[PDF] CeSAR slew blind Sway Control System for slewing cranes

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Preface

Description

1

Installation

2

Integration in the crane

controller 3

Commissioning the sway

control system 4

Parameter and Error List

5

Maintenance

6

Appendix

7

Operating Instructions

Valid for

Hardware:

Camera As of Board Revision V-MHPC-

251D

Image sensor: Omnivision 7120,

Revision 1.0

Operating System: WIN 32 CE3.0

Software:

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

Safety information

This manual contains information that you should observe to ensure your own personal safety as well as to

avoid material damage. The notices referring to your personal safety are highlighted in the manual by a

safety alert symbol; notices referring to property damage only are displayed without a safety alert symbol.

Depending on the hazard level, warnings are displayed in descending order as follows.

DANGER

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

WARNING

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

CAUTION

with a safety alert symbol indicates that minor personal injury can result if the proper precautions are not

taken.

CAUTION

without a safety alert symbol means that damage to property may occur if the proper precautions are not

taken.

NOTICE

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

In the event of a number of levels of danger occurring simultaneously, the warning corresponding to the

highest level of danger is always used. A warning on a warning triangle indicating possible personal injury

ay also include a warning relating to property damage. m Note Routines or advice for the efficient use of the device and the software optimization.

Qualified

personnel The associated device/system must only be set up and operated using this documentation. A

device/system/software must only be commissioned and operated by qualified personnel. For the purpose of

the safety information in this documentation, a "qualified person" is someone who is authorized to commission, ground, and tag equipment, systems, and circuits in accordance with established safety

procedures. A further requirement is the successful participation in a commissioning training course held by

Siemens AG.

Proper handling

ote the following: N

WARNING

This equipment/software is only allowed to be used for the applications described in the catalog and in the

technical description, and only in conjunction with third-party equipment and components recommended or approved by Siemens. This product can func tion correctly and safely only if it is transported, stored, set up, and installed correctly, and operated and maintained as recommended.

WARNING

The electronic sway control system assists in the transportation of loads by almost completely eliminating

swaying movements. The crane driver is still responsible for monitoring movements of the load on the crane and for switching off the system should any hazardous situations occur.

If the sway control system fails, the crane operator must ensure that the crane is stopped without any injury to

persons or damage to objects. The functionality of the sway control system must be disabled and the crane

operated manually without sway control until the fault has been corrected. If the fault cannot be corrected with

the aid of the product manual, please contact the Siemens AG.

Registered Trademarks

All names shown with the trademark symbol ® are registered trademarks of Siemens AG. If third parties use

any other names in this document which refer to trademarks for their own purposes, this might infringe upon

the rights of the trademark owners.

Exclusion of Liability

We have verified that the contents of this document correspond to the hardware and software described.

However, since deviations cannot be precluded entirely, we cannot guarantee full consistency. The

information given in this publication is reviewed at regular intervals and any corrections that might be

necessary are made in the subsequent editions.

Preface

Contents

This document contains instructions on how to commission the SIMOCRANE CeSAR slew/CeSAR slew

blind sway control system which is typically used to eliminate load swaying movements on slewing cranes. It

includes information about connecting, operation and commissioning. Note The product is referred to simply as CeSAR slew in the rest of the document.

Additional information

Service

I CS LS MC CR

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

E-mail:

siemens.cranes.service.nl@siemens.com

Technical Support

I DT MC CR AP

Tel.: +49 9131 98 5233

E-mail:

applications.cranes.aud@siemens.com

Table of Contents

D escription 1 1.1

Fields of application

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

The sway control system reduces the risk of collisions and accidents while ensuring faster and more accurate

positioning of the load. It can be employed in manual or automatic crane operation.

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

simultaneously.

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

Preconditions for use of the sway control system are that the load is largely guided in parallel by ropes and

that the crane is equipped with continuously controllable luffing and slewing drives.

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

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

system. 1.2

Versions

1.2.1

Standard version with camera (CeSAR slew)

The standard version of the CeSAR slew sway

control system comprises a twin camera system with integrated Power PC plus an

Ethernet-PROFIBUS gateway and RS 232

diagnostics module as additional components.

To simplify installation, the additional

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

A reflector of which the dimensions are

dependent upon the working radius of the crane will also be required.

Fig. 1-1: Standard version with camera

1.2.2

Special version without camera (CeSAR slew-blind)

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

reasons, or which operate in extreme environmental conditions such as extremely dusty atmospheres or at

very high temperatures. This unit calculates sway solely by means of a mathematical model. CeSAR slew-blind comprises a Power PC and an Ethernet-PROFIBUS gateway (when it is interfaced to PROFIBUS). The modules can be integrated in any type of control cabinet. No reflector is required.

The special version without camera is capable of eliminating most swaying movements which are generated

by luffing and slewing motions. However, it is not capable of suppressing sway caused by external forces

such as diagonal pull or wind.

All the functions referring to the camera which are described in this document are deactivated in the

CeSAR slew-blind version.

1.3

Interfacing with the crane control system

The sway control system is interfaced with the crane control system by means of Profibus-DP or, optionally,

via Ethernet with Internet Protocol (IP) and embedded UDP protocol.

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

1.4

Camera measurement (CeSAR slew only)

1.4.1

General

In order to measure load swaying movements, the camera unit must be installed on a horizontal plane close

to the rotary axis of the crane. The angle of aperture is approximately 45°. A reflector must be attached to the

load carrying device.

The camera calculates the position of the reflector relative to the crane for as long as it remains within the

field of vision. The data measured in this way are used to determine the swing angle in the tangential

direction and, by means of a precision distance measurement, in the radial direction. The advantages of taking measurements by camera as opposed to other measuring methods are listed below: the camera measuring system is contact-free and thus also wear-free, the measurement has an extremely high resolution and the actual load position relative to the crane is measured. 1.4.2

Reflectors

For more effective suppression of disturbances caused by sunlight (especially shading and reflections on the

reflector) and the suppression of artificial (low-infrared) light sources, the reflectors are equipped with infrared

LEDs as well as an infrared-blocking filter for the camera. As a result, the camera evaluates only light

information within a wavelength range of approximately 850 nm, which is invisible to the human eye.

The reflector is designed for use under the environmental conditions defined for the scope of application.

These include vibration and sea water in particular.

In the event of a measuring system malfunction, the sway control and positioning systems use the swing

angle calculated by the internal oscillation model. As soon as measured data become available again, the

oscillation model is corrected (if necessary). 1.4.3

Measuring accuracy

The absolute measuring accuracy of the camera measuring system depends on the distance between the

camera and reflector. It is approximately 0.5 mm per meter in the tangential direction and approximately

5 mm per meter in the radial direction.

The distance between the camera and the reflector can range from 1 m to 50 m. The larger the maximum distance, the larger the size of reflector required. 1.5

System requirements

A crane on which the system is to be installed must fulfill the following mechanical requirements: Parallel hoist rope guidance, i.e. complete absence of mechanical sway control elements (guying) Means of attaching the reflector to the load carrying device Means of installing the camera close to the rotary axis of the crane. The electrical crane equipment must fulfill the following requirements: Continuously controllable drives for slewing gear and working radius Preexisting conventional crane control system with PROFIBUS-DP or Ethernet/UDP Preexisting measuring systems for working radius, slewing gear position, hoisting height and load weight Power supply to the load carrying device when an active reflector is used Possibility to modify the existing crane control system to operate with the software protocol (PROFIBUS DP Master functionality).

Cranes with sway control system do not require any special acceleration or speed reserves as compared to

cranes without the system. 1.6

Operating principle of the sway control system

The sway control system uses the camera measuring system to determine the swing angle in the radial

and tangential directions. The reliability of the measuring signals is checked by various algorithms and

corrected if necessary. If a measuring signal fails, the current data are derived from a mathematical oscillation

model.

Conventional state feedback is applied as the sway control algorithm. This produces a non-periodic swing

angle characteristic. The acceleration ramp is smoothed. The acceleration times equal approximately 1.1

times the natural oscillation duration of the load oscillation. The acceleration time for an 8 m rope length is

thus 6 s.

The travel operations protect all the mechanical components of the crane and are comfortable for the crane

operator. Precise positioning is possible. There is a noticeable plugging response (greater deceleration when

the opposite direction is specified) when the values selected for setpoint and limit acceleration are different.

NOTICE

The acceleration and deceleration ramps can vary greatly. They depend on the initial swaying and the hoisting height. Generally, the sway control system has the following characteristics: The load sway is eliminated when steady-state or zero speed is reached. During slewing, a constant tangential deflection occurs as a result of the centrifugal acceleration associated with the motion, During slewing operations, the luffing drive eliminates swaying movements in the tangential direction, In positioning operation, the load only overshoots the target position by a very small amount The sway control system is configured by means of parameters.

The sway control system receives the required process information via a defined data structure. The input

and output data are normally supplied and further processed by a PLC. The sway control system calculates speed control values that are forwarded to the drives by the PLC. In this coupling, the PLC is the master, which uses the sway control system as a service computer to suppress the swaying of the load.

NOTICE

After an emergency stop, the sway control system must not be reactivated until it has been ensured (on

systems operating without a camera) that the load is not swaying and that the travel signal is briefly

canceled. Refer to Section 3.5.3 for details. 1.7

Operating modes

1.7.1

Speed control mode

1.7.1.1

Manual speed control

In speed control mode, the speed setpoint is specified by the crane driver. The crane is accelerated or

decelerated to this setpoint in such a way that the load has ceased to sway once it is reached. Speed control mode is activated by setting the corresponding operating mode bit.

In speed control mode with active sway control system (activated by input bit "AS_ON"), the internal setpoint

acceleration of the slewing gear is dependent upon the current position of the luffing gear. (See illustration

below)

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

control mode. The sway control system can be activated or deactivated by means of command bit "Sway Control ON".

When the function is switched off, the controller generates standard ramps according to the set acceleration

rates.

Position Boom Internal Setpoint Acceleration

Slewing

When the CeSAR blind version is installed, sway caused by diagonal pull or wind can only be eliminated by

the crane driver. In this case, the sway control system must first be disabled (by means of bit "AS_On"). The

crane drive must then carry out compensating movements until the load is stationary. Finally, the travel signal

must be briefly canceled in order to reference the oscillation model to 0. The crane can then be operated

again with active sway control system.

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

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

The bit "Sway control ON" is reset.

The activation speed has not been reached.

The activation time has not yet expired.

The bit "Sway control only when stopping" is set. The sway control system is only active when stopping. The hoisting gear is outside the set upper and lower sway control limits. Hoisting gear movements are possible in active speed control mode and have very little effect on the quality of the sway control. Fig. 1-3 shows the slewing operation of crane with a 20 m working radius and 40 m rope length.

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

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

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

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

The luffing gear must always be activated when a slewing motion is performed to allow the sway control

system to eliminate load sway movements in the radial direction.

1.7.1.2

Speed control in Cartesian coordinates

In narrow areas of the vessel or when working in close proximity to a neighboring crane on a vessel, it can be

useful to move the boom tip back and forth along a straight line between the vessel and the land. Control of

the slewing crane along straight lines is referred to as "control in Cartesian coordinates". The boom tip

performs a linear movement when the joy stick is deflected.

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

mode. The direction of the coordinate system (Y°) must be specified as "Slew setpoint position" in the sway

control system configuring data. The diagram below illustrates the action of the setpoint speed or joy stick.

Fig. 1-5: Speed control in Cartesian coordinates

For example, if the value 8000 (80°) is transferred as the "Slew setpoint position", deflecting the joy stick

"Slew" on its own will produce a motion in direction 80°/260° and deflecting the joy stick "Luff" on its own will

produce a motion in direction 170°/350°. It is also possible to actuate both joy sticks simultaneously.

1.7.2

Positioning mode

1.7.2.1

General

Positioning control mode allows the load to be positioned automatically in the slewing and luffing directions. In

position control mode, a specified target position is automatically approached with active sway control. Load

sway is eliminated both when maximum speed is reached and on completion of the positioning operation.

The appropriate operating mode bit must be set in order to activate positioning control mode. Positioning

commences when the travel signal is activated. The luffing gear must always be activated when a slewing

motion is performed to allow the sway control system to eliminate load sway in the radial direction. The positioning operation can be aborted at any time by setting of the "Controlled stop" signal.

The maximum and minimum positions of position control mode can be defined for the luffing gear by means

of parameters P7 and P8. It is not possible to position loads outside these limits.

In addition to the target position, a slewing direction can also be specified for the slewing gear (see command

bits for luffing and slewing in

Table 3-3

). The crane then moves to the target position in the selected slewing

direction. If no slewing direction is selected, the crane traverses the path with the smaller slewing angle. It is

not possible to set slewing gear position limits in the sway control system. Note

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

prohibited slewing zones by specifying the slewing direction bit. If the maximum permissible 360° slew

range of a crane is restricted, the relevant limits must be configured in the PLC. Fig. 1-6 shows an example of the chronological signal exchange sequence for positioning mode. Fig. 1-6: Signal exchange sequence for positioning

1.7.2.2

Positioning in Cartesian coordinates

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

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

control mode.

It must be ensured that the straight line between the start and target positions is positioned such that it does

not pass closer to the center of rotation of the crane than the minimum luffing gear position. Otherwise, an

error message is output.

WARNING

When a controlled stop command is issued during a positioning movement in Cartesian coordinates, Car tesian mode is deactivated internally in the sway control system and the axes are stopped separately with active sway control. In this case, the crane departs from the programmed straight line.

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

positioning mode.

WARNING

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

polar coordinates, nor is it permissible to change between target positions while a Cartesian positioning

movement is in progress. Either of these actions can cause the crane to move unpredictably.

1.7.2.3

Automatic inward luffing (polar coordinates)

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

In most cases, the maximum possible slewing speed of a crane increases in proportion to the proximity of the

boom to the center of rotation. Automatic inward luffing makes use of this characteristic.

An example (see

Fig. 1-7: Automatic inward luffing

) is provide in order to explain the general principle:

During positioning, the luffing gear travels from a start position of 30 m to a target position of 30 m, while the

slewing gear travels from a start position of 0° to a target position of 180°. Without automatic inward luffing,

the crane travels along the blue line. With automatic inward luffing, the crane travels along the red line.

P92

Center of rotationStart point

Target point

Motion with

automatic inward luffing

Movement of

suspension point without automatic inward luffing

Fig. 1-7: Automatic inward luffing

Automatic inward luffing can be activated via parameter P92. It defines the radius of forward and reverse

travel of the luffing gear during positioning.

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

activated.

If both points are located within this circle, automatic inward luffing has no effect and the axes are positioned

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

Other aspects of the automatic inward luffing function can be programmed with parameter P93 (see Chapter

"Parameter description").

NOTICE

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

The following must be implemented in the PLC:

If the target position is changed while positioning is still in progress and automatic inward luffing is active,

a controlled stop command must first be issued for both axes. When the crane has stopped and the travel signal has been canceled by means of signal "Positioning

complete", the new positioning process to a new target with active automatic inward luffing can be started.

When automatic inward luffing is deactivated, target positions can be changed at any time. 1.7.3

Sway neutralization mode

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

from standstill.

Sway neutralization is linked to a positioning scenario in which the target position corresponds either to the

current boom position or the load position at the instant of activation of sway neutralization.

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

sequence corresponds to that of positioning. I nstallation 2 2.1

Overview

The following connections are available on the camera:

Fig. 2-1: Overview of connections

2.2

Camera settings

Aperture setting with passive reflector in outdoor area = 7

With an active reflector, always 1.4 (IR)

These values are appropriate for most applications. For particularly dark conditions, the aperture value can

be reduced (open aperture), or increased for very bright ambient light (close aperture). In addition to this

setting, an automatic gain and offset control ensures optimum image brightness.

DANGER

The casing can fall when it is opened.

2.3

Mounting

2.3.1

Mounting the camera

The camera casing must be installed close to the rotary axis of the crane (normally near the crane driver's

cabin) on a horizontal plane with direction of view along the boom. The reflector should lie within the field of

vision of the camera when the crane is traveling in the main work area. The camera mounting position is illustrated in the sketch below:

Field of vision

Slewing axis

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

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

See photos below:

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

Fig. 2-4: Side view of cameras

DANGER

The casing can fall when it is opened.

The interface modules or the connection box (400 mm x 300 mm x 210 mm) must be installed directly next to

the camera casing.

NOTICE

The maximum permissible distance between camera casing and connection box is 22 m. 2.3.2

Setting the camera focus

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

DANGER

The casing can fall when it is opened.

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

djust the focus setting until a focused image is obtained in this position. A 2.3.3

Mounting the reflector

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