CeSAR standalone OHBC, Gantry crane
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SIMOCRANE
CeSAR standalone OHBC, Gantry
crane
Operating Instructions
valid for:
SIMOCRANE CeSAR standalone OHBC, Gantry
crane Version 4.2 SP1
02/2014
Foreword
Basic safety instructions
1
System description
2
Hardware installation
3
Interface to the crane control
system
4
Configuring instructions for
crane control system
5
Interface description
6
Function description
7
Commissioning
8
SIMOCRANE CeCOMM
diagnostic program
9
Alarm, error, and system
messages
10
Parameter list
11
Notes on servicing and
maintenance
12
Appendix
A
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Ⓟ
01/2014 Technical data subject to change
Copyright © Siemens AG 2013.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
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
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 3
Foreword
The sway control system
The sway control system SIMOCRANE CeSAR standalone OHBC, Gantry crane is part of
SIMOCRANE Advanced Technology. It can be operated with or without the SIMOCRANE
CenSOR camera measuring system.
This document contains detailed information about the system, its function, engineering,
installation and commissioning as well as service and maintenance measures.
Area of application
The sway control system is used to prevent load sway on overhead bridge cranes (OHBC)
and gantry cranes, for example, RMGs and RTGs. As a consequence, the crane operator
can position his crane precisely and quickly, therefore speedily and safely handling goods
without damaging them.
Cranes for harbors and industrial areas with trolley, gantry and either slewing gear or hoist
are suitable applications for this system. With the exception of the hoist, up to three drives
can be simultaneously moved with sway control.
Foreword
CeSAR standalone OHBC, Gantry crane
4 Operating Instructions, 02/2014
Additional information
Siemens product support for SIMOCRANE
The following addresses provide support for your SIMOCRANE products:
● Internet:
– The latest information about SIMOCRANE products, product support, and FAQs can
be found on the Internet here
(http://support.automation.siemens.com/WW/view/en/10807397/130000).
– You can find continuously updated information regarding Crane Application Notes on
the Internet here
(http://support.automation.siemens.com/WW/view/en/48342008/136000).
– You can find contact persons across the country on the Internet at Contact & Partners
/ contact persons
(http://www.automation.siemens.com/aspa_app/contactmenu.aspx?ci=yes®id=DE
F&lang=de&reduce=prodid518533&comptcID=v).
– You can find other contact persons that can support you in implementing your
requirements on the Internet at Contact & Partners / Solution Partners
(https://www.automation.siemens.com/solutionpartner/partnerfinder/Partner-
Finder.aspx?lang=en).
● Hotline for Europe:
– Tel.: +49 (0)911 895 7 222
– Fax: +49 (0)911 895 7 223
– Email: Support Europe (mailto:support.automation@siemens.com)
● Hotline for America:
– Tel.: +1 423 262 5710
– Fax: +1 423 262 2231
– Email: Support America (mailto:support.america.automation@siemens.com)
● Hotline for Asia / Pacific
– Tel.: +86 10 6475 7575
– Fax: +86 10 6474 7474
– Email: Support Asia/Pacific (mailto:support.asia.automation@siemens.com)
Siemens product support for SIMOTION and SINAMICS
The latest information about SIMOTION products, product support, and FAQs can be found
on the Internet here
(http://support.automation.siemens.com/WW/view/en/10805436/130000).
The latest information about SINAMICS products, product support, and FAQs can be found
on the Internet here
(http://support.automation.siemens.com/WW/view/en/13305690/130000).
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 5
Table of contents
Foreword ................................................................................................................................................ 3
1 Basic safety instructions ........................................................................................................................ 11
1.1 General safety instructions relating to hardware ......................................................................... 11
1.2 General safety instructions relating to software ........................................................................... 12
1.3 IT security ..................................................................................................................................... 13
2 System description ................................................................................................................................ 15
2.1 General ........................................................................................................................................ 15
2.1.1 Use of sway control ...................................................................................................................... 15
2.1.2 Trolley and gantry ........................................................................................................................ 15
2.1.3 Slewing gear or hoist ................................................................................................................... 15
2.2 System overview .......................................................................................................................... 16
2.2.1 Preconditions ............................................................................................................................... 16
2.2.2 System structure .......................................................................................................................... 16
2.2.3 Configurations .............................................................................................................................. 17
2.2.3.1 Overview ...................................................................................................................................... 17
2.2.3.2 Version without camera ............................................................................................................... 17
2.2.3.3 Version with camera .................................................................................................................... 17
2.2.3.4 Operation with slewing gear ......................................................................................................... 18
2.3 Scope of delivery.......................................................................................................................... 19
3 Hardware installation ............................................................................................................................. 21
3.1 Introduction .................................................................................................................................. 21
3.2 Mechanical installation ................................................................................................................. 23
3.3 Electrical installation .................................................................................................................... 26
3.3.1 Technical data of the SIMOTION C240 PN ................................................................................. 26
3.3.2 Specifications for insulation tests, safety class, and degree of protection .................................. 26
3.3.3 LED displays ................................................................................................................................ 27
3.3.4 Mode switch ................................................................................................................................. 28
4 Interface to the crane control system ..................................................................................................... 29
4.1 General ........................................................................................................................................ 29
4.2 Structure of the SIMATIC S7 sample blocks ............................................................................... 30
4.3 Hardware configuration in SIMATIC S7, integration into S7 project ............................................ 31
5 Configuring instructions for crane control system ................................................................................... 33
5.1 Selecting the operation modes .................................................................................................... 33
5.2 Switchover between operation with sway control ↔ conventional control ................................... 33
5.3 Pre-assignment of the interfaces ................................................................................................. 35
5.4 Sensing and monitoring the position actual values...................................................................... 35
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6 Operating Instructions, 02/2014
5.4.1 Importance of position sensing ................................................................................................... 35
5.4.2 Checking the correct position sensing ........................................................................................ 35
5.4.3 Synchronization of absolute or incremental encoders, homing .................................................. 36
5.5 Formation of the "Travelling" control bit ...................................................................................... 36
5.6 Drive activation and brake control ............................................................................................... 37
5.7 Start of travel in manual operation mode .................................................................................... 38
5.8 End of travel in manual operation mode ..................................................................................... 39
5.9 Start of travel in positioning operation mode ............................................................................... 40
5.10 End of travel in positioning operation mode ................................................................................ 41
5.11 Sway controlled stop ................................................................................................................... 42
5.12 Positioning in the manual operation mode with S_corr ............................................................... 42
5.13 Normalization .............................................................................................................................. 43
6 Interface description .............................................................................................................................. 45
6.1 General ........................................................................................................................................ 45
6.2 Input data .................................................................................................................................... 46
6.2.1 Overview of complete data structure .......................................................................................... 46
6.2.2 General block (16 bytes) ............................................................................................................. 48
6.2.2.1 Input data, general block ............................................................................................................. 48
6.2.2.2 Control bits, general block........................................................................................................... 50
6.2.3 Trolley block (16 bytes) ............................................................................................................... 51
6.2.3.1 Input data, trolley block ............................................................................................................... 51
6.2.3.2 Control bits, trolley block ............................................................................................................. 52
6.2.4 Gantry block (16 bytes) ............................................................................................................... 55
6.2.4.1 Input data, gantry block ............................................................................................................... 55
6.2.4.2 Control bits, gantry block ............................................................................................................. 56
6.2.5 Slewing gear block (16 bytes) ..................................................................................................... 60
6.2.5.1 Input data, slewing gear block..................................................................................................... 60
6.2.5.2 Control bits, slewing gear block .................................................................................................. 61
6.2.6 Hoist block (16 bytes) .................................................................................................................. 64
6.2.6.1 Input data, hoist block ................................................................................................................. 64
6.2.6.2 Control bits, hoist block ............................................................................................................... 66
6.2.7 Trailer .......................................................................................................................................... 69
6.2.8 Data from the camera ................................................................................................................. 69
6.3 Output data ................................................................................................................................. 70
6.3.1 Overview of complete data structure .......................................................................................... 70
6.3.2 General block (14 bytes) ............................................................................................................. 72
6.3.2.1 Output data, general block .......................................................................................................... 72
6.3.2.2 Status bits, general block ............................................................................................................ 73
6.3.3 Trolley block (12 bytes) ............................................................................................................... 74
6.3.3.1 Output data, trolley block ............................................................................................................ 74
6.3.3.2 Status bits, trolley block .............................................................................................................. 75
6.3.4 Gantry block (12 bytes) ............................................................................................................... 78
6.3.4.1 Output data, gantry block ............................................................................................................ 78
6.3.4.2 Status bits, gantry block .............................................................................................................. 79
6.3.5 Slewing gear block (12 bytes) ..................................................................................................... 82
6.3.5.1 Output data, slew block ............................................................................................................... 82
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CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 7
6.3.5.2 Status bits, slewing gear block ..................................................................................................... 83
6.3.6 Hoist block (12 bytes) .................................................................................................................. 86
6.3.6.1 Output data, hoist block ............................................................................................................... 86
6.3.6.2 Status bits, hoist block ................................................................................................................. 87
6.3.7 Trailer (telegram counter) ............................................................................................................ 89
6.3.8 Data to the camera ...................................................................................................................... 89
7 Function description .............................................................................................................................. 91
7.1 General ........................................................................................................................................ 91
7.1.1 Operation and characteristics ...................................................................................................... 91
7.1.2 Parameter sets ............................................................................................................................. 93
7.1.2.1 Overview ...................................................................................................................................... 93
7.1.2.2 Calling up the parameter menu .................................................................................................... 94
7.1.2.3 Activating a parameter set ........................................................................................................... 94
7.1.2.4 Editing a parameter set ................................................................................................................ 95
7.1.2.5 Changing a parameter ................................................................................................................. 95
7.1.2.6 Copying a parameter set .............................................................................................................. 96
7.1.2.7 Loading the saved parameter sets............................................................................................... 96
7.1.2.8 Save all parameter sets ............................................................................................................... 97
7.1.2.9 Switching over parameter sets ..................................................................................................... 97
7.1.2.10 Setting default values ................................................................................................................... 97
7.1.2.11 More functions.............................................................................................................................. 97
7.1.3 Operation modes.......................................................................................................................... 98
7.1.3.1 Selecting the operation mode ...................................................................................................... 98
7.1.3.2 Operation mode manual .............................................................................................................. 98
7.1.3.3 Operation mode positioning ......................................................................................................... 98
7.1.3.4 Operation mode sway neutralization ........................................................................................... 98
7.1.3.5 Fault response ............................................................................................................................. 99
7.1.4 Response in the limit switch ......................................................................................................... 99
7.1.4.1 Response in the manual operation mode .................................................................................... 99
7.1.4.2 Response in the positioning operation mode ............................................................................... 99
7.1.5 Response in the prelimit switch ................................................................................................... 99
7.1.5.1 Response in the manual operation mode .................................................................................... 99
7.1.5.2 Response in the positioning operation mode ............................................................................. 100
7.2 Operation mode manual ............................................................................................................ 101
7.2.1 Operation mode manual without sway control ........................................................................... 101
7.2.2 Operation mode manual with sway control ................................................................................ 102
7.3 Operation mode positioning ....................................................................................................... 104
7.4 Operation mode sway neutralization load position .................................................................... 105
7.5 Operation mode sway neutralization drive position ................................................................... 105
8 Commissioning ................................................................................................................................... 107
8.1 Commissioning prerequisites ..................................................................................................... 107
8.1.1 General ...................................................................................................................................... 107
8.1.2 Load measurement .................................................................................................................... 107
8.1.3 Position sensing ......................................................................................................................... 107
8.1.4 Sway control components .......................................................................................................... 107
8.2 Preparing commissioning ........................................................................................................... 108
8.2.1 Preparing the PLC program ....................................................................................................... 108
8.2.2 Preparing the converter ............................................................................................................. 108
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8 Operating Instructions, 02/2014
8.2.2.1 Converter parameter sets ......................................................................................................... 108
8.2.2.2 Acceleration and deceleration ramps ........................................................................................ 109
8.2.2.3 Initial and final rounding ............................................................................................................ 109
8.2.2.4 Minimum converter frequency ................................................................................................... 109
8.2.2.5 Speed controller of the converter .............................................................................................. 110
8.2.2.6 Velocity limits ............................................................................................................................ 110
8.2.2.7 Check of the control response .................................................................................................. 111
8.2.3 Preparing the SIMOCRANE CenSOR camera measuring system ........................................... 111
8.3 Configuring the sway control system ........................................................................................ 112
8.3.1 Overview ................................................................................................................................... 112
8.3.2 General requirements ............................................................................................................... 112
8.3.3 Setting the access code ............................................................................................................ 112
8.3.4 Setting the language ................................................................................................................. 113
8.3.5 Check of the crane control ↔ sway control system interface .................................................... 114
8.3.6 Checking the communication with the camera measuring system ........................................... 115
8.4 Operation mode manual without sway control .......................................................................... 117
8.4.1 Preparation – first steps ............................................................................................................ 117
8.4.2 Commissioning steps in the commissioning menu ................................................................... 117
8.4.2.1 Procedure .................................................................................................................................. 117
8.4.2.2 Step 0: Setting the configuration and important parameters .................................................... 119
8.4.2.3 Step 1: Aligning the camera ...................................................................................................... 121
8.4.2.4 Step 2: Determine parameters of effective pendulum length in the trolley direction ................ 123
8.4.2.5 Step 3: Determine the parameter effective pendulum length in the gantry direction ................ 123
8.4.2.6 Step 4: Determine the parameter effective pendulum length, slewing gear ............................. 124
8.4.2.7 Step 5: Simulating errors ........................................................................................................... 124
8.4.2.8 Step 6: Check the velocity......................................................................................................... 124
8.4.2.9 Step 7: Change communication addresses .............................................................................. 125
8.4.2.10 Step S: Save all parameter sets ............................................................................................... 125
8.5 Operation mode manual with sway control ............................................................................... 126
8.5.1 Preparation ................................................................................................................................ 126
8.5.2 Test runs without boosting the camera measurement signal ................................................... 126
8.5.3 Test runs with boosted camera measurement signal ............................................................... 128
8.5.4 Testing in the prelimit switch range ........................................................................................... 128
8.6 Checking and fine-tuning the sway control system ................................................................... 129
8.6.1 General ...................................................................................................................................... 129
8.6.2 Correcting the effective pendulum length ................................................................................. 129
8.6.3 Setting the permissible residual sway ....................................................................................... 132
8.6.4 Setting the velocity for zero speed detection ............................................................................ 133
8.6.5 Setting the damping factor ........................................................................................................ 133
8.6.6 Setting the switch-on delay of the drives .................................................................................. 133
8.6.7 Defining the activation velocity of the sway control .................................................................. 134
8.6.8 Pendulum length from the PLC or camera ................................................................................ 134
8.6.9 Other settings ............................................................................................................................ 135
8.7 Commissioning positioning ....................................................................................................... 136
8.7.1 General ...................................................................................................................................... 136
8.7.2 Conversion of the actual position S_act and target position S_set ........................................... 136
8.7.3 Position controller setting .......................................................................................................... 137
8.7.4 Other settings ............................................................................................................................ 138
8.8 Testing the sway neutralization modes ..................................................................................... 139
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CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 9
8.9 Stability test and monitoring functions ....................................................................................... 142
8.9.1 Stability test ................................................................................................................................ 142
8.9.2 Monitoring functions ................................................................................................................... 143
9 SIMOCRANE CeCOMM diagnostic program ....................................................................................... 145
9.1 General ...................................................................................................................................... 145
9.2 Installing ..................................................................................................................................... 146
9.3 Searching the network for SIMOTION C240 PN ....................................................................... 147
9.4 Establishing the connection ....................................................................................................... 148
9.5 Monitoring functions ................................................................................................................... 149
9.5.1 Display and operating information ............................................................................................. 149
9.5.2 The parameter menu ................................................................................................................. 152
9.6 Setting addresses ...................................................................................................................... 154
9.6.1 General ...................................................................................................................................... 154
9.6.2 Default settings .......................................................................................................................... 154
9.6.3 Setting addresses ...................................................................................................................... 155
9.6.4 Determining the changed IP address ........................................................................................ 156
10 Alarm, error, and system messages .................................................................................................... 157
10.1 General ...................................................................................................................................... 157
10.2 List of alarm, error, and system messages ................................................................................ 159
11 Parameter list ...................................................................................................................................... 171
11.1 Overview .................................................................................................................................... 171
11.2 Trolley parameters ..................................................................................................................... 172
11.3 Gantry parameters ..................................................................................................................... 182
11.4 Parameters for third drive .......................................................................................................... 193
11.4.1 Slewing gear parameters ........................................................................................................... 193
11.4.2 Hoist parameters ........................................................................................................................ 204
11.5 General parameters ................................................................................................................... 212
12 Notes on servicing and maintenance ................................................................................................... 221
12.1 General information ................................................................................................................... 221
12.2 Reflector maintenance ............................................................................................................... 221
12.3 Camera maintenance ................................................................................................................. 221
12.4 Check of the position sensing functions for the hoist after rope changing ................................ 221
A Appendix............................................................................................................................................. 223
A.1 List of abbreviations ................................................................................................................... 223
Glossary ............................................................................................................................................. 225
Table of contents
CeSAR standalone OHBC, Gantry crane
10 Operating Instructions, 02/2014
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 11
Basic safety instructions
1
1.1
General safety instructions relating to hardware
DANGER
Danger to life due to live parts and other energy sources
Touching live parts can result in death or severe injury.
• Only work on electrical equipment if you are appropriately qualified.
• Always observe the country-specific safety rules for all work.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
– Switch off the machine.
– Wait until the discharge time specified on the warning labels has elapsed.
– Check that it really is in a zero-voltage state, from phase conductor to phase
conductor and phase conductor to protective conductor.
– Check that every auxiliary circuit is de-energized.
– Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or
short-circuiting or closing valves, for example.
5. Take measures to prevent reconnection of the energy sources.
6. Make sure that the machine is completely locked out ... and that you have the right
machine.
After you have completed the work, restore the operational readiness by following the
above steps in the reverse order.
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
In the event of a fault, touching live parts can result in death or severe injury.
• Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.
Basic safety instructions
1.2 General safety instructions relating to software
CeSAR standalone OHBC, Gantry crane
12 Operating Instructions, 02/2014
WARNING
Danger to life through unexpected movement of machines when using mobile wireless
devices or mobile phones
Using mobile radios or mobile phones with a transmit power > 1 W closer than approx. 2 m
to the components may cause the devices to malfunction, influence the functional safety of
machines therefore putting people at risk or causing material damage.
• When close to components, switch off all wireless devices and mobile phones.
1.2
General safety instructions relating to software
WARNING
Danger to life if the safety instructions and residual risks are not carefully observed
If the safety instructions and residual risks are not observed in the associated hardware
documentation, accidents can occur involving severe injuries or death.
• Observe the safety instructions given in the hardware documentation.
• When assessing the risk, take into account residual risks.
WARNING
Danger to life as a result of incorrect or modified parameterization
As a result of incorrect parameterization, machines can malfunction, which in turn can lead
to injuries or death.
• Protect the parameterization (parameter assignments) against unauthorized access.
• Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY
STOP or EMERGENCY OFF).
WARNING
Danger to life posed by uncontrolled changeover between operating states
Uncontrolled changeover between operating states can cause machines to malfunction,
which in turn can lead to injuries or death.
• Include the effects of changeover between operating states in the risk analysis.
• Implement suitable safety measures, e.g. EMERGENCY OFF.
Basic safety instructions
1.3 IT security
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 13
1.3
IT security
Note
Industrial security
Siemens provides
automation and drive products with industrial security functions that
support the secure operation of plants or machines. They are an important component in a
holistic industrial security concept. With this in mind, our products undergo continuous
developm
ent. We therefore recommend that you keep yourself informed with the latest
information and updates of our products.
Information and newsletters can be found at: http://support.automation.siemens.com.
To ensure the secure operation of a plant or machine,
it is also necessary to take suitable
preventive action (e.g. cell protection concept) and to integrate the automation and drive
components into a state
-of-the-art holistic industrial security concept for the entire plant or
machine. Any third
-party products used must also be taken into account.
For more detailed information, go to: http://www.siemens.com/industrialsecurity.
WARNING
Danger as a result of unsafe operating states resulting from software manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can lead to death, severe injuries
and/or material damage.
• Update your software regularly.
Information and newsletters can be found at:
http://support.automation.siemens.com.
• Incorporate the automation and drive components into a state-of-the-art, integrated
industrial security concept for the installation or machine.
For more detailed information, go to:
http://www.siemens.com/industrialsecurity.
• Make sure that you include all installed products into the integrated industrial security
concept.
Basic safety instructions
1.3 IT security
CeSAR standalone OHBC, Gantry crane
14 Operating Instructions, 02/2014
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 15
System description
2
2.1
General
2.1.1
Use of sway control
Every movement of the gantry, trolley or slewing gear causes the load to sway. This makes
positioning more difficult, and it takes correspondingly longer. The main task of the
sway control system is to remove sway motions. This makes automatic positioning possible.
This can relieve the crane operator and increase the handling capacity.
Without an electronic sway control system, implementing crane controls in semi- and fully
automatic operation (e.g. coil storage locations in steelworks) is hardly conceivable.
Overview
● The SIMOCRANE CeSAR standalone sway control system is based on the
SIMOTION C240 PN platform. It is suitable for new systems and as a solution to
modernize old systems. The system can be simply integrated into an existing PROFIBUS
network.
● Sway motion is calculated and corrected based on a mathematical oscillation model.
● The system can be operated in one of two versions, i.e. with or without a camera.
2.1.2
Trolley and gantry
Depending on the operation mode selected, either manual operation (a velocity setpoint is
entered at the master controller) or positioning operation (a target position is entered) are
possible. The operation mode of each drive can be changed over when moving, e.g. from
the manual operation mode to positioning operation mode, and vice versa.
2.1.3
Slewing gear or hoist
The third drive can be optionally set as either slewing gear or hoist. This is selected using a
configuration parameter (P115).
Depending on the operation mode selected, either manual operation (a velocity setpoint is
entered at the master controller) or positioning operation (a target position is entered) are
possible.
The slewing gear can be operated with sway control.
System description
2.2 System overview
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16 Operating Instructions, 02/2014
2.2
System overview
2.2.1
Preconditions
● Crane control system (PLC) with PROFIBUS connection (operation with optional data
transmission rate of 500 kbit/s, 1.5 Mbit/s, 3 Mbit/s, 6 Mbit/s, or 12 Mbit/s.)
● Closed-loop controlled drives
● Position encoder for the hoist to determine the pendulum length
● Position encoder for all drives operated with positioning and sway neutralization operation
modes
● Position encoder for the slewing gear if this is:
– operated in positioning or sway neutralization mode, or
– can be rotated by more than 5° from the zero position (if the reflector rotates with the
slewing gear).
Additional hardware may be required (e.g. camera, reflector, Ethernet switch) depending on
the version.
2.2.2
System structure
The following figure shows the communication paths between the individual components.
Figure 2-1 Layout diagram of the components
System description
2.2 System overview
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 17
2.2.3
Configurations
2.2.3.1
Overview
The following configurations can be selected in parameter P115:
● Version with / without camera
● Positioning mode activated / deactivated
● Operation with slewing gear or hoist
2.2.3.2
Version without camera
This version is designed for use on cranes that cannot be equipped with a camera for
design-related reasons, or which operate in harsh environmental conditions, such as
extremely dusty atmospheres or at very high temperatures.
The sway control system ascertains the oscillation states using a mathematical oscillation
model. The version without camera is capable of eliminating most oscillations that are
caused by crane motion. However, it is not capable of suppressing oscillations caused by
external forces such as diagonal pull or wind.
The camera must be deactivated in configuration parameter P115 (option 1 = On) for the
version without a camera. All of the functions, parameters and fault messages described in
this documentation, which refer to the camera, are then suppressed and deactivated.
2.2.3.3
Version with camera
The camera-based version can also compensate for sway motion caused by external factors
(e.g. wind or diagonal pull). A camera measuring system deploys an optical, contactless
measurement technique to additionally calculate physical measured variables, i.e. distance
between the camera and reflector, pendulum deflection and rotation. The results are
incorporated in the calculation model. The calculations are performed on the SIMOTION
C240 PN.
The calculations are more accurate than with a system without a camera and sway caused
by external forces can also be eliminated.
If the measuring signal of the camera fails, only the mathematical calculation model is used.
Note
For addit
ional information about the camera, please refer to the operating instructions for the
SIMO
CRANE CenSOR camera measuring system, from edition 08/2012.
System description
2.2 System overview
CeSAR standalone OHBC, Gantry crane
18 Operating Instructions, 02/2014
2.2.3.4
Operation with slewing gear
Information on installation
On slewing gear that rotates the reflector by more than 5°, the camera and reflector must be
mounted so that the slewing motion causes the camera and reflector to rotate
simultaneously. A position encoder must also be used.
The oscillation measurements are assigned to the drives (trolley/gantry) by internal
computation based on the actual slewing gear position.
Hook slewing gear
For cranes with hook slewing gear, a position encoder is only required when the slewing
gear is automatically positioned.
Skew control
Slewing gear can be operated with a skew control system. Hook slewing gear, however,
must always be operated with the mathematical oscillation model.
System description
2.3 Scope of delivery
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 19
2.3
Scope of delivery
Depending on the application and the environmental conditions, the sway control system can
be implemented with or without the SIMOCRANE CenSOR camera measuring system. The
hardware and software required for the camera measuring system must be ordered
separately and are not listed here.
The "SIMOCRANE CeSAR standalone OHBC, Gantry crane" package includes:
● SIMOTION C240 PN
● Mounting rail
● MMC memory card for SIMOTION C240 PN, configured for sway control
The MMC memory card supplied with the system already contains all of the required
licenses.
The MMC memory card contains:
– The SIMOTION Kernel (basic system)
– Technology packages and user data (programs, configuration data, parameter
settings)
– Runtime licenses
● Product DVD
The software DVD contains:
– Installation instructions
– Readme file
□ German
□ English
– Readme_OSS
□ German
□ English
– Software
□ Setup program for the SIMOCRANE CeCOMM diagnostic program (setup file)
□ Card image for the MMC memory card
□ Application example
– Documentation Operating Instructions SIMOCRANE CeSAR standalone OHBC,
Gantry crane
□ German
□ English
– Documentation SIMOTION C Operating Instructions
□ German
□ English
System description
2.3 Scope of delivery
CeSAR standalone OHBC, Gantry crane
20 Operating Instructions, 02/2014
● Certificates for the software licenses
Product
MLFB No
Functionality
SIMOCRANE CeSAR standalone
OHBC, Gantry crane:
Basic license
6GA7200-1AA00-0AA0 Manual
Positioning
Sway neutralization
SIMOCRANE CeSAR standalone
OHBC, Gantry crane:
Manual license
6GA7200-1AA00-2AA0 Manual
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 21
Hardware installation
3
3.1
Introduction
The SIMOTION C240 PN forms the main component of the SIMOCRANE CeSAR
standalone OHBC, Gantry crane sway control system.
The following section provides an introduction to installing the SIMOTION C240 PN. Please
refer to the device documentation also supplied for further information and details.
The control algorithm is saved in the project data on the memory card supplied (MMC).
Note
The SIMOTION
C240 PN must only be used for sway control.
SIMOTION C240 PN view
Figure 3-1 SIMOTION C240 PN, from the front, open front
The following image shows the SIMOTION C240 PN module with its interfaces and front
panel elements (error and status displays).
Hardware installation
3.1 Introduction
CeSAR standalone OHBC, Gantry crane
22 Operating Instructions, 02/2014
Figure 3-2 Position of the SIMOTION C240 PN interfaces and front panel elements
Hardware installation
3.2 Mechanical installation
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 23
3.2
Mechanical installation
In this section we will explain how to prepare the SIMOTION C240 PN components for
installation and how to install them.
Installation instructions
Installing the mounting rail
1. Fit the mounting rail in a position that will allow enough room for the modules to be
installed and for the heat to dissipate (a minimum of 40 mm above and below the
mounting rail).
2. Screw the mounting rail onto the surface where it is to be affixed (screw size: M6).
Is the support a grounded metal plate or a grounded equipment mounting plate?
If so:
ensure that there is a low-resistance connection between the mounting rail and the
support. Use suitable electro-lubricant or contact washers with painted and anodized
metals, for example.
If not:
no special action required.
3. Connect the mounting rail with the protective conductor. An M6 screw is provided on the
rail for this purpose. Minimum cross-section from the cable to the protective conductor: 10
mm2.
Hang the SIMOTION C240 PN on the mounting rail
1. Hang the SIMOTION C240 PN onto the top of the rail and swing it down.
2. Screw down the module applying a torque of 0.8 to 1.1 Nm.
Insert the micro memory card (MMC)
1. Switch off the power supply module.
2. Insert the micro memory card into the module slot of the SIMOTION C240 PN by applying
slight pressure until it snaps into place. Make sure the beveled edge of the micro memory
card faces the ejector.
3. Switch the power supply module back on.
Hardware installation
3.2 Mechanical installation
CeSAR standalone OHBC, Gantry crane
24 Operating Instructions, 02/2014
Horizontal and vertical installation
You can install the rack either horizontally or vertically. The preferred position is a horizontal
one.
Figure 3-3 Horizontal and vertical installation of the SIMOTION C 240 PN
Permissible ambient temperature
● Horizontal installation: from 0 ... 55 °C
● Vertical installation: from 0 ... 40 °C
Clearances
If you comply with the minimum clearances, you will:
● Ensure that the modules are cooled,
● Have sufficient space to insert and remove the modules,
● Have sufficient space for laying cables,
● Increase the mounting height of the rack to 205 mm.
To guarantee the functionality, clearances of 40 mm must be maintained.
Note
If you use a shield connecting element, the dimensions stated are measured from the lower
edge of the sh
ield connecting element.
Hardware installation
3.2 Mechanical installation
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 25
The following diagram shows the clearances between the individual racks and the clearance
to adjacent equipment, cable ducts, cabinet walls, etc.
Figure 3-4 Clearances
Installation dimensions of modules
The following table shows the installation dimensions of modules.
Table 3- 1 Installation dimensions of modules
Modules
Module
width
Module
height
Max. installation depth
PS 307, 2 A power supply
PS 307, 5 A power supply
PS 307, 10 A power supply
50 mm
80 mm
200 mm
125 mm,
185 mm with
shield
connection
element
130 mm or 180 mm with
an open SIMOTION
C240 PN front panel
SIMOTION C240 PN
200 mm
Signal modules (SMs)
40 mm
Function modules (FM) 40 mm or
80 mm
Communication modules (CP)
40 mm
Hardware installation
3.3 Electrical installation
CeSAR standalone OHBC, Gantry crane
26 Operating Instructions, 02/2014
3.3
Electrical installation
3.3.1
Technical data of the SIMOTION C240 PN
Connection values
Table 3- 2 Connection values
Supply voltage:
24 V DC (permissible range: 20.4 ... 28.8 V)
Power consumption from 24 V • typically 0.9 A (inputs/outputs open)
• typically 1.2 A (with four encoders, 5 V)
• typically 1.9 A (with four encoders, 24 V)
Power loss
15 W
Starting current
8 A
Encoder supply 5 V max. output current
1.2 A
Encoder supply 24 V max. output current
1.2 A
Dimensions and weight
Table 3- 3 Dimensions and weight
Dimensions (W x H x D)
200 x 125 x 118
Weight (g)
approx. 1 150
3.3.2
Specifications for insulation tests, safety class, and degree of protection
Test voltages
The insulation resistance is tested in a routine test using the following test voltage to IEC
1131, Part 2:
Table 3- 4 Test voltages
Circuits with rated voltage Ue with respect to
other circuits, or with respect to ground
Test voltage
0 V < U
e
≤ 50 V
500 V DC
Protection class
Protection class I in accordance with IEC 536 (VDE 0106, Part 1), i.e. protective conductor
connection required at the mounting rail.
Hardware installation
3.3 Electrical installation
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 27
Protection against the ingress of foreign bodies and water
● Degree of protection IP 20 according to IEC 529
● In addition: Protection against the ingress of solid foreign bodies with diameters greater
than 12.5 mm
● No special protection against the ingress of water
3.3.3
LED displays
The following LED displays are on the front panel of the SIMOTION C240 PN.
Table 3- 5 Status and fault displays
LED
Significance
SF (red)
This LED indicates a fault state of the SIMOTION C240 PN.
5 V DC (green)
This LED indicates that the power supply for the electronics is ready.
RUN (green) – SIMOTION
C240 PN in RUN
This LED indicates that the user program is running.
STOPU (yellow) – SIMOTION
C240 PN in STOP user
program
This LED indicates that the technology packages (for example,
synchronous operation and cam) are active. The user program is not
active.
STOP (yellow) – SIMOTION
C240 PN in STOP
This LED indicates that no user program is running. The technology
packages are not active.
BUS1F (red) – group fault This LED indicates a fault on the PROFIBUS DP1 interface (X8) of
the SIMOTION C240 PN.
BUS2F (red) – group fault
This LED indicates a fault on the PROFIBUS DP2/MPI interface (X9)
of the SIMOTION C240 PN.
Q0 ... Q7 , I0 ... I11, B1 ... B4,
M1, M2 (green) – digital
input/digital outputs
These LEDs show the status of the digital inputs/outputs.
Hardware installation
3.3 Electrical installation
CeSAR standalone OHBC, Gantry crane
28 Operating Instructions, 02/2014
3.3.4
Mode switch
Certain operation modes can be selected using the mode switch.
Mode switch positions
The positions of the mode switch are explained in the order in which they appear on the
SIMOTION C240 PN.
Operation
mode
Explanations
RUN SIMOTION C240 PN is processing the user program and the associated system
functions:
• Reading process image inputs
• Execution of the user programs assigned to the execution system.
• Writing process image outputs
The technology packages are active in this state. They can execute commands from
the user program.
STOPU SIMOTION C240 PN is not processing any user program.
• The technology packages are active. Test and commissioning functions can be
executed. The user program is not active.
• The I/O modules (SMs) are in a safe state.
Please note:
It is only possible to switch to the "STOPU" state via the SIMOTION SCOUT
engineering system. You can switch from hardware settings "STOP" and "RUN" to
"STOPU" in SIMOTION SCOUT.
STOP SIMOTION C240 PN is not processing any user program.
• It is possible to load a complete user program.
• All system services (communications, etc.) are active.
• The I/O modules (SMs) are in a safe state.
• The technology packages are inactive, i.e. all enables are deleted. No axis
movements can be performed.
MRES
(memory
reset)
Switch setting for memory reset on the SIMOTION C240 PN.
A specific sequence of operations is required to perform a memory reset using the
mode switch (see SIMOTION C device documentation, Memory Reset chapter).
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 29
Interface to the crane control system
4
4.1
General
The SIMOTION C240 PN and the crane control system (SIMATIC S7) communicate via
PROFIBUS-DP.
All input data must be processed in the crane control system in accordance with the interface
description (see Chapter Interface description (Page 45)).
All output data must be processed in the crane control system in accordance with the
interface description.
A SIMATIC S7 sample project is provided on the DVD; this simplifies the integration into an
existing crane control system.
In principle, the procedure implemented in the SIMATIC S7 sample project can be applied to
a crane control system from another manufacturer.
Interface to the crane control system
4.2 Structure of the SIMATIC S7 sample blocks
CeSAR standalone OHBC, Gantry crane
30 Operating Instructions, 02/2014
4.2
Structure of the SIMATIC S7 sample blocks
The SIMATIC S7 sample project comprises several functions (FC) and two data blocks (DB).
The blocks are not protected and can be freely accessed. Comments make it easier to
understand the principle of operation. Input and output data are kept in two data blocks for
the send and receive data and updated.
Table 4- 1 Overview of the data and function blocks
Function
Name
Description
FC1000 SC_MAIN_INT Jump distributor: Calls all of the
sample blocks.
FC1001 SC_SEND_INT Reads input data from the data
block DB1012 and places it in
the configured PROFIBUS I/O
devices to be sent to the
SIMOTION C240 PN.
FC2005 SC_RECEIVE Transmits the output data from
the SIMOTION C240 PN out of
the PROFIBUS I/O and into
data block DB2010.
DB1012 SC_DB_SEND_INT Contains the input data for the
sway control.
DB2010 SC_DB_RECEIVE Contains the output data from
the sway control.
FC1002 SC_AXIS_INT Universal function block to
control the drives via pins. The
signals required from the crane
control should be connected
here. The input data for the
sway control is written to
DB1012. The output data from
the sway control is loaded from
DB2010.
FC2006 SC_COMMON Function block to transfer the
"General data" data block via
pins. The signals required from
the crane control should be
connected here. The input data
for the sway control is written to
DB1012. The output data from
the sway control is loaded from
DB2010.
FC2007 SC_OBST_0-15 Prepared for detour control (not
available in this version);
switches the blocked regions
0 ... 15 on or off.
FC2008 SC_OBST_16-31 Prepared for detour control (not
available in this version);
switches the blocked regions
16 ... 31 on or off.
Interface to the crane control system
4.3 Hardware configuration in SIMATIC S7, integration into S7 project
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 31
4.3
Hardware configuration in SIMATIC S7, integration into S7 project
The following image shows a SIMATIC S7 hardware configuration with a SIMOTION C240
PN in a configuration required for sway control.
After clicking on the PROFIBUS stream a SIMOTION C240 PN can be inserted as
PROFIBUS device via <Insert> <Insert object> … <Additional FIELD DEVICES> <PLC>
<SIMOTION> <SIMOTION C2xx>.
The PROFIBUS slave address for the SIMOTION C240PN (default = 100) can be set from
the properties window.
The data modules to be transferred can be configured, starting from slot 4, by double
clicking. The module addresses must match those at the two FC blocks to be transferred
"SC_RECEIVE" or "SC_SEND_INT".
Figure 4-1 Hardware configuration when using the SIMATIC S7 interface
Table 4- 2 Overview, length of the data blocks, PLC → SIMOTION
Data block
(PLC →SIMOTION)
Length
Block can be
deactivated
Addresses in the
SIMATIC S7 example
General data
14 bytes
No
2300 ... 2313
Input data, trolley
12 bytes
Yes
2314 ... 2325
Input data, gantry
12 bytes
Yes
2326 ... 2337
Input data,
slewing gear/hoist
12 bytes Yes 2338 ... 2349
Trailer (telegram
counter)
2 bytes No 2350 ... 2351
Interface to the crane control system
4.3 Hardware configuration in SIMATIC S7, integration into S7 project
CeSAR standalone OHBC, Gantry crane
32 Operating Instructions, 02/2014
Table 4- 3 Overview, length of the data blocks, SIMOTION → PLC
Data block
(SIMOTION → PLC)
Length
Block can be
deactivated
Addresses in the
SIMATIC S7 example
General data
16 bytes
No
2300 ... 2315
Output data, trolley
16 bytes
Yes
2316 ... 2331
Output data, gantry
16 bytes
Yes
2332 ... 2347
Output data,
slewing gear/hoist
16 bytes Yes 2348 ... 2363
Trailer (telegram
counter)
2 bytes No 2364 ... 2365
The properties screen form of the DP slave for inserting the universal modules for the inputs
and outputs looks as follows:
Figure 4-2 Properties screen form of the DP slave for inserting the universal modules
The start addresses, length and unit (see previous tables) must be stated under the DP
slave properties. The consistency must be set over the entire length.
The integration in the SIMATIC S7 program always depends on the interface used. The
hardware configuration is supplied with the SIMATIC S7 sample project.
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 33
Configuring instructions for crane control system
5
5.1
Selecting the operation modes
Different operation modes are available for the different drives (trolley, gantry, slewing gear
and hoist).
These operation modes are set up as follows in the SIMATIC S7 sample block FC1002 by
entering an integer value at the input OM:
1 = positioning
2 = manual
3 = sway neutralization load position
4 = sway neutralization drive position
Note
Only the posi
tioning and manual operation modes are available for the hoist.
5.2
Switchover between operation with sway control ↔ conventional
control
The sway control system must be integrated into a conventional crane control system. Data
is exchanged between the crane control and the sway control systems via a bus system. The
crane control system remains master and distinguishes between conventional operation and
operation with sway control.
Manual switchover between operation with sway control system and conventional operation
must be possible at any time. This switchover has to be implemented in the crane control
system.
In this way, you can switch over, for example, to conventional operation in case of a fault and
continue to operate the crane without the sway control system. The availability of the crane
is therefore not reduced by the sway control system.
Note
This switchover must only be possible when all drives are at a standstill (zero speed).
Conventional control
The crane control system reads in the setpoint from the master controller which is then
processed in the setpoint channel of the crane control system and transferred to the drive as
the output velocity. The "Release" control bit is reset. The output velocities of the SIMOTION
C240 PN are then no longer used.
Configuring instructions for crane control system
5.2 Switchover between operation with sway control ↔ conventional control
CeSAR standalone OHBC, Gantry crane
34 Operating Instructions, 02/2014
Operation with sway control system
The crane control system reads in the setpoint from the master controller and this is then
transferred to the SIMOTION C240 PN. The "Release" control bit is set. The output velocity
determined in the SIMOTION C240 PN is transmitted back to the crane control system and
is transferred from there to the drive.
The setpoint for the master controller can be modified in the crane control system setpoint
channel before it is transferred to the SIMOTION C240 PN (e.g. reducing to pre-limit switch
velocity can occur here). In the positioning operation mode, the corresponding output
velocities are likewise only generated when the "Release" control bit is set.
If the crane is to be operated with sway control, the output velocity transferred to the crane
control system must no longer be influenced by the crane control system or drive (e.g. by
limiting or an additional ramp). The enable signals are activated in the SIMOTION C240 PN
and the output velocities in the setpoint channel of the crane control system are not used.
Figure 5-1 Switchover with or without sway control (bypass)
Configuring instructions for crane control system
5.3 Pre-assignment of the interfaces
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 35
5.3
Pre-assignment of the interfaces
Input data must be pre-assigned depending on the operation modes, functions and the
configuration used (P115). It is important that unused functions also be pre-assigned in a
defined manner.
Examples:
● If a load measured value is not available at a crane, then this must be assigned zero at
the PLC block. The same is true for the "DigitalLiftCorrection" control bit if no information
is available about a changed load carrying device.
● The "SC_On" control bit must not be set at the data block when using the third drive as a
hoist.
● All control bits that refer to the planned detour control (not available in this version) must
also not be set.
Fault value suppression for V_set with manual operation mode
Suppression of any potential fault values in the crane control system must be ensured for
V_set = 0 to prevent any unintended motion, for instance, as follows: If V_set is less than a
certain value (e.g. 0.5%), the value 0 is transmitted to the sway control.
5.4
Sensing and monitoring the position actual values
5.4.1
Importance of position sensing
Accurate sensing of the actual position values for all drives operated in the positioning
operation mode is vitally important. For cases such as these, it is recommended that a
redundant position sensing system is provided with self-monitoring function in the PLC.
The measuring system should always provide the best possible reproducibility of the
positions with respect to reality (laser, position sensing rails etc.). In practice, basic
incremental encoders have turned out to be problematical. Absolute encoders are generally
sufficient for the hoist or slewing gear as no significant slip can be expected here.
5.4.2
Checking the correct position sensing
The sway control system is defined in such a way that a positive output velocity results in
travel motion with increasing position values (positive count direction). If this criterion is not
adhered to then the position value can be converted into an internal actual position value
using a gain factor and an offset value. This applies to all drives.
The position determined in the PLC and transmitted to the sway control system should be in
"millimeters". Position values with a precision of 1 c° (centigrade) are required for the slewing
gear. Actual value steps caused by reference marks should be minimized as far as possible.
Manually moving along a track and simultaneously recording the actual position values in the
SIMOCRANE CeCOMM diagnostic program (see SIMOCRANE CeCOMM diagnostic
program (Page 145)) makes it simpler to locate these types of fault locations.
Configuring instructions for crane control system
5.5 Formation of the "Travelling" control bit
CeSAR standalone OHBC, Gantry crane
36 Operating Instructions, 02/2014
5.4.3
Synchronization of absolute or incremental encoders, homing
The system is referenced using one or several synchronizing limit switches for each drive.
One or several limit switches must be available for each drive to monitor the position. To do
this, when the limit switch responds (edge evaluation), its known position is compared with
the system position determined at the activation time point. The position difference must lie
within an adjustable, maximum permissible range. If this is not the case, an error message is
generated. At least one of these monitoring limit switches must be positioned so that its
signal state changes once at each unloading or loading operation.
5.5
Formation of the "Travelling" control bit
WARNING
Danger to life from unexpected machine movement
For as long as the "Travelling" control bit remains set, unexpected movements may occur
after the crane has come to a standstill.
The "Travelling" control bit must be reset by the crane control system in the event of an
EMERGENCY STOP or cancellation of continued travel.
Cancellation by the sway control may be triggered by the control bits "Release,"
"Brake_closed," "Controlled stop," and all limit switches.
• The "Travelling" control bit must be activated by a deliberate action.
Travel is initiated in the sway control by setting the "Travelling" control bit (travel signal).
The "Travelling" control bit may then be set in the crane control system if all conditions
required to start travel are met, or no status applies that is intended to prevent travel (e.g.
EMERGENCY STOP activated).
If this is the case, the "Travelling" control bit can be set as soon as an operating element for
this purpose is activated by the crane operator (e.g. deflection of master controller in manual
operation mode or start button / momentary-contact foot switch in positioning operation
mode).
The "Travelling" control bit must be reset if a state occurs during travel that is intended to
prevent continued travel. There is then a stop with quick stop ramp without sway control.
If travel can be terminated without causing a fault, the "Travelling" control bit should be reset
with the "Pos_completed" status bit. The travel is then terminated with no remaining sway
and the target position is reached in positioning operation mode.
Operation mode manual
When the master controller is deflected, the set velocity (V_set) is transferred to the
sway control and the "Travelling" control bit must be set at the same time. When the master
controller is released, the set velocity is set to zero, but the "Travelling" control bit must
remain set until the sway control returns the "Pos_completed" status bit.
Configuring instructions for crane control system
5.6 Drive activation and brake control
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 37
Operation mode positioning
The "Travelling" control bit is formed in a similar way to manual operation mode. However, in
this case, a target position is entered. The set velocity V_set is not used in this mode. It is
positioned with positioning velocity.
Operation mode sway neutralization
Procedure as in the positioning operation mode. However, the target position is set internally
and depends on the selected operation mode – sway neutralization actual position or load
position (actual position + actual pendulum deflection).
Note
The "Pos_completed" status bit from the sway control system also includes the status
"SC_completed" (AND operation).
5.6
Drive activation and brake control
To activate the drive and control the brakes, we recommend using status bits "Travel_f" and
"Travel_b" from the sway control system.
If the "Travelling" control bit is set and the brake is still closed, one of the two direction
signals is set to indicate that the crane should start moving. Both direction signals result in a
travel command in the crane control system.
This way the drives are activated and the brakes opened in the crane control system. As
soon as the brakes are open, the output velocity is enabled with the "Brake_closed" control
bit. The output velocity is output and the drive starts.
Vice versa: Sway controlled travel is completed once both direction signals have been reset.
The brake can then be closed again in the crane control system.
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
s ... 1.0 s)
mean a time delay occurs between the "brake open"
signal and "brake closed" signal. For
this reason, the "brake closed" limit switch signal should always be applied to the
"Brake_closed" control bit for the particular drive. This can be used to prevent the closed
-
loop control system from manifesting a dea
d time behavior.
Configuring instructions for crane control system
5.7 Start of travel in manual operation mode
CeSAR standalone OHBC, Gantry crane
38 Operating Instructions, 02/2014
5.7
Start of travel in manual operation mode
This example shows the sequence of signals in manual operation mode.
Travel is initiated by setting the "Travelling" control bit with the master switch and by
resetting the "Brake_Closed" (output value enable) control bit.
The following signal sequence is performed:
Figure 5-2 Signal sequence when travel starts
Section 1:
Manual operation mode is selected by means of the appropriate control bit "OM_MAN" for all
the drives used.
Section 2:
The master controller is deflected. The "Travelling" control bit must be set (see Chapter
Formation of the "Travelling" control bit (Page 36)). If this is the case and no fault is present,
the direction signals, and thus the signals for opening the brake, are output (see Chapter
Drive activation and brake control (Page 37)).
Section 3:
The brake is opened. The output velocity is issued and transferred to the drives.
Configuring instructions for crane control system
5.8 End of travel in manual operation mode
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 39
5.8
End of travel in manual operation mode
This example shows the sequence of signals in manual operation mode.
Travel ends when the output velocity is low and the "Pos_completed" (positioning completed)
status bit has been set by the sway control. This is only possible if the set velocity V_set has
been set to zero.
The following signal sequence is performed:
Figure 5-3 Signal sequence when travel ends
Section 1:
Travel with maximum velocity.
Section 2:
Travel terminated by the master controller. Output velocity decreases.
Section 3:
The output velocity is zero, the "Pos_completed" status bit is set.
Section 4:
The "Travelling" control bit must be reset (see Chapter Formation of the "Travelling" control
bit (Page 36)). Direction signals are no longer output, which means that the signal to close
the brake is initiated (see Chapter Drive activation and brake control (Page 37)). The
"OM_MAN" control bit can be reset.
Section 5:
The brake has been applied.
Configuring instructions for crane control system
5.9 Start of travel in positioning operation mode
CeSAR standalone OHBC, Gantry crane
40 Operating Instructions, 02/2014
5.9
Start of travel in positioning operation mode
Requirements
● All control bits must be set or reset as described for positioning.
● The target position must not be the same as the actual position. All other signals should
have a value within the value range.
● The "Travelling" control bit must remain set for as long as the crane is moving.
If the control bit is reset, the output velocity "V_norm" of the drive is reduced along the
quick stop ramp.
The following signal sequence is performed:
Figure 5-4 Signal sequence at the start of positioning operation mode
Section 1:
The sway control system is activated and the drive is selected for operation in positioning
operation mode. A target position has been specified.
Section 2:
The positioning operation is initiated by setting the "Travelling" control bit. If no error has
occurred that is blocking the operation mode, the direction signals, and therefore the signals
for opening the brake, are output.
Section 3:
The brake is opened. The output velocity "V_norm" is transferred to the drive. Positioning
starts.
Configuring instructions for crane control system
5.10 End of travel in positioning operation mode
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 41
5.10
End of travel in positioning operation mode
Travel ends when status bit "Pos_completed" is set by the sway control system:
● The difference between the actual and target positions is less than the set positioning
accuracy.
● Status bit "SC_completed" is set.
● The output velocity is less than / equal to the zero speed detection.
The following signal sequence is performed:
Figure 5-5 Signal sequence at the end of positioning operation mode
Section 1:
Sway-controlled travel of drive towards target position.
Section 2:
Actual position approaches target position.
Output velocity "V_norm" decreases.
Section 3:
Target position reached The output velocity "V_norm" is zero. Signal "Pos_completed" is
then set.
Section 4:
The "Travelling" control bit must be reset. This causes no direction signals to be output and
so the signal to close the brake initiated. The "OM_POS" control bit can be reset.
Section 5:
The brake has been applied.
Configuring instructions for crane control system
5.11 Sway controlled stop
CeSAR standalone OHBC, Gantry crane
42 Operating Instructions, 02/2014
WARNING
Danger to life from unexpected machine movement
For as long as the "Travelling" control bit remains set, unexpected movements may occur
after the crane has come to a standstill.
The "Travelling" control bit must be reset by the crane control system in the event of an
EMERGENCY STOP or cancellation of the continued travel.
Cancellation by the sway control may be triggered by the control bits "Release,"
"Brake_closed," "Controlled stop," and all limit switches.
• The "Travelling" control bit must be activated by a deliberate action.
5.11
Sway controlled stop
The control bit "Stop" (controlled stop) can be activated separately for each drive and causes
a sway-controlled stop in all operation modes.
One possible use is to interrupt travel in positioning operation mode in order to wait for a
particular event.
Another application is the use of the dead-man switch functionality.
In cases such as these, it is not necessary to change the operation mode. This reduces the
amount of programming in the PLC.
Stopping has been completed if the "Pos_Completed" status bit is set for the relevant drive.
While braking, it is possible to withdraw the "Stop" control bit (controlled stop). As soon as
the bit has been reset and the "Travelling" control bit is set, the drive starts to move again.
5.12
Positioning in the manual operation mode with S_corr
It is possible to use the sway control in manual operation mode for an external position
controller.
The magnitude of the set velocity V_set is calculated by the following formula and must be
limited to the desired positioning velocity.
In this case:
● a: desired deceleration
● Δs: position difference
Δs = target position - actual position - distance correction by sway control (S_corr)
Velocity V_set must have a sign dependent on the direction and must be normalized.
Configuring instructions for crane control system
5.13 Normalization
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 43
5.13
Normalization
Normalization and denormalization are shown in the following diagram using a trolley as an
example.
Figure 5-6 Denormalization using a trolley as an example
The setpoint value V_set and actual value V_act are denormalized at the ratio stated
(indicated by a red border in the figure).
The output velocity V_norm is denormalized at the ratio stated (indicated by a blue border in
the figure).
Example: With P1 = 1000 mm/s and P35 = 16384, a setpoint value of V_set = 16384
corresponds to an internal setpoint value of 1000 mm/s. If an output velocity of 100 mm/s is
to be traveled, an output velocity V_norm = 1638 is provided with identical settings.
For sway control to function correctly, it must be ensured in the crane control system that the
internal velocity values in mm/s match the actual velocities really measured in mm/s. These
are measured, for example, with an external tachometer or by measuring the positions with a
tape measure.
Configuring instructions for crane control system
5.13 Normalization
CeSAR standalone OHBC, Gantry crane
44 Operating Instructions, 02/2014
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 45
Interface description
6
6.1
General
The input data will first be described followed by the output data. Control and/or status bits
within the input or output data are again subsequently listed in detail.
The input and output data are described in the tables below as follows:
Table 6- 1 Overview of the data in the interface description
Column
Contents
Name
Short form of the designation that is used in the SIMATIC S7 sample blocks or in
other parts of the documentation.
Type Precise type data:
INT, DINT: signed 16, 32-bit number
WORD: unsigned 16-bit number
REAL: Floating-point number, 32 bit
Address
Consecutive number of the bytes, starting at 0.
Designation
Plain text designation of the value to be transferred.
Unit Describes the unit and therefore size of the
values to be transferred.
The specified addresses are relative addresses and if addresses have already been
assigned, an offset must be added.
The PLC telegram (sending) contains, as the first word, an interface ID. The telegram is
evaluated appropriately on the sway control side based on this received word.
Note
The SIMOCRANE CeSAR standalone OHBC, Gantry crane sway
control system uses the
Integer version, ID = 5150.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
46 Operating Instructions, 02/2014
6.2
Input data
6.2.1
Overview of complete data structure
The data specified here is input data from the perspective of the sway control on the
SIMOTION C240 PN. The following table provides a complete overview of the data that is
sent from the PLC to the sway control:
Data block DB1012 in the SIMATIC S7 sample project corresponds to this structure.
Table 6- 2 Overall telegram structure / general block
Name
Type
Address
Designation
Unit
IF_IDNo
WORD
0-1
Interface ID
PB_ID_NR=5150
Spare
WORD
2-3
Reserve
CTRL_BITS WORD 4-5 General control bits See Table 6-9
General control bits
(Page 50)
Load
WORD
6-7
Load weight
in 10 kg steps
S_Hoist DINT 8-11 Hoist position for effective
pendulum length
± mm
Obst1_off
WORD
12-13
ObstaclesOff 0 … 15
Bits 0 ... 15
Obst2_off
WORD
14-15
ObstaclesOff 16 … 31
Bits 0 ...15
Table 6- 3 Overall telegram structure / trolley block
Name
Type
Address
Designation
Unit
CTRL_BITS WORD 16-17 Trolley control bits See Table 6-11
Trolley control bits
(Page 52)
Spare
WORD
18-19
Reserve
S_act
DINT
20-23
Actual position, trolley
S_set DINT 24-27 Target position, trolley
V_act
INT
28-29
Actual velocity, trolley
Normalized
V_set
INT
30-31
Set velocity, trolley
Normalized
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 47
Table 6- 4 Overall telegram structure / gantry block
Name
Type
Address
Designation
Unit
CTRL_BITS WORD 32-33 Gantry control bits See Table 6-13
Gantry control bits
(Page 56)
Spare
WORD
34-35
Reserve
S_act
DINT
36-39
Actual position, gantry
S_set
DINT
40-43
Target position, gantry
V_act
INT
44-45
Actual velocity, gantry
Normalized
V_set
INT
46-47
Set velocity, gantry
Normalized
Table 6- 5 Overall telegram structure / slewing gear or hoist block
Name
Type
Address
Designation
Unit
CTRL_BITS WORD 48-49 Control bits, slewing
gear/hoist
see Table 6-15
Slewing gear
control bits
(Page 61) and see
Table 6-17 Hoist
control bits
(Page 66)
CTRL_BITS2
WORD
50-51
Not used
S_act DINT 52-55 Actual position, slewing
gear/hoist
S_set DINT 56-59 Target position, slewing
gear/hoist
V_act INT 60-61 Actual velocity, slewing
gear/hoist
Normalized
V_set INT 62-63 Set velocity, slewing
gear/hoist
Normalized
Table 6- 6 Overall telegram structure / trailer
Name
Type
Address
Designation
Unit
Trailer
WORD
64-65
Telegram counter
The input data interface has the following logical block structure:
Table 6- 7 Block structure
1
General data block
(length = 8 words / 16 bytes)
2
Trolley drive data
(length = 8 words / 16 bytes)
3
Gantry drive data
(length = 8 words / 16 bytes)
4
Slewing gear/hoist drive data
(length = 8 words / 16 bytes)
5
Trailer (telegram counter)
(length = 1 word / 2 bytes)
The blocks are described in more detail in the following chapters.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
48 Operating Instructions, 02/2014
6.2.2
General block (16 bytes)
6.2.2.1
Input data, general block
Table 6- 8 PROFIBUS DP general block
Name
Type
Address
Designation
Unit
IF_IDNo
WORD
0-1
Interface version ID
PB_ID_NR=5150
Spare
WORD
2-3
Reserve
CTRL_BITS WORD 4-5 General control bits See Table 6-9
General control
bits (Page 50)
Load
WORD
6-7
Load weight
in 10 kg steps
S_Hoist DINT 8-11 Hoist position for
effective pendulum
length
± mm
Obst1_off*
WORD
12-13
ObstaclesOff 0 … 15
Bits 0 ... 15
Obst2_off*
WORD
14-15
ObstaclesOff 16 … 31
Bits 0 ... 15
Note
The signa
ls designated with * are intended for future expansions, and are deactivated in this
version. The assignment in the PLC should be realized with a fixed value of zero.
IF_IDNo - interface ident number, number of the interface version
Using this value, the interface version is selected and defined using the PLC program. The
program (ST) saved in SIMOTION interprets the incoming telegram corresponding to this
identification number.
5150
Interface Integer, for SIMOCRANE CeSAR standalone
5151
Interface Real, for SIMOCRANE SC integrated application without basic technology
5152
Interface for SIMOCRANE SC integrated application with basic technology
The specified identification numbers are decimal numbers.
Spare - reserve
Reserved for future expansions.
CTRL_BITS - general control bits
Control bits, general block (see Chapter Control bits, general block (Page 50)).
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 49
Load - actual load
The load weight is the actually measured load value in 10 kg steps. This value can be used
as basis to correct the effective pendulum length. For higher load values, the center of
gravity is shifted somewhat downwards. For trolley and gantry, there is a correction factor
P25 or P65 for each ("Analog correction of the effective pendulum length"). The transferred
load mass results in continuous extension of the pendulum length when using these
parameters in mm/kg. The parameters are defined when commissioning the system, by
determining the effective pendulum length with attached load. The two correction factors P25
and P65 can be determined based on the difference of the effective pendulum lengths.
The value must be limited to the value range 0 ... 65535 (corresponding to 0 ... 655350 kg) in
the crane control system to prevent counter overflows.
Note
Correction based on the load weight is only required for significantly fluctuating load
changes, e.g. when transporting casting ladles in a steel plant. Not all cranes are equip
ped
with load measuring equipment. For cases in which the load is relatively constant (e.g. coils
or slabs), it is sufficient to apply a fixed offset value (mm).
S_Hoist - Hoist position for effective pendulum length
This value corresponds to the actual position of the hoist which is used as a basis to
calculate the effective pendulum lengths of the drives involved. Two parameters (for each
drive) are used to convert into the effective pendulum length, for the factor and the offset.
Note
The actual po
sition of the hoist should be in mm for plausibility reasons. Only then are gain
factors obtained for the calculation into the effective pendulum length of approx. 1 or approx.
-
1.
Obst1_off* - blocked regions off, 0 ... 15 / Obst2_off* - blocked regions off, 16 ... 31
These two control words are reserved for future expansions (detour control) and are
deactivated in this version. Both words should be pre-assigned to zero in the PLC.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
50 Operating Instructions, 02/2014
6.2.2.2
Control bits, general block
Table 6- 9 General control bits
Bit no.
Name
Meaning
0
Par_Set_Bit0
Switchover, parameter set bit 0
1
Par_Set_Bit1
Switchover, parameter set bit 1
2 Traj_ON* Trajectory control ON
detour control only; not available in this version)
3
Save_Logger
Save logger file
4 Load_On_Hook* Load on the hook, take hoist offset into account
(detour control only; not available in this version)
5 ... 15
Reserve
Not used
Bits 0 to 1 - Par_Set_Bit0 and Par_Set_Bit1 (switchover parameter sets)
Switchover bits from the PLC to select parameter sets 1 to 4. Also observe parameter 101.
Par_Set_Bit1
Par_Set_Bit0
Parameter set
0
0
Parameter set 1 selected
0
1
Parameter set 2 selected
1
0
Parameter set 3 selected
1
1
Parameter set 4 selected
Bit 2 – Traj_ON * (synchronization of the trolley and gantry for 2D trajectory)
Reserved for detour control (not available in this version)
Bit 3 - Save_Logger (save the actual content of the logger to MMC)
All changes to control, operating and fault bits, as well as changes to target positions, are
written in a compressed form into a ring buffer. The content of the logger can be displayed
using the SIMOCRANE CeCOMM diagnostic program. By activating the "Save_Logger" bit
(edge controlled), the buffer content can be backed up in a file on the MMC. For example,
saving the logger file to the MMC can be helpful when analyzing faults, and should only be
used in exceptional cases due to the limited MMC memory size.
Note
The "Save Logger" function is for Siemens
-internal use only.
Bit 4 – Load_On_Hook * – load connected to the hook
Reserved for detour control with hoist (not available in this version)
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 51
6.2.3
Trolley block (16 bytes)
6.2.3.1
Input data, trolley block
Table 6- 10 PROFIBUS DP trolley block
Name
Type
Address
Designation
Unit
CTRL_BITS WORD 16-17 Trolley control bits See Table 6-11 Trolley
control bits (Page 52)
Spare
WORD
18-19
Reserve
S_act
DINT
20-23
Actual position, trolley
S_set
DINT
24-27
Target position, trolley
V_act
INT
28-29
Actual velocity, trolley
Normalized
V_set INT 30-31 Set velocity
Trolley
Normalized
CTRL_BITS - trolley control bits
Trolley control bits (see Chapter Control bits, trolley block (Page 52))
S_act - actual position, trolley
Actual position of the trolley
The actual position is only required in positioning and sway neutralization modes.
Actual position [mm] = S_act · P5 + P6
S_set - target position, trolley
Target position of the trolley
The target position is only evaluated in the positioning operation mode.
Target position [mm] = S_set · P5 + P6
V_act - actual velocity, trolley
Actual velocity of the crane control system
V_act must be transmitted from the crane control as a normalized value (see
ChapterNormalization (Page 43)).
The sway control ascertains the actual velocity with V [mm/s] = V_act · P1 : P35.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
52 Operating Instructions, 02/2014
V_set - set velocity, trolley
Specification of the set velocity as a normalized value (see Chapter Normalization
(Page 43))
The sway control determines the set velocity with V [mm/s] = V_set · P1 : P35.
The direction is defined by the sign of V_set.
Relationship between the sign of V_set and the position value:
● With V_set > 0, the trolley position value must increase.
● With V_set < 0, the trolley position value must decrease.
6.2.3.2
Control bits, trolley block
Table 6- 11 Trolley control bits
Bit no.
Name
Meaning
0
Release
Enable
1
Travelling
Travel signal
2
OM_POS
Operation mode positioning
3
OM_MAN
Operation mode manual
4
OM_SC_LO
Operation mode sway neutralization load position
5
OM_SC_DR
Operation mode sway neutralization drive position
6
PLS_F
Prelimit switch forward
7
PLS_B
Prelimit switch backward
8
Stop
Controlled stop
9
Brake_closed
Output value enable
10
SC_Only_OnStop
Sway control only when stopping
11
SC_On
Activate sway control
12
DigitalLiftCorrection
Digital effective pendulum length correction
13
--
Not used
14
LS_F
Limit switch forward
15
LS_B
Limit switch backward
Bit 0 – Release (enables the trolley)
0
Drive inhibited, quick stop during travel.
1 Operation modes and the "Travelling" control bit are evaluated.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 53
Bit 1 – Travelling (travel signal of the trolley)
0
Stop with quick stop ramp P12 without sway control.
1 Activation of the specified operation mode. The "Travelling" control bit is set at the start of a
travel motion (e.g. deflection of the master controller or start of automatic travel).
Note
Resetting the "Travelling" control bit
If the operation is to be completed with sway control, the "Travelling" control bit may only be
reset once the "Pos_completed" status bit has been set.
Bits 2 to 5 - OM (Operation Mode, trolley operation mode)
Note
Only one operation mode is valid.
Only one of the operation mode bits may be set.
Bit 2 - OM_POS (Operation Mode, positioning operation mode, trolley)
Bit 3 - OM_MAN (Operation Mode, manual operation mode, trolley)
Bit 4 - OM_SC_LO (Operation Mode, sway neutralization load position operation mode,
trolley)
Bit 5 - OM_SC_ DR (Operation Mode, sway neutralization drive position operation mode,
trolley)
0
Inactive
1
Active
Bit 6 – PLS_F (PreLimit Switch, prelimit switch forward, trolley)
0
Actuated, reduction of output velocity.
1
Not actuated.
Bit 7 – PLS_B (PreLimit Switch, prelimit switch backward, trolley)
0
Actuated, reduction of output velocity.
1
Not actuated.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
54 Operating Instructions, 02/2014
Bit 8 – Stop (controlled stop)
0
No stop.
1
Stop with setpoint acceleration trolley P3 and sway control.
Note
Resetting control bits that are relevant to travel
With a controlled stop, all the control bits relevant to travel (Release, Travelling,
Brake_closed, OM_POS, OM_MAN, SC_On, etc.) must remain se
t as for normal travel and
must not be reset again until status bit "Pos_completed" has been set.
Bit 9 – Brake_closed (output value enable)
0
Brake is open. Output velocity and direction signals are enabled.
1 Brake is closed. Output velocity is not enabled (braking along the quick stop ramp). Direction
signals are enabled.
Bit 10 – SC_Only_OnStop (sway control only when stopping)
0
Sway control always active.
1
Sway control only active when stopping.
Bit 11 – SC_On (activate sway control)
0
Do not activate sway control.
1 Activate sway control.
Bit 12 – DigitalLiftCorrection (digital correction effective pendulum length)
0
The parameter "digital correction effective pendulum length" (P24) is not used.
1 The effective pendulum length is shifted by the parameter value "digital correction effective
pendulum length" (P24).
This bit is used to take into account the occasional use of cross beams, chains, cables or
other load carrying devices.
Bit 13 – not used
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 55
Bit 14 – LS_F (Limit Switch Forward)
0
Actuated, quick stop during travel.
1
Not actuated.
Bit 15 – LS_B (Limit Switch Backward)
0
Actuated, quick stop during travel.
1
Not actuated.
Note
The prelimit and limit switch signals are low active (wire
-break proof).
6.2.4
Gantry block (16 bytes)
6.2.4.1
Input data, gantry block
Table 6- 12 PROFIBUS DP gantry block
Name
Type
Address
Designation
Unit
CTRL_BITS WORD 32-33 Gantry control bits See Table 6-13 Gantry
control bits (Page 56)
Spare WORD 34-35 Reserve
S_act
DINT
36-39
Actual position, gantry
S_set
DINT
40-43
Target position, gantry
V_act
INT
44-45
Actual velocity, gantry
Normalized
V_set
INT
46-47
Set velocity, gantry
Normalized
CTRL_BITS - gantry control bits
Gantry control bits (see Chapter Control bits, gantry block (Page 56)).
S_act – actual position, gantry
Actual position of the gantry
The actual position is only required in positioning and sway neutralization modes.
Actual position [mm] = S_act · P45 + P46
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
56 Operating Instructions, 02/2014
S_set – target position, gantry
Target position of the gantry
The target position is only evaluated in the positioning mode.
Target position [mm] = S_set · P45 + P46
V_act – actual velocity, gantry
Actual velocity of the crane control system
V_act must be transmitted from the crane control as a normalized value (see Chapter
Normalization (Page 43)).
The sway control ascertains the actual velocity with V [mm/s] = V_act · P41 : P75
V_set – set velocity, gantry
Specification of the set velocity as a normalized value (see Chapter Normalization
(Page 43))
The sway control determines the set velocity with V [mm/s] = V_set · P41 : P75.
The direction is defined by the sign of V_set.
Relationship between the sign of V_set and the position value:
● With V_set > 0, the gantry position value must increase.
● With V_set < 0, the gantry position value must decrease.
6.2.4.2
Control bits, gantry block
Table 6- 13 Gantry control bits
Bit no.
Name
Meaning
0
Release
Enable
1
Travelling
Travel signal
2
OM_POS
Operation mode positioning
3
OM_MAN
Operation mode manual
4
OM_SC_LO
Operation mode sway neutralization load position
5
OM_SC_DR
Operation mode sway neutralization drive position
6
PLS_F
Prelimit switch forward
7
PLS_B
Prelimit switch backward
8
Stop
Controlled stop
9
Brake_closed
Output value enable
10
SC_Only_OnStop
Sway control only when stopping
11
SC_On
Activate sway control
12
DigitalLiftCorrection
Digital effective pendulum length correction
13
--
Not used
14
LS_F
Limit switch forward
15
LS_B
Limit switch backward
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 57
Bit 0 – Release (enables the gantry)
0
Drive inhibited, quick stop during travel.
1
Operation modes and the "Travelling" control bit are evaluated.
Bit 1 – Travelling (travel signal of the gantry)
0
Stop with quick stop ramp P52 without sway control.
1 Activation of the specified operation mode. The "Travelling" control bit is set at the start of a
travel motion (e.g. deflection of the master controller or start of automatic travel).
Note
Resetting the "Travelling" control bit
If the operation is to be completed with sway control, the "Travelling" control bit may onl
y be
reset once the "Pos_completed" status bit has been set.
Bits 2 to 5 - OM (Operation Mode, gantry operation mode)
Note
Only one operation mode is valid.
Only one of the operation mode bits may be set.
Bit 2 - OM_POS (Operation Mode, positioning operation mode, gantry)
Bit 3 - OM_MAN (Operation Mode, manual operation mode, gantry)
Bit 4 - OM_SC_LO (Operation Mode, sway neutralization load position operation mode,
gantry)
Bit 5 - OM_SC_DR (Operation Mode, sway neutralization drive position operation mode,
gantry)
0
Inactive
1
Active
Bit 6 – PLS_F (PreLimit Switch Forward, prelimit switch forward, gantry)
0
Actuated, reduction of output velocity.
1
Not actuated.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
58 Operating Instructions, 02/2014
Bit 7 – PLS_B (PreLimit Switch Backward, prelimit switch backward, gantry)
0
Actuated, reduction of output velocity.
1
Not actuated.
Bit 8 – Stop (controlled stop)
0
No stop.
1
Stop with setpoint acceleration gantry P43 and sway control.
Note
Resetting control bits that are relevant to travel
With a controlled stop, all the c
ontrol bits relevant to travel (Release, Travelling,
Brake_closed, OM_POS, OM_MAN, SC_On, etc.) must remain set as for normal travel and
must not be reset again until status bit "Pos_completed" has been set.
Bit 9 – Brake_closed (output value enable)
0
Brake is open. Output velocity and direction signals are enabled.
1 Brake is closed. Output velocity is not enabled (braking along the quick stop ramp). Direction
signals are enabled.
Bit 10 – SC_Only_OnStop (sway control only when stopping)
0
Sway control always active.
1 Sway control only active when stopping.
Bit 11 – SC_On (activate sway control)
0
Do not activate sway control.
1
Activate sway control.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 59
Bit 12 – DigitalLiftCorrection (digital correction effective pendulum length)
0
The parameter "digital correction effective pendulum length" (P64) is not used.
1 The effective pendulum length is shifted by the parameter value "digital correction effective
pendulum length" (P64).
This bit is used to take into account the occasional use of cross beams, chains, cables or
other load carrying devices.
Bit 13 – not used
Bit 14 – LS_F (Limit Switch Forward)
0
Actuated, quick stop during travel.
1
Not actuated.
Bit 15 – LS_B (Limit Switch Backward)
0
Actuated, quick stop during travel.
1
Not actuated.
Note
The prelimit and limit switch signals are low active (wire
-break proof).
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
60 Operating Instructions, 02/2014
6.2.5
Slewing gear block (16 bytes)
6.2.5.1
Input data, slewing gear block
Table 6- 14 PROFIBUS DP slewing gear block
Name
Type
Address
Designation
Unit
CTRL_BITS WORD 48-49 Slewing gear control bits See Table 6-15 Slewing
gear control bits
(Page 61)
CTRL_BITS2
WORD
50-51
Not used
S_act DINT 52-55 Actual position, slewing
gear
S_set DINT 56-59 Target position, slewing
gear
V_act INT 60-61 Actual velocity, slewing
gear
Normalized
V_set
INT
62-63
Set velocity, slewing gear
Normalized
CTRL_BITS – slewing gear control bits
Slewing gear control bits (see Chapter Control bits, slewing gear block (Page 61))
S_act – actual position, slewing gear
Actual position of the slewing gear
Actual position [c°] = S_act · P135 + P136
Note
If the camera and reflector are also rotated by the slewing gear, the actual position of the
slewing gear will have to be communicated even if this position is not needed directly for the
slewing gear.
The measured sway oscillations are assigned to the trolley and gantry based
on the position of the slewing gear.
In this case, an incorrect slewing gear position can also result in a malfunction of the sway
control for the trolley and gantry.
S_set – target position, slewing gear
Target position of the slewing gear
The target position is only evaluated in the positioning operation mode.
Target position [c°] = S_set · P135 + P136
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 61
V_act – actual velocity, slewing gear
Actual velocity of the crane control system
V_act must be transmitted from the crane control as a normalized value (see Chapter
Normalization (Page 43)).
The sway control ascertains the actual velocity with V [c°] = V_act · P131 : P165.
V_set – set velocity, slewing gear
Specification of the set velocity as a normalized value (see Chapter Normalization
(Page 43))
The sway control determines the set velocity with V [mm/s] = V_set · P131 : P165.
The direction is defined by the sign of V_set.
Relationship between the sign of V_set and the position value:
● With V_set >0, the slewing gear position value must increase.
● With V_set < 0, the slewing gear position value must decrease.
6.2.5.2
Control bits, slewing gear block
Table 6- 15 Slewing gear control bits
Bit no.
Name
Meaning
0
Release
Enable
1
Travelling
Travel signal
2
OM_POS
Operation mode positioning
3
OM_MAN
Operation mode manual
4
OM_SC_LO
Operation mode sway neutralization load position
5
OM_SC_DR
Operation mode sway neutralization drive position
6
PLS_F
Prelimit switch forward
7
PLS_B
Prelimit switch backward
8
Stop
Controlled stop
9
Brake_closed
Output value enable
10
SC_Only_OnStop
Sway control only when stopping
11
SC_On
Activate sway control
12
DigitalLiftCorrection
Digital effective pendulum length correction
13
--
Not used
14
LS_F
Limit switch forward
15
LS_B
Limit switch backward
Bit 0 – Release (enables the slewing gear)
0
Drive inhibited, quick stop during travel.
1 Operation modes and the "Travelling" control bit are evaluated.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
62 Operating Instructions, 02/2014
Bit 1 – Travelling (travel signal of the slewing gear)
0
Stop with quick stop ramp P142 without sway control.
1 Activation of the specified operation mode. The "Travelling" control bit is set at the start of
a travel motion (e.g. deflection of the master controller or start of automatic travel).
Note
Resetting the "Travelling" control bit
If the operation is to be completed with sway control, the "Travelling" control bit may only be
reset once the "Pos_completed" status bit has been set.
Bits 2 to 5 - OM (Operation Mode, slewing gear operation mode)
Note
Only one operation mode is valid.
Only one of the operation mode bits may be set.
Bit 2 - OM_POS (Operation Mode, positioning operation mode, slewing gear)
Bit 3 - OM_MAN (Operation Mode, manual operation mode, slewing gear)
Bit 4 - OM_SC_LO (Operation Mode, sway neutralization load position operation mode,
slewing gear)
Bit 5 - OM_SC_DR (Operation Mode, sway neutralization drive position operation mode,
slewing gear)
0
Inactive
1
Active
Bit 6 – PLS_F (PreLimit Switch Forward, prelimit switch forward, slewing)
0
Actuated, reduction of output velocity.
1
Not actuated
Bit 7 – PLS_B (PreLimit Switch Backward, prelimit switch backward, slewing gear)
0
Actuated, reduction of output velocity.
1
Not actuated.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 63
Bit 8 – Stop (controlled stop)
0
No stop.
1
Stop with setpoint acceleration slewing gear P133 and sway control.
Note
Resetting control bits that are relevant to travel
With a controlled stop, all the control bits relevant to travel (Release, Travelling,
Brake_closed, OM_POS,
OM_MAN, SC_On, etc.) must remain set as for normal travel and
must not be reset again until status bit "Pos_completed" has been set.
Bit 9 – Brake_closed (output value enable)
0
Brake is open. Output velocity and direction signals are enabled.
1 Brake is closed. Output velocity is not enabled (braking along the quick stop ramp). Direction
signals are enabled.
Bit 10 – SC_Only_OnStop (sway control only when stopping)
0
Sway control always active.
1
Sway control only active when stopping.
Bit 11 – SC_On (activate sway control)
0
Do not activate sway control.
1 Activate sway control.
Bit 12 – DigitalLiftCorrection (digital correction effective pendulum length)
0 The effective pendulum length is calculated using parameters P152 (gain) and P153
(offset).
1 The effective pendulum length is calculated using parameters P154 (gain) and P155
(offset).
This bit is used to take into account the occasional use of cross beams, chains, cables or
other load carrying devices.
Bit 13 - not used
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
64 Operating Instructions, 02/2014
Bit 14 – LS_F (Limit Switch Forward)
0
Actuated, quick stop during travel.
1
Not actuated.
Bit 15 – LS_B (Limit Switch Backward)
0
Actuated, quick stop during travel.
1
Not actuated.
Note
The prelimit and limit switch signals are low active (wire
-break proof).
6.2.6
Hoist block (16 bytes)
6.2.6.1
Input data, hoist block
Table 6- 16 PROFIBUS DP hoist block
Name
Type
Address
Designation
Unit
CTRL_BITS WORD 48-49 Hoist control bits See Table 6-17 Hoist
control bits (Page 66)
CTRL_BITS2 WORD 50-51 Not used
S_act
DINT
52-55
Actual position, hoist
S_set
DINT
56-59
Target position, hoist
V_act
INT
60-61
Actual velocity, hoist
Normalized
V_set
INT
62-63
Set velocity, hoist
Normalized
CTRL_BITS – hoist control bits
Hoist control bits (see Chapter Control bits, hoist block (Page 66))
S_act – actual position, hoist
Actual position of the hoist
The actual position is only required in positioning operation mode.
Actual position [mm] = S_act · P135 + P136
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 65
S_set – target position, hoist
Target position of the hoist
The target position is only evaluated in the positioning operation mode.
Target position [mm] = S_set · P135 + P136
V_act – actual velocity, hoist
Actual velocity of the crane control system
V_act must be transmitted from the crane control as a normalized value (see Chapter
Normalization (Page 43)).
The sway control ascertains the actual velocity with V [mm/s] = V_act · P131 : P165.
V_set – set velocity, hoist
Specification of the set velocity as a normalized value (see Chapter Normalization
(Page 43))
The sway control determines the set velocity with V [mm/s] = V_set · P131 : P165.
The direction is defined by the sign of V_set.
Relationship between the sign of V_set and the position value:
● With V_set > 0, the hoist position value must increase.
● With V_set < 0, the hoist position value must decrease.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
66 Operating Instructions, 02/2014
6.2.6.2
Control bits, hoist block
Table 6- 17 Hoist control bits
Bit no.
Name
Meaning
0
Release
Enable
1
Travelling
Travel signal
2
OM_POS
Operation mode positioning
3
OM_MAN
Operation mode manual
4
-
5
-
6
PLS_F
Prelimit switch forward
7
PLS_B
Prelimit switch backward
8
Stop
Controlled stop
9
Brake_closed
Output value enable
10
--
-
11
--
-
12
--
-
13 Take_Over_VHoist* Take over hoist velocity
(detour control only; not available in this version)
14
LS_F
Limit switch forward (lifting)
15
LS_B
Limit switch backward (lowering)
Bit 0 – Release (enables the hoist)
0
Drive inhibited, quick stop during travel.
1
Operation modes and the "Travelling" control bit are evaluated.
Bit 1 – Travelling (travel signal of the hoist)
0
Stop with quick stop ramp P142.
1 Activation of the specified operation mode. The "Travelling" control bit is set at the start of a
travel motion (e.g. deflection of the master controller or start of automatic travel).
Note
Resetting the "Travelling" control bit
If the operation is to be completed with sway control, the "Travelling" control bit may only be
reset once the "Pos_completed" status bit has been set.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 67
Bits 2 and 3 - OM (Operation Mode, hoist operation mode)
Note
Only one operation mode is valid.
Only one of the operation mode bits may be set.
Bit 2 - OM_POS (Operation Mode, positioning operation mode, hoist)
Bit 3 - OM_MAN (Operation Mode, manual operation mode, hoist)
0
Inactive
1
Active
Bit 4 and bit 5 - not used
Bit 6 – PLS_F (PreLimit Switch Forward, prelimit switch forward, hoist)
0
Actuated, reduction of output velocity.
1
Not actuated.
Bit 7 – PLS_B (PreLimit Switch Backward, prelimit switch backward, hoist)
0
Actuated, reduction of output velocity.
1
Not actuated.
Bit 8 – Stop (controlled stop)
0
No stop.
1
Stop with acceleration, hoist P132.
Note
Resetting control bits that are relevant to travel
With a controlled stop, all the control bits relevant to travel (Release, Travelling,
Brake_closed, OM_POS,
OM_MAN, etc.) must remain set as for normal travel and must not
be reset again until the status bit "Pos_completed" has been set.
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
68 Operating Instructions, 02/2014
Bit 9 – Brake_closed (output value enable)
0
Brake is open. Output velocity and direction signals are enabled.
1 Brake is closed. Output velocity is not enabled (braking along the quick stop ramp). Direction
signals are enabled.
Bit 10 - not used
Bit 11 - not used
Bit 12 - not used
Bit 13 - Take_Over_VHoist* (take over hoist velocity)
Reserved for detour control (not available in this version)
Bit 14 – LS_F (Limit Switch Forward)
0
Actuated, quick stop during travel.
1
Not actuated.
Bit 15 – LS_B (Limit Switch Backward)
0
Actuated, quick stop during travel.
1
Not actuated.
Note
The signals of the prelimit and li
mit switches are low active (wire-break proof).
Interface description
6.2 Input data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 69
6.2.7
Trailer
The last two bytes are intended for a telegram counter (crane control system → SIMOTION
C240 PN)
Table 6- 18 PROFIBUS DP Trailer
Name
Type
Address
Designation
Trailer
WORD
64-65
Telegram counter
The last two bytes contain a telegram counter (crane control system → SIMOTION C240
PN).
For more information, see error message E2 (Chapter List of alarm, error, and system
messages (Page 159)).
6.2.8
Data from the camera
Table 6- 19 Data from the camera
Type
Name
Significance
Unit
DINT
TEL_COUNT
Telegram counter
BOOL CAMERA_O
K
Camera supplies valid measured values
WORD
Error_Cam
Error messages
DINT
X_POS
Deflection in x direction
mm
DINT
V_X
Velocity in the x direction
mm/s
DINT
Y_POS
Deflection in y direction
mm
DINT
V_Y
Velocity in the y direction
mm/s
DINT
Skew
Rotation
c°
DINT
V_SKEW
Velocity of rotation
c°/s
DINT
Distance
Distance between the camera and reflector
mm
There is no direct data exchange between the camera and the PLC. The measured values of
the camera (see the table) are evaluated in the sway control and are used to synchronize the
mathematical oscillation model with reality. Error bits such as "camera measuring system
impaired" (E10) or "camera measuring system faulted" (E11) are transferred to the PLC (see
chapter List of alarm, error, and system messages (Page 159)). The camera data currently
received is presented in the SIMOCRANE CeCOMM diagnostic program (screen 4).
Note
Additional informa
tion on the data exchange between the camera and the SIMOTION
C240
PN can be found in the operating instructions for the SIMOCRANE CenSOR camera
measuring system.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
70 Operating Instructions, 02/2014
6.3
Output data
6.3.1
Overview of complete data structure
The data specified here is output data from the perspective of the sway control on the
SIMOTION C240 PN. The following tables provide a complete overview of the data that is
sent from the sway control to the PLC:
Data block DB2010 in the SIMATIC S7 sample project corresponds to this structure.
Table 6- 20 General block
Name
Type
Address
Designation
Unit
StateBits WORD 0-1 Status bits, general See Table 6-27
Status bits,
general (Page 73)
ErrorBits1
WORD
2-3
Error bits 1, general
ErrorBits2
WORD
4-5
Error bits 2, general
Reserve
CamDist DINT 6-9 Measured distance between the camera
and reflector
± mm
Reserve
DINT
10-13
Not used
Table 6- 21 Trolley block
Name
Type
Address
Designation
Unit
StateBits WORD 14-15 Trolley status bits See Table 6-29
Trolley status bits
(Page 75)
V_norm INT 16-17 Output velocity, trolley Normalized
Default: 16384
V_mm_s
REAL
18-21
Output velocity, trolley
± mm/s
Deflection
INT
22-23
Pendulum deflection, trolley
± mm
S_corr INT 24-25 Distance correction by sway
control, trolley
± mm
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 71
Table 6- 22 Gantry block
Name
Type
Address
Designation
Unit
StateBits WORD 26-27 Gantry status bits See Table 6-31
Gantry status bits
(Page 79)
V_norm INT 28-29 Output velocity, gantry Normalized
Default: 16384
V_mm_s
REAL
30-33
Output velocity, gantry
± mm/s
Deflection
INT
34-35
Pendulum deflection, gantry
± mm
S_corr INT 36-37 Distance correction by sway
control, gantry
± mm
Table 6- 23 Slewing gear or hoist block
Name
Type
Address
Designation
Unit
StateBits WORD 38-39 Status bits, slewing gear/hoist see Table 6-33 Status
bits, slewing gear
(Page 83) and see
Table 6-35 Status bits,
hoist (Page 87)
V_norm INT 40-41 Output velocity, slewing gear/hoist Normalized
Default: 16384
V_mm_s
REAL
42-45
Output velocity, slewing gear/hoist
± c°/s or ± mm/s
Skew INT 46-47 Rotation ± c° (slewing gear)
Hoist = 0 (no
significance)
S_corr INT 48-49 Distance correction through sway
control, slewing gear
± c° (slewing gear)
Hoist = 0 (no
significance)
Table 6- 24 Trailer
Name
Type
Address
Designation
Unit
Trailer
WORD
50-51
Telegram counter
The output data interface has the following logical block structure:
Table 6- 25 Block structure
1
General data block
(length = 8 words / 14 bytes)
2
Trolley drive data
(length = 8 words / 12 bytes)
3
Gantry drive data
(length = 8 words / 12 bytes)
4
Slewing gear/hoist drive data
(length = 8 words / 12 bytes)
5
Trailer (telegram counter)
(length = 1 word / 2 bytes)
The blocks are explained in more detail in the following sections.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
72 Operating Instructions, 02/2014
6.3.2
General block (14 bytes)
6.3.2.1
Output data, general block
Table 6- 26 General block
Name
Type
Address
Designation
Unit
StateBits WORD 0-1 Status bits, general See Table 6-27
Status bits,
general (Page 73)
ErrorBits1
WORD
2-3
Error bits 1, general
ErrorBits2
WORD
4-5
Error bits 2, general
Reserve
CamDist DINT 6-9 Distance measured between the camera
and reflector
± mm
Reserve
DINT
10-13
Not used
StateBits – status bits, general
See Chapter Status bits, general block (Page 73).
ErrorBits1 - error bits 1 general
See Chapter Alarm, error, and system messages (Page 157) ; Table 10-1 Error messages
with error bit (Page 157)
ErrorBits2 - error bits 2 general
Not currently used. Reserve.
CamDist – distance measured between the camera and reflector
Only relevant to a version including a camera.
See the SIMOCRANE CenSOR operating instructions.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 73
6.3.2.2
Status bits, general block
Table 6- 27 Status bits, general
Bit no.
Names
Meaning
0
PAR SET
Parameter set selection bit 0
1
Parameter set selection bit 1
2
Reserve
3
Reserve
4
WATCHDOG
WATCHDOG (flashing signal 200 ms)
5 PosInFixedArea* Reserved for detour control (not available in this
version)
6
WaitForNextTransition*
Next target can be entered
7 Camera_OK Camera (SIMOCRANE CenSOR) supplies valid
values
8-15
-
Not used
Bit 0 to 1 - PAR_SET_Bit0 and PAR_SET_Bit1 (parameter set selection)
PAR_SET_Bit1
PAR_SET_Bit0
Parameter set
0
0
Parameter set 1 active
0
1
Parameter set 2 active
1
0
Parameter set 3 active
1
1
Parameter set 4 active
Bit 4 - WATCHDOG (flashing signal 200 ms)
This bit can be used to monitor communication between the crane control system and the
SIMOTION C240 PN in the crane control system.
Bit 5 - PosInFixedArea*
Reserved for future detour control (not available in this version)
Bit 6 - WaitForNextTransition*
Reserved for future detour control (not available in this version)
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
74 Operating Instructions, 02/2014
Bit 7 - Camera_OK
0 Camera error message
Possible causes:
• Communication
• The reflector is not detected.
• The reflector is located outside the visual range.
• Pollution/dirt
1 • Camera supplies valid measured values.
• The reflector is detected.
6.3.3
Trolley block (12 bytes)
6.3.3.1
Output data, trolley block
Table 6- 28 Trolley block
Name
Type
Address
Designation
Unit
StateBits WORD 14-15 Trolley status bits See Table 6-29
Trolley status bits
(Page 75)
V_norm INT 16-17 Output velocity, trolley Normalized
Default: 16384
V_mm_s
REAL
18-21
Output velocity, trolley
± mm/s
Deflection
INT
22-23
Pendulum deflection, trolley
± mm
S_corr INT 24-25 Distance correction by sway
control, trolley
± mm
StateBits – status bits, trolley
See Chapter Status bits, trolley block (Page 75).
V_norm – output velocity as normalized value
Trolley output velocity as normalized value. This value must be transferred to the drive.
V_mm_s – output velocity
Output velocity in mm/s.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 75
Deflection – pendulum deflection
Current distance of the reflector from its home position in the direction of the trolley.
When a camera is being used, the real pendulum deflection value is measured and output.
The mathematical oscillation model is calibrated with this value. Without a camera, this
output returns the pendulum deflection based on the mathematical oscillation model.
S_corr – distance correction through sway control, trolley
With external position control, the S_corr value is required to form the position difference that
is the input variable for the external position controller.
Position difference = target position - actual position - distance correction by sway control
Note
S_corr is transmitted from the sway control to the crane control system as an INT value. In
the sample block this val
ue is converted to a DINT value and can be further processed as a
DINT value.
6.3.3.2
Status bits, trolley block
Table 6- 29 Trolley status bits
Bit no.
Name
Meaning
0
Ready
Ready for operation
1
Active
Active
2
Pos_completed
Positioning and sway neutralization completed
3
SC_completed
Sway neutralization completed
4
Travel_f
Direction of travel forward
5
Travel_b
Direction of travel backward
6
SC_IsOn
Sway control on
7-15
-
Not used
Bit 0 – ready
0
Checkback signal control bit Release (Release=0)
1
Checkback signal control bit Release (Release=1)
Bit 1 – active (trolley active)
0
The output velocity is zero.
1
The drive is active and outputs the output velocity that is currently required.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
76 Operating Instructions, 02/2014
Bit 2 – Pos_completed (positioning and sway neutralization completed)
0
Operation mode manual:
The set velocity is greater than zero or the output velocity is greater than the zero speed
detection P19 or the sway has not been neutralized on the trolley.
Operation modes positioning and sway neutralization:
The position deviation is greater than the specified positioning window P9 or the sway has not
been neutralized on the trolley or the output velocity is greater than the zero speed detection
P19.
1
Operation mode manual:
The set velocity is zero and the output velocity is less than / equal to the zero speed detection
P19 and the sway has been neutralized on the trolley.
Operation modes positioning and sway neutralization:
The target position has been reached. The position deviation is within the specified positioning
window P9 and the sway has been neutralized on the trolley and the output velocity is less
than / equal to the zero speed detection P19.
Note
A minimum period of 0.5 s applies to the output velocity condi
tion less than / equal to the
zero speed detection P19 in manual operation mode with sway control. A minimum period of
1.0 s applies to output velocity less than / equal to the zero speed detection P19 and the
actual position in positioning window P9 in th
e other operation modes with sway control.
Bit 3 – SC_completed (sway neutralization completed)
0
The pendulum deflection is greater than P33 or the pendulum velocity is greater than P34.
1 The pendulum deflection is less than P33 and the pendulum velocity is less than P34 over a
period of at least 250 ms.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 77
Bit 4 - Travel_f (travel direction forward)
0 All operation modes
The "Travelling" control bit is zero or an error message is pending that prevents travel.
1 Operation mode manual
The "Travelling" control bit is set and the set velocity is greater than or equal to zero.
Operation mode positioning
The "Travelling" control bit is set and the difference between the target position and the actual
position is greater than or equal to zero.
Note
E
rror messages that prevent travel are E3, E6, and E0 if the cause of the error is in the
active parameter set.
Bit 5 - Travel_b (travel direction backward)
0 All operation modes
The "Travelling" control bit is zero or an error message is pending that prevents travel.
1 Operation mode manual
The "Travelling" control bit is set and the set velocity is less than zero.
Operation mode positioning
The "Travelling" control bit is set and the difference between the target position and the actual
position is less than zero.
Note
Error messages that prevent travel are E3, E6, and E0 if the cause of the error is in the
active parameter set.
Bit 6 – SC_IsOn (sway control on)
0
The sway control function has been deactivated.
1
The sway control function has been activated.
Under certain circumstances, the sway control function can be deactivated even though
control bit "SC_On" is set (see Chapter Operation mode manual with sway control
(Page 102)).
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
78 Operating Instructions, 02/2014
6.3.4
Gantry block (12 bytes)
6.3.4.1
Output data, gantry block
Table 6- 30 Gantry block
Name
Type
Address
Designation
Unit
StateBits WORD 26-27 Gantry status bits See Table 6-31
Gantry status bits
(Page 79)
V_norm INT 28-29 Output velocity, gantry Normalized
Default: 16384
V_mm_s
REAL
30-33
Output velocity, gantry
± mm/s
Deflection
INT
34-35
Pendulum deflection, gantry
± mm
S_corr INT 36-37 Distance correction by sway
control, gantry
± mm
StateBits – status bits, gantry
See Chapter Status bits, gantry block (Page 79)
V_norm – output velocity as normalized value
Output velocity of the gantry as normalized value.
This value must be transferred to the drive.
V_mm_s – output velocity
Output velocity in mm/s.
Deflection – pendulum deflection
Current distance of the reflector from its home position in the direction of the gantry.
When a camera is being used, the real pendulum deflection value is measured and output.
The mathematical oscillation model is calibrated with this value. Without a camera, this
output returns the pendulum deflection based on the mathematical oscillation model.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 79
S_corr – distance correction by sway control, gantry
With external position control, the S_corr value is required to form the position difference that
is the input variable for the external position controller.
Position difference = target position - actual position - distance correction by sway control
Note
S_corr is transmitted from the sway control to the crane control system as an
INT value. In
the sample block this value is converted to a DINT value and can be further processed as a
DINT value.
6.3.4.2
Status bits, gantry block
Table 6- 31 Gantry status bits
Bit no.
Name
Meaning
0
Ready
Ready for operation
1
Active
Active
2
Pos_completed
Positioning and sway neutralization completed
3
SC_completed
Sway neutralization completed
4
Travel_f
Direction of travel forward
5
Travel_b
Direction of travel backward
6
SC_IsOn
Sway control on
7-15
-
Not used
Bit 0 – ready
0
Checkback signal control bit Release (Release=0)
1
Checkback signal control bit Release (Release=1)
Bit 1 – Active (gantry active)
0
The output velocity is zero.
1
The drive is active and outputs the output velocity that is currently required.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
80 Operating Instructions, 02/2014
Bit 2 – Pos_completed (positioning and sway neutralization completed)
0
Operation mode manual:
The set velocity is greater than zero or the output velocity is greater than the zero speed
detection P59 or the sway has not been neutralized on the gantry.
Operation modes positioning and sway neutralization:
The position deviation is greater than the specified positioning window P49 or the sway has
not been neutralized on the gantry or the output velocity is greater than the zero speed
detection P59.
1
Operation mode manual:
The set velocity is zero and the output velocity is less than / equal to the zero speed detection
P59 and the sway has been neutralized on the gantry.
Operation modes positioning and sway neutralization:
The target positi
on has been reached. The position deviation is within the specified positioning
window P49 and the sway has been neutralized on the gantry and the output velocity is less
than / equal to the zero speed detection P59.
Note
A minimum period of 0.5 s app
lies to the output velocity condition less than / equal to the
zero speed detection P59 in manual operation mode with sway control. A minimum period of
1.0 s applies to output velocity less than / equal to the zero speed detection P59 and the
actual positi
on in positioning window P49 in the other operation modes with sway control.
Bit 3 – SC_completed (sway neutralization completed)
0
The pendulum deflection is greater than P73 or the pendulum velocity is greater than P74.
1 The pendulum deflection is less than P73 and the pendulum velocity is less than P74 over a
period of at least 250 ms.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 81
Bit 4 - Travel_f (travel direction forward)
0 All operation modes
The "Travelling" control bit is zero or an error message is pending that prevents travel.
1 Operation mode manual
The "Travelling" control bit is set and the set velocity is greater than or equal to zero.
Operation mode positioning
The "Travelling" control bit is set and the difference between the target position and the actual
position is greater than or equal to zero.
Note
Error messages that prevent travel are E3, E6, and E0 if the cause of the error is in the
active parameter set.
Bit 5 - Travel_b (travel direction backward)
0 All operation modes
The "Travelling" control bit is zero or an error message is pending that prevents travel.
1 Operation mode manual
The "Travelling" control bit is set and the set velocity is less than zero.
Operation mode positioning
The "Travelling" control bit is set and the difference between the target position and the actual
position is less than zero.
Note
Error messages that prevent travel are E3, E6, and E0 if the cause of the error is in the
active parameter set.
Bit 6 – SC_IsOn (sway control on)
0
The sway control function has been deactivated.
1
The sway control function has been activated.
Under certain circumstances, the sway control function can be deactivated even though
control bit "SC_On" is set (see Chapter Operation mode manual with sway control
(Page 102)).
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
82 Operating Instructions, 02/2014
6.3.5
Slewing gear block (12 bytes)
6.3.5.1
Output data, slew block
Table 6- 32 Slewing gear block
Name
Type
Address
Designation
Unit
StateBits WORD 38-39 Status bits, slewing gear See Table 6-33 Status
bits, slewing gear
(Page 83)
V_norm INT 40-41 Output velocity, slewing gear Normalized
Default: 16384
V_mm_s
REAL
42-45
Output velocity, slewing gear
± c°/s
Skew
INT
46-47
Rotation
± c°
S_corr INT 48-49 Distance correction through sway
control, slewing gear
± c°
StateBits – status bits, slewing gear
See Chapter Status bits, slewing gear block (Page 83).
V_norm – output velocity as normalized value
Output velocity of the slewing gear as normalized value.
This value must be transferred to the drive.
V_mm_s – output velocity
Output velocity in c°/s
Skew – rotation
Instantaneous rotation of the reflector out of the home position in c°.
When a camera is being used, the real rotation value is measured and output. The
mathematical oscillation model is calibrated with this value. Without a camera, this output
returns the rotation based on the mathematical oscillation model.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 83
S_corr – distance correction by sway control, slewing gear
With external position control, the S_corr value is required to form the position difference that
is the input variable for the external position controller.
Position difference = target position - actual position - distance correction by sway control
Note
S_corr is transmitted from the sway control to the crane control system as an INT value. In
the sample block this value is converted to a DINT value and can be further processed as a
DINT value.
6.3.5.2
Status bits, slewing gear block
Table 6- 33 Status bits, slewing gear
Bit no.
Name
Meaning
0
Ready
Ready for operation
1
Active
Active
2
Pos_completed
Positioning and sway neutralization completed
3
SC_completed
Sway neutralization completed
4
Travel_f
Direction of travel forward
5
Travel_b
Direction of travel backward
6
SC_IsOn
Sway control on
7-15
-
Not used
Bit 0 – ready
0
Checkback signal control bit Release (Release=0)
1
Checkback signal control bit Release (Release=1)
Bit 1 – active (slewing gear active)
0
The output velocity is zero.
1
The drive is active and outputs the output velocity that is currently required.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
84 Operating Instructions, 02/2014
Bit 2 – Pos_completed (positioning and sway neutralization completed)
0
Operation mode manual:
The set velocity is greater than zero or the output velocity is greater than the zero speed
detection P149 or the sway has not been neutralized on the slewing gear.
Operation modes positioning and sway neutralization:
The position deviation is greater than the specified positioning window P139 or the sway has
not been neutralized on the slewing gear or the output velocity is greater than the zero speed
detection P149.
1
Operation mode manual:
The set velocity is zero and the output velocity is less than / equal to the zero speed detection
P149 and the sway has been neutralized on the slewing gear.
Operation modes positioning and sway neutralization:
The target position has been reached. The position deviation is within the specified positioning
window P139 and the sway has been neutralized on the slewing gear and the output velocity
is less than / equal to the zero speed detection P149.
Note
A minimum period of 0.5 s applies to the output velocity condition less than / equal to the
zero speed detect
ion P149 in manual operation mode with sway control. A minimum period
of 1.0 s applies to output velocity less than / equal to the zero speed detection P149 and the
actual position in positioning window P139 in the other operation modes with sway control.
Bit 3 – SC_completed (sway neutralization completed)
0
The rotation is greater than P163 or the pendulum velocity is greater than P164.
1 The rotation of the load is less than P163 and the pendulum velocity is less than P164 over a
period of at least 250 ms.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 85
Bit 4 - Travel_f (travel direction forward)
0 All operation modes
The "Travelling" control bit is zero or an error message is pending that prevents travel.
1 Operation mode manual
The "Travelling" control bit is set and the set velocity is greater than or equal to zero.
Operation mode positioning
The "Travelling" control bit is set and the difference between the target position and the actual
position is greater than or equal to zero.
Note
Error messages that prevent travel are E3, E6, and
E0 if the cause of the error is in the
active parameter set.
Bit 5 - Travel_b (travel direction backward)
0 All operation modes
The "Travelling" control bit is zero or an error message is pending that prevents travel.
1 Operation mode manual
The "Travelling" control bit is set and the set velocity is less than zero.
Operation mode positioning
The "Travelling" control bit is set and the difference between the target position and the actual
position is less than zero.
Note
Error messages that pre
vent travel are E3, E6, and E0 if the cause of the error is in the
active parameter set.
Bit 6 – SC_IsOn (sway control on)
0
The sway control function has been deactivated.
1
The sway control function has been activated.
Under certain circumstances, the sway control function can be deactivated even though
control bit "SC_On" is set (see Chapter Operation mode manual with sway control
(Page 102)).
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
86 Operating Instructions, 02/2014
6.3.6
Hoist block (12 bytes)
6.3.6.1
Output data, hoist block
Table 6- 34 Hoist block
Name
Type
Address
Designation
Unit
StateBits WORD 38-39 Status bits, hoist See Table 6-35 Status
bits, hoist (Page 87)
V_norm INT 40-41 Output velocity, hoist Normalized
Default: 16384
V_mm_s
REAL
42-45
Output velocity, hoist
± mm/s
Skew
INT
46-47
Not used
S_corr
INT
48-49
Not used
StateBits – status bits, hoist
See Chapter Status bits, hoist block (Page 87).
V_norm – output velocity as normalized value
Output velocity of the hoist as normalized value.
This value must be transferred to the drive.
V_mm_s – output velocity
Output velocity in mm/s.
Skew – not used
Is always zero for the hoist.
S_corr – not used
Is always zero for the hoist.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 87
6.3.6.2
Status bits, hoist block
Table 6- 35 Status bits, hoist
Bit no.
Name
Meaning
0
Ready
Ready for operation
1
Active
Active
2
Pos_completed
Positioning completed
3
Not used
4
Travel_f
Direction of travel forward
5
Travel_b
Direction of travel backward
6-15
Not used
Bit 0 – ready
0
Checkback signal control bit Release (Release=0)
1
Checkback signal control bit Release (Release=1)
Bit 1 – active (hoist active)
0
The output velocity is zero.
1
The drive is active and outputs the output velocity that is currently required.
Bit 2 – Pos_completed (positioning completed)
0
Operation mode manual:
The set velocity is greater than zero or the output velocity is greater than the zero speed
detection P149.
Operation mode positioning:
The position deviation is greater than the specified positioning window P139 or the output
velocity is greater than the zero speed detection P149.
1
Operation mode manual:
The set velocity is zero and the output velocity is less than / equal to the zero speed detection
P149.
Operation mode positioning:
The target position has been reached. The position deviation is less than the specified
positioning window P139 and the output velocity is less than / equal to the zero speed
detection P149.
Bit 3 – not used
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
88 Operating Instructions, 02/2014
Bit 4 - Travel_f (travel direction forward)
0 All operation modes
The "Travelling" control bit is zero or an error message is pending that prevents travel.
1 Operation mode manual
The "Travelling" control bit is set and the set velocity is greater than or equal to zero.
Operation mode positioning
The "Travelling" control bit is set and the difference between the target position and the actual
position is greater than or equal to zero.
Note
Error messages that prevent travel are E3, E6, and E0 if the cause of the e
rror is in the
active parameter set.
Bit 5 - Travel_b (travel direction backward)
0 All operation modes
The "Travelling" control bit is zero or an error message is pending that prevents travel.
1 Operation mode manual
The "Travelling" control bit is set and the set velocity is less than zero.
Operation mode positioning
The "Travelling" control bit is set and the difference between the target position and the actual
position is less than zero.
Note
Error messages that prevent travel are E3, E6, a
nd E0 if the cause of the error is in the
active parameter set.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 89
6.3.7
Trailer (telegram counter)
The last two bytes are intended for a telegram counter.
Table 6- 36 PROFIBUS DP Trailer
Name
Type
Address
Designation
Trailer
WORD
50-51
Telegram counter
The last two bytes contain a telegram counter (SIMOTION C240 PN → crane control
system).
For more information, see error message E2 (Chapter List of alarm, error, and system
messages (Page 159)).
6.3.8
Data to the camera
Table 6- 37 Data to the camera (PLC → SIMOTION C240 PN → camera measuring system)
Type
Name
Meaning
Unit
DINT S_Hoist_Cam Hoist position for effective pendulum length
The value is identical with S_Hoist (input date,
general block)
mm
S_Hoist_Cam
Transferring the hoist position for effective pendulum length to the SIMOCRANE CenSOR
camera measuring system facilitates faster identification of the reflector.
The value S_Hoist (input data, general block) is sent to the value S_Hoist_Cam (data to the
camera).
Additional information can be taken from the documentation on the camera measuring
system.
Note
The communication configuration to the camera is already completely included in the project
data on the MMC provided
. The information provided is only intended to provide a better
understanding of the correlations.
Interface description
6.3 Output data
CeSAR standalone OHBC, Gantry crane
90 Operating Instructions, 02/2014
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 91
Function description
7
7.1
General
7.1.1
Operation and characteristics
The sway control receives the pendulum deflection value from the camera measuring
system. If the measuring signal fails, calculations are based on the current states of the
mathematical oscillation model.
Generally, the sway control system has the following characteristics:
● Load sway is eliminated when the steady state velocity or standstill is reached.
● In positioning operation, the load only overshoots the target position by a very small
amount.
You can assign parameters to the sway control system using the SIMOCRANE CeCOMM
diagnostic program (see Chapter Parameter sets (Page 93)). The sway control can receive
input data (e.g. control bits, setpoints) from the crane control system and transfer output data
(e.g. status bits, output values) to the crane control system via the PROFIBUS interface.
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
92 Operating Instructions, 02/2014
Operating principle of the sway control system
The characteristic of pendulum deflection is non-periodic. Acceleration is not constant. It
varies depending on the state of the oscillation model and the measured pendulum
deflection. The acceleration times are approx 1.1 times the natural oscillation duration of the
load oscillation (load sway). The travel operations place very low stress levels on the crane
structure.
The following diagram shows the travel response during operation with sway control with a
pendulum length of approx. 3.5 m:
Figure 7-1 Sway control in manual operation mode
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 93
7.1.2
Parameter sets
7.1.2.1
Overview
Parameters are assigned to the sway control system using the SIMOCRANE CeCOMM
diagnostic program as shown in the following overview:
1)
... or where a fault is detected for the relevant parameter set
2)
This parameter set is effective.
Figure 7-2 Editing parameter sets in SIMOCRANE CeCOMM
All the parameters in the parameter list are available in fours, i.e. in the form of four current
parameter sets.
To be able to respond appropriately to the requirements of individual handling tasks (e.g.
changes in acceleration), you can adjust the relevant parameter settings in the individual
current parameter sets. In other words, you can assign four different parameter values in the
four current parameter sets and switch between these sets during operation. This allows you
to operate the sway control system flexibly without needing to change parameter settings.
This does not apply to parameters P80, P100, P101, P108, P110, P115, and P159 (see
Chapter Changing a parameter (Page 95)). Changes to the settings of these parameters are
always effective simultaneously in all four current parameter sets.
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
94 Operating Instructions, 02/2014
In addition to allowing processing of current parameter sets the file manager in SIMOCRANE
CeCOMM also enables users to access and edit the four saved text files (parameter files).
These text files are located on the MMC of the SIMOTION C240 PN in the directory
/SWAYCONTROL/.
If a parameter exceeds the specified limits when it is loaded, an error message is generated
and the value of the relevant parameter is set to the default value. The error is only reset
after all parameter sets have been loaded successfully.
7.1.2.2
Calling up the parameter menu
● Parameters are entered and processed via the main menu or via another display screen.
The parameter menu is called by pressing "P" (see Chapter Monitoring functions
(Page 149)). The parameter menu contains an overview of the parameter groups that can
be displayed by page in short form with the keys "1", "2", etc.
● Parameters which are not set to their default settings are identified by a "+". When "?"
and the parameter number are entered, a detailed explanation of the parameter is
displayed together with the current value and the 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.
● If values less than 20 are input as settings for the acceleration parameters, they will be
interpreted as ramp times, and made available for transfer after conversion to the
corresponding acceleration values.
● Note the following:
– Always use the parameter menu of the SIMOCRANE CeCOMM diagnostic program to
edit the parameter sets because only then will a plausibility check be made and
incorrectly entered values rejected.
If you directly edit the stored text files (e.g. Par0.txt), no plausibility check is made and
the entire file could be rendered unusable as a result.
– If the acceleration parameters are set to values less than 20 directly in the text files,
these will not be interpreted as ramp times but as acceleration values.
● Detailed information about the parameters is contained in Chapter Parameter list
(Page 171) and the online help.
7.1.2.3
Activating a parameter set
A parameter set can be activated with the control bits "Select parameter set" (bits 0 and 1,
general control bits). The relevant active parameter set is used by the control.
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 95
7.1.2.4
Editing a parameter set
"N" Edit another parameter set
Irrespective of the active parameter set, all current parameter sets can be edited with the "N"
key - "Edit another parameter set." The required number must be entered and confirmed with
<ENTER>. The selected parameter set is displayed in the SIMOCRANE CeCOMM
diagnostic program and can then either be edited by pressing "C - Change parameter" or "Y
- Copy parameter." If no parameter set is selected here then the relevant active parameter
set can be edited upon exiting the parameter menu.
Note
When the parameter menu is selected only the parameter set which is active at this point
can be edited. If the active parameter set
changes while the parameter menu is being edited
then the parameter set which was active prior to this can still be edited. The parameter set
selected with the "N" key can continue to be edited until the parameter menu is exited again.
The active parameter
set can be edited again when the parameter set is reselected.
7.1.2.5
Changing a parameter
"C" Change parameters
The parameters of the active parameter set or of the parameter set previously selected by
pressing "N - Edit another parameter set" can be changed using the "C" function.
Please note:
Changing the following parameters always affects all four parameter sets:
P80
Assignment of camera measurement direction
P100
Access code
P101
Parameter set locked during travel
P108
Pendulum length from the PLC / from the camera
P110
Language
P115
Configuration
P159
Direction of rotation of slewing gear
Once the "C" key is activated the parameter number must be entered (e.g. "1" for parameter
P1) and completed with <ENTER>. The new value is then entered and confirmed twice with
<ENTER>.
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
96 Operating Instructions, 02/2014
Changed parameters are marked with a "+" and a different font color in the displays ("1" …
"12").
Note
Each parameter changed in the active parameter set is effective immediately but is not
stored permanently. Changed paramet
ers must also be saved permanently with "S" ("Save
all parameter sets").
All parameter sets are saved at all times.
Note
All parameters whose setting is not absolutely necessary during commissioning and which
were not therefore described explicitly in
the appropriate sections should be left with their
default settings and only changed where required.
7.1.2.6
Copying a parameter set
"Y" Copy parameter set
The parameter set that can be edited at this time can be copied to one of the other three
current parameter sets with the "Y" - "Copy parameter set" function. The number of the
target parameter set must be entered.
7.1.2.7
Loading the saved parameter sets
"R" ReLoad parameters
All saved parameter sets are loaded and the current parameter sets are therefore
overwritten with the parameter sets stored in files Par0.txt bis Par3.txt. This is useful when a
parameter has been changed but not saved and the previous version needs to be restored. If
a parameter set is copied into the directory, the parameters must also be reloaded for
updating.
The parameters are reloaded automatically upon power up.
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 97
7.1.2.8
Save all parameter sets
"S" Save all parameter sets
All current parameter sets are saved in parameter files Par0.txt to Par3.txt using this
function.
Note
Each parameter change
d in the active parameter set is effective immediately but is not
stored permanently. Changed parameters should also be permanently saved with Save "S."
All current parameter sets are saved in all cases.
7.1.2.9
Switching over parameter sets
One of the four current parameter sets can be activated via two selection bits. This enables
the sway control to be operated with different parameter settings without having to change
the parameter assignment.
The parameter P101 "Parameter set locked during travel" can be used to prevent the
switching of parameter sets during travel.
7.1.2.10
Setting default values
"D" Set default values
The parameter settings of all current parameter sets are restored to their defaults with the
"D" key.
7.1.2.11
More functions
"L" Show list of parameters
All parameters are listed.
Users can scroll through the entire list with "F2-History."
"F3-Back to Monitor" restores the monitor display.
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
98 Operating Instructions, 02/2014
"F" Search parameters
A search term can be entered. All parameters that contain this search term will be listed.
Note
A
ll set values can best be documented with the functions "L-Show list of parameters," "F2-
History," select (e.g. CTRL
-A) and "F4-Save as ..." "F3-
Back to Monitor" restores the monitor
display.
7.1.3
Operation modes
7.1.3.1
Selecting the operation mode
The operation modes are selected using the corresponding control bits and these define
whether the corresponding drive is manually operated, a velocity setpoint is entered or
automatic travel (positioning) should be realized by entering a target position. Manual
operation and positioning are in principle possible with and without sway control. However,
we recommend that the positioning operation mode is only used in conjunction with sway
control. Operation without sway control only makes sense for manual operation mode. You
can find more detailed information on this in Chapter Operation mode manual without sway
control (Page 101).
7.1.3.2
Operation mode manual
In this mode, either an individual drive can be operated, or multiple drives together. Trolley,
gantry and slewing gear are operated with sway control; however, the hoist is not.
7.1.3.3
Operation mode positioning
In this mode, either an individual drive can be operated, or multiple drives together. Trolley,
gantry and slewing gear are operated with sway control; however, the hoist is not.
7.1.3.4
Operation mode sway neutralization
The trolley, gantry and slewing gear drives which can be operated with sway control can also
operate in the sway neutralization operation mode. Using two different control bits, it is
possible to choose between the operation modes "sway neutralization load position" and
"sway neutralization drive position."
We recommend that only one drive at a time be operated in this mode.
This mode can be selected only if the control bit "SC_On" (activate sway control) is set.
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 99
7.1.3.5
Fault response
If more than one operation mode per drive is simultaneously selected, then a fault message
E01 is output (invalid operation mode). It is recommended that such a bit combination is
avoided in the PLC from the beginning, or the fault message mentioned is evaluated with a
delay.
7.1.4
Response in the limit switch
7.1.4.1
Response in the manual operation mode
The activation of a limit switch depends on the direction. If a limit switch responds then the
brake is decelerating in the corresponding direction with the quick stop ramp (P12, P52,
P142) without sway control. It can continue to travel unrestricted in the opposite direction.
7.1.4.2
Response in the positioning operation mode
The activation of a limit switch is independent of the direction. If a limit switch responds, the
brake will decelerate with the quick stop ramp (P12, P52, P142) without sway control,
irrespective of the direction of motion. The limit switch range can only be exited again if the
manual operation mode is selected. The limit switches can also be enabled drive-specifically
depending on the direction in positioning operation mode using parameter P97.
7.1.5
Response in the prelimit switch
7.1.5.1
Response in the manual operation mode
Reducing the velocity along a linear ramp
When a prelimit switch is triggered in the manual operation mode, the drive is braked at the
deceleration rate set in parameter P14 (trolley), P54 (gantry), and P144 (slewing gear).
Using parameters P13 (trolley), P53 (gantry) and P143 (slewing gear or hoist), this value can
be set as a percentage of the maximum velocity.
Braking an axis to this velocity is only possible by using a linear ramp. The sway control is
then only effective in the enabled direction, and as a consequence the effect of the sway
control system cannot be optimally executed.
Parameters P13, P53, and P143 are only intended for braking at the prelimit switches, and
are not limited by the maximum acceleration of the particular drive P4, P44, and P134.
The hoist is braked according to the setting in parameter P132. This deceleration rate is not
limited by the maximum acceleration in P134 when a prelimit switch is actuated. However
the limit is applied in cases where a prelimit switch has not been actuated.
Function description
7.1 General
CeSAR standalone OHBC, Gantry crane
100 Operating Instructions, 02/2014
Reducing the velocity, sway controlled
If softer braking with sway control is required, e.g. if the crane working range is within the
prelimit switch range, then the set velocity at the sway control (generally 10%) must be
reduced in the crane control system. This may also result in a significantly increased braking
distance.
This can be remedied by the provision of additional prelimit switches which are installed at a
greater distance from the limit switch than the prelimit switches for operation without sway
control.
Note
These prelimit switches must be used to reduce the set velocity in the crane control system.
They must not be sent to the corresponding control bits in the sway control system as this
would render th
e linear ramps operative.
If position encoders are installed then the trigger signal can also be generated via software in
the crane control system. The software limit switch must be located so that when the limit
switch is reached, the prelimit switch velocity has already been reached and the load sway
has largely been neutralized.
7.1.5.2
Response in the positioning operation mode
In the positioning operation mode, when the prelimit switch is actuated the output velocity is
reduced with sway control activated by limiting the positioning velocity to the prelimit switch
velocity. Using parameters P13 (trolley), P53 (gantry) and P143 (slewing gear or hoist), this
value can be set as a percentage of the maximum velocity (default 10%).
The deceleration in the prelimit switch range can be set using parameters P14 (trolley), P54
(gantry) and P144 (slewing gear). However, for control-related reasons, these are limited
and only effective if the value lies between the setpoint acceleration and maximum
acceleration. The setpoint acceleration level takes effect if the value is less than the setpoint
acceleration level. The axis is braked with the maximum deceleration level if the value is
greater than the maximum acceleration level.
The hoist is braked according to the setting in parameter P132. This deceleration rate is also
limited by the maximum acceleration in P134 when a prelimit switch is actuated.
Function description
7.2 Operation mode manual
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 101
7.2
Operation mode manual
7.2.1
Operation mode manual without sway control
In manual operation mode without sway control the set velocity is specified by the crane
operator. Linear acceleration or braking is then applied to this velocity. The load sway is not
taken into account.
Operating in the manual operation mode without sway control has the following significance:
● The accuracy of the setpoint channel must be reviewed at the start of commissioning.
The most practical approach is to do this without sway control activated; this is because
in this particular case, neither the camera signal nor the correct pendulum length is
required. For example, for incorrect setpoint polarities, the sway motion can be further
increased in a sway-controlled mode. This situation would then only be able to be
handled with an EMERGENCY STOP.
● To perform the commissioning steps, test runs are required, which are carried out with
the sway control deactivated.
● Internal deactivation of the sway control function (see Chapter Operation mode manual
with sway control (Page 102)) means that the travel is completed without the sway control
activated.
● If the camera signal fails during regular operation (e.g. because the reflector is dirty etc.),
then sway-controlled operation is still maintained. In this case, the mathematical
calculation model is used instead of the camera signal.
If the camera measuring system permanently reports error E10 "camera measuring
system impaired", then after 14 s, error message E11 "Camera measuring system
faulted" is generated. In this state, the sway control can only be operated based on the
mathematical calculation model. The sway control must always be deactivated if the
measured distance between the camera and the reflector is used to calculate the
pendulum length (P108 = ON).
● If the position sensing functions for the hoist report a fault in the crane control system
during regular operation, travel may only continue without the sway control active in case
the value S_Hoist (hoist position for effective pendulum length) is used to calculate the
pendulum length (P108=OFF).
● If operations are performed with pendulum lengths < P83, then travel only takes place
with the mathematical calculation model with sway control. This state can only be
maintained for a limited period, after which travel can only take place without sway control
(see also Chapter Other settings (Page 138)).
Function description
7.2 Operation mode manual
CeSAR standalone OHBC, Gantry crane
102 Operating Instructions, 02/2014
7.2.2
Operation mode manual with sway control
In manual operation mode with sway control the set velocity is specified by the crane
operator. The system accelerates or brakes to this velocity in such a way that the load sway
is eliminated by the time the acceleration or braking operation is completed.
Activating the operation mode
The manual operation mode is activated by setting the corresponding operation mode bit at
the drives (see the tables in Chapters Control bits, trolley block (Page 52), Control bits,
gantry block (Page 56), and Control bits, slewing gear block (Page 61)). This operation mode
can be started from all other operation modes without having to stop the drives. Hoist
movements are possible while the trolley, gantry, or slewing gear are being operated with
sway control and have very little effect on the quality of the sway control.
Internal deactivation of the sway control function
The sway control is internally deactivated under the following conditions (although operation
is still possible without sway control):
● The "SC_On" control bit is reset.
● The activation velocity (P20, P60, P150) was not achieved.
● The "SC_Only_OnStop" control bit has been set. The sway control system is only active
when stopping.
● The hoist is located outside the sway control limits (P84, P85).
● The pendulum length is not within the minimum/maximum length limits (P86, P87).
● The license is corrupt or missing.
Sway control only when stopping
● Sway control is active continuously (control bit "SC_Only_OnStop" = 0):
The load sway is corrected during travel and is eliminated when either a constant velocity
is reached or the crane stops moving.
● Sway control is active only during stopping (control bit "SC_Only_OnStop" = 1):
The load sway is corrected only during braking and is eliminated altogether after the
crane stops moving.
Note
Sway control can be activated only if control bit "SC_On" is set.
Function description
7.2 Operation mode manual
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 103
Activating/deactivating the sway control function
The sway control function can be activated or deactivated by means of control bit "SC_On."
When the sway control function is deactivated, the drives accelerate and decelerate at
constant rates according to the parameterized acceleration/deceleration values. The load
sway is not taken into account.
The internal activation of the sway control is indicated using status bit "SC_IsOn."
The following figure shows the travel response during operation with sway control.
①
Set velocity
②
Output velocity
③
Deflection
Figure 7-3 Sway control in manual operation mode
Once a set velocity ① has been specified the output velocity ② begins to increase in
accordance with the set acceleration rates. With this the momentary acceleration does not
remain constant as it does with operation without sway control but varies in accordance with
the requirements of the sway control. The sway control then works without any faults if the
deflection ③ is around zero during movement with constant velocity after the acceleration is
completed. The same is valid after the deceleration is completed. The deflection occurring
during the acceleration phases is physically unavoidable.
Function description
7.3 Operation mode positioning
CeSAR standalone OHBC, Gantry crane
104 Operating Instructions, 02/2014
Functions for optimizing travel behavior
The task of this function is to create a crane behavior with electronic sway control so that the
crane operator is supported by the sway control function and does not perceive it as
disturbing.
The following functions are available in manual operation mode:
● Optimum damping factors (P16, P17, P56, P57, P146, P147):
The damping factors for the sway control are set so that there is no deceleration in the
acceleration phase and no acceleration in the deceleration phase.
● Countering function:
For opposing set velocity (master controller) and output velocity signs, the deceleration is
increased in accordance with the settings in parameters P18 (P58, P148).
● No direction reversal (P89 suppress opposite direction):
As long as the set velocity is less than the value set in P89 then any travel direction
reversal that may be required by the sway control will be suppressed. In practical terms,
this means, e.g.: As long as the crane operator only issues travel commands in the
forward direction, the drive only moves forward. If sway control is active, the drive will
perform a few short forward travel movements after stopping, to reduce oscillation.
● Reduced ramps for fine positioning:
For small and brief master controller deflections, the acceleration and braking ramps are
reduced to the values from P94 and P95. This allows the crane operator to finely position
the crane. Sway motion is only excited to a low degree.
● Ramp alignment:
The ramps for operation without sway control are set so that the acceleration and braking
times are similar to those in operation with sway control.
7.3
Operation mode positioning
In the positioning operation mode, a specified target position can be approached
automatically with sway control for the trolley, gantry, and slewing gear drives.
In a configuration with hoist, a target position can also be approached automatically (without
sway control) for the hoist.
Load sway is eliminated both when positioning velocity is reached and on completion of the
positioning operation.
Control bit "OM_POS" is set to activate the positioning operation mode. Positioning starts
when the "Travelling" control bit is activated.
The positioning operation can be interrupted at any time by setting the control bit "Stop"
(controlled stop). The relevant drive stops with sway control.
The positioning operation can also be interrupted by resetting the "Travelling" control bit.
This means that the drive stops along the quick stop ramp without sway control.
The permissible positioning range can be set using the "Minimum position" parameters (P7,
P47, P137) and the "Maximum position" parameters (P8, P48, P138). Positioning outside
this range is not possible.
Function description
7.4 Operation mode sway neutralization load position
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 105
7.4
Operation mode sway neutralization load position
The sway neutralization load position operation mode (only for the version with camera) is
used to eliminate sway motion of the load from standstill.
The sway neutralization load position operation mode is the same as the positioning
operation mode except for the fact that the target position is specified internally and
corresponds to the position of the load at the moment the "Travelling" control bit is set when
the operation mode is activated.
Calculation of the load position:
Load position = actual position of the drive + pendulum deflection
Sway neutralization results in slight travel movements on both sides of the target position.
The signal sequence corresponds to that of positioning.
This operation mode exists for all sway-controlled drives.
Control bit "OM_SC_LO" is set to activate the sway neutralization load position operation
mode.
7.5
Operation mode sway neutralization drive position
"Sway neutralization drive position" operation mode (only for the version with a camera) is
used to eliminate sway motion of the load from standstill.
The sway neutralization drive position operation mode is the same as positioning operation
mode except that the target position is specified internally and corresponds to the actual
position of the drive at the moment the "Travelling" control bit is set when the operation
mode is activated.
Load sway results in slight travel movements to both sides of the target position. The signal
sequence corresponds to that of positioning.
This operation mode exists for all sway-controlled drives.
Control bit "OM_SC_DR" is set to activate the sway neutralization drive position operation
mode.
Function description
7.5 Operation mode sway neutralization drive position
CeSAR standalone OHBC, Gantry crane
106 Operating Instructions, 02/2014
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 107
Commissioning
8
8.1
Commissioning prerequisites
8.1.1
General
Commissioning of the drive system and all safety functions of the crane must be performed,
especially limit trips, safety interlocks, EMERGENCY STOP functions and centrifugal switch
and these must be functional.
8.1.2
Load measurement
If tests are conducted with load, then the load measuring equipment must also function
perfectly. In principle, commissioning of the sway control system can be performed
completely without load, with the exception of the digital and analog correction of the
effective pendulum length; the reason for this is that the load is required as input variable
here.
After completing the commissioning test runs, it is recommended that all of the operation
modes used in practice are conducted with load.
8.1.3
Position sensing
The position sensing functions for the drives, generally implemented in the crane control
system, and the corresponding limit monitoring must function (see Chapter Sensing and
monitoring the position actual values (Page 35)).
8.1.4
Sway control components
All components of the system must be installed, connected, functional, and interconnected.
A functioning SIMATIC S7 configuration (crane control without sway control) must be
provided.
Commissioning
8.2 Preparing commissioning
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108 Operating Instructions, 02/2014
8.2
Preparing commissioning
8.2.1
Preparing the PLC program
1. Configuring the hardware, integrating the SIMOTION C240 PN as a slave in an existing
PLC crane project (see Chapter Hardware configuration in SIMATIC S7, integration into
S7 project (Page 31)).
2. Configuring the PROFIBUS I/O (defining inputs and outputs in HW Config);
see Chapter Hardware configuration in SIMATIC S7, integration into S7 project
(Page 31))
3. Copying the SIMATIC S7 sample blocks to the PLC crane project and creating the
configured addresses at the receive and send blocks "SC_SEND_INT" and
"SC_RECEIVE".
4. Interconnecting the input and output pins at the FC block "SC_COMMON" and
"SC_AXIS_INT".
FC "SC_AXIS_INT" can be called a multiple number of times. The "Axis" input is used to
define the drive.
1 = trolley
2 = gantry
3 = slewing gear or hoist (only one of the two drives can be used.)
Inputs that are not relevant must be assigned a fixed value.
8.2.2
Preparing the converter
8.2.2.1
Converter parameter sets
The setpoints in the converters must be set differently for operation with the sway control
system than in conventional operation.
This is achieved using two different parameter sets:
● The first parameter set is used for the conventional crane control. The normal
acceleration and deceleration ramps must be set there.
● The second parameter set is used for operation with the sway control system. In this
case, the sway control system specifies the ramps. The parameters are set as described
in the following sections (see Acceleration and deceleration ramps (Page 109); Initial and
final rounding (Page 109)).
Commissioning
8.2 Preparing commissioning
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 109
8.2.2.2
Acceleration and deceleration ramps
The internal acceleration and deceleration ramps of the converters must be set to the lowest
permissible acceptable values (according to the specification of the manufacturer or end
customer) for the drives and mechanical components.
These extreme ramps never become effective in normal operation. They work as protective
ramp function generators in the event that there are commissioning faults or other functional
errors.
Note
Acceleration and deceleration ramps that are excessively long can result in increasing
oscillation.
CAUTION
Risk of injury and potential material damage due to unexpected movements of the crane
Unexpected jerking movements may occur during operation with sway control.
These can cause injury to unprotected persons. Damage might also be caused to
unprotected objects.
• Protect yourself against unexpected movements (e.g. by wearing a safety harness or
standing in a secure position).
• Secure freely movable objects to prevent them from slipping.
8.2.2.3
Initial and final rounding
The velocity characteristic is defined by the sway control system. Deactivate the initial and
final rounding functions to prevent falsification of this velocity curve and the consequent
reduction in sway control quality.
Note
Excessive rounding in the converter can cause sway!
8.2.2.4
Minimum converter frequency
To be able to eliminate small levels of oscillation after stopping, set the minimum frequency
of the converter to 1 Hz or lower.
Note
A minimum frequency that is set too high may result in unwanted residual oscillations.
Commissioning
8.2 Preparing commissioning
CeSAR standalone OHBC, Gantry crane
110 Operating Instructions, 02/2014
8.2.2.5
Speed controller of the converter
To achieve the best possible control response, activate the internal speed control of the
converter.
Make the following settings:
● Proportional component
● I component
Note
When setting the speed controller, make sure that the ramp response exhibits the lowest
possible level of overshoot.
8.2.2.6
Velocity limits
Where velocity needs to be limited then this limit must also be effective in the sway control
system.
To implement this limit, proceed as follows, depending on the operation mode:
● Operation mode manual:
Limitation of the set velocity V_set in the crane control system
● Operation mode positioning:
Reduction of the positioning velocity (parameter P0) by means of parameter set
switchover in the sway control system.
● Valid for all operation modes:
Use of prelimit switch function (see Chapter Response in the prelimit switch (Page 99))
Note
Limits on the output velocities outside the sway control (e.g. in the drive) can impair the
function of the sway control and
result in a following error and are therefore not permissible.
Commissioning
8.2 Preparing commissioning
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Operating Instructions, 02/2014 111
8.2.2.7
Check of the control response
The control response is checked based on the actual velocity measured for the drives.
If this value is available in the crane control system (e.g. from the frequency converter), the
value must be transmitted to the sway control (input V_act) as a normalized value. It is
provided for diagnostic purposes and is not used from a closed-loop control perspective. The
value can be used to compare the actual velocity (crane control system) with the set velocity
(SIMOTION C240 PN). Both values can be recorded with the SIMOCRANE CeCOMM
diagnostic program.
The intention is for the characteristic of the output velocity (return value from the SIMOTION
C240 PN) to match the actual drive velocity as closely as possible. The functionality of the
sway control cannot be guaranteed in the event of larger deviations.
Note
Internal calculation of the actual velocity
The internal calculation of the actual velocity is used from the m
oment the SIMOTION C240
PN powers up until the input "V_act" has a value that is not equal to zero. The internal
calculation is deactivated after this and "V_act" is used as the actual velocity until the next
power
-up.
8.2.3
Preparing the SIMOCRANE CenSOR camera measuring system
Commissioning and diagnosis of SIMOCRANE CenSOR is possible with a Web browser.
Please refer to the camera measuring system documentation for additional details.
Commissioning
8.3 Configuring the sway control system
CeSAR standalone OHBC, Gantry crane
112 Operating Instructions, 02/2014
8.3
Configuring the sway control system
8.3.1
Overview
Parameters are assigned to the sway control system using the SIMOCRANE CeCOMM
diagnostic program.
The parameters are stored in parameter sets. Detailed information on using the parameter
sets can be found in Chapter Parameter sets (Page 93).
You will find information about the parameters in Chapter Parameter list (Page 171).
8.3.2
General requirements
The following preconditions must be fulfilled before the sway control system can be
commissioned:
1. All components of the system (camera, reflector) must have been installed, connected, be
functional and interconnected.
2. The SIMOCRANE CeCOMM diagnostic program must have been installed and started.
The commissioning PC and the SIMOTION C240 PN must be connected (see Chapter
SIMOCRANE CeCOMM diagnostic program (Page 145)).
3. All communication addresses must be set (see Chapter Setting addresses (Page 154)).
4. Checking communication between the crane control system and the SIMOTION C240
PN.
5. Commissioning of the SIMOCRANE CenSOR camera measuring system must have
taken place and the communication to the SIMOTION C240 PN must have been
checked.
8.3.3
Setting the access code
The access code determines which parameters are displayed with keys "1" to "8" in the
SIMOCRANE CeCOMM parameter menu and which parameters can be edited with the "C"
(Change parameters) command.
The access code can be set with parameter P100.
The following settings are possible:
● Access code 1: Every user (crane operator, maintenance personnel)
● Access code 2: Commissioning engineer
● Access code 3: Service technician
● Access code 4: Development engineer
Commissioning
8.3 Configuring the sway control system
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 113
The relevant access code for each parameter is stated in the parameter list (see Chapter
Parameter list (Page 171)).
The meaning of this access code information is as follows:
● Access code 1: This parameter is displayed whenever P100 is set to access code 1, 2, 3
or 4.
● Access code 2: This parameter is displayed when P100 is set to access code 2, 3 or 4.
● Access code 3: This parameter is displayed when P100 is set to access code 3 or 4.
● Access code 4: This parameter is displayed when P100 is set to access code 4.
The message "No authorization!" appears when an attempt is made to change a parameter
that does not correspond to the access code.
If you want to be able to edit all parameters, set parameter P100 to 4.
Note
The access code does not influence the display in the parameter files (Par0.txt to Par3.txt),
"L" Show list of parameters, "Y" Copy parameter set, "D" Set default values, "F" Search
parameters, "S" Save all parameter sets, "R" Reload parameters.
8.3.4
Setting the language
Select a language via the menu "Options / Language" in the CeCOMM diagnostic program.
German and English are available.
The appropriate language file is then automatically opened and read. The screen displays
are updated.
Commissioning
8.3 Configuring the sway control system
CeSAR standalone OHBC, Gantry crane
114 Operating Instructions, 02/2014
8.3.5
Check of the crane control ↔ sway control system interface
Figure 8-1 Monitor function, display screen 2 "Interface"
Check the communication link between the crane control system and the sway control
system with the SIMOCRANE CeCOMM diagnostic program. This includes checking
whether data is being properly exchanged and whether the correct data formats and content
are being used.
The actual input and output data of the sway control system are displayed on the display
screen 2 "Interface". Refer to the interface description to check that these data are correct
(see Chapter Interface description (Page 45)).
Note that the values of the send and receive counters (sent / received) on display screen 2
must increase. This is a precondition of all subsequent steps because it means that the sway
control system is receiving and sending data telegrams.
Commissioning
8.3 Configuring the sway control system
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 115
8.3.6
Checking the communication with the camera measuring system
You will need the measured values of the camera in order to complete the following
commissioning steps.
This is conditional upon successful commissioning of the SIMOCRANE CenSOR camera
measuring system (see Chapter Preparing the SIMOCRANE CenSOR camera measuring
system (Page 111)).
Then check the communication link between the SIMOCRANE CenSOR camera measuring
system and the SIMOTION C240 PN as described below:
1. Open display screen 4 in the SIMOCRANE CeCOMM diagnostic program.
2. Note that incrementation of the receive counter reading is an essential requirement
because this indicates that the SIMOTION C240 PN is correctly receiving data from the
camera.
3. Check the "Status" display:
"Status OK" indicates that the reflector has been detected.
4. Check that the IP address of the camera is correctly set in the SIMOTION C240 PN in
commissioning step 7 (Change communication addresses).
Note
Incorrect setting of the communication address in the SIMOTION C
240 PN is not
detected immediately, but would have only an indirect effect, i.e. if the wrong hoist height
information is transmitted because the communication link is not functional in the send
direction.
Note
If the version with camera is used, the
n the camera must be activated using configuration
parameter P115 (default setting).
If the camera has been deactivated using configuration parameter P115, the display screen
4 depicted below will not be displayed.
Commissioning
8.3 Configuring the sway control system
CeSAR standalone OHBC, Gantry crane
116 Operating Instructions, 02/2014
Figure 8-2 Monitor function, display screen 4 "Camera"
Commissioning
8.4 Operation mode manual without sway control
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 117
8.4
Operation mode manual without sway control
8.4.1
Preparation – first steps
For safety-related reasons, we recommend that the system is initially commissioned with the
sway control deactivated. For this purpose, set the drive-specific control bit "SC_On"
temporarily to zero in the crane control system.
After you have completed commissioning step 0 (configuration and setting important
parameters) or
manually setting all required parameters, you can carry out a test run without
sway control with the load carrying device in the upper hoist position.
At the same time, activate the trace function in the SIMOCRANE CeCOMM diagnostic
program. Using the trace as a reference, you can check whether the signal sequence of the
input and output data is correct. Display screen 3 "Status of drives" is helpful at this stage
(monitor display in the SIMOCRANE CeCOMM).
Pay attention to the following signal exchange between the sway control system and the
crane control system:
● Setting of the operation mode in the crane control system
● Setting – resetting the "Travelling" control bit in the crane control system,
● Transfer of the set velocity V_set,
● Brake control with the "Travel_f" or "Travel_b" status bits (direction signals) in the crane
control system
● Output velocity V_norm output,
● Comparison of the actual velocity V_act with the output velocity V_norm
Linear ramps can be compared at this point. Depending on the manufacturer, it may also
make sense to record a trace in the converter.
If the signal exchange is correct, you can continue commissioning.
8.4.2
Commissioning steps in the commissioning menu
8.4.2.1
Procedure
The commissioning steps in the SIMOCRANE CeCOMM diagnostic program are described
below.
Start as follows:
1. Launch the SIMOCRANE CeCOMM diagnostic program.
2. Open the commissioning menu by selecting key "I" in the main menu or on the display
screens.
3. Carry out the commissioning steps in exactly the sequence specified.
Start with step "0."
Commissioning
8.4 Operation mode manual without sway control
CeSAR standalone OHBC, Gantry crane
118 Operating Instructions, 02/2014
Figure 8-3 Overview of commissioning steps
Note
The parameters ascertained during the commissioning steps are saved in all fo
ur parameter
sets upon takeover.
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
Individual st
eps can be omitted depending on the configuration.
Commissioning
8.4 Operation mode manual without sway control
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 119
8.4.2.2
Step 0: Setting the configuration and important parameters
In this commissioning step, the following parameters are successively called automatically
and must be set correctly.
The parameters listed in the table below are called only if the camera and positioning mode
have been activated with parameter P115 (default). Fewer parameters might be called
depending on the setting of this parameter.
Table 8- 1 Parameters called with P115 set to default
No.
Parameter
Designation
1
P115
Configuration
2
P85
Lower limit for sway control
3
P87
Maximum pendulum length
4
P35
Normalization value, trolley
5
P1
Maximum output velocity, trolley
6
P13
Prelimit switch velocity, trolley
7
P14
Deceleration prelimit switch, trolley
8
P2
Acceleration without sway control, trolley
9
P3
Set acceleration, trolley
10
P4
Maximum acceleration, trolley
11
P12
Quick stop ramp, trolley
12
P0
Positioning velocity, trolley
13
P7
Minimum position for positioning, trolley
14
P8
Maximum position for positioning, trolley
15
P75
Normalization value, gantry
16
P41
Maximum output velocity, gantry
17 P53 Prelimit switch velocity, gantry
18
P54
Deceleration prelimit switch, gantry
19 P42 Acceleration without sway control, gantry
20
P43
Set acceleration, gantry
21
P44
Maximum acceleration, gantry
22
P52
Quick stop ramp, gantry
23
P40
Positioning velocity, gantry
24
P47
Minimum position for positioning, gantry
25
P48
Maximum position for positioning, gantry
Commissioning
8.4 Operation mode manual without sway control
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120 Operating Instructions, 02/2014
Table 8- 2 Parameters called when hoist is selected (with P115)
No.
Parameter
Designation
26
P165
Normalization value, hoist
27
P131
Maximum output velocity, hoist
28
P143
Prelimit switch velocity, hoist
29
P132
Acceleration, hoist
30
P134
Maximum acceleration, hoist
31
P142
Quick stop ramp, hoist
32
P130
Positioning velocity, hoist
33
P137
Minimum position for positioning, hoist
34
P138
Maximum position for positioning, hoist
35
P108
Pendulum length from the PLC / from the camera
Table 8- 3 Parameters called when slewing gear is selected (with P115)
No.
Parameter
Designation
26
P165
Normalization value, slewing gear
27
P131
Maximum output velocity, slewing gear
28
P143
Prelimit switch velocity, slewing gear
29
P144
Deceleration prelimit switch, slewing gear
30
P132
Acceleration without sway control, slewing gear
31
P133
Set velocity, slewing gear
32
P134
Maximum acceleration, slewing gear
33
P142
Quick stop ramp, slewing gear
34 P159 Direction of rotation of slewing gear
35
P130
Positioning velocity, slewing gear
36 P137 Minimum position for positioning, slewing gear
37
P138
Maximum position for positioning, slewing gear
38
P88
Relation between the camera and reflector
39
P108
Pendulum length from the PLC / from the camera
Commissioning
8.4 Operation mode manual without sway control
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 121
8.4.2.3
Step 1: Aligning the camera
Note
You cannot start this commissioning step until the residual sway is close to zero.
If the configuration includes slewing gear, it must be
in the zero position.
This commissioning step senses the main direction of oscillation and the sign of the
beginning deflection. The assignment of the trolley or gantry direction to the camera x or y
measured value and its sign are determined from this information (see description of
parameter P80 in Chapter General parameters (Page 212)).
Figure 8-4 Camera image when using the SIMOCRANE CenSOR camera measuring system
If there is a gantry with sway control in addition to the trolley then this commissioning step
must be carried out twice.
A corresponding query is made at the start of the commissioning step:
Commissioning
8.4 Operation mode manual without sway control
CeSAR standalone OHBC, Gantry crane
122 Operating Instructions, 02/2014
Figure 8-5 Selecting the drive
Save the result of this assignment of the camera axes to drives in parameter P80.
Commissioning
8.4 Operation mode manual without sway control
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 123
8.4.2.4
Step 2: Determine parameters of effective pendulum length in the trolley direction
A camera must be used for this commissioning step.
The gain and offset (P22, P23) are determined for the purposes of determining the effective
pendulum length.
Depending on P108 either the value "S_Hoist" (Block general) or the value "Distance" (data
from the camera) are used for the calculation.
This is determined with two oscillation measurements at different heights.
Without a camera it is not possible to detect any deflection; this means that commissioning
steps 2 to 4 (determine parameters of eff. pendulum length...") are hidden. The parameters
must be manually determined by counting the number of oscillations during a specific time
interval. The SIMOCRANE CeCOMM diagnostic program ("Effective pendulum length" tab)
provides good support here.
When determining this parameter, it is recommended that you be online with the SIMOTION
C240 PN. Otherwise, the hoist position values must be manually entered and the results
documented.
The individual steps in the table are self-explanatory, and are each confirmed with <ENTER>
after execution. After all of these steps have been completed, the calculated values can be
transferred to the system with "F5 – send values" and saved in the relevant parameters. It
must be noted that the oscillations are counted from zero and that the count starts at a
turning point (at maximum deflection).
8.4.2.5
Step 3: Determine the parameter effective pendulum length in the gantry direction
A camera must be used for this commissioning step. Otherwise, this commissioning step
(counting the oscillations) must be performed using the SIMOCRANE CeCOMM diagnostic
program ("Effective pendulum length" tab).
The gain and offset (P62, P63) are ascertained for the purposes of calculating the effective
pendulum length.
Depending on P108 either the value "S_Hoist" (Block general) or the value "Distance" (data
from the camera) are used for the calculation.
This is determined with two oscillation measurements at different heights.
Note
If the measurement for the gantry direction was not completed (P62=0; P63=0) then the
parameters of the trolley direction are used.
If the configuration includes slewing gear, the slewing gear must be in the zero position while
commissioning steps "2" and "3" are performed.
Commissioning
8.4 Operation mode manual without sway control
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124 Operating Instructions, 02/2014
8.4.2.6
Step 4: Determine the parameter effective pendulum length, slewing gear
The SIMOCRANE CenSOR camera measuring system is required to complete this
commissioning step automatically.
Otherwise, this commissioning step (counting the oscillations) must be performed using the
SIMOCRANE CeCOMM diagnostic program ("Effective pendulum length" tab).
The gain and offset (P152, P153) are ascertained in calculating the effective pendulum
length.
Depending on P108 either the value "S_Hoist" (Block general) or the value "Distance" (data
from the camera) are used for the calculation.
The calculation is made with two skew measurements at different heights.
Depending on the load condition, control bit "DigitalLiftCorrection" can be used to apply other
values for gain and offset. To do this, the commissioning step must be carried out once
again under the load conditions applicable when the control bit "DigitalLiftCorrection" is set.
The results for gain and offset are automatically entered into P152 and P153 once again, so
note the original values beforehand. These results must then be entered manually into
parameters P154 and P155 and the original values entered into P152 and P153.
8.4.2.7
Step 5: Simulating errors
All error bits of the sway control system can be simulated in this step in order to check the
error evaluation in the crane control system.
The relevant bits can be found in the error list (see Table 10-1 Error messages with error bit
(Page 157)).
Note
Simulated errors are not entered in the error history.
8.4.2.8
Step 6: Check the velocity
The maximum output velocity can be checked with this step. It requires the crane control
system to send current actual distance values which can be converted into millimeters in the
sway control where necessary.
This step is performed by moving the drives individually with maximum velocity in manual
operation mode.
The maximum actual velocity produced at the maximum output velocity is determined from
the output velocity at the converter and the change in the actual distance value each time.
The determined velocity can be transferred into the parameter for the maximum output
velocity of the drive (P1, P41 and P131).
The set velocity for the positioning operation mode can also be transferred to the parameters
for the relevant drive (P0, P40, and P130) and is 90% of the maximum output velocity.
Commissioning
8.4 Operation mode manual without sway control
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 125
8.4.2.9
Step 7: Change communication addresses
You can change the communication addresses in the screen illustrated below (see also
Chapter Setting addresses (Page 154)).
Figure 8-6 Changing the communication address
8.4.2.10
Step S: Save all parameter sets
All parameter sets are saved.
Commissioning
8.5 Operation mode manual with sway control
CeSAR standalone OHBC, Gantry crane
126 Operating Instructions, 02/2014
8.5
Operation mode manual with sway control
8.5.1
Preparation
Once you have completed all the commissioning steps, proceed as follows to activate sway
control:
● Set the "SC_On" control bit in the crane control system.
We recommend that the first test runs be performed at medium hoist height, and initially
without boosted camera measuring signal. The camera measuring signal cannot be boosted
again until these initial test runs are successfully concluded.
8.5.2
Test runs without boosting the camera measurement signal
● To carry out test runs without boosted camera measuring signal, set parameters P21
(trolley), P61 (gantry), or P151 (slewing gear) to zero.
This will disable the cameral measuring signal. The advantage of this approach is that
you can record a signal trace in SIMOCRANE CeCOMM and use it to compare the
pendulum deflection measured by the camera with the pendulum deflection of the
mathematical model. You can also test the accuracy of the sway control settings without
camera feedback (effective pendulum length, velocities, ramps, etc.).
● Start the first test run with a low set velocity V_set (e.g. with the first stage of the master
controller). If this is successful then further test runs may follow with greater set velocity
values.
● When evaluating the trace recordings of the pendulum deflection measured by the
camera and the pendulum deflection computed by the mathematical model, pay attention
to the following points:
– Identical phase relations and amplitudes
The amplitude can be adjusted if necessary using parameters P30 (trolley), P70
(gantry) or P160 (slewing gear). If the phases are in exact opposition, parameter P80
(assignment of camera measuring direction) should be checked.
– Match between frequency of the pendulum deflection measured by the camera ↔
frequency of the pendulum deflection computed by the mathematical model
Check whether the frequency of the pendulum deflection measured by the camera
matches the frequency of the pendulum deflection computed by the mathematical
model. If they do not match, you must check the accuracy of the effective pendulum
length calculation and/or the accuracy of the transferred hoist height data, because
the mathematical model computes the frequency from the relationship T = 2 ∏ √ (l : g)
(T = period of oscillation; l = effective pendulum length).
Commissioning
8.5 Operation mode manual with sway control
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Operating Instructions, 02/2014 127
● The effectiveness of the sway control system can be easily identified when the master
controller is released at constant velocity. Only slight residual sway motion must be
present at the end of travel. Note that the initial sway on starting must be close to zero.
CAUTION
Risk of injury and potential material damage due to unexpected movements of the crane
Unexpected jerking movements may occur during operation with sway control.
These can cause injury to unprotected persons. Damage might also be caused to
unprotected objects.
• Protect yourself against unexpected movements (e.g. by wearing a safety harness or
standing in a secure position).
• Secure freely movable objects to prevent them from slipping.
● If the test runs at medium hoist height have been successful, repeat the runs at different
hoist heights to test the accuracy of the effective pendulum length measurement.
Make sure that tests are carried out at every height in the hoist range.
If the sway control system does not work correctly at certain hoist heights, you will need
to recheck the accuracy of the effective pendulum length calculation and/or the accuracy
of the transferred hoist height data. At all hoist heights, the frequency of the pendulum
deflection measured by the camera must approximately coincide with the frequency of
the pendulum deflection computed by the mathematical model.
● The effective pendulum length is calculated from the hoist height using parameters:
– Trolley: P22, P23
– Gantry: P62, P63
– Slewing gear: P152, P153
● Test runs without boosted camera measuring signal can be regarded as successful if the
following conditions are fulfilled:
– The phase relation, amplitude and frequency of the pendulum deflection measured by
the camera are identical to those of the pendulum deflection calculated by the
mathematical model.
– The residual sway at the end of travel is only minor; this applies on condition that the
initial sway at the start of travel was also minor.
– The first two criteria apply to all velocities and all hoist heights.
Commissioning
8.5 Operation mode manual with sway control
CeSAR standalone OHBC, Gantry crane
128 Operating Instructions, 02/2014
8.5.3
Test runs with boosted camera measurement signal
● If the test runs without boosted camera measuring signal have been concluded
successfully, you can now boost the camera measuring signal again.
To do this, set P21 (trolley), P61 (gantry) or P151 (slewing gear) to values other than zero
again.
● Set the parameters for boosting the camera measuring signal P21 (trolley), P61 (gantry)
or P151 (slewing gear) to the lowest possible required setting.
The higher the settings of these parameters, the greater the influence of the camera
measuring signal on the pendulum deflection computed by the mathematical model.
However, disturbance variables will also have a greater effect and may impair the overall
control quality. The value must be determined experimentally during commissioning, as it
largely depends on the controlled system as a whole. Setting values of < 0.1 have proven
successful in practice.
● Start the first test run cautiously with a low set velocity V_set (e.g. with the first stage of
the master controller).
If this is successful, you can conduct further test runs at higher set velocities. With this
configuration, initial oscillations of the load caused by disturbing effects must be
eliminated.
● Test runs with boosted camera measuring signal can be regarded as successful if the
following conditions are fulfilled:
– The residual sway at the end of travel is only minor; this applies even if initial sway
occurred at the start of travel.
– Disturbances during travel (e.g. caused by wind) must be corrected.
– The first two criteria apply to all velocities and all hoist heights.
8.5.4
Testing in the prelimit switch range
In the prelimit switch range, the velocity must be reduced in good time, so that the axis can
safely stop if the limit switch is actuated. The function is described in Chapter Response in
the prelimit switch (Page 99).
Test the travel behavior in the prelimit switch range
● Start at the lowest speed level.
● We recommend that you record a signal trace.
● The status of the prelimit switches is displayed in screen 3 "Status of drives" (monitor
display in the SIMOCRANE CeCOMM).
● Test the function of the prelimit switches at all hoist heights occurring in normal operation.
Testing with long pendulum lengths is especially important.
Commissioning
8.6 Checking and fine-tuning the sway control system
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 129
8.6
Checking and fine-tuning the sway control system
8.6.1
General
This chapter discusses all the settings required for manual operation mode that have not
been made during the commissioning phase.
The parameters can be set manually in the Parameters menu of the SIMOCRANE CeCOMM
diagnostic program.
8.6.2
Correcting the effective pendulum length
If different load carrying devices and/or variable loads are used, the center of gravity and
therefore also the pendulum length may change.
For this reason, digital and analog functions for correcting the effective pendulum length are
provided for the trolley and gantry. Only a digital correction of the effective pendulum length
is available for the slewing gear.
The effective pendulum length for each drive is displayed in mm on screen 1 (kinematics).
Digital correction of the effective pendulum length for the trolley and the gantry
Requirement
● If a new load carrying device, i.e. which is different to the usual one, is to be used and
corrected by the digital correction function, a suitable sensor (e.g. limit switch) must be
installed so that the crane control system can detect the new load carrying device. The
control bit "DigitalLiftCorrection" cannot be set correctly otherwise.
● The effective pendulum length value under normal conditions (i.e. when the usual load
carrying device is used) at medium hoist height must be known.
If this value is not known, then it needs to be calculated. To do this, carry out the relevant
commissioning steps (see Step 2: Determine parameters of effective pendulum length in
the trolley direction (Page 123) or Step 3: Determine the parameter effective pendulum
length in the gantry direction (Page 123)).
Method of operation
● If the control bit "DigitalLiftCorrection" is set for the trolley, the value of parameter P24
(digital correction effective pendulum length trolley) is added to the existing effective
pendulum length for the trolley.
● If the control bit "DigitalLiftCorrection" is set for the gantry, the value of parameter P64
(digital correction of effective pendulum length, gantry) is added to the existing effective
pendulum length for the gantry.
Commissioning
8.6 Checking and fine-tuning the sway control system
CeSAR standalone OHBC, Gantry crane
130 Operating Instructions, 02/2014
Procedure
If you are using a new load carrying device which causes a shift in the center of gravity of the
load, you need to recalculate the effective pendulum length as described below:
1. Effective pendulum length at medium hoist height under normal conditions
– The effective pendulum length value applicable to the usual load carrying device is
displayed on screen 1 (kinematics). Make a note of this value.
2. Calculate the oscillation period for the new load carrying device
– To calculate oscillation period T, perform oscillation measurements with the load
carrying device positioned at a medium hoist height.
3. Calculate the correction value for the effective pendulum length
– Calculate the effective pendulum length for the new load carrying device by the
formula: T=2·∏√l:g
– Calculate the correction value from the difference between:
Effective pendulum length (new load carrying device and effective pendulum length
(usual load carrying device)
– Enter the correction value in parameter P24 or P64 in the CeCOMM diagnostic
program.
4. Correction of the effective pendulum length in the crane control system
– When you use the new load carrying device, you must set the bit "DigitalLiftCorrection"
in the crane control system to activate the calculated correction values.
Digital correction of the effective pendulum length for the slewing gear
Requirement
● When the load condition which is to be corrected digitally is present on the crane, it must
be measured by a suitable sensor (e.g. limit switch) in the crane control system. The
control bit "DigitalLiftCorrection" cannot be set correctly otherwise.
Method of operation
Once the bit "DigitalLiftCorrection" is set, the parameters P154 (pendulum length gain under
load conditions, slewing gear) und P155 (offset pendulum length under load conditions,
slewing gear) are used to calculate the effective pendulum length - otherwise the parameters
P152 (pendulum length gain, slewing gear) and P153 (offset pendulum length, slewing gear).
Procedure
See Chapter Commissioning, Step 4: Determine the parameter effective pendulum length,
slewing gear (Page 124).
Commissioning
8.6 Checking and fine-tuning the sway control system
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 131
Analog correction of the effective pendulum length
Requirement
● To allow use of the analog correction function for the effective pendulum length, a valid
load value must be supplied at the input "Load" (load weight) by the crane control system.
The sway control system interprets this value as the total load. The weight of the load
carrying device must be entered in parameter P82 (weight of the load carrying device in
kg).
● The effective pendulum length value with the unloaded load carrying device at medium
hoist height must be known.
If this value is not known, then it needs to be calculated. To do this, carry out the relevant
commissioning steps (see Step 2: Determine parameters of effective pendulum length in
the trolley direction (Page 123) or Step 3: Determine the parameter effective pendulum
length in the gantry direction (Page 123)).
Method of operation
You can apply continuous correction of the effective pendulum length as a function of load.
The parameters P25 and P65 ("Analog correction of effective pendulum length") are
specified in the unit of measurement mm/kg and thus define in mm the increase in the
pendulum length per kg of weight. The correction value is calculated according to the
following formula:
Trolley: Analog correction = (Load-P82) · P25 if (Load-P82) > 0, otherwise 0
Gantry: Analog correction = (Load-P82) · P65 if (Load-P82) >0, otherwise 0
Procedure
1. Make a note of the effective pendulum length value with the unloaded load carrying
device at medium hoist height (see screen 1 - kinematics).
2. Calculate the effective pendulum length with loaded load carrying device at a medium
hoist height.
3. Calculate the difference between the effective pendulum lengths, i.e. with and without
load:
Effective pendulum length (with attached load) - effective pendulum length (unloaded)
4. Calculate the correction factor P25 and/or P65.
Correction factor (mm/kg) = difference between effective pendulum lengths : (total load -
weight of load carrying device)
5. Enter the correction value in parameter P25 or P65 in the CeCOMM diagnostic program.
Example:
Total load:
60 t
Weight of load carrying device:
20 t
Effective pendulum length
without load:
30 m
Effective pendulum length with
load:
32 m
Commissioning
8.6 Checking and fine-tuning the sway control system
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132 Operating Instructions, 02/2014
Result:
Parameter P82:
20,000 kg
Difference between effective
pendulum lengths:
32
m - 30 m = 2 m (with 40 t weight)
Correction factor P25 or P65:
2000 mm : 40000 kg = 0.05 mm/kg
Additional information
● If the crane control system
– does not have any information about the load mass,
– does not have any information about setting the "DigitalLiftCorrection" bit,
– but, depending on the load and/or the load carrying device in use, is detecting different
pendulum lengths with a deterioration of the sway control quality,
a compromise must be found.
One option is to vary the offset parameters to calculate the effective pendulum length
(P23, P63, P153).
● If both the digital correction and the analog correction of the effective pendulum length
are active, both correction values will be added to the original effective pendulum length.
● Where the load is relatively constant (e.g. coils or slabs), it may be more effective to use
digital correction rather than analog correction. If you use digital correction, you must set
the bit "DigitalLiftCorrection" in the crane control system after the correction value of the
effective pendulum length has been calculated.
8.6.3
Setting the permissible residual sway
The parameter for the residual sway can be separately set for each sway-controlled drive.
● Trolley: P33, P34
● Gantry: P73, P74
● Slewing gear: P163, P164
The parameters residual sway and residual pendulum velocity should only be set as low as
is required. Excessively low values extend the stopping time ("Pos_completed" and
"SC_completed") and may result in sway after stopping due to dead times.
Commissioning
8.6 Checking and fine-tuning the sway control system
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 133
8.6.4
Setting the velocity for zero speed detection
The parameters for zero speed detection can be set separately for each drive.
● Trolley: P19
● Gantry: P59
● Slewing gear: P149
● Hoist: P149
The parameters are a condition for setting the control bit "Pos_completed" (see Chapter
Interface description (Page 45)).
Excessively high values result in fast but jerky stopping.
Excessively low values result in very soft stopping, but lengthen the stopping time.
In practice, settings between 1 % and 3 % have proven successful.
8.6.5
Setting the damping factor
A damping factor (P16, P17, P56, P57, P146, P147) can be set separately for the
acceleration and deceleration phase for each sway-controlled drive. (This only applies to
manual operation mode.)
Values greater than 1.4 result in non-periodic transient responses, values less than 1.4 to
overshoot. Damping factors in the range from 1 to 1.2 are a compromise between short rise
time and slight overshoot. The difference between the damping factors for acceleration and
deceleration should not be too large, as the output velocity can otherwise change abruptly
during the transition to the deceleration phase.
Only P16, P56 and P146 are effective for the positioning operation mode.
8.6.6
Setting the switch-on delay of the drives
The output value delay of the controlled system (including frequency converter) can be set
for each drive (P27, P67, P157).
Please proceed as follows:
With camera present:
● Set the camera feed to zero (depending on drive P21, P61, P151).
● Start the trace in SIMOCRANE CeCOMM, record the pendulum deflections from the
model and from the camera.
● Begin to move in manual operation mode with pendulum deflection close to zero.
● Set the ON delay in such a way that the start of the pendulum deflections from the model
and from the camera match as closely as possible.
● Set the camera feed back to the original value.
Commissioning
8.6 Checking and fine-tuning the sway control system
CeSAR standalone OHBC, Gantry crane
134 Operating Instructions, 02/2014
Without camera:
● Start the trace in SIMOCRANE CeCOMM, record the actual velocity and delayed velocity.
● Begin to move in manual operation mode with pendulum deflection close to zero.
● Set the ON time in such a way that the start of the actual velocity and the delayed velocity
correspond as closely as possible.
8.6.7
Defining the activation velocity of the sway control
Using parameters P20, P60 and P150, for each drive, a minimum velocity as a % of the
maximum output velocity can be defined to activate the sway control. The minimum velocity
refers to setpoint V_set, and is only effective in the manual operation mode.
The sway control is inactive as long as the velocity setpoint is not reached. It is activated if
the master controller is deflected to a higher value. The sway control remains active when
stopping.
This parameter is intended to allow the drive to be precisely positioned at low velocities,
without disturbing neutralizing motion by the sway control. Pendulum deflection is still slight
in the lowest travel stage. If the crane operator wants to activate sway control in the first
stage, he can briefly deflect the master controller to the next stage and then return to the first
one.
8.6.8
Pendulum length from the PLC or camera
If the crane control system does not provide any information about the actual hoist position,
the distance between the camera and reflector as measured using the camera measuring
system can be used to determine the effective pendulum length. Parameter P108 is used to
make the selection.
Note
If the measured distance between the camera and reflector is used, when the camera fails,
sway
-controlled operation based on the mathematical calculation model can only be used to
a limited extent, or not at all.
If t
he camera fails, the distance measured between the camera and the reflector, and as a
consequence, the effective pendulum length determined from this, are no longer updated.
This means that using the distance measured between the reflector and camera only
represents a compromise solution.
Commissioning
8.6 Checking and fine-tuning the sway control system
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 135
8.6.9
Other settings
Upper limit for sway control (P84)
Outside this limit, sway control is deactivated (see Chapter Parameter list (Page 171);
parameter description for P84).
Minimum pendulum length (P86)
For smaller pendulum lengths, sway control is deactivated (see Chapter Parameter list
(Page 171); parameter description for P86).
Commissioning
8.7 Commissioning positioning
CeSAR standalone OHBC, Gantry crane
136 Operating Instructions, 02/2014
8.7
Commissioning positioning
8.7.1
General
This chapter discusses all the settings required for positioning operation mode that have not
been made during the commissioning phase.
The parameters can be set manually in the Parameters menu of the SIMOCRANE CeCOMM
diagnostic program.
8.7.2
Conversion of the actual position S_act and target position S_set
The values supplied by the crane control system for the actual position and the target
position are converted by the sway control with the parameters "Actual position factor" (P5,
P45, P135) and "Actual position offset" (P6, P46, P136)
Proceed as follows to ascertain these parameters:
The following values must be recorded at two different positions:
x1:
Position 1 in mm
x2:
Position 2 in mm
s1:
S_act (actual position) at position 1
s2:
S_act (actual position) at position 2
You can calculate the parameters "Actual position factor" (P5, P45, P135) and "Actual
position offset" (P6, P46, P136) from these four values. The SIMOCRANE CeCOMM
diagnostic program (menu "Calculations / Position parameters") will assist you.
Enter the "Factor" and "Offset" for each drive in the parameters stated above.
Note
Checking the actual position
The sway control system
requires the exact correct position values from the crane control
system. It is not therefore sufficient to determine the positions purely by calculation. The
positions shown must be remeasured directly on site during commissioning. The position
sensing an
d position monitoring functions must be ensured before the positioning operation
mode is commissioned.
Commissioning
8.7 Commissioning positioning
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 137
We recommend using identical reference systems in the crane control and sway control
systems. The position values are then the same in both systems and are easier to manage.
The factor set is then 1 and the corresponding offset is 0 mm.
Note
If the value S_act received from the crane control system and the conversion parameters are
correct, the actual velocity V_act and the output velocity V_norm mus
t be identical -
provided
that the normalization of the output velocity is correct.
Plotting a diagram with both values using SIMOCRANE CeCOMM is recommended in order
to check this.
8.7.3
Position controller setting
1. Set the position controller parameters (P15, P55; P145) to zero.
The position control will then be deactivated and the actual position ignored. As a result,
the position will be determined from the calculated values only.
2. Start the positioning process over a sufficiently large distance.
– Constant travel should take at least several seconds.
– Make sure that the distance to the end positions is sufficiently large to allow prompt
termination of travel in the event of an error.
– The setpoint and target positions must be virtually identical at the end. Minor
deviations are caused by deactivation of the position controller.
□ More significant deviations can be caused by incorrect setting of the maximum
output velocity or by limiting functions in the drive system.
□ To identify the error, deactivate the sway control system by resetting the control bit
"SC_On" or by setting damping factors P16, P56, P146 (operation without sway
control only) to zero.
3. Set the position controllers and damping factors to their default values
– Set the position controllers in such a way as to obtain a slight overshoot.
This applies to the actual velocity and the actual position. Short rise times can be
achieved in this way.
– The value of the position controller should not be greater than 0.5.
– Reduce the value if the velocity curve exhibits oscillations and the actual position
overshoots at the target position.
Note
An overshoot at the target position is often the result of an incorrectly set maximum velocity
and not from an excessively high position controller (Kp factor). Consequently, before
reducing the position controller, in controlled operation
(position controller is zero or manual
operation), it should again be checked whether for travel at constant velocity, the actual
velocity is nearly equal to the output velocity.
Commissioning
8.7 Commissioning positioning
CeSAR standalone OHBC, Gantry crane
138 Operating Instructions, 02/2014
8.7.4
Other settings
The following parameters can be set manually:
Positioning accuracy (P9, P49, P139)
The positioning accuracy should not be set lower than the minimum required value.
If the deviation between the current and target positions is smaller than the positioning
accuracy setting, the status bit "Pos_completed" (see interface description) will be set in the
positioning operation mode. Positioning continues while the mode and the travel signal
remain set.
Following error (P28, P68, P158)
The permissible difference between the calculated and actual positions of the relevant drive
can be set with the parameters. An error message is triggered if this difference is exceeded
(E7, E8, E9).
Note
The difference between the set and actual positions can be traced using the SIMOCRANE
CeCOMM diagnostic program. The less difference bet
ween the values, the better the
settings.
Upper limit for camera measurement (P83)
For pendulum lengths less than this value, only the mathematical oscillation model is
applied. The measured pendulum deflection is not taken into account.
Oscillations caused by external forces such as diagonal pull or winds are not acquired and
can therefore not be eliminated by closed-loop control. In this situation, sway-controlled
operation should only take place for a limited period, as the difference between the
calculated value and the actual oscillation becomes greater and greater over increased
periods of time.
Note
The camera measurement may therefore need to be deactivated in the case of small
pendulum lengths, i.e. if the distance between the camera and the r
eflector is very small, as
for various reasons the pendulum deflection measured may no longer be detected correctly
in some cases (e.g. if the reflector fills the camera's entire field of vision).
Commissioning
8.8 Testing the sway neutralization modes
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Operating Instructions, 02/2014 139
8.8
Testing the sway neutralization modes
This chapter provides information and instructions relating to the testing of the operation
modes "sway neutralization load position" and "sway neutralization drive position."
Requirement
● The SIMOCRANE CenSOR camera measuring system must be used
● The actual position (S_act) for the relevant drive must be available
More detailed information about the function can be found in Chapters Operation mode sway
neutralization load position (Page 105) and Operation mode sway neutralization drive
position (Page 105).
Testing the "sway neutralization load position" operation mode
1. Set the control bit "OM_SC_LO" (see Interface description (Page 45)) to select sway
neutralization load position operation mode.
2. Cause the load to sway. Start the first tests with very small amounts of sway.
3. Start travel by setting the "Travelling" control bit.
If the operation mode is functioning correctly, neutralizing motions will occur in both
directions until the sway is eliminated and the drive stops at its target position. The target
position corresponds to the position of the load at the moment the control bit "Travelling"
was set. The load position equals the total of S_act + pendulum deflection.
Note
If the sway motion is not pr
operly corrected, then you must check the previous
commissioning steps to identify the error.
Note
We recommend that you use the CeCOMM diagnostic program to record signal traces so
that you can assess the test results more accurately.
4. When the "Pos_completed" status bit is set, reset the "Travelling" control bit.
5. If the results of the first tests are successful, repeat the same tests with larger initial sway
motions.
Commissioning
8.8 Testing the sway neutralization modes
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140 Operating Instructions, 02/2014
Testing the "sway neutralization drive position" operation mode
1. Set the control bit "OM_SC_DR" (see Interface description (Page 45)) to select sway
neutralization drive position operation mode.
2. Cause the load to sway. Start the first tests with very small amounts of sway.
3. Start travel by setting the "Travelling" control bit.
If the operation mode is functioning correctly, neutralizing motions will occur in both
directions until the sway is eliminated and the drive stops at its target position. The target
position corresponds to the actual position of the drive S_act at the moment the
"Travelling" control bit was set.
Note
If the sway motion is not properly corrected, then you must check the previous
commissioning steps to iden
tify the error.
Note
We recommend that you use the CeCOMM diagnostic program to record signal traces so
that you can assess the test results more accurately.
4. When the "Pos_completed" status bit is set, reset the "Travelling" control bit.
5. If the results of the first tests are successful, repeat the same tests with larger initial sway
motions.
Commissioning
8.8 Testing the sway neutralization modes
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Operating Instructions, 02/2014 141
Troubleshooting
If the sway motion is not properly eliminated despite correct control settings, you must check
the previous commissioning steps to identify the error.
We recommend the following procedure:
1.
Check whether the sway control system works properly in manual operation mode
without a camera.
– If it does not, the following possible causes should be investigated:
□ Incorrect calculation of pendulum length,
□ Errors in basic data such as maximum output velocity or acceleration/deceleration
rates.
– Recommendation: Repeat the entire commissioning process.
2.
Check whether the sway control system works properly in manual operation mode with a
camera.
– If it does not, the following possible causes should be investigated:
□ Problem with the camera.
– Recommendation: Perform a function test on the camera.
3.
Check whether the sway control system works properly in the positioning operation
mode.
– If it does not, the following possible causes should be investigated:
□Actual position is incorrect.
– Recommendation: Recheck all the settings required for the positioning operation
mode
Commissioning
8.9 Stability test and monitoring functions
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8.9
Stability test and monitoring functions
8.9.1
Stability test
With maximum, medium and minimum pendulum lengths set the load to manual operation
mode without sway control and with heavy sway, switch to sway-controlled manual operation
and start at the moment of maximum pendulum deflection. The trolley (gantry, slewing gear)
must catch the oscillation and steady the load by moving back and forth until it comes to a
standstill.
If the sway is already too severe at the start or if the monitoring function (see Chapter
Monitoring functions (Page 143)) finds that the sway cannot be eliminated by closed-loop
control or even increases, the sway control system will output the error message E13, E14,
or E15 (sway control temporarily reduced). No output velocity is then output. The user can
reset the error again by resetting control bit "Travelling."
Possible causes for inability to eliminate sway by closed-loop control:
● A maximum acceleration that is set too low
● After the output velocity has been output, it must no longer be influenced by the sway
control system (for instance by limiting the maximum value or the acceleration in the
converter or by excessive smoothing in the converter).
● Incorrect calculation of the effective pendulum length
Possible causes of increasing sway:
● Incorrect alignment of the camera
● Incorrect setting of P80 (assignment of camera measuring system)
In this case, commissioning step 1 (Set the alignment of the camera) must be repeated.
Following successful completion these tests should be repeated in positioning operation
mode.
CAUTION
Risk of injury and potential material damage due to unexpected movements of the crane
Unexpected jerking movements may occur during operation with sway control.
These can cause injury to unprotected persons. Damage might also be caused to
unprotected objects.
• Protect yourself against unexpected movements (e.g. by wearing a safety harness or
standing in a secure position).
• Secure freely movable objects to prevent them from slipping.
Commissioning
8.9 Stability test and monitoring functions
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Operating Instructions, 02/2014 143
8.9.2
Monitoring functions
When the drives are traversing with sway control, a monitoring function is run in all operation
modes that checks whether the sway control is able to eliminate the sway or if the sway is
increasing.
It is assumed that the sway cannot be eliminated if the output velocity has changed direction
(passed through zero) nine times since control bit "Travelling" was last set. If this is the case,
no output velocity is output and error messages E13, E14, or E15 are set.
It is assumed that the sway is increasing if the amplitudes of the oscillation of the
mathematical oscillation model increased in five consecutive oscillation periods. If this is the
case, no output velocity is output and error messages E13, E14, or E15 are set.
Commissioning
8.9 Stability test and monitoring functions
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Operating Instructions, 02/2014 145
SIMOCRANE CeCOMM diagnostic program
9
9.1
General
The SIMOCRANE CeCOMM diagnostic program can be used for the following functions:
● Editing the parameter sets (see Chapter Parameter sets (Page 93))
● Monitor functions for monitoring important data
● File manager function for exchanging parameter files, etc.
● Diagram function for recording traces
● Integrated Primary Setup Tool for determining the communication addresses of the
connected stations
● Performing the commissioning steps
● Readout of error messages (current messages and history of stored error messages)
● Tool for calculating the effective pendulum length if no camera is used
● Additional functions, such as version information, calculation of position and velocity
parameters, web browser
The diagnostic program is available in German and English.
An overview is now provided of the most important functions of the SIMOCRANE CeCOMM
diagnostic program.
SIMOCRANE CeCOMM diagnostic program
9.2 Installing
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146 Operating Instructions, 02/2014
9.2
Installing
The SIMOCRANE CeCOMM diagnostic program ("Setup_CeCOMM.exe") is provided on the
DVD and can be used for commissioning. The program must be installed on the
commissioning PC (Windows). The software is installed by running "Setup_CeCOMM.exe".
An IP address that is suitable for the SIMOTION C240 PN must be set on the commissioning
PC. For default settings this is:
IP address:
192.168.1.X
(X = freely selectable)
Subnet mask:
255.255.255.0
Figure 9-1 Setting a fixed IP address
Note
The program can run under the "WINDOWS
2000," "WINDOWS 7," and "WINDOWS XP"
operating system. This requires that the user is logged on to the PC as administrator.
Note
This requires tha
t the user is logged on to the PC as administrator.
Any personal firewalls (e.g. Windows Firewall for Microsoft XP) should be deactivated or
specific exceptions permitted.
SIMOCRANE CeCOMM diagnostic program
9.3 Searching the network for SIMOTION C240 PN
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Operating Instructions, 02/2014 147
9.3
Searching the network for SIMOTION C240 PN
Figure 9-2 Calling the primary setup tool from SIMOCRANE CeCOMM
When SIMOCRANE CeCOMM is installed, the "Primary Setup Tool (abbreviation: PST)" is
also installed. This tool can be used to search the network for nodes (devices). For example,
the IP addresses of SIMOTION C240 PN and the SIMOCRANE CenSOR camera measuring
system can be scanned in this way. The Primary Setup Tool is on the DVD provided, and
can be subsequently installed.
The IP address can only be changed temporarily using the PST. The old address is again
effective after SIMOTION C240 PN is restarted. In order to permanently change the IP
address, this must be set using SIMOCRANE CeCOMM (commissioning menu, step 7 or in
the parameter menu "I")
Note
The IP address of the commissioning PC must be set so that it matches the SIMOTION
C240 PN address,
with the same subnet.
SIMOCRANE CeCOMM diagnostic program
9.4 Establishing the connection
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9.4
Establishing the connection
The symbols for establishing a communication link are arranged below the menu bar:
After the program has started, one of these symbols must be used to establish the
connection to the SIMOTION C240 PN via the Ethernet interface.
After a connection has been successfully established, the following functions are available
under the tabs:
•
Monitor: Display all diagnostic information, change parameters, display
error messages, etc.
•
File manager: User interface for copying, renaming, editing files, etc.
•
Diagram: Interface for recording, saving and loading analog and digital
signals
•
Web browser: Use the web server available on the target system. An Ethernet
connection is required
•
Telnet: Not used
•
Effective pendulum
length:
Tool for ascertaining the effective pendulum length for systems
without a camera
SIMOCRANE CeCOMM diagnostic program
9.5 Monitoring functions
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9.5
Monitoring functions
9.5.1
Display and operating information
After the connection has been established, all the available keyboard commands are
displayed when the space bar is pressed.
Figure 9-3 Monitor - Main menu
SIMOCRANE CeCOMM diagnostic program
9.5 Monitoring functions
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150 Operating Instructions, 02/2014
The basic monitor functions can be divided into three groups:
● Screens,
● Parameterization menus,
● Additional functions.
Figure 9-4 Monitor functions
The display for the prelimit switch command in display screen [3] "Status of drives" has the
following meaning (selection):
SIMOCRANE CeCOMM diagnostic program
9.5 Monitoring functions
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Operating Instructions, 02/2014 151
Table 9- 1 Explanation for display screen [3]
1+/1+
Prelimit switch forward and limit switch forward responded
1+
Prelimit switch forward responded
0
No limit switch responded
1-
Prelimit switch backward responded
1-/1-
Prelimit switch backward and limit switch backward responded
2
Prelimit switch forward and prelimit switch backward responded
0/2
Limit switch forward and limit switch backward responded
2/2
All limit switches responded
The table below lists the most important operating notes.
Table 9- 2 Operating notes
Display of the available
keyboard commands on the
main screen
Press the space bar.
Calling the display screens
Press one of the following keys:
"1"
Display kinematics
"2"
Display PROFIBUS interface
"3"
Display status of drives
"4"
Display camera status
You can toggle between screens "1" to "4".
Press the appropriate key.
Calling menus and additional
functions
Press one of the following keys:
"P" Parameter menu; see The parameter menu
(Page 152)
"I"
Commissioning menu
"ESC" Exit menu
The screen last called is displayed
"E"
Actual errors
"H"
Error history
"V"
Version information
"ENTER"
Refresh screen
"L"
only relevant for developers
Example: "Change parameter P0 on the screen":
1. Enter "PC0" (i.e.: Parameter menu - Change Parameter 0)
2. Press the "Enter" key
3. Enter the new value
4. Confirm twice using the "Enter" key
SIMOCRANE CeCOMM diagnostic program
9.5 Monitoring functions
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152 Operating Instructions, 02/2014
9.5.2
The parameter menu
Figure 9-5 Parameter menu
The Parameter menu can be called from the main menu and all display screens with the "P"
key. All parameters can be displayed, changed, saved and copied in this menu.
Note
Only those parameters that correspond to the setting
of parameter P100 "access code" are
displayed; see
General parameters (Page 212), description for P100.
The digits "1" to "8" can be used to display the parameters as groups. The "1" to "8" keys
can be used to switch arbitrarily between the display screens of the parameters. From these
display screens it is also possible to execute the functions from the parameter menu.
SIMOCRANE CeCOMM diagnostic program
9.5 Monitoring functions
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Operating Instructions, 02/2014 153
Table 9- 3 Key assignment in the parameter menu
Key
Function
"C"
Change parameters
"D"
Set default values
"I"
Change communication addresses
"S"
Save all parameter sets
"N"
Edit another parameter set
"Y"
Copy parameter set
"L"
Show list of parameters
"R"
Reload parameters
"F"
Search parameters
"T" Title of parameter set
A brief description of the parameter set may be entered (max. 20 characters).
The brief description is saved in the parameter file.
SIMOCRANE CeCOMM diagnostic program
9.6 Setting addresses
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154 Operating Instructions, 02/2014
9.6
Setting addresses
9.6.1
General
Each device must have its own IP address for communication in the Ethernet network.
Note
The IP address of the SIMOTION C240 PN may not be used for another device on the
network.
9.6.2
Default settings
IP address for SIMOTION C240 PN:
192.168.1.158
Subnet mask for SIMOTION C240 PN:
255.255.255.0
PROFIBUS DP address:
100
PROFIBUS transmission rate
1.5 Mbit/s
For camera communication via UDP
IP address for camera:
192.168.1.155
Camera port:
8500
For camera communication via PROFINET
IP address of the camera:
0.0.0.0
Camera port:
0
This setting activates PROFINET usage within the SIMOTION C240 PN for communication
with the camera.
The following IP addresses saved in the project are then used:
IP address for SIMOTION C240 PN:
192.168.0.2
Subnet mask for SIMOTION C240 PN:
255.255.255.0
IP address for camera:
192.168.0.3
Subnet mask for camera:
255.255.255.0
These addresses cannot be changed by the user.
SIMOCRANE CeCOMM diagnostic program
9.6 Setting addresses
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Operating Instructions, 02/2014 155
9.6.3
Setting addresses
You can set the Ethernet and PROFIBUS-DP addresses that the PROFIBUS transmission
rate for the SIMOTION C240 PN and the Ethernet address for the camera via the parameter
menu in the SIMOCRANE CeCOMM diagnostic program.
Please proceed as follows:
1. Call the parameter menu with the "P" key
2. Call the "I" function: Change communication addresses
Follow the instructions for SIMOCRANE CeCOMM.
Addresses can also be set via the commissioning menu by pressing the "I" key and calling
the function "7 - Change communication addresses".
Figure 9-6 Setting addresses
SIMOCRANE CeCOMM diagnostic program
9.6 Setting addresses
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156 Operating Instructions, 02/2014
Note:
● IP address of the camera
Prerequisite: P115 Without Camera = OFF
● IP address of the SIMOTION C240 PN
If you change the IP address of the SIMOTION C240 PN then the connection between
the diagnostic tool and the SIMOTION C240 PN will be lost after confirming and saving. A
new connection can be made immediately with the SIMOTION C240 PN via the new IP
address.
● Change the PROFIBUS-DP address or the PROFIBUS transmission rate for the
SIMOTION C240 PN
If you change the PROFIBUS-DP address then the SIMOTION C240 PN will restart
automatically after confirming and saving. After this boot process, a new connection with
the current IP address is required.
Note
The information on the addresses is saved in the text file "IP_Addresses.txt" in the
"SwayControl" directory on the MMC and is loaded when the SIMOTION C240 PN is booted.
(Exception: The PROFIBUS transmission rate is not stored.)
9.6.4
Determining the changed IP address
If the IP address of the SIMOTION C240 PN has been changed and is no longer recognized,
it can be determined using the Primary Setup Tool (see Searching the network for
SIMOTION C240 PN (Page 147)).
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Operating Instructions, 02/2014 157
Alarm, error, and system messages
10
10.1
General
The sway control system issues error messages and warnings to help you diagnose errors.
Each error message is transmitted to the crane control system in status word "ErrorBits1"
(see Chapter General block (14 bytes) (Page 72)).
A bit number is assigned to each error message as shown in the table below.
Warnings are not assigned a bit number and are not transmitted to the crane control system.
They are only displayed in the SIMOCRANE CeCOMM diagnostic program.
The current errors are displayed by pressing the "E" key from the main menu or the display
screens. The error history can be called using the "H" key.
Each error has a number, a name, a description and a remedial guide. All errors are self-
acknowledging and will be transmitted only while the error condition is present.
Table 10- 1 Error messages with error bit
Error no.
Bit no.
Meaning
E0
0
Invalid parameter file
E1
1
Invalid operation mode
E2
2
Fieldbus error
E3
3
Invalid target position
E4
4
Invalid hoist position (sway control off)
E5
5
Invalid pendulum length (sway control off)
E6
6
Actual position not valid
E7
7
Following error, trolley
E8
8
Following error, gantry
E9
9
Following error, slewing gear
E9
9
Following error, hoist
E10
10
Camera measuring system impaired
E11
11
Camera measuring system faulted
-
12
Reserved
E13
13
Sway control temporarily reduced, trolley
E14
14
Sway control temporarily reduced, gantry
E15
15
Sway control temporarily reduced, slewing gear
E16 Parameter file not found
E17
Parameter file with incorrect version
I18
Parameter file with incorrect number of parameters
E19
Reserved
E20
Invalid parameter value
E21
Incorrect language file
Alarm, error, and system messages
10.1 General
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Error no.
Bit no.
Meaning
E22
Language file not loaded
E23
No communication with the camera
E24
Function not included in the license
E25
No valid license available
E26
Cycle time too long
E27
Hoisting height has jumped
E28
E29
E30
Sway control only when stopping (trolley)
E31
Sway control only when stopping (gantry)
E32
Sway control only when stopping (slewing gear)
E33
Sway control off (start trolley)
E34
Sway control off (start gantry)
E35
Sway control off (start slewing gear)
E36
Controlled stop active (trolley)
E37
Controlled stop active (gantry)
E38 Controlled stop active (slewing gear)
E38
Controlled stop active (hoist)
E39 Positioning with parameter P115 deactivated
E40
Function with parameter P115 deactivated
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
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Operating Instructions, 02/2014 159
10.2
List of alarm, error, and system messages
E0 invalid parameter file
An error has occurred while loading the parameter files. This error is issued only in
conjunction with warnings E16, E17, E18 and E20. Refer to these for further information.
Significance: x = parameter set
Error values:
[x1] - parameter file missing
[x2] - incorrect version
[x3] - incorrect number of parameters
[x4] - incorrect parameter value
Error bit:
0
Error type:
Error
Remedy:
Check parameters in the parameter menu and save.
Note
Sway control response with parameter set switchover
Error message E0 has the following results in the sway control:
•
If the cause of the problem is not in the active parameter set then there is no effect on the
sway control and the drive continues to travel.
•
If the cause of the problem is in the active parameter set then the drive is braked with
setpoint acceleration and with sway control, and with the settings for the previous error-
free parameter set being used. Continued travel is then impossible.
E1 Invalid operation mode
There is no control bit set for the operation mode or there are multiple control bits set for the
operation mode or a "sway neutralization" operation mode is selected for the hoist.
Error bit:
1
Error type:
Error
Remedy:
Check PLC program. Set only one ope
ration mode bit per drive.
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
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160 Operating Instructions, 02/2014
E2 Fieldbus error
The telegram counter for the receiving telegram is not receiving any data.
Display:
● In SIMOCRANE CeCOMM: Value "received" in display screen 2 (PROFIBUS interface)
● In the PLC: Value "trailer" (telegram counter) in send block SC_DB_SEND_xxx)
Error bit:
2
Error type:
Error
Remedy:
Investigate the causes listed below.
Possible causes:
● No communication block present in the PLC
● Connection with the PLC faulty (e.g. cable disconnected)
● Incorrect PROFIBUS address
● Faulty hardware configuration, configured addressing ranges do not correspond with
those in the FC SC_MAIN_INT.
● Incorrect transmission rate
E3 Invalid target position
The target position of a drive is outside the set limits:
● Trolley P7, P8
● Gantry P47, P48
● Slewing gear P137, P138.
The relevant drive does not start, or stops with the quick stop ramp.
Error value: [Drive number]
[0] – trolley
[1] – gantry
[2] – slewing gear or hoist
Error bit:
3
Error type:
Error
Remedy:
Check parameters for limits. Check target position.
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
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E4 Invalid hoist position (sway control off)
The current position of the hoist for calculating the pendulum length is outside the set limits
(P84, P85). The sway control function is internally deactivated.
Error bit:
4
Error type:
Error
Remedy:
Check hoist position and parameters.
E5 Invalid pendulum length (sway control off)
The sway control function has been switched off because the determined pendulum length is
not within the specified limits (P86, P87).
Error value: [Drive number]
[0] – trolley
[1] – gantry
[2] – slewing gear
Error bit:
5
Error type:
Error
Remedy:
Check pendulum length and parameters.
E6 Actual position not valid
The actual position of a drive is outside the set limits:
● Trolley P7, P8
● Gantry P47, P48
● Slewing gear P137, P138.
The relevant drive does not start, or stops with the quick stop ramp.
Error value: [Drive number]
[0] - trolley
[1] - gantry
[2] - slewing gear or hoist
Error bit:
6
Error type:
Error
Remedy:
Check the current position and parameters.
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
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162 Operating Instructions, 02/2014
E7 Following error, trolley
The difference between the setpoint and actual position is greater than the value defined
using parameter P28.
Error value: [xx]
[xx] – setpoint-actual value deviation in mm
Error bit:
7
Error type:
Error
Remedy:
Check the drive and position measuring system.
E8 Following error, gantry
The difference between the setpoint and actual position is greater than the value defined
using parameter P68.
Error value: [xx]
[xx] – setpoint-actual value deviation in mm
Error bit:
8
Error type:
Error
Remedy:
Check the drive and position measuring system.
E9 Following error, slewing gear
The difference between the setpoint and actual position is greater than the value defined
using parameter P158.
Error value: [xx]
[xx] – setpoint-actual value deviation in c °
Error bit:
9
Error type:
Error
Remedy:
Check the drive and position measuring system.
E9 Following error, hoist
The difference between the setpoint and actual position is greater than the value defined
using parameter P158.
Error value: [xx]
[xx] – setpoint-actual value deviation in mm
Error bit:
9
Error type:
Error
Remedy:
Check the drive and position measuring system.
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
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E10 Camera measuring system impaired
The camera cannot temporarily detect a reflector.
This may be due to the following causes:
● The reflector is dirty.
● The lighting or visibility conditions are poor.
● The reflector is no longer within the camera's field of vision.
● The reflector is misaligned by 90°.
● The reflector is too small for the set window size, i.e. is too far away.
● The ambient light is too bright or too dark.
● The camera image is not focused.
If this alarm is active for longer than 14 s, it is replaced by error message E11.
Error bit:
10
Error type:
Alarm
Remedy:
Correct the listed error causes.
E11 Camera measuring system faulted
The camera can no longer detect a reflector over a longer period.
This may be due to the following causes:
● The reflector is dirty.
● The lighting and visibility conditions are poor.
● The reflector is no longer within the camera's field of vision.
● The reflector is misaligned by 90°.
● The reflector is too small for the set window size, i.e. is too far away.
● The ambient light is too bright or too dark.
● The camera image is not focused.
This error replaces E10 if the cause of the problem exists for longer than 14 s.
Error bit:
11
Error type:
Error
Remedy:
Correct the listed error causes.
E12 Reserved
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
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164 Operating Instructions, 02/2014
E13 Sway control temporarily reduced, trolley
It is not possible to eliminate the sway or the sway is increasing.
Error bit:
13
Error type:
Error
Remedy:
Stop the oscillation manually and check cause of the problem in Chapter
Stability test and monitoring functions (Page 142).
E14 Sway control temporarily reduced, gantry
It is not possible to eliminate the sway or the sway is increasing.
Error bit:
14
Error type:
Error
Remedy:
Stop the oscillation manually and check cause of the problem in Chapter
Stability test and monitoring functions (Page 142).
E15 Sway control temporarily reduced, slewing gear
It is not possible to eliminate the sway or the sway is increasing.
Error bit:
15
Error type:
Error
Remedy:
Stop the oscillation manually and check cause of the problem in Chapter
Stability test and monitoring functions (Page 142).
E16 Parameter file not found
A parameter file cannot be opened when the SIMOTION C240 PN powers up. The relevant
parameter set has been set to default values.
Error value: [xxxx] parameter set number (each digit stands for a parameter set involved.)
Error bit:
-
Error type:
Alarm
Remedy:
Check the parameter files involved.
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 165
E17 Parameter file with incorrect version
A parameter file contains parameters of an incorrect version. The relevant parameter set has
been set to default values.
Error value: [xxxx] parameter set number (each digit stands for a parameter set involved.)
Error bit:
-
Error type:
Alarm
Remedy:
Check the parameter files involved.
E18 Parameter file with incorrect number of parameters
A parameter file contains an incorrect number of parameters. The relevant parameter set
has been set to default values.
Error value: [xxxx] parameter set number (each digit stands for a parameter set involved.)
Error bit:
-
Error type:
Alarm
Remedy:
Check the parameter files involved.
E19 Reserved for detour control (not available in this version)
E20 Invalid parameter value
When loading existing parameter files, one or several invalid values were identified. The
relevant parameter value is set to the default value. The error is only reset after the
parameter files have been loaded successfully. The last incorrect value identified is
displayed.
Error value [abbb]: a = parameter set number, bbb = parameter number
The incorrect value is parameter "bbb" in parameter set "a".
Error bit:
-
Error type:
Alarm
Remedy:
Check parameters in the parameter menu and save.
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
CeSAR standalone OHBC, Gantry crane
166 Operating Instructions, 02/2014
E21 Incorrect language file
Errors have occurred when loading the actual language file.
Excessively long lines, i.e. longer than 77 characters, are cut off. A block (help texts for
parameter or error messages) can be a maximum of six lines long. Additional lines are
ignored.
Error value: [xxxx] line number with error in the language file
Error bit:
-
Error type:
Alarm
Remedy:
Correct the language file and power up the SIMOTION C
240 PN again
(stop/run).
E22 Language file not loaded
The actual language file was not able to be loaded.
Language file not on the MMC or corrupted.
Error value: [x] number of the language file
Error bit:
-
Error type:
Alarm
Remedy:
Check that the language file is actually on the MMC.
E23 No communication with the camera
There is no communication connection to the camera, internal telegram counter does not
increment.
Error bit:
-
Error type:
Alarm
Remedy:
Check the configuration or hardware.
E24 Function is not included in the license
There is no license available for the selected function.
Error value: [x]
[0] - Manual license missing; only manual operation mode without sway control possible
[1] - Basic license missing; only manual operation mode possible
[2] – Reserved for detour control (not available in this version)
Error bit:
-
Error type:
Alarm
Remedy:
Check license or use enabled function only
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 167
E25 No valid license available
The license is corrupt or missing. Only manual operation mode without sway control
possible.
Error bit:
-
Error type:
Alarm
Remedy:
Check and/or purchase the license
E26 Cycle time too long
The cycle time is longer than 100 ms.
Error bit:
-
Error type:
Alarm
Remedy:
Allocate DCC plan for a faster motion task in the execution system
E30 Sway control only when stopping (trolley)
The control bit "SC_Only_OnStop" is set.
Error bit:
-
Error type:
Alarm
Remedy:
Reset the control bit.
E31 Sway control only when stopping (gantry)
The control bit "SC_Only_OnStop" is set.
Error bit:
-
Error type:
Alarm
Remedy:
Reset the control bit.
E32 Sway control only when stopping (slewing gear)
The control bit "SC_Only_OnStop" is set. Only applicable for sway-controlled slewing gear.
Error bit:
-
Error type:
Alarm
Remedy:
Reset the control bit.
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
CeSAR standalone OHBC, Gantry crane
168 Operating Instructions, 02/2014
E33 Sway control off (start trolley)
The set velocity V_set is less than the activation velocity from P20. As a consequence, the
sway control is still not activated.
Error bit:
-
Error type:
Alarm
Remedy:
-
E34 Sway control off (start gantry)
The set velocity V_set is less than the activation velocity from P60. As a consequence, the
sway control is still not activated.
Error bit:
-
Error type:
Alarm
Remedy:
-
E35 Sway control off (start slewing gear)
The set velocity V_set is less than the activation velocity from P150. As a consequence, the
sway control is still not activated.
Error bit:
-
Error type:
Alarm
Remedy:
-
E36 Controlled stop active (trolley)
The control bit "Stop" is set.
Error bit:
-
Error type:
Alarm
Remedy:
Reset control bit "Stop".
E37 Controlled stop active (gantry)
The control bit "Stop" is set.
Error bit:
-
Error type:
Alarm
Remedy:
Reset control bit "Stop".
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 169
E38 Controlled stop active (slewing gear)
The control bit "Stop" is set.
Error bit:
-
Error type:
Alarm
Remedy:
Reset control bit "Stop".
E38 Controlled stop active (hoist)
The control bit "Stop" is set.
Error bit:
-
Error type:
Alarm
Remedy:
Reset control bit "Stop".
E39 Positioning with parameter P115 deactivated
The positioning operation mode has been deactivated.
Error bit:
-
Error type:
Alarm
Remedy:
Check parameter P115.
E40 Function with parameter P115 deactivated
The functionality of the third drive has been deactivated.
Error bit:
-
Error type:
Alarm
Remedy:
Check parameter P115.
E41 to E45 Reserved for detour control (not available in this version)
Alarm, error, and system messages
10.2 List of alarm, error, and system messages
CeSAR standalone OHBC, Gantry crane
170 Operating Instructions, 02/2014
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 171
Parameter list
11
11.1
Overview
Table 11- 1 Parameter categories
Trolley parameters
P0 to P35
Gantry parameters
P40 to P75
General parameters
P80 to P119
Slewing gear or hoist parameters
P130 to P165
The parameter menu of the SIMOCRANE CeCOMM diagnostic program displays only those
parameters to which access code P100 is assigned.
Access codes:
● Access code 1: Crane operator, maintenance personnel
● Access code 2: Commissioning engineer
● Access code 3: Service technician
● Access code 4: Development engineer
Set the access code to 4 in order to see all of the parameters.
Parameters which are not set to their default are displayed with a "+" symbol in front of the
parameter number in the parameter menu of the CeCOMM diagnostic program.
Saving is realized in the parameter menu as well as in the commissioning menu using the
key "S". The parameters are then saved in text files (Par0.txt to Par3.txt) on the MMC and
are loaded after a new start.
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
172 Operating Instructions, 02/2014
11.2
Trolley parameters
P0 Trolley positioning velocity
This value corresponds to the set velocity in the positioning operation mode. In order to allow
a slight overshoot (control margin), a value less than the maximum output velocity P1 should
be set (e.g. 90%).
Default: 450 [mm/s]
Min: 10 [mm/s]
Max: 4,000 [mm/s]
Access code: 1
Note
Only relevant for the positioning operation mode.
P1 Maximum trolley output velocity
The parameter is the reference value for normalizing P35. V_norm = output velocity [mm/s]
· P35 : P1). If the setting is correct (see Chapter Normalization (Page 43)), this value will be
the maximum possible velocity.
Default: 500 [mm/s]
Min: 10 [mm/s]
Max: 4,000 [mm/s]
Access code: 2
P2 Acceleration without sway control, trolley
When the sway control function is deactivated, the drive accelerates and brakes with the set
acceleration value.
Values of less than 20 that are entered are interpreted as ramp time.
Default: 100 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 1
P3 Trolley setpoint acceleration
The setpoint acceleration is a guide value in mm/s2 for accelerating and decelerating with the
sway control activated in all operation modes. The acceleration value is not constant. It
varies depending on the state of the oscillation model and the measured pendulum
deflection. Values of less than 20 that are entered are interpreted as ramp time.
Default: 150 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 1
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 173
P4 Maximum trolley acceleration
The maximum acceleration limits the acceleration of the output velocity.
Set manually according to manufacturer's or customer's specifications.
The value P4 should be between 1.5 and 2 times the P3 value. The quick stop ramp P12 is
not limited to this value.
Values of less than 20 that are entered are interpreted as ramp time.
Default: 250 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 2
P5 Position conversion factor for trolley
Conversion factor for the actual and target positions of the trolley.
Actual position = P5 · S_act + P6
Target position = P5 · S_set + P6
Default: 1
Min: -100
Max: 100
Access code: 2
P6 Position conversion offset for trolley
Offset for the actual and target positions of the trolley.
Actual position = P5 · S_act + P6
Target position = P5 · S_set + P6
Default: 0 [mm]
Min: -100,000 [mm]
Max: 100,000 [mm]
Access code: 2
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
174 Operating Instructions, 02/2014
P7 Minimum position for trolley positioning
Target position
smaller:
Error E03 (error bit 3)
Actual position
smaller:
Error E06 (error bit 9)
In both cases, the trolley does not start.
During travel, the trolley stops with quick stop ramp P12.
Target and actual position refer to the values after conversion with P5 and P6.
Default: 0 [mm]
Min: -500,000 [mm]
Max: 500,000 [mm]
Access code: 1
Note
Only relevant for the positioning operation mode.
P8 Maximum position for trolley positioning
Target position larger:
Error E03 (error bit 3)
Actual position larger:
Error E06 (error bit 9)
In both cases, the trolley does not start.
During travel, the trolley stops with quick stop ramp P12.
Target and actual position refer to the values after conversion with P5 and P6.
Default: 200,000 [mm]
Min: -500,000 [mm]
Max: 500,000 [mm]
Access code: 1
Note
Only relevant for the positioning operation mode.
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 175
P9 Trolley positioning accuracy
The positioning accuracy should not be set lower than the minimum required value. A
difference between the current and target positions that is smaller than the set positioning
accuracy is a condition for setting status bit "Pos_completed" (see Chapter Interface
description (Page 45)). Positioning will continue while the operation mode remains active
and the "Travelling" control bit remains set.
Default: 50 [mm]
Min: 3 [mm]
Max: 200 [mm]
Access code: 1
Note
Only relevant f
or the positioning operation mode.
P10 Deceleration gain for trolley
Multiplication factor for the deceleration.
Deceleration is obtained
● with active sway control from P3 · P10, for countering from P3 · P10 · P18,
● without sway control from P2 · P10 and for countering from P2 · P10 · P18.
The parameter has no influence on deceleration P14 when a prelimit switch is actuated. The
effective deceleration is limited to the maximum acceleration P4.
Default: 1
Min: 0,5
Max: 5
Access code: 1
Note
Only relevant for the manual operation mode.
P11 Not used
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
176 Operating Instructions, 02/2014
P12 Quick stop ramp trolley
Time in ms, to brake from the maximum velocity down to zero.
The drive stops along this ramp without sway control if:
● Control bit "Release" (enable) = 0
● Control bit "Travelling" (travel signal) = 0
● Control bit "Brake_closed" (output value enable) = 1
● Control bit "LS_F" or "LS_B" (limit switch) = 0
● Issue of error messages E1, E3, E6
Default: 1,000 [ms]
Min: 0 [ms]
Max: 10,000 [ms]
Access code: 2
P13 Prelimit switch velocity trolley
The output velocity is limited to this value if a limit switch has responded.
Specified as a % of the maximum output velocity P1.
Default: 10 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 1
P14 Deceleration prelimit switch trolley
Trolley deceleration when the prelimit switch is actuated.
No limit is applied in manual operation mode.
In the other operation modes, the parameter is effective only if the value is between the set
acceleration P3 and the maximum acceleration P4.
If P14<P3, then P3 is applied as the deceleration rate.
If P14>P4, then P4 is applied as the deceleration rate.
Values of less than 20 that are entered are interpreted as ramp time.
Default: 250 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 1
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 177
P15 Position controller trolley
P position controller for positioning and sway neutralization operation modes.
A value lower than zero means that the position controller and the following error monitor are
not activated until drive deceleration is about to begin (twice the braking distance before the
target position).
Default: 0,5
Min: -1
Max: 10
Access code: 3
Note
Only relevant for the positioning operation mode.
P16 Damping factor trolley (decelerating)
Damping factor for the sway control in all operation modes when decelerating.
High values result in non-periodic, transient responses, low values, in overshoot and shorter
rise times.
If the value is zero, no sway control when decelerating.
Default: 1,2
Min: 0
Max: 10
Access code: 3
P17 Damping factor trolley (accelerating)
Damping factor for sway control in the manual operation mode when accelerating.
High values result in the non-periodic transient responses, low values, to overshoot and
shorter rise times. In order to achieve fast acceleration levels, the value should be less than
when braking.
If the value is zero then there is no sway control when accelerating in manual operation
mode.
Default: 1
Min: 0
Max: 5
Access code: 3
Note
Only relevant for the manual operation mode.
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
178 Operating Instructions, 02/2014
P18 Braking gain when countering, trolley
The deceleration is multiplied by this value when the set velocity and the actual velocity have
different signs (countering). The resulting deceleration is limited to the relevant maximum
acceleration.
Default: 1,2
Min: 0,5
Max: 5
Access code: 1
Note
Only relevant for the manual operation mode.
P19 Trolley velocity for zero speed detection
Defines the output velocity for the trolley from which "zero" speed is detected. The
percentage value refers to the maximum output velocity P1.
Zero speed detection is the condition for setting the control bit "Pos_completed".
Default: 3 [%]
Min: 0 [%]
Max: 75 [%]
Access code: 2
P20 Activation velocity trolley sway control
The sway control is only activated when the absolute value of the set velocity V_set is
greater than this value.
Application: for example, fine positioning in stage 1 without sway control.
Default: 0 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 2
Note
Only relevant for the manual operation mode.
P21 Boosting of camera measuring signal in trolley dir.
Value to boost the measured deflection to the internal oscillation model.
The camera measuring system has no effect for zero.
Default: 0,1
Min: 0
Max: 1
Access code: 3
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 179
P22 Gain pendulum length for oscillation in trolley dir.
Gain for calculating the effective pendulum length.
Pendulum length = gain · S_Hoist + Offset (P108 is OFF)
Pendulum length = gain · Distance + Offset (P108 is ON)
Default: 1
Min: -20
Max: 20
Access code: 2
P23 Offset pendulum length for oscillation in trolley dir.
Offset for calculating the effective pendulum length.
Pendulum length = gain · S_Hoist + Offset (P108 is OFF)
Pendulum length = gain · Distance + Offset (P108 is ON)
Default: 0 [mm]
Min: -70,000 [mm]
Max: 70,000 [mm]
Access code: 2
P24 Digital correction of eff. pendulum length, trolley
Depending on the control bit "DigitalLiftCorrection", the parameter value is added to the
actual pendulum length.
The parameter is required to take into account the occasional use of other load carrying
devices.
Default: 0 [mm]
Min: -10,000,000 [mm]
Max: 10,000,000 [mm]
Access code: 2
P25 Analog correction of eff. pendulum length, trolley
Depending on the current load, this parameter is used to calculate a correction value for the
pendulum length which is then added to the actual pendulum length.
The parameter is required in order to take into account weight-dependent offset of the center
of gravity for significant variations in load.
Default: 0 [mm/kg]
Min: 0 [mm/kg]
Max: 70,000 [mm/kg]
Access code: 2
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
180 Operating Instructions, 02/2014
P26 Time constant 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.
Default: 0 [ms]
Min: 0 [ms]
Max: 1,000 [ms]
Access code: 2
P27 Drive switch on delay trolley
Output value delay of the controlled system (including frequency converter)
This delay is taken into account in the calculation of the mathematical model.
If the value is less than 1, the delay element is deactivated.
Default: 0 [ms]
Min: 0 [ms]
Max: 350 [ms]
Access code: 2
P28 Following error trolley
The deviation between the setpoint and actual position must not exceed the value of this
parameter during positioning. Otherwise error message E7 is generated. (0 deactivates the
monitoring.)
Default: 1,000 [mm]
Min: 0 [mm]
Max: 100,000 [mm]
Access code: 2
Note
Only relevant for the positioning operation mode.
P29 Reserved for detour control (not available in this version)
P30 Camera measuring signal gain in trolley direction
Gain factor for the camera measuring signal before it is boosted to the oscillation model.
Default: 1
Min: 0
Max: 10000
Access code: 2
Parameter list
11.2 Trolley parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 181
P31 Not used
P32 Target position offset trolley
Offset of the current position: S_act:=S_act+V[mm/s]·P32·0.001
The dynamic response when braking in the positioning operation mode can be improved
using a virtual offset of the current position (compensation for dead times).
Default: 0 [ms]
Min: 0 [ms]
Max: 2000 [ms]
Access code: 2
Note
Only relevant for the positioning operation mode.
P33 Permitted residual sway when stopping, trolley
Maximum permissible pendulum deflection
If the pendulum deflection drops below this value, status bit "SC_completed" is set.
Default: 50 [mm]
Min: 10 [mm]
Max: 300 [mm]
Access code: 1
P34 Permitted residual pendulum velocity, trolley
Maximum permissible pendulum velocity
If the pendulum velocity drops below this value, status bit "SC_completed" is set.
Default: 50 [mm/s]
Min: 10 [mm/s]
Max: 500 [mm/s]
Access code: 1
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
182 Operating Instructions, 02/2014
P35 Normalization value, trolley
With this value, the set velocity V_set specified by the PLC and the actually measured
velocity V_act are denormalized, the output velocity V_norm specified by the sway control is
normalized.
V_norm = output velocity [mm/s] · P35 :
P1
(V_norm: Output velocity out
put after
normalization)
V_set[mm/s] = V_set · P1 : P35
(V_set: denormalized setpoint in mm/s)
V_act[mm/s] = V_act · P1 : P35
(V_act: denormalized actual value in mm/s)
Default: 16384
Min: 100
Max: 32767
Access code: 2
11.3
Gantry parameters
P40 Positioning velocity, gantry
This value corresponds to the set velocity in the positioning operation mode. In order to allow
a slight overshoot (control margin), a value less than the maximum output velocity P41
should be set (e.g. 90%).
Default: 900 [mm/s]
Min: 10 [mm/s]
Max: 4,000 [mm/s]
Access code: 1
Note
Only relevant for the positioning operation mode.
P41 Maximum output velocity, gantry
The parameter is the reference value for normalizing P75. V_norm = output velocity [mm/s]
· P75 : P41). If the setting is correct (see Chapter Normalization (Page 43)), this value will
be the maximum possible velocity.
Default: 1,000 [mm/s]
Min: 10 [mm/s]
Max: 4,000 [mm/s]
Access code: 2
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 183
P42 Acceleration without sway control, gantry
When the sway control function is deactivated, the drive accelerates and decelerates with
the set acceleration value. Values of less than 20 that are entered are interpreted as ramp
time.
Default: 200 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 1
P43 Setpoint acceleration, gantry
The setpoint acceleration is a guide value in mm/s2 for accelerating and decelerating with the
sway control activated in all operation modes. The acceleration value is not constant. It
varies depending on the state of the oscillation model and the measured pendulum
deflection. Values of less than 20 that are entered are interpreted as ramp time.
Default: 300 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 1
P44 Maximum acceleration, gantry
The maximum acceleration limits the acceleration of the output velocity.
Set manually according to manufacturer's or customer's specifications.
The value P44 should be between 1.5 and 2 times the P43 value. The quick stop ramp P52
is not limited to this value.
Values of less than 20 that are entered are interpreted as ramp time.
Default: 500 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 2
P45 Position conversion factor, gantry
Conversion factor for the actual and target positions of the gantry.
Actual position = P45 · S_act + P46
Target position = P45 · S_set + P46
Default: 1
Min: -100
Max: 100
Access code: 2
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
184 Operating Instructions, 02/2014
P46 Position conversion offset, gantry
Offset for the actual and target positions of the gantry.
Actual position = P45 · S_act + P46
Target position = P45 · S_set + P46
Default: 0 [mm]
Min: -500,000 [mm]
Max: 500,000 [mm]
Access code: 2
P47 Minimum position for positioning, gantry
Target position
smaller:
Error E03 (error bi
t 3)
Actual position
smaller:
Error E06 (error bit 9)
In both cases, the gantry does not start.
During travel, the gantry stops with quick stop ramp P52.
Target and actual position refer to the values after conversion with P45 and P46.
Default: 0 [mm]
Min: -500,000 [mm]
Max: 500,000 [mm]
Access code: 1
Note
Only relevant for the positioning operation mode.
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 185
P48 Maximum position for positioning, gantry
Target position
larger:
Error E03 (error bit 3)
Actual position
larger:
Error E06 (error bit
9)
In both cases, the gantry does not start.
During travel, the gantry stops with quick stop ramp P52.
Target and actual position refer to the values after conversion with P45 and P46.
Default: 200,000 [mm]
Min: -2,000,000 [mm]
Max: 2,000,000 [mm]
Access code: 1
Note
Only relevant for the positioning operation mode.
P49 Positioning accuracy, gantry
The positioning accuracy should not be set lower than the minimum required value. A
difference between the current and target positions that is smaller than the set positioning
accuracy is a condition for setting status bit "Pos_completed" (see Chapter Interface
description (Page 45)). Positioning will continue while the operation mode remains active
and the "Travelling" control bit remains set.
Note
Only relevant for the positioning operation mode.
Default: 50 [mm]
Min: 3 [mm]
Max: 200 [mm]
Access code: 1
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
186 Operating Instructions, 02/2014
P50 Deceleration gain, gantry
Multiplication factor for the deceleration.
Deceleration is obtained
● with active sway control from P43 · P50, for countering from P43 · P50 · P58,
● without sway control from P42 · P50 and for countering from P42 · P50 · P58.
The parameter has no influence on deceleration P54 when a prelimit switch is actuated. The
effective deceleration is limited to the maximum acceleration P44.
Default: 1
Min: 0,5
Max: 5
Access code: 1
Note
Only relevant for the manual operation mode.
P51 Not used
P52 Quick stop ramp, gantry
Time in ms, to brake from the maximum velocity down to zero.
The drive stops along this ramp without sway control if:
● Control bit "Release" (enable) = 0
● Control bit "Travelling" (travel signal) = 0
● Control bit "Brake_closed" (output value enable) = 1
● Control bit "LS_F" or "LS_B" (limit switch) = 0
● Issue of error messages E1, E3, E6
Default: 1,000 [ms]
Min: 0 [ms]
Max: 10,000 [ms]
Access code: 2
P53 Prelimit switch velocity, gantry
The output velocity is limited to this value if a limit switch has responded.
(Specified as a % of the maximum output velocity P41)
Default: 10 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 1
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 187
P54 Braking deceleration prelimit switch, gantry
Gantry deceleration when the prelimit switch is actuated.
No limit is applied in manual operation mode.
In the other operation modes, the parameter is effective only if the value is between the set
acceleration P43 and the maximum acceleration P44.
If P54<P43, then P43 is applied as the deceleration rate.
If P54>P44, then P44 is applied as the deceleration rate.
Values of less than 20 that are entered are interpreted as ramp time.
Default: 500 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 1
P55 Position controller, gantry
P position controller for positioning and sway neutralization operation modes.
A value lower than zero means that the position controller and the following error monitor are
not activated until drive deceleration is about to begin (twice the braking distance before the
target position).
Default: 0,5
Min: -1
Max: 10
Access code: 3
Note
Only relevant for the positioning operation mode.
P56 Damping factor, gantry (braking)
Damping factor for the sway control in all operation modes when decelerating.
High values result in non-periodic, transient responses, low values, in overshoot and shorter
rise times.
If the value is zero, no sway control when decelerating.
Default: 1,2
Min: 0
Max: 10
Access code: 3
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
188 Operating Instructions, 02/2014
P57 Damping factor, gantry (accelerating)
Damping factor for sway control in the manual operation mode when accelerating.
High values result in the non-periodic transient responses, low values, to overshoot and
shorter rise times.
In order to achieve fast acceleration, the value should be less than for braking. If the value is
zero, in the manual operation mode there is no sway control when accelerating.
Default: 1
Min: 0
Max: 5
Access code: 3
Note
Only relevant for the manual operation mode.
P58 Braking gain when countering, gantry
The deceleration is multiplied by this value when the set velocity and the actual velocity have
different signs (countering). The resulting deceleration is limited to the relevant maximum
acceleration.
Default: 1,2
Min: 0,5
Max: 5
Access code: 1
Note
Only relevant for the manual operation mode.
P59 Velocity for zero speed detection, gantry
Defines the output velocity for the gantry from which "zero" velocity is detected. The
percentage value refers to the maximum output velocity P41.
Zero speed detection is the condition for setting the control bit "Pos_completed".
Default: 3 [%]
Min: 0 [%]
Max: 75 [%]
Access code: 2
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 189
P60 Activation velocity sway control, gantry
The sway control is only activated when the absolute value of the set velocity V_set is
greater than this value.
Application: for example, fine positioning in stage 1 without sway control.
Default: 0 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 2
Note
Only relevant for the manual operation mode.
P61 Boosting of camera measuring signal in gantry dir.
Value to boost the measured deflection to the internal oscillation model.
The camera measuring system has no effect for zero.
Default: 0,1
Min: 0
Max: 1
Access code: 3
P62 Gain pendulum length for oscillation in gantry dir.
Gain for calculating the effective pendulum length.
Pendulum length = gain · S_Hoist + Offset (P108 is OFF)
Pendulum length = gain · Distance + Offset (P108 is ON)
Default: 1
Min: -20
Max: 20
Access code: 2
P63 Offset pendulum length for oscillation in gantry dir.
Offset for calculating the effective pendulum length.
Pendulum length = gain · S_Hoist + Offset (P108 is OFF)
Pendulum length = gain · Distance + Offset (P108 is ON)
Default: 0 [mm]
Min: -70,000 [mm]
Max: 70,000 [mm]
Access code: 2
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
190 Operating Instructions, 02/2014
P64 Digital correction of eff. pendulum length, gantry
Depending on the control bit "DigitalLiftCorrection", the parameter value is added to the
actual pendulum length.
The parameter is required to take into account the occasional use of other load carrying
devices.
Default: 0 [mm]
Min: -10,000,000 [mm]
Max: 10,000,000 [mm]
Access code: 2
P65 Analog correction, effective pendulum length, gantry
Depending on the current load, this parameter is used to calculate a correction value for the
pendulum length which is then added to the actual pendulum length.
The parameter is required in order to take into account weight-dependent offset of the center
of gravity for significant variations in load.
Default: 0 [mm/kg]
Min: 0 [mm/kg]
Max: 70,000 [mm/kg]
Access code: 2
P66 Time constant current rise, gantry
The current rise and therefore the change in acceleration over time are often limited by the
converter. In order to take this delay into account when activating the oscillation model and
the position control, a first-order delay element has been provided, whose time constant is
set with this parameter. If the value is less than 1, the delay element is deactivated.
Default: 0 [ms]
Min: 0 [ms]
Max: 1,000 [ms]
Access code: 2
P67 Drive switch-on delay, gantry
Output value delay of the controlled system (including frequency converter)
This delay is taken into account in the calculation of the mathematical model.
If the value is less than 1, the delay element is deactivated.
Default: 0 [ms]
Min: 0 [ms]
Max: 350 [ms]
Access code: 2
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 191
P68 Following error, gantry
The deviation between the setpoint and actual position must not exceed the value of this
parameter during positioning. Otherwise, error message E8 is generated. (0 deactivates the
monitoring.)
Default: 1,000 [mm]
Min: 0 [mm]
Max: 100,000 [mm]
Access code: 2
Note
Only relevant for
the positioning operation mode.
P69 Reserved for detour control (not available in this version)
P70 Camera measuring signal gain in gantry direction
Gain factor for the camera measuring signal before it is boosted to the oscillation model.
Default: 1
Min: 0
Max: 10000
Access code: 2
P72 Target position offset, gantry
Offset of the current position: S_act:=S_act+V[mm/s]·P72·0.001
The dynamic response when braking in the positioning operation mode can be improved
using a virtual offset of the current position (compensation for dead times).
Default: 0 [ms]
Min: 0 [ms]
Max: 2000 [ms]
Access code: 2
Note
Only relevant for the positioning operation mode.
Parameter list
11.3 Gantry parameters
CeSAR standalone OHBC, Gantry crane
192 Operating Instructions, 02/2014
P73 Permitted residual sway when stopping, gantry
Maximum permissible pendulum deflection
If the pendulum deflection drops below this value, status bit "SC_completed" is set.
Default: 50 [mm]
Min: 10 [mm]
Max: 300 [mm]
Access code: 1
P74 Permitted residual pendulum velocity, gantry
Maximum permissible pendulum velocity
If the pendulum velocity drops below this value, status bit "SC_completed" is set.
Default: 50 [mm/s]
Min: 10 [mm/s]
Max: 500 [mm/s]
Access code: 1
P75 Normalization value, gantry
With this value, the set velocity V_set specified by the PLC and the actually measured
velocity V_act are denormalized, the output velocity V_norm specified by the sway control is
normalized.
V_norm = output velocity [mm/s] · P75 :
P41
(V_norm: Output velocity output after normalization)
V_set[mm/s] = V_set · P41 : P75
(V_set: denormalized setpoint in mm/s)
V_act[mm/s] = V_act · P41 : P75
(V_act: denormalized actual value in mm/s)
Default: 16384
Min: 100
Max: 32767
Access code: 2
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 193
11.4
Parameters for third drive
11.4.1
Slewing gear parameters
P130 Positioning velocity, slewing gear
This value corresponds to the set velocity in the positioning operation mode. In order to allow
a slight overshoot (control margin), a value less than the maximum output velocity P131
should be set (e.g. 90%).
Default: 450 [c°/s]
Min: 10 [c°/s]
Max: 4000 [c°/s]
Access code: 1
Note
Only relevant for the positioning operation mode.
P131 Maximum output velocity, slewing gear
The parameter is the reference value for normalizing P165. V_norm = output velocity [mm/s]
· P165 : P131). If the setting is correct (see Chapter Normalization (Page 43)), this value will
be the maximum possible velocity.
Default: 500 [c°/s]
Min: 10 [c°/s]
Max: 4000 [c°/s]
Access code: 2
P132 Acceleration without sway control, slewing gear
When the sway control function is deactivated, the drive accelerates and decelerates with
the set acceleration value. Values of less than 20 that are entered are interpreted as ramp
time.
Default: 100 [c°/s
2
]
Min: 1 [c°/s
2
]
Max: 4,000 [c°/s
2
]
Access code: 1
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
194 Operating Instructions, 02/2014
P133 Setpoint acceleration, slewing gear
The setpoint acceleration is a guide value in c°/s2 for accelerating and decelerating with the
sway control activated in all operation modes. The acceleration value is not constant. It
varies depending on the state of the oscillation model and the measured pendulum
deflection. Values of less than 20 that are entered are interpreted as ramp time.
Default: 150 [c°/s
2
]
Min: 1 [c°/s
2
]
Max: 4,000 [c°/s
2
]
Access code: 1
P134 Maximum acceleration rate, slewing gear
The maximum acceleration limits the acceleration of the output velocity.
Set manually according to manufacturer's or customer's specifications.
The value P134 should be between 1.5 and 2 times the P133 value. The quick stop ramp
P142 is not limited to this value.
Values of less than 20 that are entered are interpreted as ramp time.
Default: 250 [c°/s
2
]
Min: 1 [c°/s
2
]
Max: 4,000 [c°/s
2
]
Access code: 2
P135 Position conversion factor, slewing gear
Conversion factor for the actual and target positions of the slewing gear.
Actual position = P135 · S_act + P136
Target position = P135 · S_set + P136
Default: 1
Min: -100
Max: 100
Access code: 2
P136 Position conversion offset, slewing gear
Offset for the actual and target positions of the slewing gear.
Actual position = P135 · S_act + P136
Target position = P135 · S_set + P136
Default: 0 [c°]
Min: -100,000 [c°]
Max: 100,000 [c°]
Access code: 2
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 195
P137 Minimum position for slewing gear positioning
Target position
smaller:
Error E03 (error bit 3)
Actual position
smaller:
Error E06 (error bit 6)
In both cases, the slewing gear does not start.
During travel, the slewing gear stops with quick stop ramp P142.
Target and actual position refer to the values after conversion with P135 and P136.
Default: 0 [c°]
Min: -200,000 [c°]
Max: 200,000 [c°]
Access code: 1
Note
Only relevant for the positioning operation mode.
P138 Maximum position for slewing gear positioning
Target position
larger:
Error E03 (error bit
3)
Actual position
larger:
Error E06 (error bit 6)
In both cases, the slewing gear does not start.
During travel, the slewing gear stops with quick stop ramp P142.
Target and actual position refer to the values after conversion with P135 and P136.
Default: 36000 [c°]
Min: -200,000 [c°]
Max: 200,000 [c°]
Access code: 1
Note
Only relevant for the positioning operation mode.
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
196 Operating Instructions, 02/2014
P139 Positioning accuracy, slewing gear
The positioning accuracy should not be set lower than the minimum required value. A
difference between the current and target positions that is smaller than the set positioning
accuracy is a condition for setting status bit "Pos_completed" (see Chapter Interface
description (Page 45)). Positioning will continue while the operation mode remains active
and the "Travelling" control bit remains set.
Default: 50 [c°]
Min: 3 [c°]
Max: 200 [c°]
Access code: 1
Note
Only relevant for
the positioning operation mode.
P140 Deceleration gain, slewing gear
Multiplication factor for the deceleration.
Deceleration is obtained
● for active sway control from P133 · P140, for countering from P133 · P140 · P148,
● without sway control from P132 · P140 and for countering from P132 · P140 · P148.
The parameter has no influence on deceleration P144 when a prelimit switch is actuated.
The effective deceleration is limited to the maximum acceleration P134.
Default: 1
Min: 0,5
Max: 5
Access code: 1
Note
Only relevant for the manual operation mode.
P141 Not used
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 197
P142 Quick stop ramp, slewing gear
Time in ms, to brake from the maximum velocity down to zero.
The drive stops along this ramp without sway control if:
● Control bit "Release" (enable) = 0
● Control bit "Travelling" (travel signal) = 0
● Control bit "Brake_closed" (output value enable) = 1
● Control bit "LS_F" or "LS_B" (limit switch) = 0
● Issue of error messages E1, E3, E6
Default: 1,000 [ms]
Min: 0 [ms]
Max: 10,000 [ms]
Access code: 2
P143 Prelimit switch velocity, slewing gear
The output velocity is limited to this value if a limit switch has responded.
(Specified as a % of the maximum output velocity P131)
Default: 10 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 1
P144 Braking deceleration of prelimit switch, slewing gear
Slewing gear deceleration when the prelimit switch is actuated.
No limit is applied in manual operation mode.
In the other operation modes, the parameter is effective only if the value is between the set
acceleration P133 and the maximum acceleration P134.
If P144<P133, P133 is applied as the deceleration rate.
If P144>P134, P134 is applied as the deceleration rate.
Values of less than 20 that are entered are interpreted as ramp time.
Default: 250 [c°/s
2
]
Min: 1 [c°/s
2
]
Max: 4,000 [c°/s
2
]
Access code: 1
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
198 Operating Instructions, 02/2014
P145 Position controller, slewing gear
P position controller for positioning and sway neutralization operation modes.
A value lower than zero means that the position controller and the following error monitor are
not activated until drive deceleration is about to begin (twice the braking distance before the
target position).
Default: 0,5
Min: -1
Max: 10
Access code: 3
Note
Only relevant for the positioning operation mode.
P146 Damping factor, slewing gear (decelerating)
Damping factor for the sway control in all operation modes when braking. High values result
in non-periodic, transient responses, low values, in overshoot and shorter rise times.
If the value is zero, no sway control when decelerating.
Default: 1,2
Min: 0
Max: 10
Access code: 3
P147 Damping factor, slewing gear (accelerating)
Damping factor for the sway control in the manual operation mode when accelerating. High
values result in non-periodic transient responses and low values to overshoot and short rise
times. To achieve fast acceleration, the value should be lower than when braking. If the
value is zero, in the manual operation mode there is no sway control when accelerating.
Default: 1
Min: 0
Max: 5
Access code: 3
Note
Only relevant for the
manual operation mode.
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 199
P148 Braking gain when countering, slewing gear
The deceleration is multiplied by this value when the set velocity and the actual velocity have
different signs (countering). The resulting deceleration is limited to the relevant maximum
acceleration.
Default: 1,2
Min: 0,5
Max: 5
Access code: 1
Note
Only relevant for the manual operation mode.
P149 Slewing gear velocity for zero speed detection
Defines the output velocity for the slewing gear from which "zero" speed is detected. The
percentage value refers to the maximum output velocity P131.
Zero speed detection is the condition for setting the control bit "Pos_completed".
Default: 3 [%]
Min: 0 [%]
Max: 75 [%]
Access code: 2
P150 Activation velocity sway control slewing gear
The sway control is only activated when the absolute value of the set velocity V_set is
greater than this value.
Application: For example, fine positioning in stage 1 without sway control
Default: 0 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 2
Note
Only relevant for the manual operation mode.
P151 Boosting of camera signal in slewing gear dir.
Value to boost the measured deflection to the internal oscillation model.
The camera measuring system has no effect for zero.
Default: 0,05
Min: 0
Max: 1
Access code: 3
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
200 Operating Instructions, 02/2014
P152 Pendulum length gain, slewing gear
Gain for calculating the effective pendulum length if the control bit "DigitalLiftCorrection" is
not set.
Pendulum length = P152 · S_Hoist + P153 (P108 is OFF)
Pendulum length = P152 · Distance + P153 (P108 is ON)
Default: 0,33
Min: -1000
Max: 1000
Access code: 3
P153 Offset pendulum length, slewing gear
Offset for calculating the effective pendulum length if the control bit "DigitalLiftCorrection" is
not set.
Pendulum length = P152 · S_Hoist + P153 (P108 is OFF)
Pendulum length = P152 · Distance + P153 (P108 is ON)
Default: 0 [mm]
Min: -200,000 [mm]
Max: 200,000 [mm]
Access code: 3
P154 Pendulum length gain under load conditions, slew. gear
Alternative gain for calculating the effective pendulum length if the control bit
"DigitalLiftCorrection" is set.
Pendulum length = P154 · S_Hoist + P155 (P108 is OFF)
Pendulum length = P154 · Distance + P155 (P108 is ON)
Default: 1
Min: -1000
Max: 1000
Access code: 3
P155 Offset pendulum length under load cond., slew. gear
Alternative offset for calculating the effective pendulum length if the control bit
"DigitalLiftCorrection" is set.
Pendulum length = P154 · S_Hoist + P155 (P108 is OFF)
Pendulum length = P154 · Distance + P155 (P108 is ON)
Default: 0 [mm]
Min: -200,000 [mm]
Max: 200,000 [mm]
Access code: 3
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 201
P156 Time constant current rise, slewing gear
The current rise and therefore the change in acceleration over time are often limited by the
converter. In order to take this delay into account when activating the oscillation model and
the position control, a first-order delay element has been provided, whose time constant is
set with this parameter. If the value is less than 1, the delay element is deactivated.
Default: 0 [ms]
Min: 0 [ms]
Max: 1,000 [ms]
Access code: 2
P157 Drive switch-on delay, slewing gear
Output value delay of the controlled system (including frequency converter)
This delay is taken into account in the calculation of the mathematical model.
If the value is less than 1, the delay element is deactivated.
Default: 0 [ms]
Min: 0 [ms]
Max: 350 [ms]
Access code: 2
P158 Following error, slewing gear
The deviation between the setpoint and actual position must not exceed the value of this
parameter during positioning. Otherwise, error message E9 is generated. (0 deactivates the
monitoring.)
Default: 100 [c°]
Min: 0 [c°]
Max: 10,000 [c°]
Access code: 2
Note
Only relevant for the positioning operation mode.
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
202 Operating Instructions, 02/2014
P159 Direction of rotation of slewing gear
Selection 1: Direction of rotation of slewing gear
OFF:
Counter-clockwise rotation
ON:
Clockwise rotation
The direction of rotation is defined from the perspective of the trolley. The angle values for
the slewing gear either increase (1) or decrease (0) with a clockwise motion.
Default: 1 (ON)
Min: 0
Max: 1
Access code: 1
Note
Depending on the direction of rotation of the slewing gear, the parameter assigns the
appropriate pendulum deflections for the camera in the trolley and gantry directions (if P88=1
is set).
If the par
ameter value = 0 (OFF: counterclockwise rotation) the current position of the
slewing gear is negated with the change in coordinates from the deflections and pendulum
velocities measured.
P160 Camera measuring signal gain in dir. of rotation
Gain factor for the camera measuring signal before it is boosted to the oscillation model.
Default: 1
Min: 0
Max: 10000
Access code: 2
P161 Target position offset, slewing gear
Offset of the current position: S_act:=S_act+V[c °/s]·P161·0.001
The dynamic response when braking in the positioning operation mode can be improved
using a virtual offset of the current position (compensation for dead times).
Default: 0 [ms]
Min: 0 [ms]
Max: 2000 [ms]
Access code: 2
Note
Only relevant for the positioning operation m
ode.
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 203
P162 Not used
P163 Permitted residual sway when stopping, slewing gear
Maximum permissible rotation
If the rotation drops below this value, status bit "SC_completed" is set.
Default: 50 [c°]
Min: 10 [c°]
Max: 300 [c°]
Access code: 1
P164 Permitted residual rotation velocity, slewing gear
Maximum permissible pendulum velocity
If the pendulum velocity drops below this value, status bit "SC_completed" is set.
Default: 50 [c°/s]
Min: 10 [c°/s]
Max: 500 [c°/s]
Access code: 1
P165 Normalization value, slewing gear
With this value, the set velocity V_set specified by the PLC and the actually measured
velocity V_act are denormalized, the output velocity V_norm specified by the sway control is
normalized.
V_norm = output velocity [mm/s] · P165 :
P131
(V_norm: Output velocity output after
normalization)
V_set[mm/s] = V_set · P131 : P165
(V_set: denormalized setpoint in mm/s)
V_act[mm/s] = V_act · P131 : P165
(V_act: denormalized actual value in mm/s)
Default: 16384
Min: 100
Max: 32767
Access code: 2
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
204 Operating Instructions, 02/2014
11.4.2
Hoist parameters
P130 Positioning velocity, hoist
This value corresponds to the set velocity in the positioning operation mode. In order to allow
a slight overshoot (control margin), a value less than the maximum output velocity P131
should be set (e.g. 90%).
Default: 450 [mm/s]
Min: 10 [mm/s]
Max: 4,000 [mm/s]
Access code: 1
Note
Only relevant for the positioning operation mode.
P131 Maximum output velocity, hoist
The parameter is the reference value for normalizing P165. V_norm = output velocity [mm/s]
· P165 : P131). If the setting is correct (see Chapter Normalization (Page 43)), this value will
be the maximum possible velocity.
Default: 500 [mm/s]
Min: 10 [mm/s]
Max: 4,000 [mm/s]
Access code: 2
P132 Acceleration, hoist
The drive accelerates and brakes with the set acceleration value. Values of less than 20 that
are entered are interpreted as ramp time.
Default: 100 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 1
P133 Not used
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 205
P134 Maximum acceleration, hoist
The maximum acceleration limits the acceleration of the output velocity.
Set manually according to manufacturer's or customer's specifications.
The resulting setpoint acceleration from P132 · P140 · P148 is limited to this value. The
quick stop ramp P142 is not limited to this value.
Values of less than 20 that are entered are interpreted as ramp time.
Default: 250 [mm/s
2
]
Min: 1 [mm/s
2
]
Max: 4,000 [mm/s
2
]
Access code: 2
P135 Position conversion factor, hoist
Conversion factor for the actual and target positions of the hoist.
Actual position = P135 · S_act + P136
Target position = P135 · S_set + P136
Default: 1
Min: -100
Max: 100
Access code: 2
P136 Position conversion offset, hoist
Offset for the actual and target positions of the hoist.
Actual position = P135 · S_act + P136
Target position = P135 · S_set + P136
Default: 0 [mm]
Min: -100,000 [mm]
Max: 100,000 [mm]
Access code: 2
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
206 Operating Instructions, 02/2014
P137 Minimum position for hoist positioning
Target position
smaller:
Error E03 (error bit 3)
Actual position
smaller:
Error E06 (error bit 6)
In both cases, the hoist does not start.
During travel, the hoist stops with quick stop ramp P142.
Target and actual position refer to the values after conversion with P135 and P136.
Default: 0 [mm]
Min: -200,000 [mm]
Max: 200,000 [mm]
Access code: 1
Note
Only relevant for the positioning operation mode.
P138 Maximum position for hoist positioning
Target position
larger:
Error E0
3 (error bit 3)
Actual position
larger:
Error E06 (error bit 6)
In both cases, the hoist does not start.
During travel, the hoist stops with quick stop ramp P142.
Target and actual position refer to the values after conversion with P135 and P136.
Default: 20,000 [mm]
Min: -200,000 [mm]
Max: 200,000 [mm]
Access code: 1
Note
Only relevant for the positioning operation mode.
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 207
P139 Positioning accuracy, hoist
The positioning accuracy should not be set lower than the minimum required value. A
difference between the current and target positions that is smaller than the set positioning
accuracy is a condition for setting status bit "Pos_completed" (see Chapter Interface
description (Page 45)). Positioning will continue while the operation mode remains active
and the "Travelling" control bit remains set.
Default: 50 [mm]
Min: 3 [mm]
Max: 200 [mm]
Access code: 1
Note
Only relevant for the pos
itioning operation mode.
P140 Deceleration gain, hoist
Multiplication factor for the deceleration.
The deceleration results from P132 · P140 and for countering from P132 · P140 · P148.
The effective deceleration is limited to the maximum acceleration P134.
Default: 1
Min: 0,5
Max: 5
Access code: 1
Note
Only relevant for the manual operation mode.
P141 Not used
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
208 Operating Instructions, 02/2014
P142 Quick stop ramp, hoist
Time in ms, to brake from the maximum velocity down to zero.
The drive stops along this ramp if:
● Control bit "Release" (enable) = 0
● Control bit "Travelling" (travel signal) = 0
● Control bit "Brake_closed" (output value enable) = 1
● Control bit "LS_F" or "LS_B" (limit switch) = 0
● Issue of error messages E1, E3, E6
Default: 1,000 [ms]
Min: 0 [ms]
Max: 10,000 [ms]
Access code: 2
P143 Prelimit switch velocity, hoist
The output velocity is limited to this value if a limit switch has responded.
(Specified as a % of the maximum output velocity P131)
Default: 10 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 1
P144 Not used
P145 Position controller, hoist
P position controller for positioning and sway neutralization operation modes.
A value lower than zero means that the position controller and the following error monitor are
not activated until drive deceleration is about to begin (twice the braking distance before the
target position).
Default: 0,5
Min: -1
Max: 10
Access code: 3
Note
Only relevant for the positioning operation mode.
P146 to P147 Not used
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 209
P148 Braking gain when countering, hoist
The deceleration is multiplied by this value when the set velocity and the actual velocity have
different signs (countering). The resulting deceleration is limited to the relevant maximum
acceleration.
Default: 1,2
Min: 0,5
Max: 5
Access code: 1
Note
Only relevant
for the manual operation mode.
P149 Hoist velocity for zero speed detection
Defines the output velocity for the hoist from which "zero" speed is detected. The percentage
value refers to the maximum output velocity P131.
Zero speed detection is the condition for setting the control bit "Pos_completed".
Default: 3 [%]
Min: 0 [%]
Max: 75 [%]
Access code: 2
P150 Not used
P151 Not used
P152 Not used
P153 Not used
P154 Not used
P155 Not used
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
210 Operating Instructions, 02/2014
P156 Not used
P157 Not used
P158 Following error, hoist
The deviation between the setpoint and actual position must not exceed the value of this
parameter during positioning. Otherwise, error message E9 is generated. (0 deactivates the
monitoring.)
Default: 1,000 [mm]
Min: 0 [mm]
Max: 100,000 [mm]
Access code: 2
Note
Only relevant for the positioning operation mode.
P159 Not used
P160 Not used
P161 Target position offset, hoist
Offset of the current position: S_act:=S_act+V[mm/s]·P161·0.001
The dynamic response when braking in the positioning operation mode can be improved
using a virtual offset of the current position (compensation for dead times).
Default: 0 [ms]
Min: 0 [ms]
Max: 2000 [ms]
Access code: 2
Note
Only relevant for the positioning operation mode.
Parameter list
11.4 Parameters for third drive
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 211
P162 Not used
P163 Not used
P164 Not used
P165 Normalization value hoist
With this value, the set velocity V_set specified by the PLC and the actually measured
velocity V_act are denormalized, the output velocity V_norm specified by the sway control is
normalized.
V_norm = output vel
ocity [mm/s] · P165 :
P131
(V_norm: Output velocity output after
normalization)
V_set[mm/s] = V_set · P131 : P165
(V_set: denormalized setpoint in mm/s)
V_act[mm/s] = V_act · P131 : P165
(V_act: denormalized actual value in mm/s)
Default:16384
Min: 100
Max: 32767
Access code: 2
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
212 Operating Instructions, 02/2014
11.5
General parameters
P80 Assignment of camera measurement direction
Assignment of the direction of motion from gantry and trolley to the camera measurement
direction (x, y direction).
0:
ON:
Motion up or down corresponds to the trolley travel.
OFF:
Motion up or down corresponds to the gantry travel.
1:
ON:
Motion to the left corresponds to the forward direction.
OFF:
Motion to the right corresponds to the forward direction.
2:
ON:
Motion up corresponds to the forward direction.
OFF:
Motion down corresponds to the forward direction.
Default: 0 (all OFF)
Min: 0
Max: 7
Access code: 2
Note
The direction specifications relate to the camera image (see Chapter
Step 1: Aligning the
camera
(Page 121)).
•
Selection "1" is only significant for the gantry when selection "0" = ON.
•
Selection "2" is only significant for the trolley when selection "0" = ON.
•
Where selection "0" = OFF then selection "1" only applies to the trolley and selection "2"
only applies to the gantry.
The measuring range of the camera in the y
-direction is smaller than the measuring range of
the camera in the x
-direction. As a result the camera must be mounted in such a way that
the x
-direction corresponds with the direction of motion of the drive where the larger
deflection occurs in operation.
This is generally the trolley.
P81 Reserved
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 213
P82 Weight of the load carrying device
Weight of the load carrying device to determine the shift in the center of gravity. This value is
subtracted from the load weight "Load" in the "General data" interface block. The remaining
net load is used to calculate the center of gravity.
Default: 0 [kg]
Min: -50,000 [kg]
Max: 100,000 [kg]
Access code: 2
Note
The total load (load weight "Load") is transmitted in the "General data" interface block in 10
kg steps. Parameter P82, weight of the load carrying device, is subtracted from this value.
The weight of the
empty load carrying device displayed in SIMOCRANE CeCOMM must be
entered into P82 (PROFIBUS interface [2] "Load" value display screen).
P83 Upper limit for camera measurement
For pendulum lengths less than this value, only the mathematical oscillation model is
applied. The measured pendulum deflection is not taken into account.
Default: 0 [mm]
Min: 0 [mm]
Max: 100,000 [mm]
Access code: 3
P84 Upper limit for sway control
The sway control system is deactivated at hoist heights (S_Hoist) or at camera-to-reflector
distances (Distance) above this limit. The parameter P108 can be set to determine whether
"S_Hoist" or "Distance" is applicable.
Default: 100 [mm]
Min: -70,000 [mm]
Max: 70,000 [mm]
Access code: 2
Note
The effectiveness of P84 and P85 doe
s not depend on the direction. The sway control is
deactivated if the value for "S_Hoist" or "Distance" is outside the limits of P84 and P85.
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
214 Operating Instructions, 02/2014
P85 Lower limit for sway control
The sway control system is deactivated at hoist heights (S_Hoist) or at camera-to-reflector
distances (Distance) above this limit. The parameter P108 can be set to determine whether
"S_Hoist" or "Distance" is applicable.
Default: 100,000 [mm]
Min: -100,000 [mm]
Max: 100,000 [mm]
Access code: 2
Note
The effectiveness of P84 an
d P85 does not depend on the direction. The sway control is
deactivated if the value for "S_Hoist" or "Distance" is outside the limits of P84 and P85.
P86 Minimum pendulum length
The pendulum length must have a value at least the size of the set value. Otherwise it will be
set to this value and the sway control system deactivated.
Default: 1,000 [mm]
Min: 500 [mm]
Max: 100,000 [mm]
Access code: 3
P87 Maximum pendulum length
The pendulum length must not be larger than the set value. Otherwise it will be set to this
value and the sway control system deactivated.
Default: 100,000 [mm]
Min: 1,000 [mm]
Max: 100,000 [mm]
Access code: 3
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 215
P88 Relationship between camera and reflector
Mounting of the camera and the reflector with respect to the slewing gear:
1: Slewing gear rotates camera and reflector
2: Slewing gear rotates reflector, but not camera
3: Slewing gear does not rotate camera or reflector
Default: 1
Min: 1
Max: 3
Access code: 3
Note
If the setting is "1: Slewing gear rotates camera and ref
lector," the sway angle for the gantry
and trolley will be converted as a function of the slewing gear position and the setting of
parameter P159. The two other settings result in conversion not being performed.
If the setting is "2: Slewing gear rotates r
eflector, but not the camera," a zero position of -
S_act (current position of the slewing gear) is assumed for the camera deflection.
P89 Suppress opposite direction
As long as the output velocity does not reach this value (as percentage of maximum
velocity), the drive will move only in the direction specified by the crane operator.
The parameter is valid for all sway-controlled drives.
Default: 75 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 3
Note
Only relevant for the manual operation mode.
P90 Reserved for detour control (not available in this version)
P91 Reserved for detour control (not available in this version)
P92 Reserved for detour control with hoist (not available in this version)
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
216 Operating Instructions, 02/2014
P93 Reserved for detour control with hoist (not available in this version)
P94 Acceleration reduction, creeping travel
If the set velocity and the actual velocity equal less than 30 % of the maximum velocity, the
set acceleration is multiplied by this factor. The value is valid for all drives.
Default: 0,5
Min: 0.001
Max: 1
Access code: 2
Note
Only relevant for the manual operation mode with sway control.
P95 Deceleration reduction, creeping travel
If the set velocity and the actual velocity are less than 30 % of the maximum velocity, the set
acceleration is multiplied by this factor and used as deceleration setpoint. The value is valid
for all drives.
Default: 0,5
Min: 0.001
Max: 1
Access code: 2
Note
Only relevant for the manual operation mode with sway control.
P96 Rotation of the reflector
This value is added to the measured rotation in order to compensate any rotation in the
quiescent position.
Default: 0 [c°]
Min: -2000 [c°]
Max: 2000 [c°]
Access code: 1
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 217
P97 Permit positioning from the limit switch
This parameter can be used to determine whether the limit switches work depending on the
direction in positioning operation mode or whether they work independently of the direction
of motion.
0:
ON:
Limit switches on trolley work depending on the direction.
OFF:
Limit switches on trolley work independently of the direction of motion.
1:
ON:
Limit switches on gantry work depending on the direction.
OFF:
Limit switches on gantry work independently of the direction of motion.
2:
ON:
Limit switches on hoist or slewing gear work depending on the direction.
OFF:
Limit switches on hoist or slewing gear work independently of the direction of
motion.
Default: 0 (all OFF)
Min: 0
Max: 7
Access code: 1
Note
Only relevant for the positioning operation mode.
P100 Access code
Access code for changing parameters:
1: Every user
2: Commissioning engineer
3: Service technician
4: Development engineer
Default: 3
Min: 1
Max: 4
Access code: 1
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
218 Operating Instructions, 02/2014
P101 Parameter set locked during travel
Selection: 1: Parameter set locked during travel
OFF:
Switching over the parameter set is possible at any time.
ON:
It is not possible to switch between parameter sets during travel (if the control bit
"Travelling" is set for at least one drive).
Default: 1 (ON)
Min: 0
Max: 1
Access code: 2
P102 Reserved
P103 Not used
P104 Not used
P105 to P107 Reserved
P108 Pendulum length from the PLC / from the camera
Selection 1: Selection of data source to determine pendulum length
OFF:
Determination of effective pendulum length with PLC value "S_Hoist" (General block)
ON:
Determination of effective pendulum length with distance measured to the reflector,
"Distance" value (data from the camera)
Default: 0 (OFF)
Min: 0
Max: 1
Access code: 2
P109 Not used
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 219
P110 Language
Select a language:
1: German
2: English
3: German, P115 Hubwerk aktiviert
4: English, P115 Hoist activated
Default: 1
Min: 1
Max: 4
Access code: 1
P111 Not used
P112 Not used
P113 Not used
P114 Not used
P115 Configuration
Selection:
1:
ON:
System without camera (blind)
OFF:
System with camera
2:
ON:
Positioning deactivated
OFF:
Positioning activated
3:
ON:
Slewing gear activated
OFF:
Slewing gear deactivated
4:
ON:
Hoist activated
OFF:
Hoist deactivated
Default: 0 (all OFF)
Min: 0
Max: 15
Access code: 3
Parameter list
11.5 General parameters
CeSAR standalone OHBC, Gantry crane
220 Operating Instructions, 02/2014
P119 Commissioning status
Information encoded bit-by-bit about which commissioning steps have been completed
successfully.
Default: 0
Min: 0
Max: 65535
Access code: 1
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 221
Notes on servicing and maintenance
12
12.1
General information
This chapter provides only selected notes on servicing and maintenance. Please refer to the
operating instructions for comprehensive information:
● SIMOTION C
● SIMOCRANE CenSOR.
12.2
Reflector maintenance
The reflector must be cleaned regularly in accordance with the amount of dirt. All dirt and
paint residues must be removed. The reflector must be checked to ensure that it is securely
mounted as part of the regular crane inspection.
12.3
Camera maintenance
The lens and where applicable the front plate of the protective camera housing must be
checked and cleaned in accordance with the amount of dirt and contamination. The camera
must also be checked to ensure that it is securely mounted.
Note
Further information is contained in the operating instructions for the SIMOCRANE CenSOR
camera m
easuring system.
12.4
Check of the position sensing functions for the hoist after rope
changing
After carrying out maintenance work at the hoist and changing the cable, the position
sensing sensor must be checked and should be re-referenced where required.
Notes on servicing and maintenance
12.4 Check of the position sensing functions for the hoist after rope changing
CeSAR standalone OHBC, Gantry crane
222 Operating Instructions, 02/2014
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 223
Appendix
A
A.1
List of abbreviations
The following abbreviations are used in this document:
Abbreviation
Significance
c°
Centigrade
One-hundredth of a degree; unit of measurement used with the slewing gear
LS
Limit switch
Limit switch
MMC
Micro Memory Card
Memory card for non-volatile storage of the drive software and parameters
OM
Operation mode
Operation mode
PD
Pendulum
Pendulum
PS
Parameter Set
Parameter set
PCS
Prelimit switch
Prelimit switch
SC
Sway control
Sway control
Appendix
A.1 List of abbreviations
CeSAR standalone OHBC, Gantry crane
224 Operating Instructions, 02/2014
CeSAR standalone OHBC, Gantry crane
Operating Instructions, 02/2014 225
Glossary
Crane control system
In this document, the crane control system refers to the higher-level controller (PLC). A
SIMATIC S7 is a typical example of a PLC for this application.
All data exchanged between the crane control system and the sway control system is
performed via PROFIBUS.
Dead-man's switch
A dead-man's device (or dead man, dead-man's warner, dead-man's switch, dead-man's
pedal or dead-man's handle) checks whether a person is present and is able to take action,
and triggers a signal or switching action when this is not the case.
Effective pendulum length
The effective pendulum length is the pendulum length that corresponds to that of a physical
pendulum.
The oscillation period for this is T = 2 · π · √l : g.
This effective pendulum length is obtained by means of oscillation tests and differs from the
pendulum length obtained by measuring with a tape measure, as the pendulum resulting
from the real design of the crane does not meet the conditions of a physical pendulum.
The effective pendulum length is one of the fundamental input variables for the control
algorithm for the sway control.
Gantry
Gantry refers to the gantry gear.
Gantry crane
Gantry crane refers to a portal crane.
Hoist
The hoist refers to the crane's hoist mechanism.
OHBC
OHBC is an overhead bridge crane.
Glossary
CeSAR standalone OHBC, Gantry crane
226 Operating Instructions, 02/2014
RMG
RMG is a rail-mounted gantry crane.
RTG
RTG is a rubber-tired gantry crane.
SIMOCRANE CeCOMM
Diagnostic tool for the sway control system for:
● Commissioning,
● Monitoring and changing parameters,
● Displaying input and output variables,
● Creating trace records.
SIMOCRANE CenSOR
Camera measuring system for capturing
● the pendulum deflection in two directions of motion (gantry and trolley),
● the rotation when slewing gear is used,
● the distance between the camera and reflector.
Technology objects (TO)
The SIMOTION runtime system is implemented in an object-oriented rather than a function-
oriented manner, i.e. independent technology objects (TO) are used.
Technology objects have a high degree of functionality integrated into them. For example, a
TO axis contains the capability for communication with the drive, as well as measured value
processing, position control, and positioning functions.
Technology objects offer the user a technological view of actuators and sensors and provide
technological functions for these, for example, the technology object "Axis for drive and
encoder."
