool is displayed in green, otherwise in red.

Analog correction eff pendulum length = (load – P82) x P81 |if (load - P82) > 0, otherwise = 0

Digital "correction of the effective pendulum length"

If digital "correction of the effective pendulum length" is to be used, the offset must be entered in parameter P80. The command to be used is set via the "Dig_Hoist_Dist_Corr" command bit (SIMOTION D, Common control word) or "DigitalLiftCorrection" (SIMOTION C; General command bits). In this case, the value for the load in screen 2 (PROFIBUS interface) of the diagnostic tool is displayed bold.

Digital correction eff. pendulum length = P80 if bDig_Hoist_Dist_Corr = 1; otherwise = 0

The following figure provides an overview of the internal processes used to determine the distances for the oscillation model and the camera calibration.



Fig. 4-57: "Correction of the effective pendulum length"

Setting the permissible residual sway

The parameters for the residual sway (P169, P170) should only be set as small as required. Values that are too small can result in swaying after stopping because of dead times.

Parameter 169 is only effective in the deceleration phase for the time-optimized control. During travel, parameter 170 is active for the time-optimized control.

Setting the gain factor

A gain factor (P85, P86, P87, P88) can be set for the trolley, separately for the acceleration and deceleration phase. Values greater than 1.4 result in aperiodic transition characteristics, values less than 1.4 to overshoot. Gain factors in the range from 1 to 1.2 represent a compromise between shorter rise time and less overshoot. The difference between the gain factors for acceleration and deceleration should not be too large, as actuating signal jumps can occur during the transition to the deceleration phase.

Specifying minimum speed and minimum time

The Sway Control function is only activated when the activation speed (P146) and Sway Control activation delay (P147) are reached. It is recommended that both parameters be left at zero.

For the activation speed, a hysteresis of ± 5% acts to prevent a continuous activation and deactivation of the Sway Control.

Setting the switch-on delay of the drives

For each axis (P149, P150), the switch-on delay of the frequency converter after releasing the brake can be set.



4.7.3 Commissioning of the positioning

4.7.3.1 Changing the coordinate system

If an automatic positioning is to be commissioned and also the coordinate system of the trolley has to be changed, the position values must be calibrated.

In the "Calculations" window of the "CeCOMM" diagnostic program, two position values of the previous coordinate system and the two associated position values of the new coordinate system must be entered as "Measured value" and in the "Position value" column, respectively.

Fig. 4-58: Calibration of the position values for the trolley

"Calculate" determines the resolution (factor) and the offset for the trolley position sensor; these values must be entered in the P20 and P21 parameters.

4.7.3.2 Position controller setting

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

Set position controller (P160, P163) to zero and start the positioning over a longer distance

The set and the target position must be nearly identical at the end. Slight differences result through the deactivated position controller.

Greater differences can be caused by a faulty maximum actuator speed or limits in the drive system. (To correct the errors, the Sway Control function can temporary be deactivated by setting the gain factors to zero - only possible with conventional control.)

Set position controller (P160, P163) and gain factors (P85, P86, P87, P88) to default values

All controllers must be set to have a small overshoot. This affects both the speed and the target position. This achieves short rise times.

The value of the position controller should not be greater than 0.5.

The value must be reduced when the application of the controller causes an oscillating speed change and an overshoot at the target position.



Note An overshoot at the target position often results not from a large position controller value but rather from an incorrectly set limit speed. Consequently, before reducing the position controller value, in controlled operation (position controller is zero or manual operation), a recheck should be made whether for travel at constant speed, the actual speed is nearly equal to the set speed.

The control method can use negative position controller values to switch to target control. In this case, the positioning operation also uses the speed control without position control. The travel curves correspond to those for manual operation. The target control determines only the beginning and the exact course of the braking phase. A recommended value for the position controller value is -0.7.

The set speed sakv SR 2 for the target control is determined from the size of the position

control value Rk , the deceleration and the distance from the target Sa s .

A value of -0.7 specifies the time of the beginning the braking, deceleration is made with 70% of the set acceleration. During the braking phase, the target control has a control reserve of 30%, because the deceleration can be increased to 100% . Sa



4.7.3.3 On-the-fly unloading

The following setting of parameter P152 "Conventional/time-optimized control, trolley" is recommended for on-the-fly unloading:

Table 4-8: P152 setting for on-the-fly unloading

Selection Short designation On-the-fly unloading with const. deflection

On-the-fly unloading with max. deflection

1 Time-optimized control only for speed control OFF OFF

2 Time-optimized control only for automatic control

ON ON

3 On-the-fly unloading permitted ON ON

4 On-the-fly unloading with max. deflection OFF ON

5 Time-optimized control only for stopping OFF OFF

Generally, on-the-fly unloading is only used together with an automatic control (selection 2 = ON).

Selection 3 must always be on for on-the-fly unloading. In this case, the load deflection during travel towards the land and back again remains constant. If the load deviation is not to be constant, but maximum at the time of unloading, then selection 4 must also be switched on. This means:

Selection 3 = ON and 4 = OFF results in constant load deflection

Selection 3 = ON and 4 = ON results in maximum load deflection

If the time-optimized control is switched on for one or all basic operating modes (selection 12 or 1 or 2), this behavior can be restricted to the stopping procedure (selection 5 = ON).

P152 setting 5 "automatic" satisfies all supplementary conditions:

The function is not effective in manual operation

The function has no effect when "on-the-fly" is selected

This means: Travel is towards the land and the Sway Control is on. When switching over above the hopper, "On-the-fly" (FLYING bit) must be deactivated. This setting now starts to take effect. The Sway Control is "interrupted" and only switched-on again when braking. This results in less swaying being eliminated, but some time may be saved.

4.7.3.4 Other settings

The following parameters can be set manually:

Positioning range

The permissible positioning range can be set with the parameters "Minimum position" (P23, P63) and "Maximum position" (P28, P69). The values should be set halfway between the prelimit switch and the limit switch (following figure). Positioning outside of this range is not possible.



Fig. 4-59: Permissible positioning range

If a drive axis of the crane enters the range between prelimit switch and limit switch, the axis is braked with at least the ramp with which the crane would brake without Sway Control (P7).

In positioning mode, the error E35 "Starting point in an invalid area" is only considered in relation to the traversing motion of the respective axis. If the error is present in the hoist control mode, no travel job is generated for the hoisting gear and trolley axes. In positioning mode, a travel job is generated for the axis that does not have this error.

Positioning accuracy (P162, P165, P190)

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

This applies only to the position control. The target control only brings the axis to the target with the set accuracy. Control then is not (or no longer) performed because the position controller is not switched on.

Following error (P161, P164)

The following error is the difference between the calculated and the actual position and, when exceeded, initiates a fault.

4.7.4 Commissioning the hoist control

WARNING Requirement for the commissioning of the hoist control is the successful commissioning of the Sway Control and positioning functions.

In this basic operating mode, the spreader/grab moves on the path curve taking account of blocked regions.

The PLC program can be prepared so that external variable blocked regions can be transferred and/or the learning of the height profile is activated (Section 3).

All blocked regions (fixed and variable) are displayed in the diagnostic program, function diagram in the x/y representation.

Defining the limit curve parameters

The clearances to the blocked region can be set as parameters. If a double spreader is used, the width of the blocked region increases in the landside direction. The following figure provides an overview of the effect of the various parameters.



Note When the spreader is locked to a container, all fixed and variable blocked regions are increased by a fixed amount (parameter P108, maximum container height in mm). If a container is removed, i.e. if both bits "Container locked bit 0 and bit 1" are set, the blocked region is reduced by the minimum container height of exactly 2000 mm.

Fig. 4-60: Mode of operation of the limit curve parameters

Collision protection

A collision protection is activated in the software in the "hoist control" basic operating mode. Based on the current container crane position, it is determined how far the spreader is from a possible obstacle. If this is approached too closely, there is a reaction via the actuating signals (Section 4.10.4).

Override




In all AddOn modes, the travel speed on the path curve can be reduced using an externally definable override between 0% and 100%. This speed reduction is useful for commissioning purposes (test with reduced speed).

A value of 100 means maximum speed. With 0 the drive stops.

Reduction is with the set acceleration for both the hoisting gear (P51) and the trolley (P6).

The override can be specified separately for each axis and therefore used, for example, for the software-controlled prelimit switches.

Laser

The laser values in the "Hoist Control [6]" screen of the CeCOMM commissioning tools (Section 4.4.6.1) should be checked.

Note Ensure that the laser scanner is updated as fast as possible (Laser Freq. ≤ 3) so that the values can be used for calculating the travel curve.

Conditions for validity of the laser values:

Laser frequency ≤ 3 A valid value comes from the laser scanner at least every three cycles of the SIMOTION

Position difference of the trolley (distance) between two measured values < 50 cm

If the conditions are not satisfied, the values from the laser and the distance will be ignored. Should the values become invalid, they will be displayed RED, otherwise GREEN.

Commissioning Software 4.8 2D-Trajectory Commissioning

4.8 2D-Trajectory Commissioning Learning the parking position, lashing platform and lanes

The Parking position is learnt by the crane operator traveling to the position and setting the "Learn_Park_Pos" bit (bit 0 in the "STW1_PLC_Targets" control word, SIMOTION D) or "StoreParkposition" (bit 24, general command bits, SIMOTION C) for learning the position from a control element.

The Lashing position is learnt by the crane operator traveling to the position and setting the "Learn_Lash_Platf" bit (bit 1 in the "STW1_PLC_Targets" control word, SIMOTION D) or "StoreIntermediateStop" (bit 25, general command bits, SIMOTION C) for learning the position from a control element.

The Lane positions are also learnt by traveling to the position to be learnt. The "Learn_Pos_Lane" value (Targets module, SIMOTION D) or "StoreCurrentPosition" (addr. 270, HMI commands, SIMOTION C) assigns and saves the lane number of the current position (0 none; 1 Lane1; 2 Lane2, etc.).

The learnt positions "Parking position", "Position of the lashing platform" and "Position of the used lanes" are stored in the "TargetPos.txt" file in the /SWAYCONTROL/ directory on the SIMOTION.

Deleting the parking position, lashing platform and lanes

The saved parking position, the position of the lashing platform and the position of the lanes can be removed by deleting the "TargetPos.txt" file in the /SWAYCONTROL/ directory on the SIMOTION. A new file is created when one of these positions is learnt again.

If, for example, only the position of a lane is to be deleted, the appropriate line can be deleted with a simple editor (e.g. Notepad). The lane is then no longer in the "TargetPos.txt" file, but the lane remains active in the function until the SIMOTION CPU is restarted (e.g. through Power OFF and ON). Only then are the changes in the "TargetPos.txt" file effective.

NOTICE If the "TargetPos.txt" file is edited incorrectly, errors can occur while positioning in "SC Automatic" AddOn mode.

Twistlock simulation

Simulation of the loads is possible with the "CeCOMM" diagnostic program. It is used during the commissioning of the hoisting gear to test the correct functioning of the automatic mode.

Pressing the "x" key in all display screens simulates the locking of a container, and when pressed again the unlocking.


Commissioning Software 4.9 TLS Control Commissioning

WARNING

Only an empty spreader can be simulated as being loaded. Consequently, in simulation mode, the internally learnt obstacles are corrected as if a container were locked to the spreader. In such a state, travel must be performed at an adequate height (> max. container height P108) above the actually existing obstacles. Otherwise collisions can occur during automatic operation.

4.9 TLS Control Commissioning Activating TLS Control

All available functions can be activated with the parameter "Use Trim/List/Skew Control“ (P197). This calls up the input and output functions and the test commands are available.

Use of the "Trim / List / Skew [7]" display screen on the diagnostic tool for commissioning

This display screen is used for the commissioning and diagnosis of the TLS functions.The input and output signals can be monitored and also individual TLS commands can be tested.

The "Angle" skew angle output in screen 7 represents the angle supplied by the camera.



Fig. 4-61: Monitor function, "Trim / List / Skew [7]" display screen

Assignment of the cylinders

The cylinders are designated A, B, C, D and assigned as follows:

A – landside, left

B – waterside, left

C – waterside, right

D – landside, right

The assignment of the positions and output speed is made in the PLC.

Cylinder positions

The positions of the individual cylinders must be set with the parameter "Gain for the TLS cylinder positions"(P187) in such a way that when rotating through approx. 1° an offset of 100 mm (50 mm on each side) is measured.

The absolute position is not important at first. A position is saved as zero position for each cylinder (P200 - P203) and all positions in "mm" are then always positions relative to the stored zero position.

The minimum and maximum cylinder positions (P188, P189) also always refer to this zero position.



The permissible angles can be set with the TLS limit values (P194 - P196). According to the above setting of the position values, 250 corresponds to an angle of 2.5°.

TLS speeds

The speed setpoint (P180-P182) is used to approach the zero position as well as for the execution of the TLS commands. If the hydraulic cylinders only have one speed, this must be set there.

The speed value is the change of the internal position values in each time unit. If a time of 2 s is required for trimming 1°, i.e. an offset of 50 mm on each side, then the speed setpoint to be set is 25 mm/s.

The set speed can also be determined in the "Display screen TLS [7]" of the diagnostic tool. To do this, the set speeds are set to the default values and a TLS command (e.g. trim left) initiated. The values displayed as "IN-Speed" are entered as set speeds in the P180-P182 parameters.

Skew control set speed

The electronic Skew Control uses the internal slewing gear axis in the "Positioning" basic operating mode. The positioning speed is set with parameter P221 and the maximum permissible speed with P220 . With a rotation of 1°/2s, a value of 50 cgr/s should be set for the positioning speed.

TLS speed limit

For a short time a speed greater than the setpoint speed may be required with the Skew Control. The maximum permissible speed of the cylinder (P183) should be set here.

The ratio P183:P180 should correspond to the ratio P220:P221.

Pressure system

Two different pressures have been prepared. The actuator speed for each cylinder is adapted to the pressure conditions. With a low pressure, the proportional valve is opened more than with a high pressure.

The pressure threshold is selected with P184.

If the system requires a minimum pressure, this can be set with P193. As soon as the output signal exceeds the "TLS speed for zero signal" (P186), the output signal is at least the value of parameter P193.

Skew control

The actuator speed of the internal rotary axis can be adapted to the cylinder speed with the parameter P185 "TLS switch-in for Skew Control".

Output speed

In order that the cylinders are not stressed unnecessarily, the switching threshold for the cylinder activation can be adapted with parameter P186 "TLS speed for zero signal". If the cylinder control signals are less than this value, the output and the direction signals are set to zero.

Under certain circumstances, the same output speed can result in a higher lowering speed than hoisting speed because of the earth's gravitational attraction. In this case, the actuator speed during lowering should be reduced with parameter P191.

Test commands

The following functions are available for testing:

S – Test Skew Control After pressing the "S" key, the setpoint for skew must be entered and applied with <ENTER>. The cylinders then turn to reach the specified skew.




C – Test Cylinder The "C" key can be used to test the correct operation of the individual cylinders. To do this, the cylinder (1..4) and the direction (+ or -) is entered (e.g. the input of "4+" causes cylinder D to extend fully).

N – Save Zero The "N" key causes the current position of the cylinders to be stored as zero position in all parameter files.

T – Test TLS The "T" key can be used to test TLS commands. Possible inputs are:

TL Trim left TR Trim right LW List waterside LL List landside SL Skew left SR Skew right

The cylinders move in the specified direction until they reach the limit value.

R – Reset "R" (Reset) terminates any TLS command that has not yet completed.

Z – Move Zero The "Z" key causes the cylinders to be moved to the zero position.

The cylinders continue to move until the target position is reached while taking account of the positioning accuracy, even when the commands are no longer present.

Note If a TLS command has not completed, this will be done automatically at the next key click with "TLS-Reset".

Commissioning Software 4.8 2D-Trajectory Commissioning

4.10 Alarm, Error and System Messages Safety-relevant monitoring operations must operate correctly both with and without Sway Control and be fail-safe. They must be implemented in the higher-level controller (PLC).

Because parts of the TO monitoring are deactivated during the "Sway Control" basic technology mode (positioning, standstill and following error monitoring), Sway Control itself must be monitored. The following TO monitoring operations, etc., remain active:

Maximum speed

Maximum acceleration

Jerk

Encoder error

The Sway Control system monitors only what the higher-level controller cannot monitor.

4.10.1 Following error monitoring

The following error is the difference between the calculated curve and the curve actually travelled (= set-actual deviation).

The permitted deviation between the set and actual position during a travel operation in the "positioning" and "hoist control" basic operating modes is stored for each axis in the P161 (trolley), P164 (hoisting gear) and P167 (slewing gear) parameters during the commissioning.

If these tolerances are exceeded, the associated axis-related error (E41 – trolley following error, E42 – hoisting gear following error) will be initiated and travel in the "SC Automatic" AddOn mode aborted.

The following error will not be monitored when the value = 0 is set in the parameters.

Work-around: Increase the control reserve, reduce the gain factors, increase the position controller, reduce the brake derivative action time, change the following error.

Note Limitations of the speed actuating signal (e.g. in the converter) can result in the tripping of the following error and therefore should only be intended for safety reasons.

4.10.2 Velocity monitoring

The velocities of the individual axes are monitored.

A velocity error occurs when the trolley (E50), the hoisting gear (E51) or the slewing gear (E52) are not moving, are moving too fast or in the wrong direction.

This error is triggered when:

The actuator speed is > 10% of the maximum speed (P0, P40, P220) and the crane is not moving or moving in the wrong direction



The difference between the actuator speed and the actual speed > 20% of the maximum speed (P0, P40, P220) (e.g. defective drive)

The error appears with a delay of approx. 3 s. The error message is acknowledged when the axis moves.

The causes of these errors can be:

Defective encoder

Faulty connection to the drive

Brake is still closed

The speed is not monitored when the following error parameter of the axis (P161, P164, P167) is set to zero.

Work-around: Check position values and transfer of the actuator speed.

4.10.3 Start Sway Control monitoring

The warning E65 "Sway Control Off (Start)" occurs when the set activation speed (P146) has not yet been attained or the Sway Control activation delay (P147) has not yet expired. This warning is only issued in the "Speed control" basic operating mode. For the activation speed, a hysteresis of ± 5% acts to prevent a continuous activation and deactivation of the Sway Control.

The Start Sway Control monitoring with the parameters P146, P147 and P148 are only effective in the speed control mode.

4.10.4 Collision protection

Monitoring before the automatic start

Note A travel job is not executed if the current load position or the target position is in a fixed blocked region.

If the actual position is below the limit curve, a travel job is still generated. In this case, hoisting is performed until the hoist position is above the limit curve. The internal Sway Control is switched off during this phase in order to avoid collisions with adjacent containers.

If a target position below the limit curve is specified, a point is approached that is vertically above the specified target.



Note With an automatic start close to a stack of containers (obstacle), swaying of the load can result in an abort of the automatic travel. Here it is essential to avoid an inclined hoisting when picking up a container close to a further row of containers.

Monitoring during automatic operation

In the "SC Automatic" AddOn mode, collision protection is activated in the software. Based on the current container crane position, it is determined how far the spreader is from a possible obstacle. If this is approached too closely, there is a reaction via the actuating signals.

The following protection mechanisms are available:

1. Stopping with Sway Control outside the limit curve

2. Reduction of the actuating signal by further approach to the obstacle limit (without consideration of the Sway Control, only deceleration ramp)

3. Actuating signal is set to zero when the position is in the blocked region. Simultaneously the error message E37 "Actual position in the blocked region" is generated.

Normally the first protection barrier is effective. The other two protection mechanisms should be considered as additional safety functions.

After setting the travel signal again, the errors are automatically cleared when the error conditions no longer exist.

4.10.5 Application error messages


Errors can occur during the operation of an AddOn.

The "DCC_SCCommon" block returns errors with error bits. These errors can be processed in the PLC using the bits set in the "bFault1" and "bFault2" error words. Because several bits can be set at once, more than one error may be present.

NOTICE

The PLC programmer is required to evaluate the error messages of the system. In a fault situation, the manipulated values of the Sway Control system may no longer be used. Only the PLC may implement the control of the drives.

During the commissioning or a diagnosis, such errors can be detected and corrected with the "CeCOMM.EXE" diagnostic program.

The currently pending errors are displayed by pressing the "E" key from the main menu or the display screens. The error history can be called via the "H" key (Section X637H4.4.6.2X).

Each error has a number, a title, an error description and a note on the remedy.

Errors that are transferred to the PLC, are identified by an error bit. Errors without error bit should be interpreted as warnings. Both errors and warnings are visible in the "CeCOMM" diagnostic tool.

All errors are self-acknowledging and will be transferred only while they are present.

A detailed description of these errors is found in the following sections:



4.10.5.2 CenSOR M error messages

Errors that are identified by an error bit are transferred to the Sway Control system, but only error E4 is evaluated. Errors without error bit should be interpreted as warnings. Both errors and warnings are visible in the "CeCOMM" diagnostic tool.

Errors E1, E3, E4, E15 as well as a faulty connection of the camera to SIMOTION which is monitored by a watchdog, result in a message (only applies to SIMOTION D, "bCamera_OK" changes from 0 to 1) that the camera is not functioning correctly.

If error E3 is present for more than a determined time, error E4 is triggered in the Sway Control system and passed on to the SIMATIC S7.

For detailed information in a fault situation, the "CeCOMM" diagnostic tool must be connected to the camera.

E0 (Bit 0) Invalid parameter file

An error has occurred while loading the parameter files. The relevant parameter set will be set to default values.

Error values: [1] - Parameter file missing [2] - Incorrect parameter version [3] - Incorrect number of parameters [4] - Incorrect number of blocked regions [5] - Incorrect number of target positions [6] - Internal memory error Error type: Error Remedy: Check parameters in the Parameters menu and save

E1 (Bit 1) Field bus error

The SIMOTION could not establish any Ethernet communication or has not received any data for at least two seconds. Possible causes can be:

SIMOTION is in STOP

SIMOTION has no power supply

Incorrect IP address of the camera on the SIMOTION

Incorrect IP address of the SIMOTION on the camera

The Ethernet connecting cable between SIMOTION and the hub is interrupted

Type of error: Error Remedy: Check possible causes as described above



E2 (Bit 2) Camera measuring system not calibrated

A calibration was started by pressing the rotary switch on the connection box or in the commissioning menu of the diagnostic program and has not yet completed. The camera measuring is deactivated until the calibration has completed.

Type of error: Error Remedy: Complete calibration

E3 (Bit 3) Camera measuring system impaired

The camera temporarily does not identify a reflector any more. This may be due to the following causes:

The reflector is dirty

The reflector no longer lies within the camera's field of vision

The reflector is misaligned by 90° (see P2).

The reflector is too small for the set window size (P3), i.e. too far away

The ambient light is too bright or too dark

The camera image is not focused.

If this error is present for more than a determined time, this error is replaced by E4 in the camera system. The Sway Control system is informed about the faulty function.

Type of error: Error Remedy: Correct the listed causes

E4 (Bit 4) Camera measuring system faulty

The camera does not identify a reflector any more. This may be due to the following causes:

The reflector no longer lies within the camera's field of vision

The reflector is misaligned by 90° (see P2).

The reflector is too small for the set window size (P3), i.e. too far away

The ambient light is too bright or too dark

The camera image is not focused.

This error replaces E3. The Sway Control system is informed about the faulty function.

Type of error: Error Remedy: Correct the listed causes

E8 (Bit -/-) Invalid parameter value

An invalid value [X*10000+P] was found when loading parameter P in parameter set (1-4) from file parX.txt (X:0-3). The value has been set to the default value. The error is only reset after the parameter files have been loaded successfully.

Type of error: Warning Remedy: Check parameter and save



E9 (Bit -/-) Copy protection damaged

The software copy protection is damaged. A Schl.ini file exists when connecting to the camera. If this file is changed or deleted, error E9 appears.

Type of error: Warning Remedy: Request the correct copy protection from the Siemens AG

E10 (Bit -/-) Calibration switch actuated

The calibration switch in the connection box is not in the neutral position. If the calibration switch is in the neutral position, there may be a wiring error on the calibration switch.

Type of error: Warning Remedy: Complete calibration, if required, check wiring

E11 (Bit -/-) Reflector distance has jumped

The reflector distance (internal distance) has jumped to an illegal height (jumps > 10 m).

Type of error: Warning Remedy: With P102 = 0 hoisting height encoder has to be adjusted again

E12 (Bit -/-) Corrupted language file

Lines that are too long or cannot be displayed have been found when loading the language files Sprache0.txt, Sprache1.txt

Error values: 0...199 – Parameter texts 200…300 – Error texts Error type: Warning Remedy: Correct language file, save and reload

E13 (Bit -/-) Internal floating-point data error

A floating-point error has occurred during the calculation.

100:SNAN 200:QNAN 300:NINF 400:ND 500:PD 600:PINF

0-9: controller, 10-19: oscillation model, 20-29: VSet, 30-39: oscillation model + offset, 40-49: RT

Type of error: Warning Remedy: -

E14 (Bit -/-) Incorrect IP address

The entered or readin IP address of the peer entity is incorrect. It does not have the form x.x.x.x

(0 ≤ x ≤ 255)

Type of error: Warning Remedy: Enter a valid IP address in the parameter menu

E15 (Bit 5) Invalid distance

The externally specified distance provides outside the set limits (parameter list CenSOR M P32, P33).



The Sway Control system is informed about the faulty function.

Type of error: Error Remedy: Check external distance and parameters

E18 (Bit -/-) Number of received message frames in % too low

The number of received message frames in % is too low.

Type of error: Warning Remedy: Check PLC cycle time, increase parameter sampling time

4.10.5.3 AddOn technology error list

Overview

The errors from the Sway Control system are categorized as follows:

General and severe errors E0 to E19

Error in the limit or prelimit switch area E20 to E29

Error in automatic operation E30 to E49

Other errors 1 E50 to E59

Other errors 2 E60 to E69

The categorization can be adapted specifically for the project by the PLC programmer.

Table 4-9 Error categories

Category Meaning A Display on the CMS, manual and automatic mode permitted B Display on the CMS, manual mode permitted and automatic mode not permitted C Display on the CMS, manual and automatic mode not permitted

Brief description

The assignment of the error bits to the error messages in the output data and the concurrent output to the DCC blocks (SIMOTION D) are as follows:



Table 4-10 Error messages from the Sway Control System to the PLC

Error Bit Block for

SIMOTION D Brief description

Cat.

General and severe errors E0 - Common Cycle time too long - E1 13 Common Error in the DCC chart (only SIMOTION D) C E2 14 Common Copy protection damaged C E3 3 Common License error C E4 12 Camera Camera measuring system faulted A E5 1 Trolley Invalid basic operating mode, trolley B E6 1 Hoist Invalid basic operating mode, hoisting gear B E7 9 Trolley Invalid basic operating mode at the limit switch, trolley B

E8 9 Hoist Invalid basic operating mode at the limit switch, hoisting

gear B

E9 - Hoist Hoisting height has jumped - E10 0 Common Invalid parameter file C E11 - Common Invalid parameter value - E12 - Common Incorrect language file - E13 Field bus error (only for SIMOTION C) E14-E19 - Reserved - Error in the limit or prelimit switch area E20 - Trolley Forward prelimit switch switches incorrectly, trolley - E21 - Hoist Upper prelimit switch switches incorrectly, hoisting gear - E22 - Trolley Backward prelimit switch switches incorrectly, trolley - E23 - Hoist Lower prelimit switch switches incorrectly, hoisting gear - E24 - Trolley Forward limit switch switches incorrectly, trolley - E25 - Hoist Upper limit switch switches incorrectly, hoisting gear - E26 - Trolley Backward limit switch switches incorrectly, trolley - E27 - Hoist Lower limit switch switches incorrectly, hoisting gear - E28-E29 Reserved - Error in automatic operation E30 31 No way found E31 4 Trolley Invalid target position, trolley B E32 4 Hoist Invalid target position, hoisting gear B E33 16 Obstacles Too many variable blocked regions B E34 24 Common Group error abort, hoist control B E35 17 Common Starting point in an invalid region B E36 18 Common Starting point in variable blocked region A E37 28 Common Actual position in blocked region B E38 25 Common Target in fixed blocked region B E39 - - -- - E41 29 Trolley Following error, trolley B E42 30 Hoist Following error, hoisting gear B E43 - - Crane geometry /dynamic response is incorrect - E44-E49 Reserved - Other errors 1 E50 11 Trolley Speed error, trolley B E51 11 Hoist Speed error, hoisting gear B E52 11 TLS Speed error, slewing gear B E53 Encoder error, trolley (only SIMOTION C) - E54 Encoder error, hoisting gear (only SIMOTION C)



Bit Block for Cat. Error Brief description

SIMOTION D E55 TLS Normalization error E56-E59 Reserved Other errors 2 E60 15 Common Load stuck B E61 7 Common Sway Control Off (pendulum length) A E62 6 Common Start of positioning with too much swaying B E63 10 Trolley Sway Control temporarily reduced, trolley B E64 19 TLS Sway Control temporarily reduced B E65 - Trolley Sway Control Off (start) - E66 - Trolley Sway Control only when stopping - E67 - Common Controlled stop active - E68 - Internal floating-point data error -

General and severe errors

E0 (Bit -/-) Cycle time too long

The cycle time is greater than 100 ms.

Type of error: Warning Remedy: Hang the DCC chart in a faster task

E1 (Bit 13) Error in the DCC chart (only SIMOTION D)

The DCC chart is faulty at least one DCC block is missing for the selected application.

Type of error: Error Remedy: Add missing DCC block (for a system without camera (GSU), P102 must be set to 0 = ship unloader (without camera)).

E2 (Bit 14) Copy protection corrupted

The license is damaged or missing. The Sway Control function is deactivated.

Type of error: Error Remedy: Create and transfer a license key

E3 (Bit 3) License error

A basic operating mode has been selected, but there is no license for this.

Type of error: Error Remedy: Reset command bit or purchase license

E4 (Bit 12) Camera measuring system faulty

The camera does not identify a reflector any more. This may be due to the following causes: The reflector is not in the field of vision of the camera, is rotated through 90° (camera parameter P2), is too far away for the set window size (camera parameter P3) or the environment is too light or too dark or the camera image is not in focus.



Type of error: Error Remedy: Check camera and connection to camera, if the system is blind, set P102 = 0

E5 (Bit 1) Invalid basic operating mode, trolley

An unavailable basic operating mode or several basic operating modes at the same time cannot be selected. The error message also appears when the "Hoist control" basic operating mode has been selected for only one axis.

Type of error: Error Remedy: Check the PLC program, set only one operating mode bit for each travel axis

E6 (Bit 1) Invalid basic operating mode, hoisting gear

An unavailable basic operating mode or several basic operating modes at the same time cannot be selected. The error message also appears when the "Hoist control" basic operating mode has been selected for only one axis.

Type of error: Error Remedy: Check the PLC program, only set one operating mode bit for each travel axis

E7 (Bit 9) Invalid basic operating mode in the limit switch, trolley


Type of error: Error Remedy: Activate "Speed control" basic operating mode

E8 (Bit 9) Invalid basic operating mode in the limit switch, hoisting gear


Type of error: Error Remedy: Activate "Speed control" basic operating mode

E9 (Bit -/-) Hoisting height has jumped

The hoisting gear position has jumped to an illegal height (> 10 m).

Type of error: Warning Remedy: Reference hoisting height encoder again

E10 (Bit 0) Invalid parameter file

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

Error values: [1] - Parameter file missing [2] - Incorrect parameter version [3] - Incorrect number of parameters [4] - Incorrect number of blocked regions [5] - Incorrect number of target positions



[6] - Internal memory error Error type: Error Remedy: Check parameters in the parameter menu, save and reload

E11 (Bit -/-) Invalid parameter value

An invalid value [X*10000+P] was found when loading parameter P in parameter set (1-4) from file parX.txt (X:0-3). The value has been set to the default value. The error is only reset after the parameter files have been loaded successfully.

Type of error: Warning Remedy: Check parameters in the parameter menu, save and reload

E12 (Bit -/-) Corrupted language file

Lines that are too long or cannot be displayed have been found when loading the language files Sprache0.txt, Sprache1.txt.

Error values: 0…199 – Parameter texts 200..300 – Error texts 300..400 – Commissioning texts Error type: Warning Remedy: Correct language file

E13 (Bit 2) Field bus error (only SIMOTION C)

The Sway Control could not establish communication to the PLC (general commands, Bit 13 "Watchdog" not set).

Type of error: Error Remedy: Check the cable, check the PLC, set Bit 13 "Watchdog"

E14 - E19 Reserve

Error in the limit or prelimit switch area

E20 (Bit -/-) Forward prelimit switch switches incorrectly, trolley

The prelimit switch in the forward direction became active for negative speed or inactive for positive speed.

Type of error: Warning Remedy: Exchange forward and backward prelimit switch signals

E21 (Bit -/-) Upper prelimit switch switches incorrectly, hoisting gear

The prelimit switch in the forward direction became active for negative speed or inactive for positive speed.

Type of error: Warning Remedy: Exchange upper and lower prelimit switch signals



E22 (Bit -/-) Backward prelimit switch switches incorrectly, trolley

The prelimit switch in the backward direction became active for positive speed or inactive for negative speed.

Type of error: Warning Remedy: Exchange forward and backward prelimit switch signals

E23 (Bit -/-) Lower prelimit switch switches incorrectly, hoisting gear

The prelimit switch in the backward direction became active for positive speed or inactive for negative speed.

Type of error: Warning Remedy: Exchange upper and lower prelimit switch signals

E24 (Bit -/-) Forward limit switch switches incorrectly, trolley

The limit switch switches for the wrong direction of motion or is switched simultaneously with the prelimit switch in the opposite direction.

Type of error: Warning Remedy: Exchange forward and backward limit switch signals

E25 (Bit -/-) Upper limit switch switches incorrectly, hoisting gear


Type of error: Warning Remedy: Exchange upper and lower limit switch signals

E26 (Bit -/-) Backward limit switch switches incorrectly, trolley


Type of error: Warning Remedy: Exchange forward and backward limit switch signals

E27 (Bit -/-) Lower limit switch switches incorrectly, hoisting gear


Type of error: Warning Remedy: Exchange upper and lower limit switch signals

E28 – E29 Reserve

Error in automatic operation



E30 (Bit 31) No way found

The hoist control could not find a path between the starting position and the target position:

With "On-the-fly unloading", the highest point of the calculated travel curve is greater than the target. Automatic does not start

The target cannot be reached because an obstacle lies in front. Automatic starts although the target is placed before the obstacle Error category A

Type of error: Error Remedy: Check starting position and target position as well as blocked regions

E31 (Bit 4) Invalid target position, trolley

The target position of the trolley is outside the set limits (P23, P28).

Type of error: Error Remedy: Check parameters for limits

E32 (Bit 4) Invalid target position, hoisting gear

The target position of the hoisting gear is outside the set limits (P63, P69).

Type of error: Error Remedy: Check parameters for limits

E33 (Bit 16) Too many variable blocked regions

An attempt has been made to transfer more than 200 variable blocked regions.

Type of error: Error Remedy: Check PLC program

E34 (Bit 24) Group error abort, hoist control

A travel job in the hoist control basic operating mode has been aborted. Refer to other error messages for the exact cause of the error.

Type of error: Error Remedy: Evaluate other error messages

E35 (Bit 17) Starting point in an invalid region

The load is outside the set limits. If the error is present in the hoist control mode, no travel job is generated for the hoisting gear and trolley axes. In positioning mode, a travel job is generated for the axis that does not have this error.

Type of error: Error Remedy: Traverse manually to valid regions. Check fixed blocked regions and limits.

E36 (Bit 18) Starting point in variable blocked region

The load is in a variable blocked region at the time a travel operation is started with hoist control. This error does not result in a cancellation and remains pending until the region is exited.



Type of error: Error Remedy: Check the start position and the variable blocked region

E37 (Bit 28) Actual position in blocked region

The actual position has violated a fixed or variable blocked region. The course has deviated too far from the setpoint.

Type of error: Error Remedy: Increase the control reserve, reduce the gain factors, increase the position controller, reduce the brake derivative action time

E38 (Bit 25) Target in fixed blocked region

The target position is in a fixed blocked region. A travel job is not generated.

Type of error: Error Remedy: Check the target position and the fixed blocked region

E41 (Bit 29) Trolley following error

The difference between the actual and the set position is greater than the set permissible following error (P161), see Section 4.10.1

Type of error: Error Remedy: Increase the control reserve, reduce the gain factors, increase the position controller, reduce the brake derivative action time, change the parameter

E42 (Bit 30) Hoisting gear following error

The difference between the actual and the set position is greater than the set permissible following error (P164), see Section 4.10.1

Type of error: Error Remedy: Increase the control reserve, reduce the gain factors, increase the position controller,

reduce the brake derivative action time, change the following error.

E43 (Bit -/-) Crane geometry /dynamic response is incorrect

Inconclusive value combinations have been determined. Correct functioning cannot be guaranteed.

Type of error: Warning Remedy: Check parameters

E44 – E49 Reserve

Other errors 1

E50 (Bit 11) Trolley speed error



The trolley does not move, moves too fast or in an incorrect direction. The error is triggered when:

The actuator speed is > 10% of the maximum speed (P0) and the crane is not moving or moving in the wrong direction

The difference between the actuator speed and the actual speed > 20% of the maximum speed (P0) (e.g. defective drive)

The error appears with a delay of approx. 3 s. The error message is acknowledged when the trolley moves.


Defective encoder



The error is not signaled when the following error parameter of the axis (P161) is set to zero.

Type of error: Error Remedy: Check position values and transfer of the actuator speed

E51 (Bit 11) Hoisting gear speed error

The hoisting gear does not move, moves too fast or in an incorrect direction. The error is triggered when:



The error appears with a delay of approx. 3 s. The error message is acknowledged when the hoisting gear moves.


Defective encoder





E52 (Bit 11) Speed error during skew

The slewing gear does not move, moves too fast or in an incorrect direction. The error is triggered when:





The error appears with a delay of approx. 3 s. The error message is acknowledged when the trolley moves.


Defective encoder





E53 Encoder error, trolley (only SIMOTION C, not for PROFINET)

An encoder has not been found.

Type of error: Error Remedy: Check the encoder and cabling and/or deactivate the encoder -> parameter 22

E54 Encoder error, hoisting gear (only SIMOTION C)

An encoder has not been found.

Type of error: Error Remedy: Check the encoder and cabling and/or deactivate the encoder -> parameter 62

E55 Normalization error (only SIMOTION C)

The maximum acceleration corresponds to a normalized velocity change of less than 1.

Error bit: - Remedy: Use a larger normalization

E56 – E59 Reserve

Other errors 2

E60 (Bit 15) Load stuck

The load has stuck when starting to move.

Type of error: Error Remedy: Control crane manually or change P105.

E61 (Bit 7) Sway Control Off (pendulum length).

The Sway Control function has been switched off as the hoisting height is not within the specified limits (P83, P84).

Type of error: Error Remedy: Check parameters



E62 (Bit 6) Start of positioning with too much swaying

The positioning motion was started when there was too much swaying.

Type of error: Error Remedy: Eliminate swaying manually, check parameter P156

E63 (Bit 10) Trolley Sway Control temporarily reduced

Because of large swaying movements, the gain factor for trolley has been temporarily significantly reduced for stability reasons.

Type of error: Error Remedy: Eliminate swaying manually

E64 (Bit 19) Anti-skew temporarily reduced

Because of large swaying movements, the gain factor for skewing has been temporarily significantly reduced for stability reasons.

Type of error: Error Remedy: Eliminate swaying manually

E65 (Bit -/-) Sway Control Off (start)

The set activation speed (P146) has not been reached or the Sway Control activation delay (P147) has not yet elapsed, in order to start the Sway Control function. This warning is only issued in the "Speed control" basic operating mode.


E66 (Bit -/-) Sway Control only when stopping

The command bit "Sway Control only when stopping" is set.

Type of error: Warning Remedy: Reset command bit

E67 (Bit -/-) Controlled stop active

The command bit "Controlled stop" is set.

Type of error: Warning Remedy: Reset "Controlled stop" bit

Note Only SIMOTION C: If both bits are set ("Stop_contr" for the trolley and for the hub) only the bit set for trolley is displayed. If this is then reset manually, the status of log0 is displayed for both bits, even though the last incoming bit is set.



Note Only SIMOTION D: The value displayed in square brackets in CeCOMM for this product has no significance.

E68 (Bit -/-) Internal floating-point data error

A floating-point error has occurred during the calculation.

Error values: 100:SNAN 200:QNAN 300:NINF 400:ND 500:PD 600:PINF 0-9: controller, 10-19: oscillation model, 20-29: VSet, 30-39: oscillation model + offset, 40-49: RT


4.10.5.4 CeCOMM diagnostic software

Operating errors in the "Monitor" function are normally displayed in the monitor status line. An example is the "Display screen not assigned" message.

4.10.6 Troubleshooting/FAQs

Table 4-11 Troubleshooting/FAQs

Scenario Possible causes and remedy

Camera does not receive any message frames although the PLC receives data. Error message "Field bus error". The status LEDs of the Sway Control system and the camera connection are lit up on the hub. However, only the transmit LED of the camera flashes.

Check the hardware configuration.

Crane does not settle after completion of the travel motion.

Check minimum frequency and ramp-up time of the converter. The actual pendulum length differs greatly from the internally calculated effective pendulum length (screen 01 in the CeCOMM). Calibrate hoisting height (commissioning steps 2 and 3 on the Sway Control system).

Sway Control system starts swaying movements.

Check acceleration and deceleration ramps of the converter, remove any roundings and check the control parameters of the converter. Set the alignment of the camera (commissioning step 1 on Sway Control system).

Crane moves a short distance on its own for no reason.

Camera loses the reflector and for a short time finds objects in the vicinity similar to reflectors. Determine minimum window size (commissioning step 3 on camera). Change the low-pass frequency factor (P28-30 on the camera), restrict the camera search area (P15, P16 on the camera), increase the contrast (P0, P1 on the camera).

List oscillations occur with a higher frequency Activation of the low-pass filter (camera P28-30) for




Scenario Possible causes and remedy than the swaying movement. the appropriate drive axis (typical value: 2-3) and

reduction of the camera injection (SIMOTION P123, P124) (typical value: 0.015).

Residual swaying movements are always or occasionally too large.

Check ramps and speed controller of the converter.

Trolley moves uncontrolled and the automatic start does not react at all.

Display the currently pending errors with the diagnostics tool. If error E2 is active, the license has been deleted or damaged Check licenses.

Empty main menu (space bar) in the CeCOMM diagnostic tool

License is damaged or missing. Error E2 "Copy protection damaged" is displayed on the "Faults" display screen ("E" key). Check licenses.

Camera measuring system faulty (E4 error). This message does not automatically result in cancellation of the automatic travel. If this message is present permanently, there is a hardware fault. If it occurs sporadically, there is a problem detecting the reflector. The system integrator must decide whether the automatic travel is to be interrupted.

General Information 5 5.1 Maintenance and Service

5.1.1 Reflector

The reflector must be cleaned regularly depending on the degree of soiling. If only light dust contamination is present, a yearly inspection/cleaning is sufficient. If, however, heavy dust contamination prevails, the reflector must be cleaned in 4-6 weekly intervals. The secure reflector mounting must be checked as part of the regular crane inspection.

5.1.2 Camera

The front window of the camera protective housing must be inspected and cleaned regularly at the intervals specified in "Reflector". The secure mounting of the camera must be checked. After changing the reflector or the cable, the camera must be recalibrated using the "CeCOMM" diagnostic software (semiautomatic commissioning).

5.1.3 Update of the camera software

When the camera software is updated, the files selected in the file manager (see Fig. 5-1) must be transferred to the "/FlashFx/" directory of the camera.

The tick on the "Read only" file attribute (F2 - Attributes) must be removed because otherwise would only appear to be copied although actually nothing happens.


General Information 5.1 Maintenance/Service


After the copy action, the version must be checked in the version display ("V" key).

Fig. 5-1: Update of the camera software

General Information 5.2 Technical Data

5.2 Technical Data

5.2.1 Camera technical data

The CenSOR M camera measuring system can be used under the following mechanical and climatic conditions:

Table 5-1 Mechanical and climatic operational conditions CenSOR M

Condition Permissible range

Storage temperature -25° C … + 85° C

Operating temperature -25° C … + 60° C

Maximum humidity 85% without condensation

Atmospheric pressure 1,060 -700 hPa (corresponds to a height up to 3000 m)

Vibration in operation (sinusoidal vibration) Vibration in operation (constant amplitude) in accordance with DIN EN 60068-2-68, IEC 68-2-6

10 - 58 Hz: 0.35 mm 58 - 150 Hz: 50 m/s²

Shock resistance in accordance with DIN EN 60068-2-27, IEC 68-2-27

10 g amplitude, 6 ms duration

Power requirement 8...24 V (± 10% ripple) Typ. 300 mA at 12 V, max. 450 mA Typ. 3.5 W, max. 5 W

Serial I/O 9-pin Sub-D socket (RS232)

Weight Approx.350 g



5.2.2 Dimension drawings

5.2.2.1 Camera

Fig. 5-2: Camera

5.2.2.2 Camera protective housing

Weather protection enclosure



Fig. 5-3: Weather protection enclosure, front view

Fig. 5-4: Weather protection enclosure, side view

Fig. 5-5: Weather protection enclosure, top view

5.2.2.3 Reflector

Reflector 500 mm active



Fig. 5-6: Reflector 500 mm active, front view

Fig. 5-7: Reflector 500 mm active, rear and side view



Reflector 800 mm active

Fig. 5-8: Reflector 800 mm active, front view

Fig. 5-9: Reflector 800 mm active, rear and side view



5.2.3 Circuit diagrams

HUB circuit diagram

Fig. 5-10: HUB circuit diagram



Camera measuring system circuit diagram

Fig. 5-11: Camera measuring system circuit diagram



Reflector circuit diagram

Fig. 5-12: Reflector circuit diagram

5.2.4 Spare parts / accessories

Order number Item

6GA7200-0AA01-0AA0 SIMOCRANE SC INTEGRATED: STS/GSU: Basic Control

6GA7200-0AA01-1AA0 SIMOCRANE SC INTEGRATED: STS/GSU: Advanced Control

6GA7200-1AA01-0AA0 SIMOCRANE SC Standalone: STS/GSU: Basic Control 6GA7200-1AA01-1AA0 SIMOCRANE SC Standalone: STS/GSU: Advanced Control

6GA7201-0AA02-0AA0 Reflector 500 mm, active, IR

6GA7201-0AA03-0AA0 Reflector 800mm, active, IR

6GA7202-1AA00-0AA0 CenSOR M, camera measuring system for cranes, IR, aluminum housing, 16 mm lens, - 25 … 60° C

6GA7202-1AA10-0AA0 CenSOR M, camera measuring system for cranes, IR, stainless steel housing, 16 mm lens, - 25 … 60° C

6GA7202-1AA11-0AA0 CenSOR M, camera measuring system for cranes, IR, stainless steel




housing, 16 mm lens, - 25 … 80° C

6GA7202-1AA00-1AA0 CenSOR M, camera measuring system for cranes, IR, aluminum housing, 25 mm lens, - 25 … 60° C

6GA7202-1AA10-1AA0 CenSOR M, camera measuring system for cranes, IR, stainless steel housing, 25mm lens, - 25 … 60° C

6GA7202-1AA11-1AA0 CenSOR M, camera measuring system for cranes, IR, stainless steel housing, 25mm lens, - 25 … 80° C

General Information 5.3 Parameters

5.3 Parameters

5.3.1 CenSOR M parameter list

5.3.1.1 Overview

The parameters for configuring the CenSOR M camera are assigned as follows:

Camera/reflector parameters P0 to P19

Distance parameters P20 to P39

General parameters 1 P40 to P59

General parameters 2 P100 to P119

5.3.1.2 Camera/reflector parameters

The following parameter list on the camera can be used to establish a connection between the camera and the PC for diagnostic purposes or for manually changing parameters.

P0 Gain of the video input

Gain of the video signal. For zero, the automatic gain control will be activated. The maximum value is 64.

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

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

64 The gain results from ¼ of the current offset of the video input. This allows the gain also to be maintained depending on the brightness of the reflector.

Default: 64 min: 0 max: 64 Access code: 2

P1 Offset of the video input

Exposure time of the camera. The exposure time can be set to a value between 1 and 255. If the exposure time is set automatically, the brightness of the complete image or the brightness of the reflector must be chosen as setting. The maximum value is 511.

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

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

256 Automatic exposure time depending on the brightness of the reflector when the reflector was recognized, otherwise search for the optimum exposure time.



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


P2 Reflector type and alignment

Selection:

0 Black-and-white reflector: White areas, bottom left and top right 1 Black-and-white reflector: White areas, top left and bottom right

The parameter specifies how the white areas of the standard reflector are aligned. An incorrect setting will cause error E4 when a connection is established with the Sway Control system or with the camera.


P3 Window size for the reflector recognition

This parameter increases the internal reflector model. The largest possible value must be set for the largest distance between the camera and the reflector. An incorrect setting will cause error E4 when a connection is established with the Sway Control system or with the camera.

0 Automatic size control (distance-dependent).

1-10 Fixed window size.

11-20 Fixed window size (1..10) when no reflector was recognized, otherwise automatic size control.


P4 Reflector recognition limit (complete image)

The probability for the recognition of the reflector determined by the correlation function is compared with this factor. Only when the determined probability has at least this value is the reflector accepted as being recognized. The value is used for the search in the complete image.

Default: 700 [‰] min: 300 [‰] max: 1000 [‰] Access code: 2

P5 Size of the white reflector area

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

Default: 100 [mm] min: 10 [mm] max: 10000 [mm] Access code: 0

P6 Measuring reliability of the camera



The value specifies the degree of the required measuring reliability for determining the reflector size. Up to 16 characteristics are checked here. If more than ten characteristics are specified to be checked, a reflector will be used only when the reflector size was determined using the characteristics.


P7 Upper reflector position for camera calibration

For this reflector distance (internal, calibrated value), the upper measured value is acquired for the camera calibration.


P8 Lower reflector position for camera calibration

For this reflector distance (internal, calibrated value), the lower measured value is acquired for the camera calibration.


P9 Camera offset in the X direction

Value from the automatic camera calibration.

Default: 0 [mm] min: - 3000 [mm] max: 3000 [mm] Access code: 3

P10 Camera offset in the Y direction



P11 Camera offset in the Z direction

Value from the automatic camera calibration. If the value is zero, a newer calibration procedure with higher accuracy will be used. If the traditional calibration procedure should be used, prior to the calibration, the value must be set to a non-zero value.


P12 Camera skew in the X direction


Default: 0 min: - 200000 max: 200000 Access code: 3



P13 Camera skew in the Y direction



P14 Minimum reflector contrast

For the image evaluation, the contrast between the bright and dark areas must have at least this value. The measured contrast can lie between 0 and 255. Normally, the contrast of a reflector lies within the range 40 to 100, where the contrast of an active reflector is higher than that of a passive reflector.


P15 Limiting of the global search (X)

If the reflector was not found, the horizontal image area in which the reflector is searched can be limited. For 0% or 90%, all 640 image columns or only the middle 64 image columns will be searched for the presence of a reflector, respectively.

Default: 0 [%] min: 0 [%] max: 90 [%] Access code: 2

P16 Limiting of the global search (Y)

If the reflector was not found, the vertical image area in which the reflector is searched can be limited. For 0% or 90%, all 480 image rows or only the middle 48 image rows will be searched for the presence of a reflector, respectively.

Default: 0 [%] min: 0 [%] max: 90 [%] Access code: 2

P17 Focal length of the lens

The 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.


P18 Monochrome limit

Selection:

0 Arithmetic average of the reflector (default) 1 Suppress dark disturbances on white areas (shadows) 2 Suppress light disturbances on dark areas

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




P19 Reflector recognition limit (reflector environment)

The probability for the recognition of the reflector determined by the correlation function is compared with this factor. Only when the determined probability has at least this value is the reflector accepted as being recognized. The value is used only for searching near a recognized reflector.

Default: 600 [‰] min: 300 [‰] max: 1000 [‰] Access code: 2

5.3.1.3 Distance parameters

P20 Distance sensor resolution

Calibration value for the external distance position.


P21 Distance sensor offset

Calibration value for the external distance position.


P22 X measured value resolution

Calibration value for the measured value output.


P23 X measured value offset



P24 Y measured value resolution



P25 Y measured value offset





P26 Rotation angle measured value resolution



P27 Rotation angle measured value offset



P28 X measured value smoothing time constant

Smoothing time constant for smoothing the measured value (first order delay element). If the parameter value is zero, the smoothing is deactivated.

Default: 0 [s] min: 0 [s] max: 1000 [s] Access code: 1

P29 Y measured value smoothing time constant



P30 Rotation angle measured value smoothing time constant



P31 Distance measured value smoothing time constant



P32 Minimum reflector distance

The reflector distance must have a value at least the size of the set value. Otherwise it will be set to this value.




P33 Maximum reflector distance

The reflector distance may not be larger than the set value. Otherwise it will be set to this value.


5.3.1.4 General parameters 1

P42 Second camera available

If a second camera is used in the Ethernet network (e.g. to acquire large measuring ranges), this parameter must be set to 1. The device then deactivates its send function while it is not receiving any data from the PLC. If the parameter is set to zero, the camera sends irrespective of whether or not it is receiving data.


P43 Commissioning status

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


P44 Diagnostics value

Depending on the set value, the diagnostics variable is assigned 10 and sent to CeCOMM.

0 Measured value in pixels 1 Measured value in mm/degrees 2-Velocity 3-Acceleration 4-Score 5-Mean value of the gray values 6-Unsmoothed measured value


P45 Save camera image once

Selection:

0 Do not save 1 Save once unconditionally 2 Save once in case of an incorrect size measurement 3 Save once in case of an incorrect center determination

If this parameter is non-zero, the camera image will be saved as the "BildBin.txt" file for further offline processing.

The save operation causes the camera to be blocked for several seconds. After performing the command, the parameter will be automatically reset to zero.




5.3.1.5 General parameters 2

P100 Access code

Selection:

0 every user 1 commissioning engineers 2 service technicians 3 developers

Access code for changing parameters.


P101 Sampling time

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

Default: 70 [ms] min: 40 [ms] max: 200 [ms] Access code: 2

P102 Reflector position from external (0) / internal (1)

0 Reflector position is read using the PROFIBUS DP interface 1 Reflector position is determined from the size of the reflector. >1 Fixed reflector distance in mm

The parameter "Size of the white reflector area" must be set correctly for a correct measurement.


P103 Ethernet/PROFIBUS interface

Selection:

0 CenSOR standard interface 1 HIPAC PROFIBUS interface


P110 Language

Selection:

0 German 1 English

This parameter specifies the language used by the diagnostic software.

Irrespective of the setting of the P110 (language) and the P100 (access code), the language can also be set with the CeCOMM commissioning software (Windows Options/Language menu function).




P111 Passive (0) or active (1) reflector

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


P112 Reflector distortion

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


5.3.2 AddOn technology parameter list

5.3.2.1 Overview of the parameter list

The parameters for the configuration of the Sway Control system are grouped as follows:

Trolley parameters P0 to P39

Hoisting gear parameters P40 to P79

Sway Control parameters P80 to P99

General parameters P100 to P119

Camera/reflector parameters P120 to P139

Travel behavior parameters P140 to P159

Controlled variable parameters P160 to P179

TLS parameters P180 to P219

Slewing gear parameters P220 to P239

Option parameters

Parameters, in which one or more options can be selected, are identified by a"#" in front of the character string. Selected options are specified with the corresponding digit; options that are not selected with a dot ".".

Examples of parameter P152 (conventional/time-optimized control, trolley):



#..... None of the five options has been selected #.23.. Options 2 and 3 of five options have been selected #123.5 Options 1, 2, 3 and 5 of five options have been selected

Note Only the default values are specified for the parameters with selection options, but not the minimum and maximum.

5.3.2.2 Trolley parameters

P0 Maximum actuator speed, trolley

Speed limit in mm/s. The set value corresponds to the maximum attainable speed. The maximum speed is the speed attained when sending the normalizing value P103 (only available for SIMOTION C). Normalization is not required for SIMOTION D.

Default: 3500 [mm/s] min: 10 [mm/s] max: 5000 [mm/s] Access code: 0 Display: Always

Note After confirmation of the parameter P0, a prompt will be made whether the P1, P7, P6 and P5 parameters should be updated. The updating is appropriate only when the speeds and accelerations dependent on P0 have already been entered and only P0 is adapted again. For this "update", the P1, P7, P6 and P5 parameters will be changed in the same ratio as P0.

P1 Positioning speed, trolley

This value (in mm/s) corresponds to the maximum speed in the "Positioning" and "Hoist control" basic operating modes. In order to allow a slight overshoot, a value of 90% of the maximum actuator speed (P0) should be set. Set manually according to manufacturer or customer specifications. Record in order to check the speed setpoint in positioning mode.


P2 Prelimit switch speed, trolley

Percentage velocity value of P0 within the prelimit switches. With P115 = 0. If a prelimit switch has responded, the speed manipulated value is limited to this value. With P115 = 1. This value is used for the dynamic prelimit switches (P24, P27).

Default: 10 [%] min: 0 [%] max: 100 [%] Access code: 0 Display: Always

P3 Trolley speed for zero speed signal



If the target position of the trolley has been reached and the actuator speed is less than P3/100*P0, no further direction signal is output. The brake can be closed.


P4 Speed reduction factor for horizontal target point approach

Percentage value of the positioning speed of the trolley (P1). The maximum speed setpoint is reduced by this factor when a horizontal target point approach is performed (VSet=P1*P4/100).


P5 Maximum acceleration, trolley

Acceleration limit in mm/s². The set value corresponds to the maximum drive acceleration/deceleration. The value should be approx. 50..100% above the maximum acceleration (P6). Input values less than 20 are interpreted as ramp time.

Set manually according to manufacturer or customer specifications.

Default: 550 [mm/s²] min: 1 [mm/s²] max: 2000 [mm/s²] Access code: 0 Display: Always

P6 Set acceleration, trolley

The set acceleration is an internal acceleration variable in mm/s². It is effective in all basic operating modes not only in the acceleration, but also in the deceleration phase (depending on P115). Input values less than 20 are interpreted as ramp time. Set manually according to manufacturer or customer specifications. The value should be approx. 75% of the maximum acceleration (P5).


P7 Acceleration without Sway Control / minimum acceleration

With P7 the drive accelerates/decelerates in the speed control basic mode when the Sway Control is deactivated. Input values < 20 are interpreted as ramp time. With time-optimized control, P7 acts as the set acceleration. The exact method of operation can be found in the Operating Instructions in Sections 3.3, 4.7.1, 4.7.2, 4.7.3.4.


P8 Deceleration gain, trolley

Gain factor for the increase or decrease of the deceleration. The deceleration results from P6 * P8, with countering from P6 * P8 * P142.

Default: 1 min: 0,5 max: 5 Access code: 2 Display: Always



P9 Reduction factor for set acceleration, trolley, automatic travel

This parameter can be used to reduce the set acceleration in the "Hoist control" basic operating mode. The parameter acts only with time-optimized control.


P10 Acceleration reduction factor for horizontal target point approach

Percentage value of the set acceleration of the trolley (P6). The maximum speed setpoint is reduced by this factor when a horizontal target point approach is performed (ASet = P6*P10/100).


P11 Trolley rounding for operation without Sway Control

Initial and final rounding of the trolley setpoint. The percentage value is based on the ramp-up time to the maximum speed. The rounding is active when the parameter is greater than zero and the Sway Control is deactivated.


P12 Smoothing of torque setpoint, trolley

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

Default: 350 [ms] min: 0 [ms] max: 5000 [ms] Access code: 2 Display: Always

P20 Resolution of position sensor, trolley

Calibration value for the trolley position.

Default: 1 min: - 100 max: 100 Access code: 1 Display: Always

P21 Offset of position sensor, trolley

Calibration value for the trolley position.

Default: 0 [mm] min: - 200000 [mm] max: 200000 [mm] Access code: 1 Display: Always

P22 Encoder increments per millimeter for trolley

Factor for the conversion of the counted encoder pulses over a distance in mm.



Default: 0 [1/mm] min: - 500000 [1/mm] max: 500000 [1/mm] Access code: 2 Display: Always

NOTICE

This parameter is visible in the CeCOMM diagnostic tool, but is not relevant for this product as it is not possible to connect encoders directly.

P23 Minimum position for positioning, trolley

Smaller target positions are ignored. Note that the limitation refers to calibrated target positions (after conversion with resolution and offset). Error E31 is triggered for smaller target positions of the trolley.


Note If parameter P23 is changed, the internally learned obstacles on the waterside are set to the maximum values. Therefore, a new learning travel operation is required. This also applies when a parameter set switchover is performed and the parameter sets have different values for P23.

P24 Position for trolley VES speed backwards

Position where the trolley must have reached the prelimit switch speed (P2). The position where the trolley is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115 = 1.


P25 Waiting position, trolley

This parameter specifies the waiting position of the trolley. The trolley waits at this position until the bit "NO_WAIT_POS" has been set by the PLC. This function can be used, for example, for container cranes with several trolleys for mutual locking.

Default: 100000 [mm] min: 0 [mm] max: 500000 [mm] Access code: 0 Display: Always

P26 Trolley position, start of waterside

Trolley position that corresponds to the start of the waterside. The offset approach (P34) only applies to the waterside.


P27 Position for trolley VES speed forwards



Position where the trolley must have reached the prelimit switch speed (P2). The position where the trolley is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115 = 1.


P28 Maximum position for positioning, trolley

Larger target positions are ignored. Note that the limitation refers to calibrated target positions (after conversion with resolution and offset). Error E31 is triggered for larger target positions of the trolley.



P29 Trolley position, end of waterside

Trolley position that corresponds to the end of the waterside. The offset approach (P34) only applies to the waterside.

If obstacles are to be expected at positions > P28, then the value for P29 must also be increased: P29 > P28 + 0.5 * P106 (spreader width). Therefore, either an obstacle always remains or the maximum possible target position has been really approached using the learning travel.


P30 On-the-fly unloading abort speed

For on-the-fly unloading, the "open grab" signal will be reset once the trolley undershoots the specified speed.

At the same time, the bit for the target changeover (CHANGE_TARGET) is set.

Default: 500 [mm/s] min: 0 [mm/s] max: 50000 [mm/s] Access code: 1 Display: Only for GSU (P102, selection 0 = ON)

P31 Distance for opening the grab

For on-the-fly unloading, the "open grab" state bit will be set when the distance between the grab and the target position is smaller than this parameter value.

Default: 1000 [mm] min: 0 [mm] max: 50000 [mm] Access code: 1 Display: Only for GSU (P102, selection 0 = ON)

P32 Travel clearance of trolley to limit curve



Travel clearance that must be maintained when traveling around the limit curve in the trolley direction. Minimum travel clearance of the trolley in addition to the safety clearance of the limit curve.


P33 Safety clearance, trolley

Safety clearance to obstacle limit in the trolley direction. This parameter is used to define the safety zone (smart slowdown with Sway Control stop). If the target is in this area, it is not approached and the trolley stops before this area.


P34 Offset for target point approach

This parameter only applies for target point approaches on the waterside. If the parameter is not equal to zero, a target position is approached that is offset by this value in the trolley direction. The trolley then travels to the target position.


P35 Position offset during unloading

When learning target positions, the value for the trolley is changed by this parameter. The value is limited internally to a spreader width.


P36 Position offset during loading

When learning target positions, the value for the trolley is changed by this parameter. The value is limited internally to a spreader width.


P37 Bay Scanner position offset

Deviation of the laser position from the trolley position. Positive values mean that the Bay Scanner measuring laser is offset by this value from the defined trolley position in the waterside direction.

Default: 5000 [mm] min: - 10000 [mm] max: 10000 [mm] Access code: 1 Display: Only for STS (P102, selection 1 = ON)

P38 Time constant for PT1 element



With the PT1 element, the actuating signal is delayed and rounded off in order to minimize trim oscillations for time-optimized-Sway Control. With value=0, the PT1 element has no effect. The higher value, the greater the rounding

Default: 0 s Access code: 1 Display: Always

P39 Frequency of the grab (input shaper)

Trim oscillations of the grab (double pendulum) can be minimized with the input shaper. The parameter causes a distortion of the converter signal depending on the specified frequency. With values less than 0.2 Hz, the function is deactivated.

Default: 0 Hz min: 0.2 [Hz] max: 5 [Hz] Access code: 1 Display: Always

5.3.2.3 Hoisting gear parameters

P40 Maximum actuator speed, hoisting gear

Speed limit in mm/s. The set value corresponds to the maximum attainable speed. The maximum speed is the speed attained when sending the normalizing value P103 (only available for SIMOTION C). Normalization is not required for SIMOTION D.


Note After confirmation of the parameter P40, a prompt will be made whether the P41, P51 and P50 parameters should be updated. The updating is appropriate only when the speeds and accelerations dependent on P40 have already been entered only P40 has to be adapted again. For this "update", the P41, P51 and P50 parameters will be changed in the same ratio as P40.

P41 Positioning speed, hoisting gear

This value (in mm/s) corresponds to the maximum speed in the "Positioning" and "Hoist control" basic operating modes. In order to allow a slight overshoot, a value of 90% of the maximum actuator speed (P40) should be set. Set manually according to manufacturer or customer specifications. Record in order to check the speed setpoint in positioning mode.


P43 Prelimit switch speed, hoisting gear

Percentage velocity value of P0 within the prelimit switches. With P115 = 0. If a prelimit switch has responded, the speed manipulated value is limited to this value. With P115 = 1. This value is used for the dynamic prelimit switches (P64, P68).


P44 Hoisting speed for zero speed signal



If the target position of the hoisting gear has been reached and the actuator speed is less than P44/100*P40, no further direction signal is output. The brake can be closed.


P45 Hoisting speed reduction

Percentage value of the positioning speed when hoisting (P41). The maximum speed setpoint is reduced by this factor. Applies in the "Hoist control" and "Positioning" basic operating modes (VSet = P41*P45/100)


P46 Immersion point speed limit

For the transition of the trolley speed from 10% above to 10% below the speed, the current immersion point is set on the waterside. The value refers to the maximum speed of the trolley.


P47 Reduction of speed when raising

Factor for the reduction of the speed until the bit "Slack rope" is no longer set.

Default: 0,1 min: 0 max: 1 Access code: 2 Display: Always

NOTICE

If the value = 0 is set, this reduction is not active and lifting is performed at full speed.

P49 Reduction of speed when lowering

Just before putting the load down (P74), the lowering speed is determined from the positioning speed and this reduction factor (P41 * P49).


NOTICE

If the value = 0 is set, this reduction is not active and lowering is performed at full speed.

P50 Maximum acceleration, hoisting gear

Acceleration limit in mm/s². The set value corresponds to the maximum drive acceleration/deceleration. The value should be approx. 50..100% above the maximum acceleration (P51). Input values less than 20 are interpreted as ramp time.



Set manually according to manufacturer or customer specifications.


P51 Set acceleration, hoisting gear

The set acceleration is an internal acceleration variable in mm/s². It is effective not only in the acceleration, but also in the deceleration phase. Input values less than 20 are interpreted as ramp time. Set manually according to manufacturer or customer specifications. The value should be approx. 75% of the maximum acceleration (P50).


P52 Deceleration gain, hoisting gear

Gain factor for the increase or decrease of the deceleration. The deceleration results from P51 * P52, with countering from P51 * P52 * P142. The gain factor is only effective in the speed control mode.


P53 Acceleration reduction when hoisting

Percentage value of the set acceleration when hoisting (P51). The set acceleration is reduced by this factor when hoisting. Applies in the "Hoist control" and "Positioning" basic operating modes (ASet = P51*P53/100)


P54 Hoisting gear rounding

Initial and final rounding of the hoisting gear setpoint. The percentage value is based on the ramp-up time to the maximum speed. The rounding is active when the parameter is greater than zero. It is only effective in the speed control mode.


P55 Smoothing of torque setpoint, hoisting gear



P60 Effective pendulum length resolution

Calibration value for the effective pendulum length



Default: - 1 min: - 100 max: 100 Access code: 1 Display: Always

P61 Effective pendulum length offset

Calibration value for the effective pendulum length


P62 Encoder increments per millimeter for hoisting rear


Default: 0 [1/mm] min: - 500000 [1/mm] max: 500000 [1/mm] Access code: 2 Display: Always

NOTICE


P63 Minimum position for positioning, hoisting gear

Smaller target positions are ignored. Please note that the limitation refers to non-calibrated target positions. Error E32 is issued for smaller target positions of the hoisting gear.



P64 Position for hoisting gear VES speed lowering

Position where the hoisting gear must have reached the prelimit switch speed (P43). The position where the hoisting gear is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115 = 1 and the trolley is located on the landside (see P26).


P65 Hoisting gear waiting position

This parameter specifies the waiting position of the hoist. The hoisting gear waits at this position until the bit "NO_WAIT_POS" has been set by the PLC.




P66 Minimum hoisting height, landside

Below the minimum hoisting height on the landside, the "bStart_Auto_OK" state bit is not set. If this bit is used for starting the automatic, a start is not possible. If the state bit is not processed, only the hoisting gear is operated below the minimum hoisting height on the landside at the automatic start, then also the trolley. P66 is only effective in the "Hoist control" basic operating mode.


P67 Minimum hoisting height waterside

Below the minimum hoisting height on the waterside, only the hoisting gear is operated at the automatic start, then also the trolley. P67 is only effective in the "Hoist control" basic operating mode.


P68 Position for hoisting gear VES speed hoisting

Position where the hoisting gear must have reached the prelimit switch speed (P43). The position where the hoisting gear is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115 = 1.


P69 Maximum position for positioning, hoisting gear

Larger target positions are ignored. Please note that the limitation refers to non-calibrated target positions. Error E32 is issued for larger target positions of the hoisting gear.



P70 Safe height on land

An automatic travel on land will always stop above this position. At start in this area, initially only the hoisting gear is operated until the limit is exceeded. P70 is only effective in the "Hoist control" basic operating mode.

Default: - 10000 [mm] min: - 10000 [mm] max: 200000 [mm] Access code: 0 Display: Always



P71 Travel clearance of hoisting gear to limit curve

Travel clearance that must be maintained when traveling around the limit curve in the hoisting gear direction. Minimum travel clearance of the hoisting gear in addition to the safety clearance of the limit curve.


P72 Safety clearance, hoisting gear

Safety clearance above the limit curve. This parameter is used to define the safety zone (smart slowdown). If the target is in this area, it is not approached and the trolley stops before this area.


P74 Distance for automatic lowering

As of this distance to the target, lowering is performed with reduced speed (P49).


P75 Horizontal trolley travel to the hopper (only GSU)

Setting the trolley travel distance over the hopper without hoisting motion.

Value 1 activates an automatic determination.

Default: 1 [mm] min: 0 [mm] max: 100000 [mm] Access code: 1 Display: Only GSU

P76 Horizontal trolley travel to the ship (only GSU)

Setting the trolley travel distance over the hopper without hoisting motion.

Value 1 activates an automatic determination.

Default: 1 [mm] min: 0 [mm] max: 100000 [mm] Access code: 1 Display: Only GSU

5.3.2.4 Sway Control parameters

P80 Digital correction of the effective pendulum length

Shift in the center of gravity of the load, with "Dig_Hoist_Dist_Corr" bit set (SIMOTION D) or "DigitalLiftCorrection" (SIMOTION C).



Default: 0 [mm] min: -10000000 [mm] max: 10000000 [mm] Access code: 1 Display: Always

P81 Analog correction of the effective pendulum length

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

Default: 0.02 [mm/kg] min: -70000 [mm/kg] max: 70000 [mm/kg] Access code: 1 Display: Always

P82 Weight of the load carrying device

Weight of the load carrying device to determine the shift in the center of gravity. If the load is the same as the weight of the load carrying device, then there is no shift in the center of gravity.

Default: 12500 [kg] min: -20000 [kg] max: 20000 [kg] Access code: 0 Display: Always

P83 Upper limit for Sway Control

For a smaller (effective) pendulum length, the Sway Control is deactivated (E61).


P84 Lower limit for Sway Control

For a larger (effective) pendulum length, the Sway Control is deactivated (E61).


P85 Trolley gain factor (deceleration)

Gain factor for the conventional Sway Control in all basic operating modes when decelerating. Large values result in aperiodic transition characteristics, small values in overshoot.


P86 Trolley gain factor (acceleration)

Gain factor for the conventional Sway Control in manual operation when accelerating. Large values result in aperiodic transition characteristics, small values in overshoot. To achieve fast accelerations operations, the value should be less than for deceleration.


P87 Gain factor for skew (deceleration)



Gain factor for the conventional Sway Control in all basic operating modes when decelerating. Large values result in aperiodic transition characteristics, small values in overshoot.

Default: 1,2 min: 0 max: 10 Access code: 2 Display: Only for TLS (P197, selection 1 = ON)

P88 Gain factor for skew (acceleration)

Gain factor for the conventional Sway Control in manual operation when accelerating. Large values result in aperiodic transition characteristics, small values in overshoot. To achieve fast accelerations operations, the value should be less than for deceleration.

Default: 1 min: 0 max: 10 Access code: 2 Display: Only for TLS (P197, selection 1 = ON)

P89 Hoisting height offset for 20 ft Skew Control

Offset for the conversion of the hoisting position to the effective pendulum length. The value is only used for the Skew Control.

Default: 0 [mm] min: -200000 [mm] max: 200000 [mm] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P90 Linear hoisting height factor for 20 ft Skew Control

Linear gain factor for the conversion of the hoisting position to the effective pendulum length. The value is only used for the Skew Control.

Default: 0,5 min: -1000 max: 1000 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P91 Hoisting height offset for 30 ft Skew Control



P92 Linear hoisting height factor for 30 ft Skew Control



P93 Hoisting height offset for 40/45 ft Skew Control





P94 Linear Hoisting height factor for 40/45 ft Skew Control



5.3.2.5 General parameters

P100 Access code

Selection:

0 crane operators, maintenance staff 1 commissioning engineers 2 service technicians 3 developers (password protected)

Access code for changing parameters.

Default: 1 Access code: 0 Display: Always

P101 Parameter set locked during travel

Selection:

0 The active parameter set can be switched over during travel 1 The active parameter set can only be switched over at standstill


P102 Configuration

Selection:

0 ship unloader (without camera) 1 STS (with camera)


P103 Normalizing value (only available for SIMOTION C)

The parameter contains the normalizing factor for all speeds and accelerations that are transferred via the field bus. If the parameter is set, for example, to 28,000, then a speed setpoint of –14,000 corresponds to half the negative maximum speed of the relevant axis.

Default: 32767 min: 10 max: 32767 Access code: 1 Display: Always



P104 Diagnostics value

Depending on the set value, the diagnostics variable is assigned 10 and sent to CeCOMM.

0-2 limits, 3-5 setpoints, 6-8 actual values, 9-11 manipulated variables, 12-14 delayed manipulated variables, 15-17 oscillation model, 18-21 camera measured values. 26 setpoint-actual-value difference (position) each in the sequence, position-speed-acceleration.


P105 Maximum inclined hoisting angle (only STS)

If the inclined hoisting is greater than this angle, error E60 "Load is stuck" is triggered. The evaluation is performed by comparing the oscillation model with the camera measurement. The monitoring can be deactivated by setting the parameter to values less than 0.6.

Default: 0 [°] min: 0 [°] max: 500000 [°] Access code: 2 Display: Always

P106 Spreader / container / grab width

The obstacles are increased in size by half the width left and right for the travel path calculation and monitoring.


NOTICE

If the parameter is changed, the internal targets are initialized and all the learnt lanes are deleted.

Note For P106 < 1000 mm, a switchover is made to the MODEL MODE. Because of the different dimensions, smaller safety areas than on the real crane apply.

P107 Hoist offset to the spreader/grab

The limit curve is increased in height by the value of this parameter for the travel path calculation and monitoring. This is useful when the hoisting gear position does not correspond to the lower edge of the spreader/grab.


P108 Maximum container height

The height of the highest possible container. When the bit "Container locked" is set, all obstacles (fixed and variable) are increased by this parameter value.




Note For P108 < 1000 mm, a switchover is made to the MODEL MODE. Because of the different dimensions, smaller safety areas than on the real crane apply.

P109 Automatic mode

Selection:

1 automatic travel only to land 2 for travel to land, a lane MUST be specified

This parameter only applies when no external targets are specified.

Default: 2 Access code: 1 Display: Only for STS (P102, selection 1 = ON)

P110 Language

Selection:

0 German 1 English

This parameter specifies the language used by the diagnostic software.

Irrespective of the setting of the P110 (language) and the P100 (access code), the language can also be set with the CeCOMM commissioning software (Windows Options/Language menu function).


P111 Smoothing factor for actual speeds

This parameter can be used to smooth the determined actual speed. The factor acts on the actual speeds of all axes. Small values cause more intensive smoothing; the maximum value 1.0 produces no smoothing.


P115 Prelimit switch configuration

Deceleration of the trolley and the hoisting gear before the minimum or maximum position to VES speed. The dynamic prelimit switches (P24, P27, P64, P68) are enabled and disabled.

Meaning:

0 dynamic prelimit switches deactivated, bits for prelimit switches active 1 dynamic prelimit switches activated.


P116 Maximum rotation angle for passive Skew Control



With passive Skew Control, the permissible rotation angle of the load after being put down corresponds to this value.

Default: 0 [cgr] min: 0 [cgr] max: 10000 [cgr] Access code: 2 Display: Always

P117 Request for encoder synchronization (SIMOTION C)

If the difference of the axis position between the encoder signal and the signal via PROFIBUS is greater than this value, status bit no. 14 of the relevant axis is set and therefore an encoder synchronization requested. As long as this value corresponds to the default value (=0), the bit is not set.


NOTICE SIMOTION D


5.3.2.6 Camera/reflector parameters

P120 Assignment of camera axes to drive axes

Selection:

1 Motion up or down corresponds to trolley travel. 2 Motion to the left corresponds to the forwards direction. 3 Motion up corresponds to the forwards direction.

The motions are evaluated as seen from the camera image in the "CeCOMM".

Default: #... Access code: 1 Display: Only for STS (P102, selection 1 = ON)

P121 Delay of camera data, trolley

Delay of the camera signal from the image recording until switching in to the oscillation model.

Default: 0 [ms] min: 0 [ms] max: 10000 [ms] Access code: 2 Display: Only for STS (P102, selection 1 = ON)

P122 Camera data delay for skewing

Delay of the camera signal from the image recording until switching in to the oscillation model.

Default: 0 [ms] min: 0 [ms] max: 10000 [ms] Access code: 2 Display: Only for STS (P102, selection 1 = ON)

P123 Gain of the camera measuring signal

Value for switching in the camera measuring signal to the internal oscillation model. The camera measurement has no effect with a value of zero.



Default: 0,03 min: 0 max: 1 Access code: 1 Display: Only for STS (P102, selection 1 = ON)

P124 Gain of the camera measuring signal while skewing

Value for switching in the camera measuring signal to the internal oscillation model. The camera measurement has no effect with a value of zero.

Default: 0,05 min: 0 max: 1 Access code: 1 Display: Only for STS (P102, selection 1 = ON) and TLS (P197, selection 1 = ON)

P125 Camera fixed - reflector rotated

Selection:

0 Slewing drive rotates camera and reflector (e.g. trolley slewing gear) 1 Slewing drive rotates reflector, but not the camera (e.g. TLS cylinder)

Mounting of the camera and the reflector with respect to the skew

Default: #1 Access code: 2 Display: Only for STS (P102, selection 1 = ON)

P126 Upper limit for camera measurement

The camera measurement is deactivated for pendulum lengths shorter than this value.

Default: 0 [mm] min: 0 [mm] max: 100000 [mm] Access code: 0 Display: Only for STS (P102, selection 1 = ON)

P127 Tripping time for camera error

Time which elapses before a camera error (E4) is signaled to the PLC.

Default: 14 [s] min: 0 [s] max: 100 [s] Access code: 1 Display: Always

5.3.2.7 Travel behavior parameters

P140 Transfer time for the actuator speed

Specifies the time required for the transfer of the actuator speed to the drive. It is approximately the sum of the sampling times of the Sway Control and the PLC.


P141 Suppress opposite direction

As long as this percentage value of the maximum speed is not attained in manual operation, the drive axis is only moved in the direction specified by the crane operator.




P142 Deceleration increase with countering

The deceleration is increased by this value when the speed setpoint and the actual speed have different signs (countering). This parameter only applies for the trolley, when Sway Control is on, when the control mode has been selected conventionally (not for time-optimized) and only for the speed control basic mode.


P143 Acceleration reduction, fine travel

If the speed setpoint and the actual speed are less than 30% of the maximum speed, the set acceleration is multiplied by this factor. This parameter only applies for the trolley, when Sway Control is on, when the control mode has been selected conventionally (not for time-optimized) and only for the speed control basic mode.

Default: 0,5 min: 0,001 max: 1 Access code: 2 Display: Always

P144 Deceleration reduction, fine travel

If the speed setpoint and the actual speed are less than 30% of the maximum speed, the set acceleration is multiplied by this factor and used as deceleration setpoint. The parameter is only effective in the speed control basic mode and applies only to the trolley.

The parameter does not act for time-optimized travel or when the Sway Control is off.

Default: 0,5 min: 0,001 max: 1 Access code: 2 Display: Always

P145 Variable acceleration for the time-optimized control

A variable acceleration range can be specified for the time-optimized control. The control tries to vary the acceleration in such a way that simple ramps result. The acceleration is then in the range (100%-value)*ASet_wSC. . (100%+value)*ASet_wSC or AMax.

With ASet_wSC - Set acceleration without Sway Control

AMax - Maximum acceleration


P146 Activation speed of the Sway Control

If the absolute value of the speed setpoint is greater than this value, the Sway Control is activated after expiry of the switch-on delay P147. A hysteresis of ± 5% acts to prevent a continuous activation and deactivation of the Sway Control. Warning E65 is active as long as the speed has not been reached.


P147 Sway Control switch-on delay



The absolute value of the speed setpoint must be greater than the activation speed P146 at least for this period so that the Sway Control is activated. Warning E65 is present if this period has not yet elapsed.


P148 Sway Control switch-off delay

The absolute value of the speed setpoint must be less than the activation speed P146 at least for this period so that the Sway Control is deactivated.


P149 Drive switch-on delay, trolley

Switch-on delay of the drive, after which the brake is opened. A dead time of the drive is specified so that Sway Control is informed and can be taken into consideration for the model behavior. If the value is less than 1, the delay element is deactivated.

Vactuator

Brake closed

Vactual

Travel signal

ON delay

Fig. 5-13: ON delay


P150 Drive switch-on delay, hoisting gear



P151 Drive switch-on delay during skewing




Default: 0 [ms] min: 0 [ms] max: 1000 [ms] Access code: 2 Display: Only for TLS (P197, selection 1 = ON)

P152 Conventional/time-optimized control, trolley

Selection:

1 Time-optimized control only for speed control 2 Time-optimized control only for automatic control 3 On-the-fly unloading permitted (only for GSU) 4 On-the-fly unloading with max. deflection (only for GSU) 5 Time-optimized control only for stopping (only for GSU)

If all options are "OFF", the conventional control is always active.

WARNING Parameter P152 can only be changed during standstill, as otherwise jumps occur in the manipulated variable.

Default: Access code: 1 Display: Always

P153 Time constant for current rise, trolley

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.


P154 Time constant for current rise, hoisting gear



P155 Current rise time constant for Sway Control





P156 Permissible initial sway

Automatic positioning can only be started when the initial sway is less than this parameter. Error E62 is triggered if the initial sway is greater. The value refers to the calculated average load deflection for acceleration operations. If 0% is set as permissible initial sway, then it is possible to start with every initial sway.


5.3.2.8 Controlled variable parameters

P160 Position controller, trolley

P-position controller for the automatic positioning. Negative values activate a target control instead of the position control. The absolute value of a negative value determines the steepness of the deceleration ramp. ABrake=fabs(P160)*P6. The parameter should be set greater than 0 when using the time-optimized algorithms.

Default: 0,5 min: -1 max: 10 Access code: 1 Display: Always

P161 Following error, trolley

Permissible deviation between the set and actual position during a travel operation in the "Positioning" and "Hoist control" basic operating modes. If this value is exceeded, the travel operation is aborted and an error message (E41) generated. If the value = 0 is set, this function is not active.


P162 Positioning accuracy, trolley

Tolerance within which a positioning operation should be completed.


P163 Position controller, hoisting gear

P-position controller for the automatic positioning. Negative values activate a target control instead of the position control. The absolute value of a negative value determines the steepness of the deceleration ramp. ADecel=fabs(P163)*P51

Default: 0,5 min: -1 max: 10 Access code: 1 Display: Always



P164 Following error, hoisting gear

Permissible deviation between the set and actual position during a travel operation in the "Positioning" and "Hoist control" basic operating modes. If this value is exceeded, the travel operation is aborted and an error message (E42) generated.


P165 Positioning accuracy, hoisting gear



P166 Position controller for skewing

P-position controller for the automatic positioning. Negative values activate a target control instead of the position control. The absolute value of a negative value determines the steepness of the deceleration ramp. ADecel=fabs(P166)*P225


P167 Following error for Skew Control

Permissible deviation between the set and actual position during a travel operation in the "Positioning" and "Hoist control" basic operating modes. If this value is exceeded, the travel operation is aborted.

Default: 3000 [mm] min: 0 [mm] max: 500000 [mm] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P168 Positioning accuracy for skewing


Default: 20 [cgr] min: 1 [cgr] max: 200 [cgr] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P169 Permissible residual sway

Largest permissible load deflection after completion of a trolley motion. When the load deflection falls below this value, the signal "Sway neutralized" will be set.


P170 Residual sway after time-optimized acceleration



The parameter specifies how large the swaying motion may be after a time-optimized acceleration operation. P169 is always used for stopping.


P171 Quality of the time-optimized control

This parameter specifies the quality of the time-optimized control. Higher quality reduces the acceleration and deceleration times and increases the required CPU time.


5.3.2.9 TLS parameters

P180 Speed setpoint of the TLS cylinders

Cylinder speed when activating trim, list or skew.

Default: 12 [mm/s] min: 1 [mm/s] max: 1000 [mm/s] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P183 Maximum speed for TLS cylinders

Maximum cylinder speed that may occur with trim, list, skew and activated Skew Control.


P184 Speed for pressure 1/2 switchover

The signal for higher pressure is set above this speed.


P185 TLS switch-in for Skew Control

The manipulated variable determined for the Skew Control is multiplied by this value and switched into the TLS cylinder actuating signals.

Default: 1 min: -100000 max: 100000 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P186 TLS speed for zero signal

If the control calculates an actuator speed that is less than this value, then zero and no direction is output for the speed.

Default: 15 [%] min: 0 [%] max: 75 [%] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)



P187 Gain for the TLS cylinder positions

Calibration value for the TLS cylinder positions.

Default: 1 min: 0,0001 max: 200000 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P188 Minimum TLS cylinder position

Limit for the TLS cylinder positions.

Default: -10000 [mm] min: -200000 [mm] max: 200000 [mm] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P189 Maximum TLS cylinder position

Limit for the TLS cylinder positions.


P190 Positioning accuracy of TLS cylinders


Default: 20 [mm] min: 0.01 [mm] max: 200000 [mm] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P191 Reduction of lowering actuator speed

The lowering speed of the TLS cylinders can be greater than the hoisting speed by this amount of actuator speed. In this case, the actuator speed for the lowering should be reduced with this parameter.

Default: 100 [%] min: -100 [%] max: 100 [%] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P192 Switch-off delay of the pump

The output signal for the pressure control is reduced by this set delay.

Default: 3 [s] min: 0 [s] max: 100000 [s] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P193 Minimum pressure, normalized

The hydraulic cylinders start to move as of this output value.


P194 Trim limit

Limit of the difference between the left and right cylinder positions.




P195 List limit

Limit of the difference between the front and back cylinder positions.


P196 Skew limit

Limit of the difference between the diagonals A and B cylinder positions.


P197 Use trim/list/Skew Control

Selection:

1 Trim/list/Skew Control On 2 Use the same positions on the land- and waterside

If the TLS control is to be used, the slewing gear is used in conjunction with the TLS cylinders. It can be specified whether the same TLS positions should apply on the land- and waterside or deviate from each other.

Default: Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P198 Permissible residual sway TLS

Largest permissible load deflection after completion of a cylinder motion. When the load deflection falls below this value, the signal "Sway neutralized" will be set.


P199 TLS initial swaying

This value must be exceeded in order to start with the sway neutralization.


P200 Zero position of cylinder A

Position that is approached when the command bit "Approach zero position" is set.


P201 Zero position of cylinder B





P202 Zero position of cylinder C



P203 Zero position of cylinder D



P204 Normalizing value for TLS cylinder

The parameter contains the normalizing factor for the speeds that are transferred via the field bus. If the parameter is set, for example, to 28000, then a speed setpoint of -14000 corresponds to half the negative maximum speed of the cylinder.


5.3.2.10 Slewing gear parameters

P220 Maximum actuator speed for skewing

Speed limit in cgr/s. The set value corresponds to the maximum attainable speed. The maximum speed is the speed attained when sending the normalizing value P204.

Default: 500 [cgr/s] min: 10 [cgr/s] max: 4000 [cgr/s] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

Note After confirmation of the parameter P220 , a prompt will be made whether the P221, P226, P225 and P224 parameters should be updated. The updating is appropriate only when the speeds and accelerations dependent on P220 have already been entered only P220 has to be adapted again. For this "update", the P221, P226, P225 and P224 parameters will be changed in the same ratio as P220.

P221 Positioning speed for skewing

This value corresponds to the maximum speed in the "Positioning" basic operating mode. In order to allow a slight overshoot, a value of 90% of the maximum actuator speed (P220) should be set. Set manually according to manufacturer or customer specifications. Record in order to check the speed setpoint in positioning mode.



Default: 450 [cgr/s] min: 10 [cgr/s] max: 4000 [cgr/s] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P222 Prelimit switch speed for skewing

Percentage speed value within the prelimit switches.

Default: 10 [%] min: 0 [%] max: 100 [%] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P223 Speed of rotation for zero speed signal

If the target position of the slewing gear has been reached and the actuator speed is less than P223/100*P220, no further direction signal is output. The brake can be closed.

Default: 3% Default: 3 [%] min: 0 [%] max: 75 [%] Access code: 2 Display: Only for TLS (P197, selection 1 = ON)

P224 Maximum acceleration for skewing

Acceleration limit in cgr/s². The set value corresponds to the maximum drive acceleration/deceleration. The value should be approx. 50..100% above the set acceleration (P225). Input values less than 20 are interpreted as ramp time. Set manually according to manufacturer or customer specifications.

Default: 250 [cgr/s²] min: 0.1 [cgr/s²] max: 1000 [cgr/s²] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P225 Set acceleration for skewing

The set acceleration is an internal acceleration variable in cgr/s². It is effective not only in the acceleration, but also in the deceleration phase. The set acceleration is attained with deactivated Sway Control. Input values less than 20 are interpreted as ramp time. Set manually according to manufacturer or customer specifications. The value should be approx. 75% of the maximum acceleration (P224).


P226 Acceleration without Sway Control

When the Sway Control is deactivated, the drive accelerates/decelerates with the set acceleration value. The value is used as minimum deceleration when the prelimit switch range is reached. Input values < 20 are interpreted as ramp time. Set manually according to manufacturer or customer specifications. The drive must be braked with this deceleration from full speed at the prelimit switch down to prelimit switch speed (P222) at the limit switch.


P227 Gain of the deceleration while skewing



Gain factor for the increase or decrease of the deceleration. The deceleration results from P225 * P227, with countering from P225 * P227 * P142.

Default: 1 min: 0,5 max: 5 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P228 Smoothing of torque setpoint for skewing



P229 Resolution of rotation angle sensor

Calibration value for the rotational position.

Default: 1 min: -100 max: 100 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P230 Offset of rotation angle sensor

Calibration value for the rotational position.

Default: 0 [cgr] min: -100000 [cgr] max: 100000 [cgr] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P231 Encoder increments per millimeter for skewing


Default: 0 [1/mm] min: -500000 [1/mm] max: 500000 [1/mm] Access code: 2 Display: Only for TLS (P197, selection 1 = ON) NOTICE SIMOTION D


P232 Minimum position for positioning for skewing

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

Default: -5000 [cgr] min: -200000 [cgr] max: 200000 [cgr] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P233 Maximum position for positioning for skewing

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



Default: 5000 [cgr] min: -200000 [cgr] max: 200000 [cgr] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P239 Commissioning status

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


5.4 Appendix

5.4.1 CeCOMM commissioning software

5.4.1.1 Monitor menu tree

The menu assistance of the screens in the "Monitor" tab is explained using the following table. The display screens can be reached from the "main menu" with the keys "1" to "7". The display screens, menus and additional functions listed in the right-hand column can be called from each of these display screens.

1 Display kinematics

2 Display PROFIBUS Interface

3 Display status of travel axes

4 Display common bits

5 Display autocheck

6 Display hoist control

7 Display Trim/List/Skew

1 Display kinematics

2 Display PROFIBUS Interface

3 Display status of travel axes

4 Display common bits

5 Display autocheck

6 Display hoist control

7 Display Trim/List/Skew

B Fixed Blocked regions

G Display Variable Blocked regions

I Commissioning menu

P Parameters menu

L Logger

E Fault



H Fault History

V Version Info

? Return to main menu

! Stop diagnosis

X Twistlock simulation

Space Return to main menu

ENTER Build a new display

B Fixed Blocked Regions

1 Display blocked regions

I Add blocked regions

C Change blocked regions

D Delete blocked regions

S Save all sets of parameters/areas

R Reload parameters

F Display interpolation points

ESC Return to last selected display – page 1 to 7


E Fault ESC Return to last selected display – page 1 to 7

? Help for selected fault

H Fault history


G Display Variable Blocked Regions

Any key Return to last selected display – page 1 to 7

H Fault History ESC Return to last selected display – page 1 to 7

E Fault

ENTER Return to last selected display – page 1 to 7

I Commissioning menu

0 Set Configuration and Parameters

1 Set alignment of the camera

2 Calibrate hoist high (TROLLEY)

3 Calibrate hoist high (SKEW CONTROL)



4 Simulate errors

5 Determine speed limit

6 Save all parameters

? Help for selected commissioning step



L Logger H Display first page

E Display last page

B One page backward

F One page forward

S Save logged signal sequences



P Parameters menu

1, 2 Display trolley parameters

3, 4 Display hoisting gear parameters

5 Display Sway Control parameters

6 Display general parameters

7 Display camera parameters

8 Display driveability parameters

9 Display controller parameters

10, 11 Display TLS parameters

12 Display skew drives parameters



5 Display trolley parameters









C Change parameters

D Set default values for all sets

F Search parameters

I Communication address

L Parameters/areas listing

N Different parameters/areas set

R Reload parameters

S Save all sets of parameters/areas

Y Copy parameters/areas set

T Title of set of parameters - only camera

? Help for parameter



V Version Info Any key Return to last selected display

! Stop diagnosis Space Restart of diagnosis

X Twistlock simulation

X Stop Twistlock simulation

Fig. 5-14: Monitor menu tree

5.4.2 Bibliography

Ref. 1: PROFIBUS and PROFINET, PROFIdrive Profile Drive Technology PROFIBUS User Organization e. V. Haid-und-Neu-Straße 7, D-76131 Karlsruhe http://www.profibus.com Order No.: 3.172 Version 4.1, May 2006

Ref. 2: SIMOCRANE Basic Technology V2.0 Operating Instructions SIMOCRANE_Basic_Technology_de-DE.pdf, 06/2008 Edition

Ref. 3: SIMOTION D4x5 Manual D4x5_Betreiben_de-DE.pdf, 08/2008 Edition

Ref. 4: SIMOTION D4x5 Commissioning and Hardware Installation Manual, D4x5_Inbetriebnehmen_de-DE.pdf, 08/2008 Edition



5.4.3 Abbreviations

BT: Basic Technology

BW: Backward

CF: CompactFlash Card

CMS: Crane Management System

COP: Crane Operator Panel

CW: Clockwise

CCW: Counter-clockwise

DCC: Drive Control Chart

DN: Down

DS: Tandem Spreader

FW: Forward

GSU: Grab Ship Unloader

HO: Hoist

IO: Input/Output variables

LS: Landside

LH: Left hand

MCC: Motion Control Chart

RH: Right hand

RMG: Rail-Mounted Gantry Crane

RT: Run time

SC: Sway Control

ST: Structured text

STS: Ship to shore (Quayside Container) Crane

STW: Control word

SW: Software

TLS: Trim/list/skew

TO: Technology Object in SIMOTION; symbol for a moving axis

TR: Trolley

UP: Up

WS: Waterside

ZSW: Status word

5.4.4 Terminology (German/English)




English German English German Backward Rückwärts Right hand Rechte Seite Boom Ausleger Ship-to-shore crane Containerbrücke Clockwise Uhrzeigersinn Slew gear Drehwerk Closing Gear Schliesswerk Sway Control Pendelregelung Counter clock wise Gegenuhrzeigersinn Trolley Katze Down abwärts Up aufwärts Forward vorwärts Gantry Fahrwerk Gantry - Slave Fahrwerk - slave Grab Ship Unloader Greiferkran, Schiffsentlader Hoist Hubwerk Holding Gear Haltewerk Input/Output variables

Eingabe-/Ausgabevariablen

Left hand Linke Seite

Index Access code

Camera measuring system............................ 248 Sway Control system..................................... 261

Actual position value........................................... 102 Actual speed ....................................................... 103 AddOn

Configuring .................................................... 202 Import............................................................... 80

AddOn DCC library ............................................... 29 AddOn FB library .................................................. 48

Copying............................................................ 90 AddOn system

Minimum configuration .................................. 118 Alarm messages ................................................. 289 Application

Sway Control for container cranes .................. 70 Sway Control with 2D-Trajectory and Bay Scanning.......................................................... 71 Sway Control with TLS Control ....................... 77 TLS Control ..................................................... 76

Application error messages ................................ 291 Automatic.................................................... 145, 157 Basic operating mode......................................... 128

Hoist control............................................. 72, 135

Speed control .................................................129 Bay scanner ........................................................214 Bay Scanner values

Conversion .....................................................124 Blocked region.......................................................72 Blocked regions.......................................... 136, 155

Definition ..........................................................72 Delete .................................................... 162, 163 General features ............................................161 Transfer ................................................. 161, 162

Brightness ...........................................................255 Calibration

Camera measurement ...................................254 Camera

Brightness.....................................................243 Connecting ...................................................243 Fine focus .....................................................243 Lens settings ................................................243

Camera image Checking ........................................................250

Camera measuring system Configuring.....................................................247 Fine adjustment..............................................255 Functions........................................................239

Index

Interface......................................................... 239 Operating principle ........................................ 239 Save parameters ........................................... 255 Simulate errors .............................................. 255

Camera measuring system commissioning Requirements ................................................ 248

Camera parameters Manual setting ............................................... 255

Characteristics Sway Control................................................ 263

Collision protection .................................. 282, 290 Commissioning

2D-Trajectory................................................. 278 Hoist control................................................... 281 Positioning ..................................................... 278 Sway Control ......................................... 269, 270 Sway Control system..................................... 263 TLS Control ................................................... 285

Commissioning menu ......................................... 218 Commissioning requirements


Commissioning steps Sway Control ................................................. 269 Sway Control system..................................... 269

Communication Checking PLC-SIMOTION D......................... 262

Communication test ............................................ 112 Configuration

Camera measuring system......................... 251 PROFIBUS ...................................................... 81 S7 .................................................................. 121 Sway Control system............................. 139, 264

Configuring Sway Control ................................................... 78

Connecting Camera.......................................................... 243 Hub................................................................ 243 Overview........................................................ 241 Reflector ....................................................... 243

Consistency Checking.......................................................... 95

Control bits Common ........................................................ 172 Hoist............................................................... 175 Obstacles....................................................... 185 Targets........................................................... 181 TLS ................................................................ 179 Trolley............................................................ 177

Conventional control ........................................... 264 Converter

Acceleration and deceleration ramps ....... 260 Initial and final rounding............................. 260 Limitation...................................................... 261

Minimum frequency .....................................260 Parameter sets .............................................260 Preparing........................................................260 Speed controller ...........................................260

Copying I/O variables............................................89 cylinder ................................................................167 Cylinder positions ................................................286 DCC block

DCC_SCCamera..............................................45 DCC_SCCommon............................................30 DCC_SCDiag ...................................................47 DCC_SCHoist ..................................................32 DCC_SCObstacles ..........................................42 DCC_SCTargets ..............................................40 DCC_SCTLS....................................................37 DCC_SCTrolley................................................35

DCC blocks Inserting............................................................92

Definition I/O peripherals..................................................86 Message frame ................................................88

Definitions..............................................................71 Deletion

Positions .......................................................284 Dependency matrix ...............................................16 Determining the minimum window size...............254 Diagnostic program

Functions........................................................207 Diagram...............................................................221

Characteristics ...............................................234 Print ................................................................232 Shortcuts ........................................................229 X/Y display .....................................................235 Zoom ..............................................................229

Distance measurement .......................................255 Double spreader....................................................74 Dynamic prelimit switch

Sway Control ................................................264 Error list

Sway Control system .....................................295 Error messages

Sway Control ..................................................291 FAQ

Sway Control system .....................................306 FB_CommonAddOn ToPLC..................................50 FB_CommonPLCToAddOn...................................48 FB_HoistAddOn ToPLC ........................................53 FB_HoistPLCToAddOn .........................................52 FB_ObstaclesAddOn ToPLC ................................65 FB_ObstaclesPLCToAddOn .................................63 FB_Receive_Analysis ...........................................66 FB_Send_Preparation...........................................66 FB_TargetsAddOn ToPLC ....................................62 FB_TargetsPLCToAddOn .....................................61


Index

FB_TLSAddOn ToPLC ......................................... 59 FB_TLSPLCToAddOn .......................................... 57 FB_TrolleyAddOn ToPLC..................................... 56 FB_TrolleyPLCToAddOn...................................... 54 Field weakening.................................................. 100 Following error .................................................... 261 Following error monitoring .................................. 289 Function blocks

Sway Control ................................................... 29 Functions

Diagnostic program ....................................... 207 Global variables

Basic technology ............................................. 27 Naming scheme............................................... 26 TO objects ....................................................... 28

Hardware configuration SIMATIC .......................................................... 84 SIMOTION....................................................... 82

Height profile Reset (delete) ................................................ 163

Hoist control........................................................ 135 Activation ....................................................... 135 Characteristics............................................... 135 Commissioning .............................................. 281 Interruption .................................................... 150 Monitoring functions ...................................... 290

Hoisting gear acceptance ................................... 153 Hoisting height

Calibrate ........................................................ 273 Hub

Connecting ................................................... 243 Hydraulic control ...................................... 168, 169 I/O address ranges ............................................... 85 I/O peripherals

Definition.......................................................... 86 Immersion point .................................................. 158 Import

AddOn.............................................................. 80 Installation

DCC library ...................................................... 80 Installing/mounting

Camera.......................................................... 240 Hub................................................................ 241 Reflector ....................................................... 241

Interface Camera measuring system............................ 239 Diagnostic program ....................................... 208

IP Address Camera measuring system............................ 244

JAVA Runtime .................................................... 111 Language


Language files

Copying ..........................................................111 Laser........................................................... 214, 283 Laser scanner......................................................214 Learning

Positions .......................................................284 Lens ....................................................................255 Lens settings

Camera ..........................................................243 License key

Creating..........................................................112 Limit curve .............................................................73 Limit curve parameters.....................................281 Limiting the search area......................................256 List .......................................................................168 Load deflection ....................................................213 Logic

Brake signal ...................................................123 Mode-independent .........................................123 Travel signal...................................................123

MCC charts Copying ............................................................91

Measuring Distance .........................................................239 Offset..............................................................239 Rotation angle ................................................239

Measuring reliability Camera measuring system ............................256

Message frame Definition ..........................................................88

Minimum time ....................................................277 Monitoring

Automatic .......................................................290 Start Sway Control .........................................290

Obstacles ..............................................................71 Offset Land..........................................................157 Offset Water ........................................................157 On-the-fly unloading ............................................136

Activation........................................................134 Open grab ...........................................................152 Operating conditions

Camera measuring system ............................311 Operating mode switchover ................................153 Operation

Diagnostic program........................................205 Oscillation model

Mathematical ..................................................263 Override...................................................... 151, 283 Parameter set............................................ 202, 269

Switching ......................................................202 Parameterizing/addressing ................ 201, 243, 247 Parameters

Effectiveness ................................................203 Entering, editing ...........................................202 Saving............................................................203


Index

Path curve............................................................. 73 Pendulum length

Effective ................................................. 213, 273 PLC program

Preparing ....................................................... 259 Polarities ............................................................... 28 Position controller ............................................... 278 Position offset ..................................................... 157 Position setpoint ................................................... 99 Positioning .......................................................... 131

Abort .............................................................. 131 Activation ....................................................... 131 Automatic....................................................... 131

Positioning complete........................................... 101 Positioning range................................................ 280

Permissible .................................................... 281 Pressure system................................................. 287 PROFIBUS

Configuration ................................................... 81 PROFIBUS address.............................................. 81 PROFIBUS connection

Configuring ...................................................... 82 PROFIBUS DP interface .................................... 170

Common input data ....................................... 170 Common output data ..................................... 185 Hoist input data.............................................. 174 Hoist output data ........................................... 191 Obstacles input data...................................... 183 Obstacles output data.................................... 195 Targets input data.......................................... 180 Targets output data ....................................... 194 TLS input data ............................................... 178 TLS output data ............................................. 193 Trolley input data ........................................... 176 Trolley output data......................................... 192

Project Transfer ......................................................... 110

Reflector Connecting ................................................... 243

Reflector type...................................................... 255 Determine ...................................................... 251

Residual sway Setting........................................................... 277

S7 Brief description of blocks.............................. 122 Configuration ................................................. 121 Structure ........................................................ 121

Save position ...................................................... 284 SC Automatic...................................... 136, 145, 156

End of a travel motion.................................... 148 Manual hoisting motion.................................. 149 Possible settings.................................... 149, 157 Start on the waterside.................................... 150

SC Semi Automatic............................................. 153

SC Speed Control .............................. 140, 156, 169 Control............................................................140 End of a travel motion ....................................143 Possible settings ............................................144 Start of a travel motion ...................................142

SCOUT project Transferring....................................................111

Send text file........................................................208 Setup

DCC library.......................................................80 Signal characteristics ..........................................113 Signal flow ...........................................................113 Skew....................................................................168 Skew control............................................... 168, 287

Speed setpoint ...............................................287 Speed control ............................................. 129, 271

Activation........................................................129 Status bits

Common.........................................................186 Hoist ...............................................................191 Obstacles .......................................................195 Targets ...........................................................195 TLS.................................................................193 Trolley.............................................................192

Sway Control Activating/deactivating ...................................144 Activation........................................................138 Basic operating mode ....................................128 commissioning ...............................................270 Commissioning...............................................263 Configuring...............................................78, 202 Deactivation ...................................................130 Fine adjustment..............................................275 Priorities .........................................................167 TLS commands ..............................................168

Sway Control algorithms Sway Control ................................................264

Sway Control configurations ...............................139 Sway Control system commissioning

Requirements.................................................259 Sway Control system interface description .........170 Sway Control system parameters

Camera and reflector .....................................347 Save ...............................................................275 Trolley.............................................................330

Target generator......................................... 136, 157 Time-optimized control ........................................264 TLS

Cylinder ..........................................................288 Move zero.......................................................288 Reset ..............................................................288 Save zero .......................................................288 Skew control...................................................287 Speed limit......................................................287


Index


Speeds........................................................... 287 Test................................................................ 288

TLS commands................................................... 166 TLS Control................................................. 166, 170

Activation ....................................................... 166 Trim..................................................................... 168 Twistlock simulation ........................................ 284 Variable blocked regions .................................... 162

Velocity monitoring ..............................................289 Velocity setpoint ....................................................98 Weather protection enclosure .........................312 Window size.......................................................256 Windows menu functions

Diagnostic program: .......................................207 Zero position

Approach/save ...............................................168

simocrane sc integrated - siemens...simocrane sc integrated 2 simatic s7 configuration 3...

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