solution _ emerson

June 05 Sales Conference - Amsterdam

www.servo-payesh.com

[email protected] +98(21)44839534-44838867

Crane Industry seminar


Give you a personal impression about:

• The crane industry

• Competitors

• Our experiences

• Trends

• Some do’s and don’ts

• and …..



Segments crane market

• Port & Terminal equipment for handling:

– containers

– bulk

– cargo

• Industrial Cranes (mainly Overhead cranes)

• Tower / Construction Cranes

• Specials (heavy lift, offshore pedestal,

nuclear waste, etc.)


• Port & Terminal equipment for container terminal operations

– Ship-to-Shore cranes

– Rail mounted gantry cranes

– Rubber Tired gantry cranes

– Straddle carriers

– Reach Stackers

– Terminal Tractors

Port & Terminal equipment: container handling


• Port & Terminal equipment for container terminal operations

– Ship-to-Shore cranes

– Rail mounted gantry cranes

– Rubber Tired gantry cranes

– Straddle carriers

– Reach Stackers

– Terminal Tractors

• Port & Terminal equipment: container handling


Container handling: Ship to Shore (STS) cranes

Main Hoist

Two @ 200 to 750kW

Trolley

One @ 132 to 315 kW or

Four @ 45 to 110 kW

Boom Hoist

One @ 75 to 315 kW

Gantry

8 to 16 @ 11 to 22kW

Typ

ical D

rives

Full AC for new cranes

DC for retrofits

Boom

Spreader (trim&list) Trolley

Gantry

E-room

Trolley traveling is

prohibited when the boom

is up


• Trends:

– Increasing demands (extended boom due to bigger ships; Panamax,

Post-Panamax and Superpost-Panamax)

– Twinlift (2 containers in 1 move)

– High speeds, high accelerations (full rope trolleys)

– Second trolley

– Semi-automation (anti-sway and position control)

– More and more leasing of port equipment and because of this

remote condition monitoring is getting more important

Container handling: Ship to Shore (STS) cranes

HV-supply by a cable reel

Control from a cabin connected to

the trolley

PLC-controlled

Crane management system


Container handling concepts

Reachstackers

Rubber tired gantry cranes

Rail mounted gantry cranes

Straddle carriers


Container handling: Gantry cranes

Hoist

One @ 150 to 350 kW

Trolley

Four @ 11 to 22 kW

Gantry

Four @ 11 to 30 kW

Typ

ica

l D

rive

s

AC for new cranes

DC for retrofits

Rail mounted Gantry cranes:

• Supply by cable reel

• Power regeneration

Rubber tired Gantry cranes:

• Supply from diesel generator set

• Automatic steering control

• Braking resistors required


Container handling: Straddle Carriers Typ

ical D

rives

AC for new carriers

DC for retrofits

Hoist

One @ 90 to 150 kW

Gantry

Four @ 11 to 30 kW

Straddle carriers:

• Supply from diesel generator set

• Steering control

• Braking resistors required

• Each wheel is driven (highly advantaged control)

Straddle carriers are standard and built in series


Highlights: Container Terminal Operations

• Business is booming; a lot of container terminals are extended or will be

developed due to the increasing economical activities in the Far-East; so

a lot of new built container cranes at the moment






• Besides local Port Authorities also the Fleet operators do develop their

own terminal operations (Maersk, NYK, P&O, PSA, Hutchison

Whampoa)








Whampoa)

• Scale-factors are important (cost-saving) ; recent merge between Maersk

and P&O








Whampoa)


and P&O

• OEMs have changed to one-stop-and-shop companies; although

business is good – prices are under pressure due to competition from

Asia








Whampoa)


and P&O

• OEMs have changed to one-stop-and-shop companies; all do business is

good – prices are under pressure due to competition from Asia

• It’s a global market and the containers are highly standardized (20’, 30’,

40’ and 45’)








Whampoa)


and P&O

• OEMs have changed to one-stop-and-shop companies; all do business is

good – prices are under pressure due to competition from Asia

• It’s a global market and the containers are highly standardized (20’, 30’,

40’ and 45’)

• There’s a difference in companies that are involved in intercontinental

and Short Sea Shipping (continental)


Port & Terminal Cranes: bulk handling

• Port & Terminal equipment for bulk handling

– Ship unloaders

– Mobile grab cranes

– Barge mounted (floating) grab

cranes

– Slewing grab cranes

– Stacker reclaimers

– Scraper reclaimers

– Bucket wheel reclaimers


Bulk handling: Ship unloaders

Close

1 or 2 @ 150 to 700 kW

Trolley

1 or 2 @ 150 to 500 kW

Gantry

8 to 16 @ 11 to 50 kW

Full AC for new cranes

DC for retrofits

Typ

ica

l D

rive

s

50 – 85 tonnes grab cranes (180m/min) for unloading

ships only. The bucket empties above a hopper.

From the hopper further transport by conveyor belts

Boomhoist

1 or 2 @ 75 to 160 kW

Hoist

1 or 2 @ 150 to 700 kW

Mainly handling iron ore and coal


Bulk handling: Slewing grab cranes

Closing

One @ 150 to 350 kW

Slewing

2 to 4 @ 15 to 37 kW

Gantry

8 to 16 @ 11 to 30 kW

AC for new cranes

DC for retrofits

Typ

ica

l D

rive

s

Luffing

One @ 75 to 150 kW

16 – 36 tonnes Lemniscate Floating grab

crane may have a diesel generator set as

power supply.

Hoist

One @ 150 to 350 kW In most cases

slewing grab

cranes do have

hook duty too.

Jib crane


Highlights: Bulk handling

• Business is tough; no serious expending market size

• For this reason mainly one-off sales and more chances in

retrofitting

• Built for purpose


Port & Terminal Cranes: cargo handling

• Port & Terminal equipment for cargo handling

– Jib cranes

– Mobile cranes

– Double boom cranes or double-link

level luffing cranes


Highlights: Cargo handling

• Business is tough; no serious in size expending market, due to the

benefits of the highly standardized containers.





• The smaller OEM’s specialized on this market segment where the design

to the needs of the end-user specs is required.





• The smaller OEM’s specialized on this market segment where the design

to the needs of the end-user specs is required.

• For the mobile cranes it is more a buy with or without the extras from the

catalogue.


Major OEMs – Port & Terminal Cranes (1)

OEM Head Office /

Production Website

Incumbent Drive

Supplier Comments

KCI (Konecranes,

Noell, Caillard)

Finland / Malaysia /

France / Germany www.konecranes.com Vacon, Siemens Commercially tied with Vacon (brandlabel)

Liebherr Germany / Austria /

Ireland www.lcc.liebherr.com Liebherr Brandlabeling CTWW?!

ZPMC China www.zpmc.com Siemens, ABB,

Yaskawa, CT Market leader, strong in price-competition

Kalmar (Partek) Finland / Holland www.kalmarind.com Siemens In 2002 Kone Corp took over Partek /

Kalmar

Kunz Austria www.kuenz.com Siemens

Gottwald Germany www.gottwald.com Siemens

Mobile cranes, gantry cranes and AGVs.

Part of Demag, 20% ownwership of

Siemens

Fantuzzi Reggiane Italy www.reggiane.com

Voest-Alpine Austria www.vamh.com Siemens Bulk handling

Femont Belgium www.femont.com Siemens Small local player

Paceco US, Spain www.pacecocorp.com

IMPSA Argentina www.impsaportsystems.com


Major OEMs – Port & Terminal Cranes (2)

OEM Head Office /

Production Website

Incumbent Drive

Supplier Comments

MAN-Takraf Germany www.man-takraf.de

Hilgers Germany www.hilgers-ag.de Local player

MHI Hiroshima

cranes

Mitsubishi

Japan www.mhi.co.jp


Industrial Overhead Traveling Cranes

Hoist

1 or 2 @ 7,5 to 300 kW

Cross Travel

1 to 4 @ 1,5 to 45 kW

AC Drives Used

Typ

ical

Dri

ves

Long Travel

2 or 4 @ 22 to 45 kW

Supply mainly via conductor

lines and shoegears


Highlights: Industrial overhead cranes

• There is the huge market for standard industrial overhead cranes that

focuses on loads up to 10-tons. Mainly the single or double girder cranes

are equipped with ‘Wire rope hoists’.






• The standard industrial crane market is highly competitive and money

driven. Implementing drives depends of the clients specs. OEMs do have

their own (brand-labeled) drive.






• The standard industrial crane market is highly competitive and money

driven. Implementing drives depends of the clients specs. OEMs do have

their own (brand-labeled) drive.

• Heavy duty cranes are more designed to the clients needs and therefore

in this area there are other smaller more specialized, local companies

active.


Major OEMs – Standard Overhead Cranes

OEM Head Office /

Production Website

Incumbent

Drive

Supplier

Comments

Kone Finland www.konecranes.com Vacon brandlabel

Demag Germany www.demagcranes.de Demag

(Dedrive)

Abus Germany www.abus-kransysteme.de

P&H US www.morriscranes.com


Construction – (Mobile) Tower Cranes

Hoist

One @ up to 45 kW

Slew

One @ up to 7,5 kW

AC on all electric driven cranes

Typ

ical

Dri

ve

s

From 1mt up to 30mt load and radius up to 50 meters

Trolley

One @ up to 7,5 kW


Highlights: (Mobile) Tower cranes

• For the tower cranes it is more a sales from the catalogue.




• These cranes are not automatically equipped with speed controlled

motors.





motors.

• There are mobile tower cranes, these cranes are mounted on a truck and

can easily be erected on site.





motors.



• Some OEMs choose for hydraulic driven solutions others for electric

driven.





motors.



• Some OEMs choose for hydraulic driven solutions others for electric

driven.

• Huge rental market


Major OEMs – (Mobile) Tower Cranes

OEM Head Office /

Production Website

Incumbent

Drive

Supplier

Comments

MAN Wolffkran Germany www.wolffkran.de

Liebherr Austria www.liebherr.com Liebherr Self-made

Potain France www.potain.com LS

Arcomet Belgium www.arcomet.com

MTC Holland www.mtc-cranes.com CT / LS Mobile cranes

Terex Germany, Italy www.comedil.com Brands: Peiner,

Comedil


Specials

• The market for specials is significant and divers for its

purpose:

– Heavy lift cranes

– Marine and offshore pedestal cranes

– Cranes especially for handling nuclear waste

– Cranes especially for the automotive industry

– Etc.


Price break-down: STS-crane

• STS-crane (53 – 100 tonnes) 4,8 – 6,8 mln €




• E-installation 0,7 – 1,1 mln € (15 – 20%)





• AC-drives including AFE 0,09 – 0,13 mln € (2 – 3%)






• AC-motors 0,10 – 0,12 mln € (2 – 3%)






• AC-motors 0,10 – 0,12 mln € (2 – 3%)

Conclusion:

Drives and motors are not dominant!


E-installation: STS-crane

•Motors

•Drives including DC-bus and AFE (or ERE-unit)

•MV-supply including cable reel, MV-switch and transformer

•LV Distribution

•PLC control

•Safety and control devices

•Load measuring device

•Auxiliary equipment

•Condition monitoring

•Walkway lighting and floodlights

•Operator control equipment

•Spreader cable reel

•Communication equipment

•Crane diagnose

•Cabling, festoon system, mounting and installation parts

•Spreader control

•Anti sway system

•Project management

•Engineering (hard- & software)

•Commissioning (FAT and SAT)

•Warranty

•Training


Typical drive system for a STS-crane

e

Hoist Crane travel

2 x 8 x 12 kW

1500/1800 rpm

M M M M M

Boom hoist Trolley 600 kW

1000/2000 rpm

Common DC-bus

M

500 or 690 V Kalmar Industries B.V.

52-tons container STS-crane

Bidirectional feed/regeneration unit

Dyn 11

690 / 400 V

Auxiliary supply

4 x 25 kW

1500 rpm

e M e

80 kW

1500 rpm

e

Cable reel

M M M M e M M M M M M M M M

5,5 kW

1500 rpm

Mains conditioning


Channels to Market – Port & Terminal Cranes

Drive Suppliers

Terminal Operators

Re

tro

fit

System Integrators CT Systems (via DCs)

Re

tro

fit

New

New

New

Crane OEM (some OEMs incl. systembuilding)

(e.g. PSA, Maersk, Sealand, P&O, Hutchison - Whampoa)

(e.g. Siemens, independents)


Centre of Excellence

Siemens Nederland N.V.

P.O. Box 16068

2500 BB The Hague

The Netherlands

Siemens - Scope of Supply

• SIMOREG DC-MASTER

• DC Motors

• SIMOVERT AC MASTERDRIVE

• AC Motors

• Slipring motor drives

• SIMATIC S7 PLC

• Trim, list and skew-control

• SICMA Crane Management System

• HIPAC anti-sway system

• TOUCHMATIC anti-sway system

• Safety PLC

• Electronic Steering

• Active Safe Stability System

• Automated positioning: (gantry & trolley)

• Spreader position detection with camera

Total solution supplier:

Project management, engineering, wide range of standard products, assembly, installation,

commissioning, after sales, financing


Centre of Excellence

ABB Automation Technologies

Crane Systems

SE-721 67 Västerås, Sweden

ABB - Scope of Supply

• DC Drives

• DC Motors

• AC Drives

• AC Motors

• PLC

• ASTAT – Crane Controller

• AutoControl – three axis anti-sway

• GrabControl – minimum stress

• PosControl

• SwayControl



commissioning, after sales


Yaskawa - Scope of Supply

• AC Drive sales only


Tmeic GE - Scope of Supply



commissioning, after sales

• DC Drives

• DC Motors

• AC Drives

• AC Motors

• GE Fanuc PLC

• Crane Management System

• GrabControl – minimum stress

• PosControl

• Anti Sway Control


Competitor Market in the Harbor Crane Industry

Supplier Centre of

Excellence Website Scope of Supply Comments

Siemens The Hague,

Holland

www.siemens.nl/cranes

Drives

Total solutions

Finance

Market Leader

Europe

ABB www.abb.com/cranes Drives

Total solutions

Yaskawa Japan Drives only

Schneider France www.schneider-electric.com Drives

Total solutions

Alstom France

Vacon Finland www.vacon.com Drives only Brand: Kone

Rockwell US www.automation.rockwell.com/drivesystems

CT www.controltechniques.com

Drives / Systems

GE US www.geindustrial.com/cwc

Tmeic GE US

www.tmge.com

Drives/

Total solutions

Joint venture: GE,

Toshiba, Mitsubishi

http://www.siemens.nl/cranes

http://www.abb.com/cranes

http://www.schneider-electric.com/



http://www.vacon.com/

http://www.automation.rockwell.com/drivesystems

http://www.controltechniques.com/

http://www.geindustrial.com/cwc

http://www.tmge.com/


Technical do’s and don’ts (1)

• Don’t use just one drive to control more than one slewing motor; the

polygon effect will cause unbalance between the motors





• Do consider closed loop for the slewing movement





• Do consider closed loop for the slewing movement

• Modernizing the control of an existing MG-set (Ward-Leonard) is not an

easy job. In general the job is risky and needs special skills with a

minimum impact on sales, so don’t be to easy on this. In our (CTBV)

perspective it is only useful to help existing clients or in cases where there

is more to win.



• Having always the crane movements

working together, a common DC-bus

system is a must for harbor cranes!

Siemens has two ‘regen’ concepts:

Active Front End (AFE) and thyristor

technology called the ERE. ERE is very

cost effective and in most cases

unbeaten. Do consider there is a

possibility with the Mentor as

regenerating unit, but has got serious

technical limitations.

Supply voltage:

500/690 Vac

Common DC-bus

IGBT

bridge

LCL-filter

Common DC-bus

Rectifier

bridge

choke

Thyristor

bridge

Supply voltage:

500/690 Vac

AFE ERE



• CT doesn’t have anti-sway control! CTBV

has developed slew control to create a

better feel on the stick for the crane-driver.

For anti-sway there are two open loop and

closed loop. In closed loop there’s a

sensor on the spreader, hook or bucket. By

means of a camera (Vision) the position is

constantly detected. In a processor the

dedicated software is responsible for the

correction on the trolley movement.

Companies that are selling anti-sway

control are CePlus (Magdeburg, Germany)

and Arck (Ramonville, France)


• For anti-sway on ship unloaders open

loop can be an option. Positioning

above the hopper is not critical in most

cases.



CTBV’s experiences so far

• Learn from the past, to plan the future (1):

• Port & Terminal cranes are the ‘High-End’ of the market





• Being successful in that field, can have a spin-off effect





• Being successful in that field, can have a spin-off effect

• Port & Terminal cranes and heavy duty cranes:

a conservative market with specialized system-integrators

in most cases competitors in industrial automation;

so the first thing they ask for is references.



• System integrators do like to sell systems first;

in most cases they follow the paved roads created by the

successful excepted brands.







• So, in most cases market penetration only selling drives,

DC or AC, has been highly in-successful.







• So, in most cases market penetration only selling drives,

DC or AC, has been highly in-successful.

• CTBV started at the bottom, to convince end-users of our

knowledge of systems and drives, and concentrate

on retrofits.




• Our successes where in almost all cases DC-retrofits

(MG-sets and static converters).

Competition in this area is limited and added value (software)

integrated in the drives.

Software CTBV has developed:

• grab control

• slew control

• load/speed control in fieldweakening




• Our successes where in almost all cases DC-retrofits

(MG-sets and static converters).

Competition in this area is limited and added value (software)

integrated in the drives.

Software CTBV has developed:

• grab control

• slew control

• load/speed control in fieldweakening

• Modernizing a crane-installation, retrofitting, is most of the

times considered if the reliability is at stake.

• CTBV’s experiences so far



• Retrofitting a crane-installation is a matter of limiting

responsibilities.




• Retrofitting a crane-installation is a matter of limiting

responsibilities.

• By creating our own system-solutions in Holland one

our former competitors, a system-integrator, started

working with CT-products.




• PLC control is fully excepted also in the crane business,

and the amount of I/O considered the best solution for

new built crane-systems.

De-centralized control in Mentor or Unidrive SP is in new built

cranes not an advantage, for instance on crane-systems

being partly modernized.










• The drives-part is more dominant in a retrofit-project then

in a turnkey new built crane-installation.










• The drives-part is more dominant in a retrofit-project then

in a turnkey new built crane-installation.

• For turnkey new built crane-installations an project-oriented

organization with crane-partners is a must!



And…… (1)

• To become a champion in cranes we need to focus on the target!

That’s why I am very pleased with this initiative to appoint a Crane

development manager to interchange ideas and crane technology.


And…




• A global strategy on cranes is of major importance!


And…




• A global strategy on cranes is of major importance!

• Spreading the same news all over is highly important to develop the global

market.


• Please consider for Port and Terminal cranes!!

– The drives-budget in not of an overwhelming percentage of the

E-installation ( ~ 10-12%)

– The success of competitors in industrial automation: they penetrated

the market at a crucial time.

For example: Siemens started in the 80’s on a full integrated

automation project for Terminal operator ECT in Rotterdam, at that

time this was a prestigious project.

This has had a huge spin-off, a ‘Centre of Excellence’ in The Hague

(Holland) for crane-technology.

And…


• For (mobile) tower cranes and simple industrial cranes an all-in drive-solution

in this market-segment important.

And…


• For (mobile) tower cranes and simple industrial cranes an all-in drive-solution

in this market-segment important.

• System-integrators don’t take the disadvantages, the components for the

drive-system need to be plug and play for all needs.

And…


And…


It’s global market!

The Crane Industry


Let’s support each other,

to create a

win-win situation

for all of us!

It’s global market!

The Crane Industry


Crane champion!!

M.N.

The Crane Industry

solution _ emerson

Documents

gantry cranes hoist

new cranes dc

important container

shore sts cranes hvsupply

shore sts cranes main

new carriers dc

leasing of port equipment

lot of container terminals