SC integrated OHBC, Gantry crane
___________________
___________________
___________________
___________________
___________
___________________
___________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
SIMOCRANE
SC integrated OHBC, Gantry crane
Operating Instructions
valid for:
SIMOCRANE SC integrated OHBC, Gantry crane
Version 4.2 SP1 SIMOCRANE Basic Technology as
from Version 3.0
02/2014
Foreword
Basic safety instructions
(software)
1
System description
2
Description of the AddOn
sway control system
3
Adding the AddOn sway
control system to the user
project
4
Interface to the crane control
system
5
Configuring instructions for
crane control system
(SIMATIC S7)
6
Interface description
7
Function description
8
Commissioning
9
SIMOCRANE CeCOMM
diagnostic program
10
Alarm, error, and system
messages
11
Parameter list
12
Notes on servicing and
maintenance
13
Appendix
A
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Ⓟ
01/2014 Technical data subject to change
Copyright © Siemens AG 2014.
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.
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 3
Foreword
The AddOn sway control system
The AddOn sway control system "SIMOCRANE SC integrated OHBC, Gantry crane" is part
of the SIMOCRANE Advanced Technology and is designed for crane control systems with
SIMOTION D435-2 DP/PN and SIMOCRANE Basic 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.
Applications
The AddOn 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. The trolley, gantry, and slewing gear can be
operated simultaneously with sway control.
Requirement (area of validity)
This manual is valid for use with the following product versions:
Hardware:
● SIMOTION D435-2 DP/PN as of version V4.3 SP1
● SINAMICS as of version V4.5
● SIMOCRANE CenSOR V2.0 (optional)
Software
● SIMOCRANE Basic Technology as of version V3.0
● SIMOTION SCOUT as of version V4.3 SP1
● Drive Control Chart (DCC) options package as of version V2.2 SP1
● SIMOCRANE CeCOMM as of Version V4.4.1.23
Foreword
SC integrated 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).
● Support request on the Internet:
– Support Request
(http://support.automation.siemens.com/WW/llisapi.dll?aktprim=99&lang=en&referer=
%2fWW%2f&func=cslib.csinfo2&siteid=csius&extranet=standard&viewreg=WW&grou
pid=4000002)
● 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).
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 5
Table of contents
Foreword ................................................................................................................................................ 3
1 Basic safety instructions (software) ....................................................................................................... 13
1.1 General safety instructions .......................................................................................................... 13
1.2 IT security ..................................................................................................................................... 14
2 System description ................................................................................................................................ 15
2.1 General ........................................................................................................................................ 15
2.1.1 Field of application of the AddOn sway control system ............................................................... 15
2.1.2 Trolley and gantry ........................................................................................................................ 15
2.1.3 Slewing gear or hoist ................................................................................................................... 16
2.2 System overview .......................................................................................................................... 17
2.2.1 Preconditions ............................................................................................................................... 17
2.2.2 System structure .......................................................................................................................... 18
2.2.3 Configurations .............................................................................................................................. 18
2.2.3.1 Overview ...................................................................................................................................... 18
2.2.3.2 Version without the SIMOCRANE CenSOR camera measuring system..................................... 19
2.2.3.3 Version with the SIMOCRANE CenSOR camera measuring system .......................................... 19
2.2.4 Operation with slewing gear ......................................................................................................... 19
2.2.4.1 Guidelines for installation ............................................................................................................. 19
2.2.4.2 Hook slewing gear ....................................................................................................................... 20
2.2.4.3 Skew control ................................................................................................................................. 20
2.3 Scope of delivery.......................................................................................................................... 21
3 Description of the AddOn sway control system ...................................................................................... 23
3.1 Software structure ........................................................................................................................ 23
3.1.1 Overview ...................................................................................................................................... 23
3.1.2 MCC source files .......................................................................................................................... 25
3.1.2.1 Structure ....................................................................................................................................... 25
3.1.2.2 Sequence of the MCC source file "AddOn_SC_OHBC" .............................................................. 26
3.1.2.3 Sequence of the MCC source file "Camera" ................................................................................ 28
3.1.3 AddOn FB library "AddOn_FB_Library" ....................................................................................... 30
3.1.4 Control structure........................................................................................................................... 31
3.1.4.1 Operation mode "Manual" without sway control .......................................................................... 31
3.1.4.2 Operation mode "manual" with sway control ............................................................................... 31
3.1.4.3 Operation mode "Positioning" without sway control .................................................................... 31
3.1.4.4 Operation mode "Positioning" with sway control ......................................................................... 32
3.1.4.5 Using an external position controller ............................................................................................ 32
3.2 Description of DCC blocks ........................................................................................................... 33
3.2.1 Overview ...................................................................................................................................... 33
3.2.2 DCC_SC_COMMON .................................................................................................................... 35
3.2.3 DCC_SC_TROLLEY .................................................................................................................... 37
3.2.4 DCC_SC_GANTRY ...................................................................................................................... 39
3.2.5 DCC_SC_SLEW_HOIST .............................................................................................................. 40
Table of contents
SC integrated OHBC, Gantry crane
6 Operating Instructions, 02/2014
3.2.6 DCC_SC_CAMERA .................................................................................................................... 42
3.2.7 DCC_SC_DIAG ........................................................................................................................... 44
4 Adding the AddOn sway control system to the user project ................................................................... 45
4.1 Precondition ................................................................................................................................ 45
4.1.1 Functional project ........................................................................................................................ 45
4.1.2 Suitable standard application ...................................................................................................... 46
4.1.3 Setting the system cycle clocks .................................................................................................. 47
4.2 Overview of the configuring steps to be performed .................................................................... 48
4.3 Run the setup file ........................................................................................................................ 49
4.4 Import the SCOUT project of the AddOn sway control system ................................................... 50
4.5 PROFIBUS configuration ............................................................................................................ 51
4.5.1 Overview ..................................................................................................................................... 51
4.5.2 Configuring the connection between SIMATIC S7 and the AddOn sway control system .......... 52
4.5.2.1 SIMOTION hardware configuration ............................................................................................. 52
4.5.2.2 Communication with SIMATIC S7 ............................................................................................... 55
4.6 Copying I/O variables .................................................................................................................. 61
4.7 Copying the AddOn FB library .................................................................................................... 63
4.8 Copying the MCC source file ...................................................................................................... 67
4.9 Inserting DCC blocks .................................................................................................................. 68
4.9.1 Importing DCC block libraries ..................................................................................................... 68
4.9.2 Copying the DCC "SwayControl" ................................................................................................ 71
4.9.3 Mode of representation of blocks in the DCC ............................................................................. 72
4.10 Connection to SIMOCRANE Basic Technology and technology objects ................................... 73
4.11 Adapting the user project without use of the SIMOCRANE CenSOR camera measuring
system ......................................................................................................................................... 74
4.12 Adapting the user project with use of the SIMOCRANE CenSOR camera measuring
system with a PROFINET interface ............................................................................................ 75
4.12.1 Adding camera MV440 to the hardware configuration ................................................................ 75
4.12.2 Copying I/O variables of the camera ........................................................................................... 79
4.12.3 Copying the MCC source file "Camera" ...................................................................................... 80
4.13 Adapting the user project for a configuration with a hoist ........................................................... 81
4.14 Integrating the MCC source files "AddOn_SC_OHBC" and "Camera" into the execution
system ......................................................................................................................................... 82
4.15 Saving, compiling and checking consistency .............................................................................. 83
4.16 Downloading the user project to the CF card.............................................................................. 84
4.16.1 General ........................................................................................................................................ 84
4.16.2 Transfer via an existing online connection .................................................................................. 84
4.16.3 Transfer by means of a card reader ............................................................................................ 85
4.17 Transferring language files, online help files and JAVA files to the CF card .............................. 87
4.18 Creating the license key and downloading it to the CF card ....................................................... 88
5 Interface to the crane control system ..................................................................................................... 89
5.1 General ........................................................................................................................................ 89
Table of contents
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 7
5.2 Structure of the SIMATIC S7 sample blocks ............................................................................... 90
5.3 Commissioning the SIMATIC S7 sample blocks ......................................................................... 92
5.4 Communication tests between SIMATIC S7 ↔ AddOn sway control system .............................. 92
6 Configuring instructions for crane control system (SIMATIC S7) ............................................................ 95
6.1 Selecting the operation modes .................................................................................................... 95
6.2 Switchover from operation without AddOn sway control ↔ operation with AddOn sway
control .......................................................................................................................................... 95
6.3 Pre-assignment of the interfaces ................................................................................................. 96
6.4 Sensing and monitoring the position actual values...................................................................... 97
6.4.1 Importance of position sensing .................................................................................................... 97
6.4.2 Checking the correct position sensing ......................................................................................... 97
6.4.3 Synchronizing absolute or incremental encoders, referencing .................................................... 97
6.5 Generating the "Travelling" control bit ......................................................................................... 98
6.6 Drive activation and brake control................................................................................................ 99
6.7 Travel in operation mode "manual" ............................................................................................ 100
6.7.1 Start of travel .............................................................................................................................. 100
6.7.2 End of travel ............................................................................................................................... 101
6.8 Travel in operation mode "positioning" ...................................................................................... 102
6.8.1 Start of travel .............................................................................................................................. 102
6.8.2 End of travel ............................................................................................................................... 103
6.9 Controlled stop ........................................................................................................................... 104
6.10 Positioning in the operation mode "manual" with S_corr ........................................................... 105
6.11 Normalization ............................................................................................................................. 105
7 Interface description ............................................................................................................................ 107
7.1 Overview .................................................................................................................................... 107
7.2 Interface to the SIMATIC S7 ...................................................................................................... 110
7.2.1 Input data ................................................................................................................................... 110
7.2.1.1 Overview of complete data structure ......................................................................................... 110
7.2.1.2 Input data, general ..................................................................................................................... 110
7.2.1.3 Control bits, general ................................................................................................................... 112
7.2.1.4 Input data, trolley........................................................................................................................ 113
7.2.1.5 Trolley control bits ...................................................................................................................... 114
7.2.1.6 Input data, gantry ....................................................................................................................... 117
7.2.1.7 Gantry control bits ...................................................................................................................... 118
7.2.1.8 Input data, slewing gear ............................................................................................................. 121
7.2.1.9 Slewing gear control bits ............................................................................................................ 122
7.2.1.10 Input data, hoist.......................................................................................................................... 125
7.2.1.11 Hoist control bits......................................................................................................................... 126
7.2.1.12 Trailer (2 bytes) .......................................................................................................................... 129
7.2.2 Output data ................................................................................................................................ 129
7.2.2.1 Overview of complete data structure ......................................................................................... 129
7.2.2.2 Output data, general .................................................................................................................. 130
7.2.2.3 Status bits, general .................................................................................................................... 131
7.2.2.4 Output data, trolley ..................................................................................................................... 132
Table of contents
SC integrated OHBC, Gantry crane
8 Operating Instructions, 02/2014
7.2.2.5 Trolley status bits ...................................................................................................................... 133
7.2.2.6 Output data, gantry ................................................................................................................... 136
7.2.2.7 Gantry status bits ...................................................................................................................... 137
7.2.2.8 Output data, slewing gear ......................................................................................................... 140
7.2.2.9 Status bits, slewing gear ........................................................................................................... 141
7.2.2.10 Output data, hoist ...................................................................................................................... 144
7.2.2.11 Status bits, hoist ........................................................................................................................ 145
7.2.2.12 Trailer (telegram counter) .......................................................................................................... 146
7.3 Interface to the camera ............................................................................................................. 147
7.3.1 Input data .................................................................................................................................. 147
7.3.2 Output data ............................................................................................................................... 148
7.4 Interface to SIMOCRANE Basic Technology and technology objects ...................................... 149
7.4.1 AddOn sway control system - SIMOCRANE Basic Technology ............................................... 149
7.4.2 AddOn sway control system - technology object ...................................................................... 150
8 Function description ............................................................................................................................. 151
8.1 General ...................................................................................................................................... 151
8.1.1 AddOn sway control function .................................................................................................... 151
8.1.2 Parameter sets .......................................................................................................................... 153
8.1.2.1 Overview ................................................................................................................................... 153
8.1.2.2 Calling up the parameter menu ................................................................................................. 154
8.1.2.3 Activating a parameter set ........................................................................................................ 154
8.1.2.4 Editing a parameter set ............................................................................................................. 155
8.1.2.5 Changing a parameter .............................................................................................................. 155
8.1.2.6 Copying a parameter set ........................................................................................................... 156
8.1.2.7 Loading the saved parameter sets ............................................................................................ 156
8.1.2.8 Saving all sets of parameters .................................................................................................... 157
8.1.2.9 Switching over parameter sets .................................................................................................. 157
8.1.2.10 Setting default values ................................................................................................................ 157
8.1.2.11 More functions ........................................................................................................................... 158
8.1.3 Operation modes ....................................................................................................................... 158
8.1.3.1 Selecting the operation mode ................................................................................................... 158
8.1.3.2 Operation mode "manual" ......................................................................................................... 158
8.1.3.3 Operation mode "positioning" .................................................................................................... 158
8.1.3.4 Operation mode "sway neutralization" ...................................................................................... 159
8.1.3.5 Fault response .......................................................................................................................... 159
8.1.4 Response in the limit switch ...................................................................................................... 159
8.1.4.1 Response in the "manual" operation mode ............................................................................... 159
8.1.4.2 Response in the "positioning" operation mode ......................................................................... 159
8.1.5 Response in the prelimit switch ................................................................................................ 160
8.1.5.1 Response in the "manual" operation mode ............................................................................... 160
8.1.5.2 Response in the "positioning" operation mode ......................................................................... 161
8.2 Operation mode "manual" ......................................................................................................... 162
8.2.1 Operation mode "manual" without sway control ....................................................................... 162
8.2.2 Operation mode "manual" with sway control ............................................................................ 163
8.3 Operation mode "positioning" .................................................................................................... 165
8.4 Operation mode "sway neutralization load position" ................................................................. 165
8.5 Operation mode "sway neutralization drive position" ................................................................ 166
9 Commissioning .................................................................................................................................... 167
Table of contents
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 9
9.1 Commissioning prerequisites ..................................................................................................... 167
9.1.1 General ...................................................................................................................................... 167
9.1.2 Load measurement .................................................................................................................... 167
9.1.3 Position sensing ......................................................................................................................... 167
9.1.4 Sway control components .......................................................................................................... 167
9.2 Preparing commissioning ........................................................................................................... 168
9.2.1 Preparation of the user project and the SIMATIC S7 ................................................................ 168
9.2.1.1 Integrating the AddOn sway control system .............................................................................. 168
9.2.1.2 Commissioning the SIMATIC S7 sample blocks ....................................................................... 168
9.2.2 Preparing the SIMOCRANE CenSOR camera measuring system ............................................ 168
9.3 Configuring the AddOn sway control system ............................................................................. 169
9.3.1 Overview .................................................................................................................................... 169
9.3.2 General preconditions ................................................................................................................ 169
9.3.3 Setting the access code ............................................................................................................. 170
9.3.4 Setting the language .................................................................................................................. 170
9.3.5 Checking the interface crane control system ↔ AddOn sway control system ........................... 171
9.3.6 Checking the communication with the camera measuring system ............................................ 172
9.4 Operation mode "manual" without sway control ........................................................................ 174
9.4.1 Preparation – first steps ............................................................................................................. 174
9.4.2 Commissioning steps in the commissioning menu .................................................................... 174
9.4.2.1 Procedure ................................................................................................................................... 174
9.4.2.2 Step 0: Setting the configuration and important parameters ..................................................... 176
9.4.2.3 Step 1: Aligning the camera ....................................................................................................... 178
9.4.2.4 Step 2: Determine parameters of effective pendulum length in the trolley direction ................. 180
9.4.2.5 Step 3: Determine parameters of effective pendulum length in the gantry direction ................. 180
9.4.2.6 Step 4: Determine parameters of effective pendulum length for slewing gear .......................... 181
9.4.2.7 Step 5: Simulating errors ........................................................................................................... 181
9.4.2.8 Step 6: Determining the velocity ................................................................................................ 181
9.4.2.9 Step 7: Change communication addresses ............................................................................... 182
9.4.2.10 Step S: Saving parameters ........................................................................................................ 182
9.5 Operation mode "manual" with sway control ............................................................................. 183
9.5.1 Preparation ................................................................................................................................. 183
9.5.2 Test runs without boosted camera signal .................................................................................. 183
9.5.3 Test runs with boosted camera signal ....................................................................................... 185
9.5.4 Testing in the prelimit switch range............................................................................................ 185
9.6 Checking and fine-tuning the sway control system.................................................................... 186
9.6.1 General ...................................................................................................................................... 186
9.6.2 Correction of the effective pendulum length .............................................................................. 186
9.6.2.1 Application .................................................................................................................................. 186
9.6.2.2 Digital correction of the effective pendulum length for the trolley and the gantry ...................... 186
9.6.2.3 Digital correction of the effective pendulum length for the slewing gear ................................... 188
9.6.2.4 Analog correction of the effective pendulum length ................................................................... 188
9.6.2.5 Additional information ................................................................................................................ 190
9.6.3 Setting the permissible residual sway ........................................................................................ 190
9.6.4 Setting the velocity for zero speed detection ............................................................................. 191
9.6.5 Setting the damping factor ......................................................................................................... 191
9.6.6 Setting the switch-on delay of the drives ................................................................................... 191
9.6.7 Defining the activation velocity of the sway control ................................................................... 192
9.6.8 Functions for optimizing travel behavior .................................................................................... 193
9.6.9 Pendulum length from SIMATIC S7 or camera ......................................................................... 193
Table of contents
SC integrated OHBC, Gantry crane
10 Operating Instructions, 02/2014
9.7 Commissioning positioning ....................................................................................................... 194
9.7.1 Conversion of the actual position S_ACTUAL and the target position S_TARGET.................. 194
9.7.2 Position controller setting .......................................................................................................... 195
9.7.3 Other settings ............................................................................................................................ 196
9.8 Testing the sway neutralization modes ..................................................................................... 197
9.9 Stability test and monitoring functions ...................................................................................... 200
9.9.1 Stability test ............................................................................................................................... 200
9.9.2 Monitoring functions .................................................................................................................. 201
10 SIMOCRANE CeCOMM diagnostic program ........................................................................................ 203
10.1 General ...................................................................................................................................... 203
10.2 Installing .................................................................................................................................... 204
10.3 Searching the network for SIMOTION D435-2 DP/PN ............................................................. 205
10.4 Establishing the connection ...................................................................................................... 206
10.5 Monitoring functions .................................................................................................................. 207
10.5.1 Display and operating information ............................................................................................ 207
10.5.2 The parameter menu ................................................................................................................. 209
10.6 Setting addresses ..................................................................................................................... 211
10.6.1 General ...................................................................................................................................... 211
10.6.2 Default settings ......................................................................................................................... 211
10.6.3 Setting addresses ..................................................................................................................... 212
10.6.4 Searching for the changed IP address ...................................................................................... 213
11 Alarm, error, and system messages ..................................................................................................... 215
11.1 General ...................................................................................................................................... 215
11.2 List of alarm, error, and system messages ............................................................................... 217
12 Parameter list ...................................................................................................................................... 229
12.1 Overview ................................................................................................................................... 229
12.2 Trolley parameters .................................................................................................................... 230
12.3 Gantry parameters .................................................................................................................... 240
12.4 Parameters for third drive .......................................................................................................... 251
12.4.1 Slewing gear parameters .......................................................................................................... 251
12.4.2 Hoist parameters ....................................................................................................................... 262
12.5 General parameters .................................................................................................................. 270
13 Notes on servicing and maintenance .................................................................................................... 279
13.1 General information ................................................................................................................... 279
13.2 Reflector maintenance .............................................................................................................. 279
13.3 Camera maintenance ................................................................................................................ 279
13.4 Check of the position sensing functions for the hoist after rope changing ............................... 279
A Appendix ............................................................................................................................................. 281
A.1 Diagrams showing SIMOTION D435-2 DP/PN connections .................................................... 281
Table of contents
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 11
A.2 Interconnection of DCC blocks in DCC SwayControl (when BT is used) .................................. 284
A.3 List of abbreviations ................................................................................................................... 287
A.4 References ................................................................................................................................. 288
Glossary ............................................................................................................................................. 289
Table of contents
SC integrated OHBC, Gantry crane
12 Operating Instructions, 02/2014
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 13
Basic safety instructions (software)
1
1.1
General safety instructions
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 (software)
1.2 IT security
SC integrated OHBC, Gantry crane
14 Operating Instructions, 02/2014
1.2
IT security
Note
Industrial security
Siemens provides automation and drive products wi
th 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
development. 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 su
itable
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.
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 15
System description
2
2.1
General
2.1.1
Field of application of the AddOn sway control system
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 AddOn
sway control system is to neutralize sway. This makes automatic positioning possible. This
can relieve the crane operator and increase the handling capacity.
Without an electronic sway control system, implementing crane control systems in semi- and
fully automatic operation (e.g. coil storage locations in steelworks) is hardly conceivable.
The technology module T300 with MASTERDRIVES drive for crane-specific technology was
used in the previous crane application solution. Since mid 2007, the new industry solution
SIMOCRANE Basic Technology has been available.
The new platform based on a SIMATIC S7 - SIMOTION - SINAMICS hardware configuration
contains the motion control of all main drives of a crane. The modular construction makes it
possible to customize the system to the associated crane.
The sway control system described in these operating instructions is designed as an AddOn
for the purpose of extending the existing industry solution SIMOCRANE Basic Technology
with SIMOTION D435-2 DP/PN.
Overview
● The AddOn sway control system SIMOCRANE SC integrated OHBC, Gantry Crane can
be integrated into a SIMOTION D435-2 DP/PN.
● Sway motion is calculated and corrected based on a mathematical oscillation model.
● The system can be operated in one of two configurations, i.e. with or without a
SIMOCRANE CenSOR camera measuring system.
2.1.2
Trolley and gantry
Depending on the selected operation mode, 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 while the crane is moving,
e.g. from "manual" operation mode to "positioning" operation mode, and vice versa.
System description
2.1 General
SC integrated OHBC, Gantry crane
16 Operating Instructions, 02/2014
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 selected operation mode, 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
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 17
2.2
System overview
2.2.1
Preconditions
● Crane control system (PLC) with PROFIBUS/PROFINET interface
● SIMOTION D435-2 DP/PN as target hardware with SIMOCRANE Basic Technology V3.0
● Closed-loop controlled drives
● Encoder for the hoist for pendulum length calculation
● Encoder for all drives operated with positioning and sway neutralization operation modes.
● 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.
System description
2.2 System overview
SC integrated OHBC, Gantry crane
18 Operating Instructions, 02/2014
2.2.2
System structure
The following diagram shows an example of the communication paths between the individual
components.
Figure 2-1 Layout diagram of the components
The necessary process information is supplied to the AddOn sway control system via:
● the crane control system,
● the SIMOTION D435-2 DP/PN (signals from SIMOCRANE Basic Technology and the
technology objects), and
● the SIMOCRANE CenSOR camera measuring system (optional).
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
System description
2.2 System overview
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 19
2.2.3.2
Version without the SIMOCRANE CenSOR camera measuring system
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 AddOn sway control system calculates 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 using configuration parameter P115 (setting 1 = On) for the
version without 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 the SIMOCRANE CenSOR camera measuring system
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 calculate additional physical measured variables, i.e. distance
between the camera and reflector, pendulum deflection and rotation. The results are
incorporated in the mathematical oscillation model.
Unlike in the system without a camera, the mathematical oscillation model is compared with
the value really measured by the camera and oscillations caused by external sources can
also be eliminated.
If the measuring signal of the camera fails, only the mathematical oscillation model is used.
Note
For additional information about the camera, please refer to the operating instructions for the
SIMO
CRANE CenSOR camera measuring system, from edition 08/2012.
2.2.4
Operation with slewing gear
2.2.4.1
Guidelines for 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. An 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.
System description
2.2 System overview
SC integrated OHBC, Gantry crane
20 Operating Instructions, 02/2014
2.2.4.2
Hook slewing gear
For cranes with hook slewing gear, an encoder is only required when the slewing gear is
automatically positioned.
The camera and the reflector are not rotated simultaneously with the slewing gear on cranes
with hook slewing gear.
2.2.4.3
Skew control
Slewing gear can be operated with a skew control system. By contrast, hook slewing gear
must always be operated with the mathematical oscillation model.
System description
2.3 Scope of delivery
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 21
2.3
Scope of delivery
Depending on the application and the environmental conditions, the AddOn sway control
system can be used 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 SC integrated OHBC, Gantry crane" package includes:
● Product DVD
The software DVD contains:
– Readme file
□ German
□ English
– Setup program for the SIMOCRANE CeCOMM diagnostic program (setup file)
– Setup program for installing the required AddOn DCC library
The DCC library is installed when the "setup.exe" file is run.
– A sample project with all the required components. This is copied into the user project.
– Language files and online help files
□ “Sprache0.txt ” to “ Sprache3.txt ”
□ “Help_D_chm ” and “ Help_E_chm ”
– Parameter files
"Par0.txt" to "Par3.txt"
– Address settings
□ "IP_Addresses.txt"
– Java Runtime
□ "bufferOHBC.jar"
□ "jinvoke.xml"
□ "Simotion.jar"
□ "VMconfig.ini"
□ "JCONSOLE.txt"
– Operating instructions for SIMOCRANE SC integrated OHBC, Gantry crane
□ German
□ English
– Operating instructions for SIMOTION D435-2 DP/PN
□ German
□ English
System description
2.3 Scope of delivery
SC integrated OHBC, Gantry crane
22 Operating Instructions, 02/2014
● Certificates for the software licenses
The following licenses are available for the AddOn sway control system:
Product
Article No.
Functionality
SIMOCRANE SC integrated OHBC,
Gantry crane:
Basic license
6GA7200-0AA00-0AA0
Manual
Positioning
Sway neutralization
SIMOCRANE SC integrated OHBC,
Gantry crane:
Manual license
6GA7200-0AA00-2AA0 Manual
The functional scope determines which license is required.
Because the memory card (CF card) is not part of the scope of delivery of the AddOn
sway control system, a license key must be created and transferred to the CF card. This
is done using the supplied "Certificate of License" (see Creating the license key and
downloading it to the CF card (Page 88)).
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 23
Description of the AddOn sway control system
3
3.1
Software structure
3.1.1
Overview
Important software components for the AddOn sway control system:
● Address list
● SIMATIC S7 sample blocks
(can be accessed when the sample project is opened with the SIMATIC Manager)
● MCC source file "AddOn_SC_OHBC"
Function: Communicates with SIMATIC S7, SIMOCRANE Basic Technology, and the
technology objects
● MCC source file "Camera"
Function: Communicates with the camera
● DCC chart "SwayControl" with the currently installed Sway control DCC library
Function: Implements all sway control functions
● AddOn FB library "AddOn_FB_Library"
Function: Comprises all functions and function blocks implemented in the Structured Text
programming language. They are only used to implement data exchange.
● DCC library
The AddOn DCC library comprises a collection of blocks that are implemented as "Drive
Control Charts" (DCC) blocks. DCC is a representation which supports graphical
configuring and interconnecting. The blocks are already wired to each other and
preconfigured in the sample project.
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
24 Operating Instructions, 02/2014
The following diagram provides an overview of the PROFIBUS-based system of
communication.
Figure 3-1 Software structure of the AddOn sway control as exemplified by the trolley
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 25
3.1.2
MCC source files
3.1.2.1
Structure
The MCC source files have the following structure:
● The MCC source file "AddOn_SC_OHBC" contains the MCC (Motion Control Chart)
"AddOnMCC"
in which the following function blocks are called:
– FB_AddOnSC_ReceiveFromPLC_BT (in conjunction with SIMOCRANE Basic
Technology)
– FB_AddOnSC_SendToPLC (transmit data, identical for all interfaces)
● The MCC source file "Camera" contains the MCCs "cameramcc" and
"Cam_MV440_mcc".
The following function blocks are called in MCC "cameramcc":
– FB_Receive_Analysis (only when a camera is installed)
– FB_Send_Preparation (only when a camera is installed)
The following function blocks are called in MCC "Cam_MV440_mcc":
– FB_ReadWrite_MV440 (only when a camera is installed)
Explanation
An MCC source file contains flow charts in the form of MCCs. One of the tasks of the
modules contained in the flow charts is to call function blocks (Structured Text). The AddOn
sway control system contains the MCC source files "AddOn _SC_OHBC" and "Camera".
In cyclical operation, the receive function blocks are processed first followed by the send
function blocks.
The function blocks are connected to the SIMATIC S7 by means of globally declared
variables in the I/O area (ADDRESS LIST).
Global variables are used to provide the connection between the function blocks and the
DCC blocks and between the SIMOCRANE Basic Technology (BT) and the DCC blocks.
In order to ensure a high quality of control and eliminate runtime losses, the output velocities
of the drives are transmitted directly to the relevant technology objects. The current position
values are also read directly from the drive.
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
26 Operating Instructions, 02/2014
3.1.2.2
Sequence of the MCC source file "AddOn_SC_OHBC"
The MCC "AddOnMCC" is processed in the sequence illustrated below in the MCC source
file "AddOn_SC_OHBC":
Figure 3-2 Modules in the MCC "AddonMCC"
The function block "FB_AddOnSC_ReceiveFromPLC_BT" is called in the module "Receive
PLC".
The data received from the crane control system are processed with the aid of the function
block and forwarded to the global variables DCC_In and DCC_Out. The variables must be
interconnected with the DCC blocks in the CFC editor. These interconnections are already
made in the sample project supplied with the package.
Figure 3-3 SCOUT address list of PROFIBUS inputs for AddOn_SC_OHBC
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 27
Figure 3-4 Interface of function block "FB_AddOnSC_ReceiveFromPLC_BT"
The variables designated VAR_INPUT in the column ON/OFF (variable type) are the
PROFIBUS receive data from the crane control system.
The variables designated VAR_OUTPUT in the column ON/OFF are provided for the
purpose of interconnecting the DCC blocks in the DCC.
The variable "bError" is set if the received interface identification number (word 0 in the
receive telegram) does not tally with the called function. In this example, the expected
identification number is 5152, i.e. the identifier for SIMOCRANE Basic Technology (see also
Input data, general (Page 110)).
When the SIMOCRANE Basic Technology is in use, the crane control system transfers only
control words to the AddOn sway control. The other data are made available via the interface
to the SIMOCRANE Basic Technology and the other technology objects. The module
"DCC_In.Trolley.V_Set" in which variables are assigned is positioned immediately
downstream of the module "Receive PLC"
The module "Send PLC" calls the function block "FB_AddOnSC_SendToPLC". The output
values and status bits computed by the sway control system are processed and returned to
the crane control system via PROFIBUS.
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
28 Operating Instructions, 02/2014
Figure 3-5 SCOUT, example of address list of PROFIBUS output data to the crane control system
The module "Trolley_1.DefaultMotionIn" (variable assignments) transfers the output
velocities calculated by the sway control system to the technology objects.
3.1.2.3
Sequence of the MCC source file "Camera"
The MCCs "cameramcc“ and "Cam_MV440_mcc" are processed in the MCC source file
"Camera".
The chart "cameramcc" processes communication functions via the Ethernet UDP. The chart
"Cam_MV440_mcc" is used to process communication functions via PROFINET.
The active communication channel is determined on the basis of the IP address of the
camera. Communication via PROFINET is generally recommended. If PROFINET is used,
the CBE30-2 module is required.
Figure 3-6 MCC "Cam_MV440_mcc" (PROFINET communication)
The function block "FB_ReadWrite_MV440" processes the data exchange with the camera
on the basis of handshake signals and also prepares the sent and received data. The
measurement results and status information are assigned to globally defined variables of the
MCC source file "Camera". The camera data are processed in the DCC blocks
"DCC_SC_COMMON" and "DCC_SC_CAMERA".
The function block "FB_ReadWrite_MV440" is executed only if the IP address of the camera
that is set in the SIMOCRANE CeCOMM diagnostic program is zero.
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 29
Figure 3-7 Interface of function block "FB_ReadWrite_MV440"
Figure 3-8 MCC "cameramcc" (UDP communication)
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
30 Operating Instructions, 02/2014
Figure 3-9 Module "Camera" (UDP communication)
3.1.3
AddOn FB library "AddOn_FB_Library"
The AddOn FB library "AddOn_FB_Library" contains the ST source files "Camera" and
"ComPLC".
ST source file "Camera"
The ST source file "Camera" contains the following function blocks:
● FB_Camera_Selection
● FB_Receive_Analysis
● FB_Send_Preparation
● FB_ReadWrite_MV440
The ST source file "Camera" contains the following function:
● CenSOR_Error
ST source file "ComPLC"
The ST source file "ComPLC" contains the following function blocks:
● FB_AddOnSC_ReceiveFromPLC_BT (in conjunction with SIMOCRANE Basic
Technology)
● FB_AddOnSC_ReceiveFromPLC_INT (integer interface)
● FB_AddOnSC_ReceiveFromPLC_REAL (real interface)
● FB_AddOnSC_SendToPLC (transmit data, identical for all interfaces)
The diagram below illustrates the principle by which the AddOn sway control system is
activated in SIMOCRANE Basic Technology and the method of application of the sway
control output velocities.
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 31
3.1.4
Control structure
3.1.4.1
Operation mode "Manual" without sway control
In this mode, the AddOn sway control only contains the setpoint channel with a ramp-
function generator. The ramp-up and ramp-down of the output velocity that is output depend
on the set accelerations without sway control. V_set is used as the set velocity. There are
other ways of influencing the setpoint, e.g. prelimit switch function.
3.1.4.2
Operation mode "manual" with sway control
In addition to the function (described above), the output velocity is influenced by the sway
control algorithm. This controls the existing sway. This lengthens the ramp-up and ramp-
down times of the output velocity and they are no longer linear.
The influence of the sway control can be set by the damping factors (P16, P17, P56, P57,
P146, P147).
The current value of the existing sway is calculated by means of a mathematical oscillation
model. If a camera is used, the mathematical oscillation model is constantly compared with
the value really measured by the camera.
3.1.4.3
Operation mode "Positioning" without sway control
Case 1: The position controller (P15, P55, P145) is set to values greater than zero
In this case, a position controller is active that calculates a set velocity as a function of the
target position S_Target, the actual position S_Act, the active accelerations, and the
positioning velocity. The sway control algorithm is not active.
Case 2: The position controller (P15, P55, P145) is set to values less than zero
In this case, the position controller is effective shortly before the braking phase. Otherwise,
see case 1.
Description of the AddOn sway control system
3.1 Software structure
SC integrated OHBC, Gantry crane
32 Operating Instructions, 02/2014
3.1.4.4
Operation mode "Positioning" with sway control
Case 1: The position controller (P15, P55, P145) is set to values greater than zero
In this case, a position controller has the effect of positioning without sway control, but the
sway control algorithm is active. For that reason, a correction value S_Corr is additionally
subtracted at the position controller input. In this case, the sway control algorithm provides
the correction value S_Corr. The influence of the sway control can be set by the damping
factor (P16, P56, P146).
Case 2: The position controller (P15, P55, P145) is set to values less than zero
In this case, the position controller is effective shortly before the braking phase. Otherwise,
see case 1.
3.1.4.5
Using an external position controller
The correction value S_Corr (path correction by sway control) is also transmitted through the
interface to the SIMATIC S7. This enables the user to use sway control with an external
position controller, too. For more details, see Chapter Positioning in the operation mode
"manual" with S_corr (Page 105).
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 33
3.2
Description of DCC blocks
3.2.1
Overview
Structure of DCC "SwayControl"
The DCC chart "SwayControl" consists of the following DCC blocks:
● DCC_SC_COMMON
● DCC_SC_TROLLEY
● DCC_SC_GANTRY
● DCC_SC_SLEW_HOIST
● DCC_SC_CAMERA
● DCC_SC_DIAG
Note
The name of the AddOn DCC chart "SwayControl" must not be changed or else it will
become imposs
ible to perform diagnostics with the SIMOCRANE CeCOMM diagnostic
program.
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
34 Operating Instructions, 02/2014
Table 3- 1 Overview of blocks in DCC chart "SwayControl"
No
.
Function
Brief description
1 General All drive data and camera measured values are acquired concurrently in
the "DCC_SC_COMMON" block. All data is grouped and the output values
are calculated. The block also controls the communication to the
SIMOCRANE CeCOMM diagnostic program. This block must be present.
2 Camera The block "DCC_SC_CAMERA" makes data available for the
communication with the camera and accepts the camera measured
values.
3 Trolley control The block "DCC_SC_TROLLEY" controls the trolley in all operating
modes. The behavior of the trolley is influenced by the control signals
generated by the block. Apart from status bits, etc., the block also issues
an output velocity.
4 Gantry control The block "DCC_SC_GANTRY" controls the gantry in all operating modes.
The behavior of the gantry is influenced by the control signals generated
by the block. Apart from status bits, etc., the block also issues an output
velocity.
5 Slewing gear or
hoist control
The block "DCC_SC_SLEW_HOIST" controls either slewing gear or a hoist
(without sway control) in all operation modes. The behavior of the slewing
gear or hoist is influenced by the control signals generated by the block.
Apart from status bits, etc., the block also issues an output velocity.
6 Diagnostics
The inputs and outputs for the SIMOCRANE CeCOMM diagnostic program
are controlled by the block "DCC_SC_DIAG."
Note
The source code of every DCC block is closed.
A license is required.
Unless otherwise stated, the following statements apply to all DCC blocks:
Firmware version
● SIMOTION Drive Based (D4x5): Firmware V4.3 or higher
● SINAMICS: Firmware V4.5.0 or higher
Configuring
The DCC blocks in "SwayControl" operate in the sampling time of the SIMOTION
interpolator cycle (T2).
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 35
3.2.2
DCC_SC_COMMON
Icon
Brief description
This function block contains basic functions for all DCC blocks as well as sway control
functions. It must always be used.
Method of operation
The block "DCC_SC_COMMON" provides data for communication with the crane control
system; these include all data that are not drive-specific.
All data are merged and the output values computed internally in the block.
Furthermore, the Java application block "Buffer_OHBC.jar" provides the addresses for a
shared data memory area. This memory area is used both for communication with the
SIMOCRANE CeCOMM diagnostic program and for file read and write operations
(parameters, language, etc.).
The three last outputs of the block are in the background in the default setting. They specify
memory locations and buffer sizes for the Java communication. Their comments must not be
changed.
Connections
The DCC block inputs are connected by means of the global variables of the MCC source
file "AddOn_SC_OHBC" with the outputs of the block "FB_AddOnSC_ReceiveFromPLC_BT".
The DCC block outputs are interconnected with the inputs of the block
"FB_AddOnSC_SendToPLC" by means of global variables.
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
36 Operating Instructions, 02/2014
Table 3- 2 Connections of "DCC_SC_COMMON"
Name
Type
Data
type
Pre-interconnection of
"AddOn_SC_OHBC"
Meaning
IFIDENT_NO
IN
UINT
DCC_In.Common.IFIdent_No
PB interface identifier
CTRL_BITS
IN
WORD
DCC_In.common.Ctrl_Bits
Control bits, general
LOAD
IN
UINT
DCC_In.Common.Load
Load in 10 kg
S_HOIST IN DINT DCC_In.Common.S_Hoist Hoist position for
effective pendulum
length
OBSTCLS0_15_OFF IN WORD (not visible)
No interconnection
Reserved for future
functions
OBSTCLS16_31_OFF IN WORD (not visible)
No interconnection
Reserved for future
functions
TLGRM_COUNT IN WORD DCC_In.Tlgrm_Count Telegram counter
from PLC
OLD_IF415_ON IN BOOL (not visible)
No interconnection
Compatibility mode to
old system
CeSARmaxx 4.1.5
STATUS_BITS OUT WORD DCC_Out.Common.Status_Bits Status bits, general
ERROR_BITS OUT WORD DCC_Out.Common.Error_Bits
Error bits sway control
system
DISTANCE_CAM OUT UDINT DCC_Out.Common.CamDist Camera-to-reflector
distance
TLGRM_COUNT_O OUT WORD DCC_Out.Common.Tlgrm_Count Telegram counter to
PLC
PARSET_NO OUT USINT No interconnection Selected parameter
set
WATCHDOG OUT BOOL No interconnection
Watchdog / life bit 200
ms
Error OUT BOOL No interconnection Error present from
block
Error_No OUT DINT No interconnection Error present from
block
ISEND_DATAP OUT DINT (not visible)
No interconnection
Start address send
buffer
IRECEIVE_DATAP OUT DINT (not visible)
No interconnection
Start address receive
buffer
IBUFFER_SIZE OUT DINT (not visible)
No interconnection
Size of data buffer
area
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 37
Error messages
If an error occurs, output "Error" is set and the error number is output at output "Error_No". If
several errors are present, the oldest error will be displayed.
Status word "ERROR_BITS" (sway control system error bits) can be used to transfer error
messages to the crane control system. For information about individual error bits, refer to
Chapter Alarm, error, and system messages (Page 215).
Figure 3-10 Block DCC_SC_COMMON, DCC interconnections
3.2.3
DCC_SC_TROLLEY
Icon
Brief description
This block controls the trolley in all operation modes.
Method of operation
The behavior of the trolley is influenced by the control signals generated by the block. In
addition to status signals, the block also issues an output velocity.
Connections
The DCC block inputs are connected by means of the global variables of the MCC source
file "AddOn_SC_OHBC" with the outputs of the block "FB_AddOnSC_ReceiveFromPLC_BT".
The DCC block outputs are interconnected with the inputs of the block
"FB_AddOnSC_SendToPLC" by means of global variables.
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
38 Operating Instructions, 02/2014
Table 3- 3 Connections of "DCC_SC_TROLLEY"
Name
Type
Data type
Pre-interconnection of
"AddOn_SC_OHBC"
Meaning
CTRL_BITS IN WORD DCC_In.Trolley.
Ctrl_Bits
Trolley control bits
V_ACTUAL
IN
REAL
DCC_In.Trolley.V_actual
Trolley actual velocity in mm/s
V_SET
IN
REAL
DCC_In.Trolley.V_set
Trolley set velocity in mm/s
S_ACTUAL
IN
LREAL
DCC_In.Trolley.S_actual
Trolley actual position in mm
S_TARGET
IN
LREAL
DCC_In.Trolley.S_target
Trolley target position in mm
V_SET_MM_S IN BOOL No interconnection
Invisible in the DCC
Default setting is "1" because
SIMOCRANE Basic Technology is used.
0 = V_SET and V_ACTUAL are interpreted
as a normalized value.
1 = V_SET and V_ACTUAL are interpreted
as a value in mm/s.
STATUS_BITS
OUT
WORD
DCC_Out.Trolley.Status_Bits
Trolley status bits
V_NORM
OUT
INT
DCC_Out.Trolley.V_norm
Normalized output velocity for trolley
V_MM_S
OUT
REAL
DCC_Out.Trolley.V_mm_s
Trolley output velocity in mm/s
S_DEFL
OUT
INT
DCC_Out.Trolley.S_deflect
Deflection in trolley direction
S_CORR OUT INT DCC_Out.Trolley.S_corr Distance correction by sway control, trolley
Error
OUT
BOOL
No interconnection
Error present from block
Error_No OUT DINT No interconnection Error number from block
Error messages
If an error occurs, output "Error" is set and the error number is output at output "Error_No". If
several errors are present, the oldest error will be displayed.
Figure 3-11 Block DCC_SC_TROLLEY, DCC interconnections
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 39
3.2.4
DCC_SC_GANTRY
Icon
Brief description
This block controls the gantry in all operation modes.
Method of operation
The behavior of the gantry is influenced by the control signals generated by the block. In
addition to status signals, the block also issues an output velocity.
Connections
The DCC block inputs are connected by means of the global variables of the MCC source
file "AddOn_SC_OHBC" with the outputs of the block "FB_AddOnSC_ReceiveFromPLC_BT".
The DCC block outputs are interconnected with the inputs of the block
"FB_AddOnSC_SendToPLC" by means of global variables.
Table 3- 4 Connections of "DCC_SC_GANTRY"
Name
Type
Data type
Pre-interconnection of
"AddOn_SC_OHBC"
Meaning
CTRL_BITS
IN
WORD
DCC_In.Gantry.Ctrl_Bits
Gantry control bits
V_ACTUAL
IN
REAL
DCC_In.Gantry.V_actual
Gantry actual velocity in mm/s
V_SET
IN
REAL
DCC_In.Gantry.V_set
Gantry set velocity in mm/s
S_ACTUAL
IN
LREAL
DCC_In.Gantry.S_actual
Gantry actual position in mm
S_TARGET
IN
LREAL
DCC_In.Gantry.S_target
Gantry target position in mm
V_SET_MM_S IN BOOL No interconnection
Invisible in the DCC
Default setting is "1" because SIMOCRANE
Basic Technology is used.
0 = V_SET and V_ACTUAL are interpreted
as a normalized value.
1 = V_SET and V_ACTUAL are interpreted
as a value in mm/s.
STATUS_BITS
OUT
WORD
DCC_Out.Gantry.Status_Bits
Gantry status bits
V_NORM
OUT
INT
DCC_Out.Gantry.V_norm
Normalized output velocity for gantry
V_MM_S
OUT
REAL
DCC_Out.Gantry.V_mm_s
Gantry output velocity in mm/s
S_DEFL
OUT
INT
DCC_Out.Gantry.S_deflect
Deflection in crane direction
S_CORR
OUT
INT
DCC_Out.Gantry.S_corr
Distance correction by sway control, gantry
Error
OUT
BOOL
No interconnection
Error present from block
Error_No
OUT
DINT
No interconnection
Error number from block
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
40 Operating Instructions, 02/2014
Error messages
If an error occurs, output "Error" is set and the error number is output at output "Error_No". If
several errors are present, the oldest error will be displayed.
Figure 3-12 Block DCC_SC_GANTRY, DCC interconnections
3.2.5
DCC_SC_SLEW_HOIST
Icon
Brief description
This block controls the slewing gear or hoist (P115) in all operation modes.
Method of operation
The behavior of the slewing gear or hoist is influenced by the control signals generated by
the block. In addition to status signals, the block also issues an output velocity.
Connections
The DCC block inputs are connected by means of the global variables of the MCC source
file "AddOn_SC_OHBC" with the outputs of the block "FB_AddOnSC_ReceiveFromPLC_BT".
The DCC block outputs are interconnected with the inputs of the block
"FB_AddOnSC_SendToPLC" by means of global variables.
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 41
Table 3- 5 Connections of "DCC_SC_SLEW_HOIST"
Name
Type
Data type
Pre-interconnection of
"AddOn_SC_OHBC"
Meaning
CTRL_BITS
IN
WORD
DCC_In.Slew_Hoist.Ctrl_Bits
Control bits for slewing gear or hoist
V_ACTUAL
IN
REAL
DCC_In.Slew_Hoist.V_actual
Actual velocity of slewing gear or hoist in mm/s
V_SET
IN
REAL
DCC_In.Slew_Hoist.V_set
Set velocity of slewing gear or hoist in mm/s
S_ACTUAL IN LREAL DCC_In.Slew_Hoist.S_actual Actual position of slewing gear or hoist in c° or
mm
S_TARGET IN LREAL DCC_In.Slew_Hoist.S_target Target position of slewing gear or hoist in c° or
mm
V_SET_MM_S IN BOOL No interconnection
Invisible in the DCC
Default setting is "1" because SIMOCRANE
Basic Technology is used.
0 = V_SET and V_ACTUAL are interpreted as a
normalized value.
1 = V_SET and V_ACTUAL are interpreted as a
value in mm/s.
STATUS_BITS
OUT
WORD
DCC_Out.Slew_Hoist.Status_Bits
Status bits of slewing gear or hoist
V_NORM OUT INT DCC_Out.Slew_Hoist.V_norm Normalized output velocity for slewing gear or
hoist
V_MM_S
OUT
REAL
DCC_Out.Slew_Hoist.V_mm_s
Output velocity of slewing gear or hoist in mm/s
S_DEFL OUT INT DCC_Out.Slew_Hoist.S_deflect Angle of rotation of load in direction of rotation
(slewing gear only)
S_CORR OUT INT DCC_Out.Slew_Hoist.S_corr Distance correction by sway control (for slewing
gear only)
Error
OUT
BOOL
No interconnection
Error present from block
Error_No
OUT
DINT
No interconnection
Error number from block
Error messages
If an error occurs, output "Error" is set and the error number is output at output "Error_No". If
several errors are present, the oldest error will be displayed.
Figure 3-13 Block DCC_SC_SLEW_HOIST, DCC interconnections
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
42 Operating Instructions, 02/2014
3.2.6
DCC_SC_CAMERA
Icon
Brief description
The block makes data available for the communication with the camera and accepts the
camera measured values.
Method of operation
The block does not communicate directly with the camera. The ST programs in the FB
blocks "FB_Receive_Analysis" and "FB_Send_Preparation" are required for this purpose.
The functions are implemented in the library "AddOn_FB_Library".
Connections
1. UDP communication (MCC "Cameramcc")
The DCC block inputs are connected by means of the global variables of the MCC source
file "Camera" with the outputs of the function block "FB_Receive_Analysis".
The output "S_HOIST" of the DCC block is interconnected with the input of function block
"FB_Send_Preparation" by means of a global variable.
2. PROFINET communication (MCC "Cam_MV440_mcc")
The DCC block inputs are connected by means of the global variables of the MCC source
file "Camera" with the outputs of the function block "FB_ReadWrite_MV440".
The output "S_HOIST" of the DCC block is interconnected with the input of function block
"FB_ReadWrite_MV440" by means of a global variable.
The other outputs of the DCC block, the IP address of the camera and the local port
number are used to configure the communication system using the SIMOCRANE
CeCOMM diagnostic program. The configuration files are stored in file "IP_Addresses.txt"
on the flash card in directory "SwayControl". The file is read in when the SIMOTION
system is restarted.
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 43
Table 3- 6 Connections of "DCC_SC_CAMERA"
Name
Type
Data type
Pre-interconnection of "MCC_Camera"
Meaning
TEL_COUNT
IN
DINT
Camera.camera_counter
Telegram counter from camera
CAMERA_OK
IN
BOOL
Camera.camera_cam_camera_ok
Camera values are valid
ERROR_CAM
IN
UINT
Camera.camera_cam_error
Error word from camera
X_POS
IN
DINT
Camera.camera_cam_x_pos
Deflection in x direction in mm
V_X IN DINT Camera.camera_cam_v_x Pendulum velocity in x direction in
mm/s
Y_POS
IN
DINT
Camera.camera_cam_y_pos
Deflection in y direction in mm
V_Y IN DINT Camera.camera_cam_v_y Pendulum velocity in y direction in
mm/s
SKEW
IN
DINT
Camera.camera_cam_skew
Rotation in c°
V_SKEW
IN
DINT
Camera.camera_cam_v_skew
Velocity of rotation in c°/s
DISTANCE IN DINT Camera.camera_cam_distance Distance measured between camera
and reflector in mm
S_HOIST OUT DINT Camera.camera_s_hoist Hoist position from crane control
system to camera matches input
"S_Hoist" of "DCC_SC_COMMON"
IP_ADDR_0 OUT USINT Camera.camera_sc_addr[0] IP address 0 of camera when UDP
communication is selected
IP_ADDR_1 OUT USINT Camera.camera_sc_addr[1] IP address 1 of camera when UDP
communication is selected
IP_ADDR_2 OUT USINT Camera.camera_sc_addr[2] IP address 2 of camera when UDP
communication is selected
IP_ADDR_3 OUT USINT Camera.camera_sc_addr[3] IP address 3 of camera when UDP
communication is selected
PORT OUT USINT Camera.camera_portlocal Local UDP port for receive telegrams
from camera
Error
OUT
BOOL
No interconnection
Error present from block
Error_No
OUT
DINT
No interconnection
Error number from block
Figure 3-14 Block DCC_SC_CAMERA, DCC interconnections
Description of the AddOn sway control system
3.2 Description of DCC blocks
SC integrated OHBC, Gantry crane
44 Operating Instructions, 02/2014
3.2.7
DCC_SC_DIAG
Icon
Brief description
The block controls the inputs and outputs for the SIMOCRANE CeCOMM diagnostic
program.
Method of operation
This block may not operate in the T1 execution level. The task runtime must be at least
5 ms. The block can require up to 4 ms of computation time.
Connections
The inputs and outputs of the DCC block do not have to be connected. They are connected
internally with the block "DCC_SC_Common".
Table 3- 7 Connections of "DCC_SC_DIAG"
Name
Type
Default
Data type
Pre-interconnection
Meanings
DIAG_ON
IN
1
BOOL
Diagnostics ON
STATUS OUT 0 INT Diagnostic status
see below
Diagnostic status
1
Diagnostics is activated
2
Invalid memory locations and buffer sizes for Java communic
ation (block
"DCC_SC_COMMON" is missing)
3
Block is deactivated (DIAG_ON = 0)
Figure 3-15 Block DCC_SC_DIAG, no DCC interconnections required
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 45
Adding the AddOn sway control system to the user
project
4
4.1
Precondition
4.1.1
Functional project
The AddOn sway control system can only be installed in a fully functional SIMOTION
SCOUT project with integrated SIMOCRANE Basic Technology, version V3.0 or higher.
Moreover, the Crane_DCC_Library suitable for SIMOCRANE Basic Technology Version 3.0
must be installed on your PC (see Operating Instructions SIMOCRANE Basic Technology).
Otherwise, it is not possible to make any changes to the project because error-free
compilation will not be possible.
● Checking the version of SIMOCRANE Basic Technology:
– Open SIMOTION SCOUT.
– Select the container "D435-2."
Click "Select technology packages" in the shortcut menu.
– Check the TP version of TP_crane_dcc_library_SIMOTION_4_1_5
● Checking correct functioning:
– Save and compile project with the icon "Save project and compile changes"
– Select the container "D435-2."
Select "Check consistency" in the shortcut menu.
This project is referred to as the "user project" in this document. It forms the basis for
expansion with the AddOn sway control system.
Note
Backing up the data of the user project
The extension of the user project is described step by step in t
he sections below. To avoid
data loss in case of error, we recommend creating a backup copy of the original user project.
Store this backup copy in a safe place.
Adding the AddOn sway control system to the user project
4.1 Precondition
SC integrated OHBC, Gantry crane
46 Operating Instructions, 02/2014
4.1.2
Suitable standard application
The product SIMOCRANE Basic Technology includes several standard applications for
different crane types.
The AddOn sway control system SIMOCRANE SC integrated OHBC, Gantry crane" is
suitable for the following standard applications:
● RMG (Rail-Mounted Gantry) crane
– Trolley
– Gantry
– Hoist or slewing gear
● RTG (Rubber-Tyred Gantry) crane
– Trolley
– Gantry
– Hoist
● OHBC (Overhead Bridge Crane)
– Trolley
– Gantry
– Hoist
● Easy RTG (simple Rubber-Tyred Gantry) crane
– Trolley
– Gantry
– Hoist
Adding the AddOn sway control system to the user project
4.1 Precondition
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 47
4.1.3
Setting the system cycle clocks
Check the task runtime settings.
To do this, select container D435-2 in SIMOTION SCOUT.
The system cycle clocks can be set in menu "Target system/Expert/Set system cycle
clocks", as illustrated in the screenshot below.
Figure 4-1 Setting the task runtimes
Adding the AddOn sway control system to the user project
4.2 Overview of the configuring steps to be performed
SC integrated OHBC, Gantry crane
48 Operating Instructions, 02/2014
4.2
Overview of the configuring steps to be performed
The following steps must be performed in succession:
1. Perform setup (installation of the DCC library) (Chapter Run the setup file (Page 49))
2. Import the SCOUT project of the AddOn sway control system (Chapter Import the
SCOUT project of the AddOn sway control system (Page 50))
3. Configure PROFIBUS (Chapter PROFIBUS configuration (Page 51))
4. Copy I/O variables (Chapter Copying I/O variables (Page 61))
5. Copy AddOn FB library (Chapter Copying the AddOn FB library (Page 63))
6. Copy MCC source files (Chapter Copying the MCC source file (Page 67))
7. Add DCC blocks (Chapter Inserting DCC blocks (Page 68))
8. Connect to SIMOCRANE Basic Technology and technology objects (Chapter Connection
to SIMOCRANE Basic Technology and technology objects (Page 73))
9. Adapt the user project without use of the SIMOCRANE CenSOR camera measuring
system (Chapter Adapting the user project without use of the SIMOCRANE CenSOR
camera measuring system (Page 74))
10.Adapt the user project with use of the SIMOCRANE CenSOR camera measuring system
with a PROFINET interface (Chapter Adapting the user project with use of the
SIMOCRANE CenSOR camera measuring system with a PROFINET interface (Page 75))
11.Adapt the user project for a configuration with a hoist (Chapter Adapting the user project
for a configuration with a hoist (Page 81))
12.Integrate the MCC source files "AddOn_SC_OHBC" and "Camera" into the execution
system (Chapter Integrating the MCC source files "AddOn_SC_OHBC" and "Camera" into
the execution system (Page 82))
13.Save, compile and check consistency (Chapter Saving, compiling and checking
consistency (Page 83))
14.Download language files, online help files and JAVA files to the CF card (Chapter
Transferring language files, online help files and JAVA files to the CF card (Page 87))
15.Download the user project to the CF card (Chapter Downloading the user project to the
CF card (Page 84))
16.Create the license key and download it to the CF card (Chapter Creating the license key
and downloading it to the CF card (Page 88))
17.Perform communication tests (Chapter Communication tests between SIMATIC S7 ↔
AddOn sway control system (Page 92))
Adding the AddOn sway control system to the user project
4.3 Run the setup file
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 49
4.3
Run the setup file
Note
To install the AddOn DCC library, SCOUT must be closed.
To install the required DCC library, the supplied "Setup.exe" file must be run. Follow the
instructions displayed during the installation. This installation process adds the current DCC
blocks to the DCC library.
Figure 4-2 Installing the AddOn DCC library
Adding the AddOn sway control system to the user project
4.4 Import the SCOUT project of the AddOn sway control system
SC integrated OHBC, Gantry crane
50 Operating Instructions, 02/2014
4.4
Import the SCOUT project of the AddOn sway control system
The sample SCOUT project of the AddOn sway control system must be imported next. This
is referred to as the "sample project" below.
Note
To import a project in "XML format", SCOUT must be open, but all the projects closed.
Click the icon to start the import of a SCOUT project. To import the project, the
"SC_integrated_OHBC.xml" file on the DVD must be selected. After clicking "OK" to confirm,
enter an arbitrary project name in the following window and select a target folder for the
project.
Note
The sample project is stored as a zip file on the DVD. The ZIP file must first be extracte
d
with the WinZip application outside the project. Data which can be imported with Scout will
then be made available. The project created by this method can also be opened with the
SIMATIC Manager so that the SIMATIC S7 sample blocks can be accessed.
Figure 4-3 Importing the SCOUT project of the AddOn sway control system
After clicking "OK" to confirm, the project will be imported and compiled.
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 51
4.5
PROFIBUS configuration
4.5.1
Overview
The SIMATIC S7 crane control system and the drive-based SIMOTION D435-2 DP/PN
exchange data by means of PROFIBUS DP.
The following PROFIBUS addresses have been assigned to the PROFIBUS DP interfaces at
the SIMOTION D435-2 DP/PN:
Table 4- 1 PROFIBUS DP interfaces at the SIMOTION D435-2 DP/PN
PROFIBUS DP interface
Communication between
PROFIBUS address
DP SIMATIC S7 and SIMOCRANE Basic
Technology
44
DP/MPI SIMATIC S7 and AddOn sway control
system
45
DP Integrated
SIMOTION and SINAMICS
Internal
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
52 Operating Instructions, 02/2014
4.5.2
Configuring the connection between SIMATIC S7 and the AddOn sway control
system
4.5.2.1
SIMOTION hardware configuration
Follow the steps described below to configure the DP/MPI interface of the SIMOTION D435-
2 DP/PN:
1. Open the hardware configuration in the user project:
Double-click the container marked "D435-2" in the project navigator of the user project.
2. Open the properties dialog for interface DP/MPI:
Double-click on the interface DP/MPI.
Figure 4-4 SIMOTION D435-2 DP/PN hardware configuration
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 53
3. Set the PROFIBUS address of the DP/MPI interface of the SIMOTION D435-2 DP/PN to
"45".
Figure 4-5 Object properties of the DP/MPI interface
4. Configure the CPU as a DP slave (= intelligent DP slave):
– Click on tab "Operating mode" in the properties dialog of the DP/MPI interface
– Select the option "DP slave".
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
54 Operating Instructions, 02/2014
5. Check the box "Programming, status/modify or other programming device functions and
unconfigured communication connections possible".
Figure 4-6 Selecting operation mode "DP slave"
Note
Once the interface has been configured as a DP slave, the DP master system associated
with the DP/MPI interface is no longer visible in the hardware configuration.
6. Compile the hardware configuration in SIMOTION SCOUT.
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 55
4.5.2.2
Communication with SIMATIC S7
The communication link to the SIMATIC S7 can be configured with SIMOTION SCOUT.
Requirement: The SIMATIC S7 project of the crane control system is also integrated in the
user project.
1. Open NetPro by clicking on button "Configure network".
Figure 4-7 Opening NetPro
2. Open the properties dialog for the DP interface of SIMATIC S7:
Double-click on the DP interface of the SIMATIC station in NetPro.
3. Set the transmission rate for the PROFIBUS interface to 1.5 Mbit/s.
Figure 4-8 Netpro overview
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
56 Operating Instructions, 02/2014
4. Link between SIMATIC S7 and SIMOTION D435-2 DP/PN:
– Click on the DP interface of the SIMATIC station (see screenshot above "Netpro
overview").
– Double-click on "C2xx/P3xx/D4xx-ISlave" under "Configured stations" in the catalog
"Network selection".
– The properties dialog of the DP slave opens next (see screenshot below).
Figure 4-9 Object properties of the DP slave
– Click on the button labeled "Couple" in the properties box.
– The linked slave is then displayed in the "Active coupling" box below.
Note
The coupling cannot
be separated again once the properties dialog of the DP interface of
the SIMATIC station has be closed with the "OK" button.
Note
Communication between the SIMATIC S7 and the SIMOTION 435
-2 DP/PN can only be
configured after the coupling has been est
ablished.
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 57
5. Configuring the data link between SIMATIC S7 and the AddOn sway control system:
Configure the I/O address areas as specified in the tables below and figure "Configuration
of the I/O address areas":
I/O address area of the input data SIMATIC S7 → AddOn sway control system
Block
Functions
PROFIBUS
address
Length
(byte)
I/O
address area
DCC_SC_COMMON
General
45
16
2300-2315
DCC_SC_TROLLEY
Trolley
45
4
2316-2319
DCC_SC_GANTRY
Gantry
45
4
2320-2323
DCC_SC_SLEW_HOIST Slewing gear or
hoist
45 4 2324-2327
Trailer Telegram
counter
45 2 2328-2329
I/O address area of the output data AddOn sway control system → SIMATIC S7
Block
Functions
PROFIBUS
address
Length
(byte)
I/O
address area
DCC_SC_COMMON
General
45
14
2300-2313
DCC_SC_TROLLEY
Trolley
45
12
2314-2325
DCC_SC_GANTRY
Gantry
45
12
2326-2337
DCC_SC_SLEW_HOIST Slewing gear or
hoist
45 12 2338-2349
Trailer Telegram
counter
45 2 2350-2351
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
58 Operating Instructions, 02/2014
6. Click on the "New" button in the properties dialog on the "Configuration" tab.
After this, an input screen form opens with the properties of the input and output data to
be created:
Figure 4-10 Properties of the input bytes
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 59
Figure 4-11 Properties of the output bytes
7. Configure the data exchange in the properties dialog of the DP/MPI interface of the
SIMOTION D435-2 DP/PN as illustrated in the screenshot below:
Figure 4-12 Configuring the I/O address areas
Adding the AddOn sway control system to the user project
4.5 PROFIBUS configuration
SC integrated OHBC, Gantry crane
60 Operating Instructions, 02/2014
8. Enter all the input and output data from the figure "Configuring the I/O address areas" in
this input screen.
Proceed as shown in the input screen form in section 7 using the example of input and
output data with start address 2300.
Enter data in the following boxes:
– "Mode",
– "Address type" for DP partner master (the address type is automatically set for the
local slave.)
– "Address" for DP partner master,
– "Address" for local slave,
– "Length",
– "unit" and
– "consistency".
9. Compile the network configuration in NetPro.
Adding the AddOn sway control system to the user project
4.6 Copying I/O variables
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 61
4.6
Copying I/O variables
The I/O variables specified in the ADDRESS LIST are used in the communication process.
Receive and send process data must be configured for each communication node.
To be able to copy the I/O variables from the sample project into the user project, you must
open the user project and the sample project with SIMOTION SCOUT.
The I/O variables of the sample project are displayed in the screenshot below:
Figure 4-13 Overview of I/O variables in SCOUT (communication between SIMATIC S7 and
SIMOTION D435-2 DP/PN)
Adding the AddOn sway control system to the user project
4.6 Copying I/O variables
SC integrated OHBC, Gantry crane
62 Operating Instructions, 02/2014
To copy, the "ADDRESS LIST" container is activated in the sample project. The I/O variables
are then selected in the symbol browser and copied with the shortcut menu (opened with the
right mouse button). The I/O variables are inserted in the user project with SIMOCRANE
Basic Technology by activating the "ADDRESS LIST" container, selecting the first free cell in
the symbol browser and then the Paste command.
Note
The I/Os "mv440" then only have to be copied if the SIM
OCRANE CenSOR camera
measuring system is used.
Adding the AddOn sway control system to the user project
4.7 Copying the AddOn FB library
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 63
4.7
Copying the AddOn FB library
The "AddOn_FB_Library" is selected in the sample project and copied with the context menu
command.
The library is inserted in the user project by selecting the container labeled "LIBRARIES"
followed by the Paste command.
①
User project
②
Sample project
Figure 4-14 Copying the "AddOn_FB_Library" in the sample project
①
User project
②
Sample project
Figure 4-15 Pasting the "AddOn_FB_Library" into the user project
Adding the AddOn sway control system to the user project
4.7 Copying the AddOn FB library
SC integrated OHBC, Gantry crane
64 Operating Instructions, 02/2014
The newly added library "AddOn_FB_Library" must now be compiled again.
Figure 4-16 User project, accept and compile library
Adding the AddOn sway control system to the user project
4.7 Copying the AddOn FB library
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 65
If an error message is output, as shown in the screenshot below, you still have to assign the
matching "technology packages/technology objects" to the "AddOn_FB_Library" library.
Figure 4-17 Possible error message when compiling the newly added library
Adding the AddOn sway control system to the user project
4.7 Copying the AddOn FB library
SC integrated OHBC, Gantry crane
66 Operating Instructions, 02/2014
Select the container "AddOn_FB_Library" and open the "Properties" window so that you can
select
TPs/TOs.
Figure 4-18 Selecting technology packages/technology objects
Adding the AddOn sway control system to the user project
4.8 Copying the MCC source file
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 67
4.8
Copying the MCC source file
After successful compilation of the library, the MCC source file "AddOn_SC_OHBC" can be
copied into the user project.
● Open the user project and the sample project.
● Copy the MCC source file from the sample project into the user project.
①
User project
②
Sample project
Figure 4-19 Copying the MCC source file in the sample project
①
User project
②
Sample project
Figure 4-20 Pasting the MCC source file of the user project in container Programs
Adding the AddOn sway control system to the user project
4.9 Inserting DCC blocks
SC integrated OHBC, Gantry crane
68 Operating Instructions, 02/2014
4.9
Inserting DCC blocks
4.9.1
Importing DCC block libraries
1. Open a DCC of your choice, such as Gantd_1, in the user project.
2. Select the menu item "Options" → "Block types…".
Figure 4-21 Updating block types
Adding the AddOn sway control system to the user project
4.9 Inserting DCC blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 69
3. Select "OK" in the following pop-up window.
Figure 4-22 Pop-up for updating the DCC library
The available libraries are now shown on the left-hand side with the previously-imported
libraries shown on the right-hand side.
4. Import of libraries
Note
Only impor
t the most recently available library.
Click the right-pointing arrow key.
Figure 4-23 Available and installed libraries
Adding the AddOn sway control system to the user project
4.9 Inserting DCC blocks
SC integrated OHBC, Gantry crane
70 Operating Instructions, 02/2014
The library is displayed on the right side of the screen.
Figure 4-24 Available and installed libraries are identical
Adding the AddOn sway control system to the user project
4.9 Inserting DCC blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 71
4.9.2
Copying the DCC "SwayControl"
1. Copy the DCC "SwayControl" from the sample project
– Select the DCC "SwayControl" in the container "PROGRAMS".
– Open the context menu with a right click.
– Select the menu item "Copy".
①
User project
②
Sample project
Figure 4-25 Copying the DCC chart from the sample project
2. Paste the DCC "SwayControl" into the user project:
– Select the container "PROGRAMS".
– Open the context menu with a right click.
– Select the menu item "Paste".
Figure 4-26 Pasting the DCC into the user project
Adding the AddOn sway control system to the user project
4.9 Inserting DCC blocks
SC integrated OHBC, Gantry crane
72 Operating Instructions, 02/2014
4.9.3
Mode of representation of blocks in the DCC
The mode of representation of blocks in the DCC might differ from the mode illustrated in this
document. Proceed as follows to adjust the settings:
1. Open the DCC "SwayControl" with a double click.
2. Open the "Options" menu in the DCC and select options "Settings" → "Display…" to open
the window "Display settings".
3. Select the mode "Function symbol" in the box "Block headers".
4. Open the "Options" menu in the DCC and select options "Settings" → "Block width / Sheet
bars"…" to open the window "Settings for blocks / sheet bars".
5. Select the option "Wide" under "Block width".
Adding the AddOn sway control system to the user project
4.10 Connection to SIMOCRANE Basic Technology and technology objects
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 73
4.10
Connection to SIMOCRANE Basic Technology and technology
objects
Variable assignments which are supplied by or linked to technology objects are implemented
in the MCC source file "AddOn_SC_OHBC in the sample project. These technology objects
are contained in the user project (see Chapter AddOn sway control system - technology
object (Page 150)).
Variable assignments which are supplied by the MCC source files of the SIMOCRANE Basic
Technology of the user project are also implemented (see Chapter AddOn sway control
system - SIMOCRANE Basic Technology (Page 149)).
To ensure that these assignments can be made in the sample project, the relevant
technology objects and MCC source files must also be included as dummies in the project.
These are specifically:
● Dummies for technology objects:
– Gantry_1,
– Trolley_1,
– SlewingGear_1
● Dummies for MCC source files:
– Gantp_1,
– Trollp_1,
– Slewingp_1
These dummies contain the required connection variables, but do not perform any other
function.
NOTICE
Possible malfunction if the placeholders are copied into the user project
Copying the placeholders into the user project overwrites important data. This can result in
malfunctioning.
• Never copy the placeholders into the user project.
Note
Backing up the data of the user project
To avoid data loss in case of error, we recommend creating a backup copy of the original
user project.
Store this backup copy in a safe place.
Note
This procedure can be applied only if the names of the technology objects and MCC source
files contained as dummies in the sample project are identical to the names of the real
technology objects and MCC source files in the user project
.
Adding the AddOn sway control system to the user project
4.11 Adapting the user project without use of the SIMOCRANE CenSOR camera measuring system
SC integrated OHBC, Gantry crane
74 Operating Instructions, 02/2014
4.11
Adapting the user project without use of the SIMOCRANE CenSOR
camera measuring system
After it has been copied into the user project, the DCC "SwayControl" still contains the
"prewired" DCC block "DCC_SC_Camera". This block needs to be removed from the DCC
wiring chart. To do this, open the DCC "SwayControl", select chart/sheet 2, select block
"DCC_SC_Camera" and delete it using the context menu command (right mouse button).
The chart must be compiled again after the block has been deleted.
Figure 4-27 Deleting block "DCC_SC_Camera" from DCC "SwayControl" and recompiling DCC
afterwards
Note
The ST source file "Camera" in library "AddOn_FB_Library" can also be deleted. Even if it is
not deleted, the project will still compile correctly.
Adding the AddOn sway control system to the user project
4.12
Adapting the user project with use of the SIMOCRANE CenSOR camera measuring system with a PROFINET interfa
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 75
4.12
Adapting the user project with use of the SIMOCRANE CenSOR
camera measuring system with a PROFINET interface
4.12.1
Adding camera MV440 to the hardware configuration
To insert the camera into the hardware, proceed as follows:
● Open the hardware configuration of the user project and add the module CBE30-2 at slot
X1400 if it is not already present.
● Then insert a new PROFINET IO system with the name "Camera" by right-clicking slot
X1400.
● Select the Ethernet subnet "Camera" and insert the device "Camera MV440" in the
hardware configuration. The I/O address areas of the MV440 in the AddOn sample
project are defined as follows:
mv440_receive:
Input 260…291
mv440_control_byte:
Input 292
mv440_send:
Output 260…291
mv440_status_byte:
Input 292
These I/O address areas can be adjusted.
The screenshots below illustrate the individual steps of the process.
Adding the AddOn sway control system to the user project
4.12 Adapting the user project with use of the SIMOCRANE CenSOR camera measuring system with a
PROFINET interface
SC integrated OHBC, Gantry crane
76 Operating Instructions, 02/2014
Figure 4-28 Inserting module CBE30-2 into the SIMOTION D435-2 DP/PN in the hardware
configuration
Proceed as follows to set the IP address of the CBE30-2:
● Right mouse click on X1400 (slot CBE30-2)
● Object properties
● General tab
● Interface/address
Adding the AddOn sway control system to the user project
4.12 Adapting the user project
with use of the SIMOCRANE CenSOR camera measuring system with a PROFINET interfa
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 77
Figure 4-29 Inserting the PROFINET IO system "Camera"
Figure 4-30 Inserting camera MV440 into the PROFINET IO system "Camera"
Adding the AddOn sway control system to the user project
4.12 Adapting the user project with use of the SIMOCRANE CenSOR camera measuring system with a
PROFINET interface
SC integrated OHBC, Gantry crane
78 Operating Instructions, 02/2014
Figure 4-31 Checking/setting the I/O addresses of "camera MV440"
Adding the AddOn sway control system to the user project
4.12
Adapting the user project with use of the SIMOCRANE CenSOR camera measuring system with a PROFINET interfa
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 79
4.12.2
Copying I/O variables of the camera
In the sample project, select the I/O address area of the camera MV440 and copy it into the
user project.
The I/O address areas of the camera MV440 in the HW configuration must coincide with the
address list in the user project.
Figure 4-32 Copying the I/O addresses of the camera MV440
Adding the AddOn sway control system to the user project
4.12 Adapting the user project with use of the SIMOCRANE CenSOR camera measuring system with a
PROFINET interface
SC integrated OHBC, Gantry crane
80 Operating Instructions, 02/2014
4.12.3
Copying the MCC source file "Camera"
● Open the user project and the sample project.
● Copy the MCC source file from the sample project into the user project.
①
User project
②
Sample project
Figure 4-33 Pasting the MCC source file "Camera" into the user project
Note
Additional information on the data exchange between the camera and the SIMOTION D435
-
2 DP/PN can be found i
n the operating instructions for the SIMOCRANE CenSOR camera
measuring system.
Adding the AddOn sway control system to the user project
4.13 Adapting the user project for a configuration with a hoist
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 81
4.13
Adapting the user project for a configuration with a hoist
Please proceed as follows:
1. Replace the variables "Slewing_1…" with "Hoist_1…" in the "DCC_In.Trolley.V_Set"
module of the MCC chart "AddOnMCC" (see also Chapter Software structure (Page 23)).
2. Assign the output velocity "DCC_Out.Slew_Hoist.V_mm_s" to the TO variable
"Hoist_1.defaultMotionIn.velocity" in the "Trolley_1.DefaultMotionIn" module of the MCC
chart "AddOnMCC."
Figure 4-34 Variable assignment: SIMOCRANE Basic Technology → AddOn sway control system
Figure 4-35 Variable assignment: AddOn sway control system → technology object
Adding the AddOn sway control system to the user project
4.14 Integrating the MCC source files "AddOn_SC_OHBC" and "Camera" into the execution system
SC integrated OHBC, Gantry crane
82 Operating Instructions, 02/2014
4.14
Integrating the MCC source files "AddOn_SC_OHBC" and "Camera"
into the execution system
The MCCs from the two MCC source files must be integrated into the execution levels of the
execution system.
The execution levels specify the execution sequence of the programs (MCCs). Each
execution level contains one or more tasks to which you can assign programs.
Proceed as follows to assign MCCs to an execution level:
1. Double-click the element "Execution system" in the project navigator.
The window containing the execution system and the program assignment appears in the
working area.
2. Click on BackgroundTask in order to select the BackgroundTask for program assignment.
All programs to which tasks can be assigned are displayed in the Program assignment
box on the left of the screen. The program name consists of the name of the MCC source
file and the name of the MCC (program name = "MCC_Source_File.MCC").
3. In order to assign MCCs "AddOn_SC_OHBC.AddonMCC" and "Camera.cameramcc" to
the BackgroundTask, select them with the mouse in the list box "Programs" and then click
on the button ">>".
4. Use the same method to assign the program "Camera.Cam_MV440_mcc" to the
IPOsynchronousTask.
5. The assigned programs then appear in the list box "Programs used".
6. You can also view the assignment results in the execution system display window (see
screenshot below).
Figure 4-36 Assigning MCCs to the BackgroundTask
Adding the AddOn sway control system to the user project
4.15 Saving, compiling and checking consistency
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 83
Note
There is no need to integrate MCCs "Camera.cameramcc" and "Cam
era.Cam_MV440_mcc"
if the configuration does not include a camera.
4.15
Saving, compiling and checking consistency
You can compile and save the user project by selecting button "Save project and compile
changes" (see screenshot below):
Figure 4-37 Saving and compiling
Then press the "Ctrl + Alt + K" key combination to perform a consistency check. The project
should now be free from any errors.
Adding the AddOn sway control system to the user project
4.16 Downloading the user project to the CF card
SC integrated OHBC, Gantry crane
84 Operating Instructions, 02/2014
4.16
Downloading the user project to the CF card
4.16.1
General
The user project must be transferred to the CF card. This can be done via an online
connection, or offline using a commercially available card reader.
4.16.2
Transfer via an existing online connection
Figure 4-38 Transferring the user project online
Note
After the user project has been transferred, the SIMOTION D435
-2 system must be
restarted.
Adding the AddOn sway control system to the user project
4.16 Downloading the user project to the CF card
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 85
4.16.3
Transfer by means of a card reader
● Select container "D435-2" in the user project.
● Open the shortcut menu with the right mouse button.
● Select menu option "Load to file system...".
Figure 4-39 Copying the user project to CF card directly
Adding the AddOn sway control system to the user project
4.16 Downloading the user project to the CF card
SC integrated OHBC, Gantry crane
86 Operating Instructions, 02/2014
Figure 4-40 Selecting the CF card in the card reader as the target
Adding the AddOn sway control system to the user project
4.17 Transferring language files, online help files and JAVA files to the CF card
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 87
4.17
Transferring language files, online help files and JAVA files to the
CF card
After completion of the configuring with SIMOTION "SCOUT", the following files must be
transferred to the CF card of the SIMOTION D435-2 DP/PN.
Copying language files and online help files from the DVD
A directory named "SWAYCONTROL" must be created on the CF card. Into this directory,
the
● language files "Sprache0.txt" to "Sprache3.txt," the
● online help files "Help_D.chm" and "Help_E.chm," and the
● parameter files "Par0.txt" to "Par3.txt"
● Address settings "IP_Addresses.txt"
must be copied from the DVD.
Copying JAVA Runtime from the DVD
From the directory "CD_1/Software/JAVA" directory on the DVD, copy the files:
● bufferOHBC.jar
● jinvoke.xml
● Simotion.jar
● VMconfig.ini
● JCONSOLE.txt
into the main directory of the CF card.
Adding the AddOn sway control system to the user project
4.18 Creating the license key and downloading it to the CF card
SC integrated OHBC, Gantry crane
88 Operating Instructions, 02/2014
4.18
Creating the license key and downloading it to the CF card
A license key is required and must be transferred to the CF card. Please proceed as follows:
● Have the Certificate of License supplied with the product to hand.
● Follow the Internet link License (https://workplace.automation.siemens.com/pls/swl-
pub/SWL_MAIN_MENU.NAVIGATION_HEAD?a_lang_id=E&a_action=) and carry out the
instructions at the website.
● When requested, enter the license number and the delivery note number.
At the end of this process, you will receive a license key consisting of a combination of
letters and numbers. This license key is valid only for the CF card you are using.
● Transfer the license key to the CF card in either online or offline mode.
To transfer the key in online mode, proceed as follows:
– Select the container "D435-2" in SIMOTION SCOUT.
– Select the option "LICENSES" in the context menu.
A window containing an overview of the required licenses will appear in the working
area.
– Click the "Perform licensing..." button.
– Follow the instructions and enter your license key when requested to do so.
To transfer the key in offline mode, proceed as follow
– Transfer the license key directly to path KEYS/SIMOTION/keys.txt on the CF card.
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 89
Interface to the crane control system
5
5.1
General
The SIMOTION D435-2 DP/PN communicates with the crane control system 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 107)).
All output data must be processed in the crane control system in accordance with the
interface description.
In the sample project, you will find SIMATIC S7 sample blocks that can be used for
incorporation into an existing crane control system.
This chapter describes the process of linking SIMOCRANE SC integrated OHBC, Gantry
crane into a configuration which includes SIMOCRANE Basic Technology and a SIMATIC
S7 system.
It is in principle possible to use another make of PLC in place of the SIMATIC S7.
Interface to the crane control system
5.2 Structure of the SIMATIC S7 sample blocks
SC integrated OHBC, Gantry crane
90 Operating Instructions, 02/2014
5.2
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.
Table 5- 1 Overview of data blocks and function blocks for the interface when SIMOCRANE Basic
Technology is used
Function
Name
Description
FC2020 SC_MAIN_BT This is the central block which needs to be called in
OB1 of the user program. It is in this block that all other
functions are called. All settings which are required to
set up a functional communication link are made in this
block. All user data are also entered in this block (as the
input and output data of the called functions).
FC2021 SC_SEND_BT The input data of the AddOn sway control system are
written to the I/O address area from send data block
DB2013 in function FC2021. For this purpose, the data
block number and the start addresses as stated in
Chapter Communication with SIMATIC S7 (Page 55)
must be entered as the input data for function FC2021
(in function FC2020).
FC2005 SC_RECEIVE The output data of the AddOn sway control system are
written from the I/O address area to receive data block
DB2010 in function FC2005.
For this purpose, the data block number and the start
addresses as stated in Chapter Communication with
SIMATIC S7 (Page 55) must be entered as the input
data for function FC2005 (in function FC2020).
FC2006 SC_COMMON Function for transferring general data. The user data
are described in detail in Chapter Interface description
(Page 107)
. The block requires the number of the
receive data block and the send data block.
FC2022 SC_AXIS_BT Universal function for communicating with drives. The
function FC2022 is called in function FC2020 in each
drive used and supplied with the data specific to the
drive. The user data are described in Chapter Interface
description (Page 107).
The block requires the number of the receive data block
and the send data block.
DB2013
SC_DB_SEND_BT
Contains the input data for the sway control.
DB2010
SC_DB_RECEIVE
Contains the output data from the sway control.
OB82 If this diagnostic interrupt OB is not programmed, the
CPU of the SIMATIC S7 switches to the STOP state if a
diagnostic interrupt is activated.
Interface to the crane control system
5.2 Structure of the SIMATIC S7 sample blocks
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 91
* These data are required for a functioning communication. The settings are made at the input data
of the relevant FCs in FC2020. These data are already set in the sample blocks and usually no
longer have to be changed.
Figure 5-1 SIMATIC S7 sample blocks
Interface to the crane control system
5.3 Commissioning the SIMATIC S7 sample blocks
SC integrated OHBC, Gantry crane
92 Operating Instructions, 02/2014
5.3
Commissioning the SIMATIC S7 sample blocks
Proceed as follows to commission the SIMATIC S7 sample blocks:
1. Isolate the drives from the power supply, e.g. by opening the main switch (actuate
Emergency Off button)
2. This will ensure that none of the drives can start up independently if an error occurs.
3. Transfer all functions and data blocks to the SIMATIC S7 user project
4. Before any data blocks are transferred, make sure that none of the block numbers is
assigned more than once to prevent overwriting of important blocks in the user program.
5. Set the correct start addresses and data block numbers for sending and receiving
6. FC2022 (SC_AXIS_BT) is called multiple times (once for each drive used). The drive for
which FC2022 has been called is determined at input "AXIS" as indicated below:
1 = Trolley
2 = Gantry
3 = Slewing gear / hoist (Only one drive can be selected. The drive is selected with
parameter P115).
7. Call FC2020 in OB1 of the SIMATIC S7 user program
8. If required: Transfer OB82 to the SIMATIC S7 user program
9. The control bit "Operation Mode Sway Control" (from the SIMATIC S7 to SIMOCRANE
Basic Technology) must be reset.
This ensures that the output velocities of the AddOn sway control system will not be
applied yet.
The communication system is now functional and you can start to program and test the user
data.
5.4
Communication tests between SIMATIC S7 ↔ AddOn sway control
system
Preconditions
● The SIMATIC S7 sample blocks have been commissioned as described in Chapter
Interface to the crane control system (Page 89).
● The drives must be isolated from the power supply (e.g. by actuation of the Emergency
Off button).
● The control bit "Operation Mode Sway Control" (from the SIMATIC S7 to SIMOCRANE
Basic Technology) must be reset.
Interface to the crane control system
5.4 Communication tests between SIMATIC S7 ↔ AddOn sway control system
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 93
Procedure
The most effective way to test the communication path is to set the control bit "Release" of
one of the drives used (this is implemented in function FC2020 in the SIMATIC S7). Setting
this control bit also sets the status bit "Ready" of the drive in question. This means that the
communication path from the AddOn sway control system to the SIMATIC S7 can also be
tested.
When the Release control bit is set (or is generated by an alternating signal, for example, by
a bit of the clock memory), this signal must arrive at the DCC block (see diagram of DCC
blocks in the DCC SwayControl).
It must also be possible to view the bit in display screen 1 (PROFIBUS interface) with the
SIMOCRANE CeCOMM diagnostic program. (see Fig. "SIMOCRANE CeCOMM diagnostic
program display screen 2"). Furthermore, the readings of the telegram counters "Sent" and
"Received" must also be incremented if the communication link is functioning properly.
The status bit "Ready" can be viewed in the same way in the DCC chart and with the
SIMOCRANE CeCOMM diagnostic program. This bit must also be visible as an input bit in
function FC2020 in the SIMATIC S7.
Figure 5-2 DCC blocks in DCC SwayControl
Interface to the crane control system
5.4 Communication tests between SIMATIC S7 ↔ AddOn sway control system
SC integrated OHBC, Gantry crane
94 Operating Instructions, 02/2014
Figure 5-3 SIMOCRANE CeCOMM diagnostic program display screen 2
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 95
Configuring instructions for crane control system
(SIMATIC S7)
6
6.1
Selecting the operation modes
Different operation modes are available for the individual drives (trolley, gantry, slewing gear
or hoist).
These operation modes are set up as follows in the SIMATIC S7 sample block FC2020
(SC_Main_BT) by entering an integer value at the input OM of FC2022 (SC_Axis_BT):
1 = positioning
2 = manual
3 = sway neutralization load position
4 = sway neutralization drive position
Note
Only the "positioning" and "manual operation" modes are available for the hoist.
6.2
Switchover from operation without AddOn sway control ↔ operation
with AddOn sway control
Note
This switchover must only be possible when all drives are at a standstill (zero speed).
Operation without AddOn sway control
The set velocity V_set is read in by the SIMATIC S7 and transferred to SIMOCRANE Basic
Technology in the SIMOTION D. The control bit "Operation Mode Sway Control" (from the
SIMATIC S7 to SIMOCRANE Basic Technology) must be reset. The control bit "Release"
(from the SIMATIC S7 to the AddOn sway control system) must also be reset.
The output velocities are then transferred directly from SIMOCRANE Basic Technology to
the technology objects of the relevant drives. With this configuration, the AddOn sway control
system does not perform any function.
Configuring instructions for crane control system (SIMATIC S7)
6.3 Pre-assignment of the interfaces
SC integrated OHBC, Gantry crane
96 Operating Instructions, 02/2014
Operation with AddOn sway control
The set velocity V_set is read in by the SIMATIC S7, transferred to SIMOCRANE Basic
Technology in the SIMOTION and finally forwarded to the AddOn sway control system. The
control bit "Operation Mode Sway Control" (from the SIMATIC S7 to SIMOCRANE Basic
Technology) must be set.
The control bit "Release" (from the SIMATIC S7 to the AddOn sway control system) must
also be set.
The output velocities are then transferred from the AddOn sway control system to the
technology objects of the relevant drives. With this configuration, the output velocities from
SIMOCRANE Basic Technology do not perform any function.
The set velocity V_set can be modified (e.g. reduced to prelimit switch velocity) before it is
passed to the AddOn sway control in the SIMATIC S7 or the SIMOTION D (SIMOCRANE
Basic Technology). However, the output velocity issued by the AddOn sway control system
must not be manipulated in any way (e.g. by a limiting function or an additional ramp).
6.3
Pre-assignment of the interfaces
Input data must be pre-assigned in the SIMATIC S7 depending on the operation modes,
functions and the configuration used (P115). It is important that functions that are not used
must also be pre-assigned as defined.
Examples:
● If a load measured value is not available, then this must be assigned zero. The same is
true for the "DigitalLiftCorrection" control bit if no information is available about a changed
load carrying device.
● The control bit "SC_On" must not be set if the third drive is employed 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 in order to prevent any unintended motions, 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.
Configuring instructions for crane control system (SIMATIC S7)
6.4 Sensing and monitoring the position actual values
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 97
6.4
Sensing and monitoring the position actual values
6.4.1
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.).
6.4.2
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). To fulfill this criterion,
a gain factor (P5, P45, P135) and an offset value (P6, P46, P136) can be applied to convert
the position 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 203)) makes it simpler to locate these types of fault locations.
6.4.3
Synchronizing absolute or incremental encoders, referencing
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.
Configuring instructions for crane control system (SIMATIC S7)
6.5 Generating the "Travelling" control bit
SC integrated OHBC, Gantry crane
98 Operating Instructions, 02/2014
6.5
Generating the "Travelling" control bit
WARNING
Danger to life from unexpected machine movement
Unexpected movements may occur after the crane comes to a standstill while the
"Travelling" control bit is set.
"Travelling" must be reset by the crane control system in the event of an EMERGENCY
STOP or cancellation of the continued travel.
Potential triggers for a cancellation by the sway control are the control bits "Release",
"Brake closed", "Controlled stop" and all limit switches.
• The "Travelling" control bit must be activated by a conscious action.
Travel is initiated in the sway control by setting the "Travelling" control bit (travel signal).
The travel signal may then be set in the crane control system if all conditions required to start
travel are met, or if there is no state intended to prevent travel (e.g. EMERGENCY STOP
activated).
If this is the case, then the "Travelling" control bit can be set as soon as a corresponding
actuator is activated by the crane driver (e.g. 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 which is intended to
prevent continued travel. There is then a stop with quick stop ramp without sway control.
If the travel can be terminated without a fault, then the "Travelling" control bit should be reset
with the "Pos_completed" status bit. The travel is then terminated with no residual 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; the "Travelling" control bit must be set simultaneously. When the master
controller is released, the set velocity is set to zero; however, the travel signal must remain
active until the sway control sets the status bit "Pos_completed".
Operation mode "positioning"
The "Travelling" control bit is generated according to similar principles applicable to "Manual"
operation mode. However, in this case, a target position is entered. The set velocity "V_set"
is not used in this operation mode. It is positioned with positioning velocity.
Configuring instructions for crane control system (SIMATIC S7)
6.6 Drive activation and brake control
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 99
Operation mode "sway neutralization"
Same procedure applies as in the "positioning" operation mode. 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 status bit "Po
s_completed" from the sway control system also includes the status
"SC_completed" (AND operation).
6.6
Drive activation and brake control
Use of status bits "Travel_f" and "Travel_b" is recommended for drive activation and brake
control.
If the "Travelling" control bit is set and the brake is still closed, then one of the two direction
signals is set to indicate that the crane should move. 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 by control bit "Brake_closed".
The output value is provided 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 t
imes (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" signal should always be applied to the "Brake_closed" control
bit of the relevant drive. This can be used to prev
ent the closed-loop control system from
manifesting a dead time behavior.
Configuring instructions for crane control system (SIMATIC S7)
6.7 Travel in operation mode "manual"
SC integrated OHBC, Gantry crane
100 Operating Instructions, 02/2014
6.7
Travel in operation mode "manual"
6.7.1
Start of travel
This example shows the sequence of signals in operation mode "manual".
Travel is initiated when the "Travelling" control bit is set by actuation of the master controller.
The following signal sequence is performed:
Figure 6-1 Signal sequence at the start of travel in operation mode "manual"
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
Generating the "Travelling" control bit (Page 98)). If this is the case and no fault is present,
direction signals are output which cause the brake to open (see Chapter Drive activation and
brake control (Page 99)).
Section 3:
The brake is opened. The output velocity is issued and transferred to the drives.
Configuring instructions for crane control system (SIMATIC S7)
6.7 Travel in operation mode "manual"
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 101
6.7.2
End of travel
This example shows the sequence of signals in operation mode "manual".
Travel ends when the "Pos_completed" status bit (positioning completed) is set by the
sway control. This requires that the set velocity "V_Set" is set to zero.
The following signal sequence is performed:
Figure 6-2 Signal sequence at the end of travel in operation mode "manual"
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 Generating the "Travelling" control bit
(Page 98)). Direction signals are no longer output and closure of the brake is therefore
initiated (see Chapter Drive activation and brake control (Page 99)).
Section 5:
The brake has been applied.
Configuring instructions for crane control system (SIMATIC S7)
6.8 Travel in operation mode "positioning"
SC integrated OHBC, Gantry crane
102 Operating Instructions, 02/2014
6.8
Travel in operation mode "positioning"
6.8.1
Start of travel
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 the entire period that the crane is moving.
If the travel signal is canceled, the output velocity "V_mm_s" of the drive is reduced along
the quick stop ramp.
The following signal sequence is performed:
Figure 6-3 Signal sequence at the start of travel in operation mode "positioning"
Section 1:
The sway control system is activated and the drive is selected for operation in "positioning"
mode. A target position has been specified.
Section 2:
The positioning operation is initiated by setting of "Travelling" control bit. If no fault has
occurred that disables the operation mode, direction signals are output which cause the
brake to open (see Chapter Drive activation and brake control (Page 99)).
Section 3:
The brake is opened. The output velocity "V_mm_s" is transferred to the drive.
Configuring instructions for crane control system (SIMATIC S7)
6.8 Travel in operation mode "positioning"
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 103
6.8.2
End of travel
Travel is terminated if the status bit "Pos_completed" is set:
● The difference between the current and target positions is less than the set positioning
accuracy.
● The status bit "SC_completed" is set.
● The output velocity is less than or equal to the zero speed detection.
The following signal sequence is performed:
Figure 6-4 Signal sequence at the end of travel in operation mode "positioning"
Section 1:
Sway-controlled travel of drive towards target position.
Section 2:
Actual position approaches target position.
Output velocity "V_mm_s" decreases.
Section 3:
Target position reached The output velocity "V_mm_s" is zero. The signal "Pos_completed"
is then set.
Section 4:
The "Travelling" control bit must be reset. This will prevent the output of any further direction
signals and so initiate closure of the brake.
Configuring instructions for crane control system (SIMATIC S7)
6.9 Controlled stop
SC integrated OHBC, Gantry crane
104 Operating Instructions, 02/2014
Section 5:
The brake has been applied.
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 cancelation of continued travel.
Cancelation by the sway control system 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.
6.9
Controlled stop
The control bit "Stop" (controlled stop) can be activated separately for each drive and brings
the drive to a sway-controlled standstill 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
crane control programming requirements.
Stopping is complete when the status bit "Pos_completed" 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.
Configuring instructions for crane control system (SIMATIC S7)
6.10 Positioning in the operation mode "manual" with S_corr
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 105
6.10
Positioning in the operation mode "manual" 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
therefore 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 direction-dependent sign and must be available as a quantity in
mm/s.
6.11
Normalization
When SIMOCRANE Basic Technology is used (if control bit "V_SET_MM_S = 1), the receive
data for the set velocity "V_set" and the actual velocity "V_act" are interpreted as physical
quantities in mm/s. The output velocity "V_mm_s" is also transmitted as a physical quantity in
mm/s.
The values do not need to be normalized in this instance.
Configuring instructions for crane control system (SIMATIC S7)
6.11 Normalization
SC integrated OHBC, Gantry crane
106 Operating Instructions, 02/2014
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 107
Interface description
7
7.1
Overview
The following interfaces are described in this chapter:
● Interface to the SIMATIC S7
● Interface to the camera
● Interface to SIMOCRANE Basic Technology and technology objects
Interface to the SIMATIC S7 / interface to the camera
The input and output data are described as follows in the tables in Chapters Interface to the
SIMATIC S7 (Page 110) and Interface to the camera (Page 147):
Table 7- 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 AddOn sway control system SIMOCRANE SC integrated OHBC,
Gantry crane uses the
interface for the SIMOCRANE SC integrated application with SIMOCRANE Basic
Technology, identification number = 5152.
Interface description
7.1 Overview
SC integrated OHBC, Gantry crane
108 Operating Instructions, 02/2014
Interface to SIMOCRANE Basic Technology and technology objects
The function blocks are connected to the SIMATIC S7 by means of global variables in the
I/O area (SIMOTION SCOUT address list).
Global variables are used to provide the connection between the function blocks and the
DCC blocks and between the SIMOCRANE Basic Technology and the DCC blocks.
For more information, see Chapter Interface to SIMOCRANE Basic Technology and
technology objects (Page 149).
Note
If the MCC source files "AddOn_SC_OHBC" and "C
amera" and DCC chart "SwayControl"
are imported, the global variables already exist and the connections in the CFC editor have
already been made.
Using the example of the trolley, the diagram below illustrates the signal flow from the send
data block "SC_DB_SEND_BT" in the SIMATIC S7 to the DCC block "DCC_SC_TROLLEY"
(control word) and back to the receive data block "SC_DB_RECEIVE" in the SIMATIC S7
(status word).
Interface description
7.1 Overview
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 109
Figure 7-1 Signal flow between SIMATIC S7 and the DCC block as exemplified by the trolley
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
110 Operating Instructions, 02/2014
7.2
Interface to the SIMATIC S7
7.2.1
Input data
7.2.1.1
Overview of complete data structure
The following table provides a complete overview of the data which are sent from the
SIMATIC S7 to the AddOn sway control system:
These data are contained in the data block DB1013 (SC_DB_SEND_BT) in the SIMATIC S7
sample blocks.
Table 7- 2 Overview of complete structure of input data
No.
Name
Length
Note
1 General block 16 bytes See Table 7-3 PROFIBUS DP general
block (Page 110)
2 Trolley block 4 bytes See Table 7-5 PROFIBUS DP trolley
block (Page 113)
3 Gantry block 4 bytes See Table 7-7 PROFIBUS DP gantry
block (Page 117)
4 Slewing gear block or hoist block 4 bytes See Table 7-9 PROFIBUS DP slewing
gear block (Page 121) or Table 7-11
PROFIBUS DP hoist block (Page 125)
5 Trailer 2 bytes See Table 7-13 PROFIBUS DP Trailer
(Page 129)
You will find information on selecting the operation modes in the relevant Chapter Selecting
the operation modes (Page 95).
7.2.1.2
Input data, general
Table 7- 3 PROFIBUS DP general block
Name
Type
Address
Designation
Unit
IF_IDNo
WORD
0-1
Interface version ID
PB_ID_NR=5152
Spare
WORD
2-3
Reserve
CTRL_BITS WORD 4-5 General control bits See Table 7-4
General control
bits (Page 112)
Load WORD 6-7 Load weight in 10 kg steps
S_Hoist DINT 8-11 Hoist position for
effective pendulum
length
± mm
Reserved_3
WORD
12-13
ObstaclesOff 0 … 15
Bits 0 ... 15
Reserved_4
WORD
14-15
ObstaclesOff 16 … 31
Bits 0 ... 15
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 111
Note
The signals 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
This value is used to select the interface variant. The function blocks stored in the ST source
file "ComPLC" interpret the incoming telegram in accordance with this identification number.
5150
Interface Integer, for SIMOCRANE CeSAR standalone
5151 Interface Real, for SIMOCRANE SC integrated application without SIMOCRANE
Basic Technology
5152 Interface for SIMOCRANE SC integrated application with SIMOCRANE 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 (Page 112)).
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 in order to prevent counter overflows.
Note
Correction based on the load weight is only required for significantly fluctuating load
cha
nges, e.g. when transporting casting ladles in a steel plant. Not all cranes are equipped
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).
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
112 Operating Instructions, 02/2014
S_Hoist - Hoist position for effective pendulum length
This value corresponds to the current 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 current position 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.
Reserved_3 - ObstaclesOff 0 ... 15 / Reserved_4 - ObstaclesOff 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 crane control
system.
7.2.1.3
Control bits, general
Table 7- 4 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 Reserved_0 Trajectory control ON
detour control only; not available in this version)
3
Save_Logger
Save logger file
4 Reserved_1 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 crane control system to select parameter sets 1 to 4. Also observe
parameter P101.
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 - Reserved_0 (synchronization of the trolley and gantry for 2D trajectory)
Reserved for detour control (not available in this version)
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 113
Bit 3 - Save_Logger (save the current content of the logger to the CF card)
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 CF card. For example,
saving the logger file to the CF card can be helpful when analyzing faults, and should only be
used in exceptional cases due to the limited storage capacity of the CF card.
Note
The "Save Logger" function is for Siemens
-internal use only.
Bit 4 - Reserved_1 – load on the hook
Reserved for detour control with hoist (not available in this version)
7.2.1.4
Input data, trolley
Table 7- 5 PROFIBUS DP trolley block
Name
Type
Address
Designation
Unit
CTRL-BITS WORD 16-17 Trolley control bits See Table 7-6 Trolley control
bits (Page 114)
Spare
WORD
18-19
Reserve
CTRL-BITS - trolley control bits
Trolley control bits (see Chapter Trolley control bits (Page 114))
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
114 Operating Instructions, 02/2014
7.2.1.5
Trolley control bits
Table 7- 6 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 (trolley enable)
0
Drive inhibited, quick stop during travel.
1 Operation modes and travel signal are evaluated.
Bit 1 - Travelling (travel signal of the trolley)
0 Stop with quick stop ramp P12 without sway control.
1 Trigger travel motion. The travel signal 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 onc
e the status bit "Pos_completed" has been set.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 115
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.
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 t
o 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.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
116 Operating Instructions, 02/2014
Bit 9 - Brake_closed (output value enable)
0
Brake is open. Output value and direction signals are enabled.
1 Brake is closed. Output value 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
Bit 14 - LS_F (Limit Switch Forward)
0
Actuated, quick stop during travel.
1
Not actuated.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 117
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).
7.2.1.6
Input data, gantry
Table 7- 7 PROFIBUS DP gantry block
Name
Type
Address
Designation
Unit
CTRL-
BITS
WORD 20-21 Gantry control bits See Table 7-8 Gantry control
bits (Page 118)
Spare
WORD
22-23
Reserve
CTRL-BITS - gantry control bits
Gantry control bits (see Chapter Gantry control bits (Page 118)).
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
118 Operating Instructions, 02/2014
7.2.1.7
Gantry control bits
Table 7- 8 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 axis 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 gantry)
0
Drive inhibited, quick stop during travel.
1 Operation modes and travel signal are evaluated.
Bit 1 - Travelling (travel signal of the gantry)
0 Stop with quick stop ramp P52 without sway control.
1
Trigger travel motion. The travel signal 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 status bit "Pos_completed" has been set.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 119
Bits 2 to 5 - OM (Operation Mode, gantry operation mode)
Note
Only one operation mode is valid.
Only one of the operat
ion 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, gantry)
0
Actuated, reduction of output velocity.
1
Not actuated.
Bit 7 - PLS_B (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 contro
lled 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.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
120 Operating Instructions, 02/2014
Bit 9 - Brake_closed (output value enable)
0
Brake is open. Output value and direction signals are enabled.
1 Brake is closed. Output value 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" (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.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 121
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).
7.2.1.8
Input data, slewing gear
Table 7- 9 PROFIBUS DP slewing gear block
Name
Type
Address
Designation
Unit
CTRL-BITS WORD 24-25 Slewing gear control bits See table Table 7-10 Slewing
gear control bits (Page 122)
CTRL-
BITS2
WORD 26-27 Not used
CTRL-BITS - slewing gear control bits
Slewing gear control bits (see Chapter Slewing gear control bits (Page 122))
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
122 Operating Instructions, 02/2014
7.2.1.9
Slewing gear control bits
Table 7- 10 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
OMC_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 (slewing gear enable)
0
Drive inhibited, quick stop during travel.
1 Operation modes and travel signal are evaluated.
Bit 1 - Travelling (slewing gear travel signal)
0 Stop with quick stop ramp P142 without sway control.
1 Trigger travel motion. The travel signal 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 status bit "Pos_completed" has been set.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 123
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_AX (Operation Mode, sway neutralization axis position operation mode,
slewing gear)
0
Inactive
1
Active
Bit 6 - PLS_F (PreLimit Switch Forward, slewing gear)
0
Actuated, reduction of output velocity.
1
Not actuated
Bit 7 - PLS_B (PreLimit Switch Backward, slewing gear)
0
Actuated, reduction of output velocity.
1
Not actuated.
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, O
M_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.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
124 Operating Instructions, 02/2014
Bit 9 - Brake_closed (output value enable)
0
Brake is open. Output value and direction signals are enabled.
1 Brake is closed. Output value 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
Bit 14 - LS_F (Limit Switch Forward)
0
Actuated, quick stop during travel.
1
Not actuated.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 125
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).
7.2.1.10
Input data, hoist
Table 7- 11 PROFIBUS DP hoist block
Name
Type
Address
Designation
Unit
CTRL-BITS WORD 24-25 Hoist control bits See Table 7-12 Hoist
control bits (Page 126)
CTRL-
BITS2
WORD 26-27 Not used
CTRL-BITS - hoist control bits
Hoist control bits (see Chapter Hoist control bits (Page 126))
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
126 Operating Instructions, 02/2014
7.2.1.11
Hoist control bits
Table 7- 12 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 (hoist enable)
0
Drive inhibited, quick stop during travel.
1
Operation modes and travel signal are evaluated.
Bit 1 - Travelling (hoist travel signal)
0
Stop with quick stop ramp P142.
1
Trigger travel motion. The travel signal 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, the "Travelling" control bit may only be reset once the
status bit "Pos_completed" is set.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 127
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, hoist)
0
Actuated, reduction of output velocity.
1
Not actuated.
Bit 7 - PLS_B (PreLimit Switch Backward, hoist)
0
Actuated, reduction of output velocity.
1
Not actuated.
Bit 8 - Stop (controlled stop)
0
No stop.
1
Stop with setpoint 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
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
128 Operating Instructions, 02/2014
Bit 9 - Brake_closed (output value enable)
0
Brake is open. Output value and direction signals are enabled.
1 Brake is closed. Output value 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 limit switches are low active (wire
-break proof).
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 129
7.2.1.12
Trailer (2 bytes)
Table 7- 13 PROFIBUS DP Trailer
Name
Type
Address
Designation
Unit
Trailer
WORD
28 - 29
Telegram counter
The last two bytes contain a telegram counter (crane control system → SIMOTION D435-2
DP/PN).
For more information, see error message E2 (Chapter List of alarm, error, and system
messages (Page 217)).
7.2.2
Output data
7.2.2.1
Overview of complete data structure
The following tables provide a complete overview of the data which are sent from the AddOn
sway control system to the SIMATIC S7:
These data are contained in the data block DB2010 (SC_DB_RECEIVE) in the SIMATIC S7
sample blocks.
Table 7- 14 Overview of complete structure of output data
No.
Name
Length
Note
1 General block 14 bytes See Table 7-15 PROFIBUS DP general block
(Page 130)
2 Trolley block 12 bytes See Table 7-17 PROFIBUS DP trolley block
(Page 132)
3 Gantry block 12 bytes See Table 7-19 PROFIBUS DP gantry block
(Page 136)
4 Slewing gear block or
Hoist block
12 bytes See Table 7-21 PROFIBUS DP slewing gear block
(Page 140) or Table 7-23 PROFIBUS DP hoist block
(Page 144)
5
Trailer
2 bytes
See Table 7-25 PROFIBUS DP Trailer (Page 146)
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
130 Operating Instructions, 02/2014
7.2.2.2
Output data, general
Table 7- 15 PROFIBUS DP general block
Name
Type
Address
Designation
Unit
STATUS_BI
TS
WORD 0-1 Status bits, general See Table 7-16
Status bits,
general
(Page 131)
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
STATUS_BITS - general status bits
See Chapter Status bits, general (Page 131).
ErrorBits1 - error bits 1 general
See Chapter Alarm, error, and system messages (Page 215) ; Table 11-1 Error messages
with error bit (Page 215)
ErrorBits2 - error bits 2 general
Not currently used. Reserve.
CamDist - distance measured between the camera and reflector
See the SIMOCRANE CenSOR operating instructions.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 131
7.2.2.3
Status bits, general
Table 7- 16 Status bits, general
Bit no.
Names
Meaning
0
PAR_SET_Bit0
Parameter set selection bit 0
1
PAR_SET_Bit1
Parameter set selection bit 1
2
Reserve
3
Reserve
4
WATCHDOG
WATCHDOG (flashing signal 200 ms)
5 not_used1 Reserved for detour control (not available in this
version)
6 not_used2 Next target can be entered
Reserved for detour control (not available in this
version)
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 D435-2 DP/PN in the crane control system.
Bit 5 - not_used1
Reserved for future detour control (not available in this version)
Bit 6 - not_used2
Reserved for future detour control (not available in this version)
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
132 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.
7.2.2.4
Output data, trolley
Table 7- 17 PROFIBUS DP trolley block
Name
Type
Address
Designation
Unit
STATUS_BITS WORD 14-15 Trolley status bits See Table 7-18
Trolley status bits
(Page 133)
V_norm INT 16-17 Output velocity as normalized value
Not used for the variant with
SIMOCRANE Basic Technology
V_mm_s
REAL
18-21
Output velocity, trolley
± mm/s
S_DEFL
INT
22-23
Pendulum deflection, trolley
± mm
S_corr INT 24-25 Distance correction by sway
control, trolley
± mm
STATUS_BITS - trolley status bits
See Chapter Trolley status bits (Page 133).
V_norm - output velocity as normalized value
The output velocity is passed to the crane control system as a normalized value.
This is not required in the variant with SIMOCRANE Basic Technology.
V_mm_s - output velocity in mm/s
The output velocity is passed to the crane control system in mm/s.
This is not required in the variant with SIMOCRANE Basic Technology.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 133
S_DEFL - 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 deflection value is measured and output. The
mathematical oscillation model is calibrated with this value. Without a camera, this output
returns the load deflection based on the mathematical oscillation model.
S_corr - distance correction by sway control, trolley
With external position control, the "S_corr" value is required to form the position difference
which represents 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.
7.2.2.5
Trolley status bits
Table 7- 18 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
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
134 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 condition less than / equal to the
zero speed detection P19 in manual operation mode with sw
ay 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 the 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
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 135
Bit 4 - Travel_f (travel direction forward)
0 All operation modes
Control bit "Travelling" is zero or an error message is pending that prevents travel.
1 Operation mode manual
Control bit "Travelling" is set and the set velocity is greater than or equal to zero.
Operation mode positioning
Control bit "Travelling" 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 par
ameter set.
Bit 5 - Travel_b (travel direction backward)
0 All operation modes
Control bit "Travelling" is zero or an error message is pending that prevents travel.
1 Operation mode manual
Control bit "Travelling" is set and the set velocity is less than zero.
Operation mode positioning
Control bit "Travelling" 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.
In 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 163)).
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
136 Operating Instructions, 02/2014
7.2.2.6
Output data, gantry
Table 7- 19 PROFIBUS DP gantry block
Name
Type
Address
Designation
Unit
STATUS_BITS WORD 26-27 Gantry status bits See Table 7-20
Gantry status bits
(Page 137)
V_norm INT 28-29 Output velocity, gantry
This is not used in the variant with
SIMOCRANE Basic Technology.
V_mm_s
REAL
30-33
Output velocity, gantry
± mm/s
S_DEFL
INT
34-35
Pendulum deflection, gantry
± mm
S_corr INT 36-37 Distance correction by sway
control, gantry
± mm
STATUS_BITS - gantry status bits
See Chapter Gantry status bits (Page 137)
V_norm - output velocity as normalized value
The output velocity is passed to the crane control system as a normalized value.
This is not required in the variant with SIMOCRANE Basic Technology.
V_mm_s - output velocity
The output velocity is passed to the crane control system in mm/s.
This is not required in the variant with SIMOCRANE Basic Technology.
S_DEFL - pendulum deflection
Current distance of the reflector from its home position in the direction of the gantry.
If a camera is 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
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 137
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 transm
itted 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.
7.2.2.7
Gantry status bits
Table 7- 20 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
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
138 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 position 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 applies 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 / equ
al to the zero speed detection P59 and the
actual position 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 of the load is less than P73 and the pendulum velocity is less than
P74 over a period of at least 250 ms.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 139
Bit 4 - Travel_f (travel direction forward)
0 All operation modes
Control bit "Travelling" is zero or an error message is pending that prevents travel.
1 Operation mode manual
Control bit "Travelling" is set and the set velocity is greater than or equal to zero.
Operation mode positioning
Control bit "Travelling" 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
Control bit "Travelling" is zero or an error message is pending that prevents travel.
1 Operation mode manual
Control bit "Travelling" is set and the set velocity is less than zero.
Operation mode positioning
Control bit "Travelling" 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.
In 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 163)).
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
140 Operating Instructions, 02/2014
7.2.2.8
Output data, slewing gear
Table 7- 21 PROFIBUS DP slewing gear block
Name
Type
Address
Designation
Unit
STATUS_BITS WORD 38-39 Status bits, slewing gear See Table 7-22 Status
bits, slewing gear
(Page 141)
V_norm INT 40-41 Output velocity, slewing gear
This is not used in the variant with
SIMOCRANE Basic Technology.
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°
STATUS_BITS - slewing gear status bits
See Chapter Status bits, slewing gear (Page 141).
V_norm - output velocity as normalized value
The output velocity is passed to the crane control system as a normalized value.
This is not required in the variant with SIMOCRANE Basic Technology.
V_mm_s - output velocity
The output velocity is passed to the crane control system in c°/s.
This is not required in the variant with SIMOCRANE Basic Technology.
Skew - rotation
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 load skew based on the mathematical oscillation model.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 141
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
t
he sample block, this value is converted to a DINT value and can be further processed as a
DINT value.
7.2.2.9
Status bits, slewing gear
Table 7- 22 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
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
142 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 detection 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 detec
tion 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
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 143
Bit 4 - Travel_f (travel direction forward)
0 All operation modes
Control bit "Travelling" is zero or an error message is pending that prevents travel.
1 Operation mode manual
Control bit "Travelling" is set and the set velocity is greater than or equal to zero.
Operation mode positioning
Control bit "Travelling" 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
Control bit "Travelling" is zero or an error message is pending that prevents travel.
1 Operation mode manual
Control bit "Travelling" is set and the set velocity is less than zero.
Operation mode positioning
Control bit "Travelling" 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 despite the control
bit 11 "SC_On" being set (see Chapter Operation mode "manual" with sway control
(Page 163)).
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
144 Operating Instructions, 02/2014
7.2.2.10
Output data, hoist
Table 7- 23 PROFIBUS DP hoist block
Name
Type
Address
Designation
Unit
STATUS_BITS WORD 38-39 Status bits, hoist See Table 7-24 Status
bits, hoist (Page 145)
V_norm INT 40-41 Output velocity, hoist
This is not used in the variant with
SIMOCRANE Basic Technology.
V_mm_s
REAL
42-45
Output velocity, hoist
± mm/s
Skew
INT
46-47
Not used
S_corr
INT
48-49
Not used
STATUS_BITS - hoist status bits
See Chapter Status bits, hoist (Page 145).
V_norm - output velocity as normalized value
The output velocity is passed to the crane control system as a normalized value.
This is not required in the variant with SIMOCRANE Basic Technology.
V_mm_s - output velocity
The output velocity is passed to the crane control system in mm/s.
This is not required in the variant with SIMOCRANE Basic Technology.
Skew - not used
Is always zero for the hoist.
S_corr - not used
Is always zero for the hoist.
Interface description
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 145
7.2.2.11
Status bits, hoist
Table 7- 24 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
7.2 Interface to the SIMATIC S7
SC integrated OHBC, Gantry crane
146 Operating Instructions, 02/2014
Bit 4 - Travel_f (travel direction forward)
0 All operation modes
Control bit "Travelling" is zero or an error message is pending that prevents travel.
1 Operation mode manual
Control bit "Travelling" is set and the set velocity is greater than or equal to zero.
Operation mode positioning
Control bit "Travelling" 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 cau
se of the error is in the
active parameter set.
Bit 5 - Travel_b (travel direction backward)
0 All operation modes
Control bit "Travelling" is zero or an error message is pending that prevents travel.
1 Operation mode manual
Control bit "Travelling" is set and the set velocity is less than zero.
Operation mode positioning
Control bit "Travelling" 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, an
d E0 if the cause of the error is in the
active parameter set.
7.2.2.12
Trailer (telegram counter)
Table 7- 25 PROFIBUS DP Trailer
Name
Type
Address
Designation
Unit
Trailer
WORD
50 - 51
Telegram counter
The last two bytes contain a telegram counter (SIMOTION D435-2 DP/PN → crane control
system).
For more information, see error message E2 (Chapter List of alarm, error, and system
messages (Page 217)).
Interface description
7.3 Interface to the camera
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 147
7.3
Interface to the camera
7.3.1
Input data
Table 7- 26 Connections of "DCC_SC_CAMERA"
Type
Name
Meaning
Unit
DINT
TEL_COUNT
Telegram counter
BOOL
CAMERA_OK
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 217)). The camera data currently
received is presented in the SIMOCRANE CeCOMM diagnostic program (screen 4).
Note
Additional information on the data exchange betwee
n the camera and the SIMOTION D435-
2 DP/PN can be found in the operating instructions for the SIMOCRANE CenSOR camera
measuring system.
Interface description
7.3 Interface to the camera
SC integrated OHBC, Gantry crane
148 Operating Instructions, 02/2014
7.3.2
Output data
Table 7- 27 Data to the camera (crane control system → SIMOTION D435-2 DP/PN → camera
measuring system)
Type
Name
Meaning
Unit
DINT S_HOIST Hoist position for effective pendulum length
The value is identical to "S_Hoist" (see Input data,
general (Page 110))
mm
S_HOIST
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" (see Input data, general (Page 110)) is sent to the value "S_HOIST"
(data to the camera).
Additional information can be taken from the documentation on the camera measuring
system.
Interface description
7.4 Interface to SIMOCRANE Basic Technology and technology objects
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 149
7.4
Interface to SIMOCRANE Basic Technology and technology objects
7.4.1
AddOn sway control system - SIMOCRANE Basic Technology
SIMOCRANE Basic Technology → AddOn sway control system
The following signals are transferred via the global variables of the MCC source file
"AddOn_SC_OHBC" from SIMOCRANE Basic Technology to the AddOn sway control
system:
Table 7- 28 Variables SIMOCRANE Basic Technology → AddOn sway control system
BT variable
Format
Meaning
Unit
AddOn variable
Trolley_1_Comvelocity REAL Set velocity for trolley
from SIMOCRANE Basic
Technology
± mm/s DCC_In.Trolley.V_Set
Trolley_1_TargetPosition LREAL Target position for trolley
from SIMOCRANE Basic
Technology
± mm DCC_In.Trolley.S_Target
Gantry_1_Comvelocity REAL Set velocity for gantry
from SIMOCRANE Basic
Technology
± mm/s DCC_In.Gantry.V_Set
Gantry_1_TargetPosition LREAL Target position for gantry
from SIMOCRANE Basic
Technology
± mm DCC_In.Gantry.S_Target
Slewing_1_Comvelocity
or
Hoist_1_Comvelocity
REAL Set velocity for slewing
gear or hoist from
SIMOCRANE Basic
Technology
± mm/s or
c°/s
DCC_In.Slew_Hoist.V_Set
Slewing_1_TargetPosition
or
Hoist_1_TargetPosition
LREAL Actual position for
slewing gear or hoist
from SIMOCRANE Basic
Technology
± mm
or c°/s
DCC_In.Slew_Hoist.S_Target
Interface description
7.4 Interface to SIMOCRANE Basic Technology and technology objects
SC integrated OHBC, Gantry crane
150 Operating Instructions, 02/2014
7.4.2
AddOn sway control system - technology object
Technology object → AddOn sway control system
Table 7- 29 Variables involved in technology object → AddOn sway control system signal flow
TO variable
Format
Meaning
Unit
AddOn variable
Trolley_1_ActualVelocity
REAL
Trolley actual velocity
± mm/s
DCC_In.Trolley.V_Actual
r64Actualposition_Trolley1
LREAL
Trolley actual position
± mm
DCC_In.Trolley.S_Actual
Gantry_1_ActualVelocity
REAL
Gantry actual velocity
± mm/s
DCC_In.Gantry.V_Actual
r64ActualPosition_Gantry1
LREAL
Gantry actual position
± mm
DCC_In.Gantry.S_Actual
Slewing_1_ActualVelocity
or
Hoist_1_ActualVelocity
REAL Actual velocity,
Slewing gear or hoist
c° or ± mm/s DCC_In.Slew_Hoist.V_Actual
r64Actualposition_Slewing1
or
r64Actualposition_Hoist1
REAL Actual position,
slewing gear or hoist
c° or ± mm DCC_In.Slew_Hoist.S_Actual
AddOn sway control system → technology object
Table 7- 30 Variables involved in AddOn sway control system → technology object signal flow
TO variable
Format
Meaning
Unit
AddOn variable
Trolley_1.defaultMotionIn.velocity
REAL
Output velocity, trolley
± mm/s
DCC_Out.Trolley.V_mm_s
Gantry_1.defaultMotionIn.velocity
REAL
Output velocity, gantry
± mm/s
DCC_Out.Gantry.V_mm_s
Slewing_1.defaultMotionIn.velocity
or
Hoist_1.defaultMotionIn.velocity
REAL Output velocity,
slewing gear or hoist
c°/s or
mm/s
DCC_Out.Slew_Hoist.V_mm_s
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 151
Function description
8
8.1
General
8.1.1
AddOn sway control function
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 153)). 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.
Operating principle of the sway control system
A non-periodic characteristic of the load deflection is obtained. The acceleration value is not
constant. It varies depending on the state of the mathematical oscillation model and the
measured pendulum deflection. The acceleration times equal approximately 1.1 times the
natural oscillation duration of the load oscillation. The travel operations place very low stress
levels on the crane structure.
Function description
8.1 General
SC integrated OHBC, Gantry crane
152 Operating Instructions, 02/2014
The following diagram shows the travel response in operation with sway control with a
pendulum length of approx. 3.5 m:
①
Set velocity
②
Output velocity
③
Deflection
Figure 8-1 Sway control in "manual" operation mode
Function description
8.1 General
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 153
8.1.2
Parameter sets
8.1.2.1
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 8-2 Editing parameter sets in the SIMOCRANE CeCOMM diagnostic program
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 each of the
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 having to change parameter settings.
This does not apply to parameters P80, P100, P101, P108, P110, P115, and P159 (see
Chapter Changing a parameter (Page 155)). Changes to the settings of these parameters
are always effective simultaneously in all four current parameter sets.
Function description
8.1 General
SC integrated OHBC, Gantry crane
154 Operating Instructions, 02/2014
In addition to allowing processing of current parameter sets the file manager in the
SIMOCRANE CeCOMM diagnostic program also enables users to access and edit the four
saved text files (parameter files).
These text files are located on the CF card of the SIMOTION D435-2 DP/PN in the directory
/SWAYCONTROL/.
8.1.2.2
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 207)). 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 lower 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 software in
order to edit the parameter sets as this is the only method which guarantees a
plausibility check on the file and ensures that input errors will be rejected.
If you directly edit the stored text files (e.g. Par0.txt) instead, they will not be checked
for plausibility 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 229) and the online help.
8.1.2.3
Activating a parameter set
A parameter set can be activated with the control bits "Par_Set_Bit0" and "Par_Set_Bit1"
(bits 0 and 1, general control bits). The relevant active parameter set is used by the control.
Function description
8.1 General
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 155
8.1.2.4
Editing a 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
the "Enter" key. 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 b
eing 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 par
ameter set is reselected.
8.1.2.5
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.
Note:
Changes to the following parameters are implemented in all 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 the "Enter" key. The new value is then entered and confirmed twice
with the "Enter" key.
Function description
8.1 General
SC integrated OHBC, Gantry crane
156 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 parameters must also be saved per
manently 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 s
hould be left with their
default settings and only changed where required.
8.1.2.6
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.
8.1.2.7
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" to "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
8.1 General
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 157
8.1.2.8
Saving all sets of parameters
"S" Save all sets of parameters
All current parameter sets are saved in parameter files "Par0.txt" to "Par3.txt" with this
function.
Note
Each parameter changed in the ac
tive 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.
8.1.2.9
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 assignments.
The parameter P101 "Parameter set locked during travel" can be used to prevent the
switching of parameter sets during travel.
8.1.2.10
Setting default values
"D" Set default values
The parameter settings of all current parameter sets are restored to their defaults with the
"D" key.
Function description
8.1 General
SC integrated OHBC, Gantry crane
158 Operating Instructions, 02/2014
8.1.2.11
More functions
"L" Show list of parameters
All parameters are listed.
It is possible to scroll through the entire list with "F2 Scroll".
"F3 Back to Monitor" restores the monitor display.
"F" Search parameters
A search term can be entered. All parameters that contain this search term will be listed.
Note
All
set values can best be documented with the functions "L Show list of parameters", "F2
Scroll", selection (e.g. with CTRL+A) and "F4 Save as ...".
"F3 Back to Monitor" restores the
monitor display.
8.1.3
Operation modes
8.1.3.1
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. The "manual"
and "positioning" operation modes 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 is meaningful in practice only in "manual"
operation mode. You can find more detailed information on this in Chapter Operation mode
"manual" without sway control (Page 162).
8.1.3.2
Operation mode "manual"
In this mode, either a single drive or a group of drives can be operated. Trolley, gantry and
slewing gear can be operated with sway control, but not the hoist.
8.1.3.3
Operation mode "positioning"
In this mode, either a single drive or a group of drives can be operated. Trolley, gantry and
slewing gear can be operated with sway control, but not the hoist.
Function description
8.1 General
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 159
8.1.3.4
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.
8.1.3.5
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.
8.1.4
Response in the limit switch
8.1.4.1
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.
8.1.4.2
Response in the "positioning" operation mode
The activation of a limit switch is independent of the direction. If a limit switch responds then
– irrespective of the direction of motion – the brake is decelerating with the quick stop ramp
(P12, P52, P142) without sway control. The limit switch range can be exited again only if the
"manual" operation mode is selected. The limit switches can also be enabled for specific
drives depending on the direction in "positioning" operation mode using parameter P97.
Function description
8.1 General
SC integrated OHBC, Gantry crane
160 Operating Instructions, 02/2014
8.1.5
Response in the prelimit switch
8.1.5.1
Response in the "manual" operation mode
Reducing the velocity along a linear ramp
When a prelimit switch is actuated in the "manual" operation mode, the drive is braked at the
deceleration rate set in parameter P14 (trolley), P54 (trolley) and P144 (slewing gear) down
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.
A linear ramp must always be used to decelerate a drive to this velocity. 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 provided exclusively for braking at the prelimit switches,
and are not limited by the maximum acceleration of the relevant 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.
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 corresp
onding control bits in the sway control system as this
would render the 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.
Function description
8.1 General
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 161
8.1.5.2
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. This is achieved 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 responds.
Function description
8.2 Operation mode "manual"
SC integrated OHBC, Gantry crane
162 Operating Instructions, 02/2014
8.2
Operation mode "manual"
8.2.1
Operation mode "manual" without sway control
In "manual" operation mode without sway control the set velocity V_Set is specified by
SIMOCRANE Basic Technology. Linear acceleration or braking is then applied to this
velocity. The load sway is ignored.
When operating the crane in "manual" operation mode without sway control, the following
points must be noted:
● 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 could then only be brought under
control 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 163)) 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
oscillation 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 oscillation model. The sway control must always be deactivated if the
measured distance to the camera 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 faulty position is used to calculate the effective pendulum length.
● If operations are performed with pendulum lengths < P83, then travel only takes place
with the mathematical oscillation model with sway control. This state can only be
maintained for a limited period, Travel can subsequently only take place without sway
control (see also Chapter Other settings (Page 196)).
Function description
8.2 Operation mode "manual"
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 163
8.2.2
Operation mode "manual" with sway control
In "manual" operation mode with sway control the set velocity V_Set is specified by
SIMOCRANE Basic Technology. The system accelerates or brakes to this velocity in such a
way that all load sway is eliminated by the time the acceleration or braking operation is
completed.
Activating the operation mode
"Manual" operation mode is activated by setting the relevant operation mode bit at the drives
(see the tables in Chapters Trolley control bits (Page 114), Gantry control bits (Page 118),
and Slewing gear control bits (Page 122)). 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 is 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
8.2 Operation mode "manual"
SC integrated OHBC, Gantry crane
164 Operating Instructions, 02/2014
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 ignored.
Internal activation of the sway control is indicated in 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 8-3 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
8.3 Operation mode "positioning"
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 165
8.3
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 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 brakes to a standstill 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.
8.4
Operation mode "sway neutralization load position"
The "sway neutralization load position" operation mode (only for the version with the
SIMOCRANE CenSOR camera measuring system) is used to eliminate load sway 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.
Function description
8.5 Operation mode "sway neutralization drive position"
SC integrated OHBC, Gantry crane
166 Operating Instructions, 02/2014
8.5
Operation mode "sway neutralization drive position"
The "sway neutralization drive position" operation mode (only for the version with the
SIMOCRANE CenSOR camera measuring system) is used to eliminate load sway from
standstill.
The "sway neutralization drive 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 actual position of the drive at the moment the "Travelling" control bit is set
when the operation mode is activated.
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_DR" is set to activate the "sway neutralization drive position" operation
mode.
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 167
Commissioning
9
9.1
Commissioning prerequisites
9.1.1
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.
9.1.2
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 the system has been fully commissioned, it is advisable to conduct test runs under load
in all operation modes used in practice.
9.1.3
Position sensing
The position sensing functions for the travel gear, generally implemented in the PLC, and the
corresponding limit monitoring must function (see Chapter Sensing and monitoring the
position actual values (Page 97)).
9.1.4
Sway control components
All components of the system must be installed, connected, functional and interconnected
Commissioning
9.2 Preparing commissioning
SC integrated OHBC, Gantry crane
168 Operating Instructions, 02/2014
9.2
Preparing commissioning
9.2.1
Preparation of the user project and the SIMATIC S7
9.2.1.1
Integrating the AddOn sway control system
Expand the user project by adding the AddOn sway control system.
The relevant instructions can be found in Chapter Adding the AddOn sway control system to
the user project (Page 45)).
9.2.1.2
Commissioning the SIMATIC S7 sample blocks
Commission the SIMATIC S7 sample blocks.
The relevant instructions can be found in Chapter Interface to the crane control system
(Page 89)).
9.2.2
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
9.3 Configuring the AddOn sway control system
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 169
9.3
Configuring the AddOn sway control system
9.3.1
Overview
The SIMOCRANE CeCOMM diagnostic program is used to assign parameters to the AddOn
sway control system.
The parameters are stored in parameter sets. Detailed information on using the parameter
sets can be found in Chapter Parameter sets (Page 153).
Note
Detailed information on the parameters is provided in Chapter
Parameter list (Page 229).
9.3.2
General preconditions
The following preconditions must be fulfilled before the AddOn 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 launched.
The commissioning PC and the SIMOTION D435-2 DP/PN must be connected (see
Chapter SIMOCRANE CeCOMM diagnostic program (Page 203))
3. All communication addresses must be set (see Chapter Setting addresses (Page 211)).
4. The communication link between the SIMATIC S7 and the AddOn sway control system
must have been tested (see Chapter Communication tests between SIMATIC S7 ↔
AddOn sway control system (Page 92))
5. The SIMOCRANE CenSOR camera measuring system must have been commissioned,
including a successful communication test between SIMOCRANE CenSOR and the
SIMOTION D435-2 DP/PN
Commissioning
9.3 Configuring the AddOn sway control system
SC integrated OHBC, Gantry crane
170 Operating Instructions, 02/2014
9.3.3
Setting the access code
The access code determines which parameters are displayed with the SIMOCRANE
CeCOMM diagnostic program with keys "1" to "8" in the 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
The relevant access code for each parameter is stated in the parameter list (see Chapter
Parameter list (Page 229)).
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" Cop
y parameter set, "D" Set default values, "F" Search
parameters, "S" Save all parameter sets, "R" Reload parameters.
9.3.4
Setting the language
Select a language in the SIMOCRANE CeCOMM diagnostic program via menu items
"Options / Language". German and English are available.
The appropriate language file is then automatically opened and read. The screen displays
are updated.
Commissioning
9.3 Configuring the AddOn sway control system
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 171
9.3.5
Checking the interface crane control system ↔ AddOn sway control system
Figure 9-1 Monitor function, display screen 2 "Interface"
Check the communication link between the crane control system and the AddOn sway
control system using 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 current input and output data of the AddOn 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 107)).
Note that incrementation of the send and receive counter readings (sent / received) in
display screen 2 is essential. This is a vital condition for all further steps because it indicates
that the AddOn sway control system is sending and receiving data telegrams.
Commissioning
9.3 Configuring the AddOn sway control system
SC integrated OHBC, Gantry crane
172 Operating Instructions, 02/2014
9.3.6
Checking the communication with the camera measuring system
You will need the measured values of the camera 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 168)).
Then check the communication link between the SIMOCRANE CenSOR camera measuring
system and the SIMOTION D435-2 DP/PN as described below:
1. Check that the IP address of the camera is correctly set in the SIMOTION D435-2 DP/PN
in commissioning step 7 (Change communication addresses).
Note
Incorrect setting of the communication address in the SIMOTION D435
-2 DP/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.
2. Note that incrementation of the receive counter reading is an essential requirement
because this indicates that the SIMOTION D435-2 DP/PN is correctly receiving data from
the camera.
3. Check the "Status" display:
"Status OK" indicates that the reflector has been detected.
4. Open display screen 4 in the SIMOCRANE CeCOMM diagnostic program.
Note
If the version with the SIMOCRANE CenSOR camera measuring system is used, then the
camera must be activated using configuration parameter P115 (default setting).
If the camera has been deactivated using configuration parameter P115, then the
subsequently
shown screen 4 is not displayed.
Commissioning
9.3 Configuring the AddOn sway control system
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 173
Figure 9-2 Monitor function, display screen 4 "Camera"
Commissioning
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
174 Operating Instructions, 02/2014
9.4
Operation mode "manual" without sway control
9.4.1
Preparation – first steps
For safety-related reasons, we recommend that the system is initially commissioned with the
sway control deactivated. To do this, 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 diagnostic program).
Check the signal sequence between the AddOn sway control system and the crane control
system as specified in Chapters Start of travel (Page 100) and End of travel (Page 101).
If the signal sequence is correct, continue with commissioning.
9.4.2
Commissioning steps in the commissioning menu
9.4.2.1
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 the display
screens.
3. Carry out the commissioning steps, making sure that you follow the specified sequence
exactly.
Start with step "0".
Commissioning
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 175
Figure 9-3 Overview of commissioning steps
The commissioning process must be started at the first step and continued step-by-step.
Note
The parameters ascertained during the commissioning steps are saved in all four 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 steps can be omitted depending on the confi
guration.
Commissioning
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
176 Operating Instructions, 02/2014
9.4.2.2
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 9- 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
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
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
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 177
Table 9- 2 Parameters called when hoist is selected (with P115)
No.
Parameter
Designation
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 9- 3 Parameters called when slewing gear is selected (with P115)
No.
Parameter
Designation
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
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
178 Operating Instructions, 02/2014
9.4.2.3
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, the slewing gear 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.
Figure 9-4 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.
Commissioning
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 179
A corresponding query is made at the start of the commissioning step:
Figure 9-5 Selecting the drive
Save the result of this assignment between camera axes and drives in parameter P80.
Commissioning
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
180 Operating Instructions, 02/2014
9.4.2.4
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.
The calculation is based on 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 the parameters, it is recommended that you are online with the
SIMOTION D435-2 DP/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 the
"Enter" key 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. Note that the oscillations are counted from zero and that the count starts at an
inflection point (at maximum deflection).
9.4.2.5
Step 3: Determine parameters of effective pendulum length in the gantry direction
A camera must be used for this commissioning step. Otherwise it must be performed
manually (by counting oscillations) using the SIMOCRANCE CeCOMM diagnostic program
(tab "Effective pendulum length").
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.
The calculation is based on two oscillation measurements at different heights.
Note
If the measurement for the gantry direction was not completed (P6
2=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
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 181
9.4.2.6
Step 4: Determine parameters of effective pendulum length for slewing gear
The SIMOCRANE CenSOR camera measuring system is required to complete this
commissioning step automatically.
Otherwise it must be performed manually (by counting oscillations) using the SIMOCRANCE
CeCOMM diagnostic program (tab "Effective pendulum length").
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 conditions, 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.
9.4.2.7
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 functions in the SIMATIC S7.
The relevant bits can be found in the error list (see Table 11-1 Error messages with error bit
(Page 215)).
Note
Simulated err
ors are not entered in the error history.
9.4.2.8
Step 6: Determining the velocity
The maximum output velocity can be checked with this step. It requires transmission of the
current actual distance values from the technology objects so that they can be converted into
millimeters in the AddOn sway control system if necessary.
The drives must be moved individually at maximum velocity in "manual" operation mode.
The maximum actual velocity produced at the maximum output velocity is determined from
the output velocity to the technology object and the change in the actual distance value over
time. The calculated velocity can be transferred into the parameters for the maximum output
velocity of the relevant 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
9.4 Operation mode "manual" without sway control
SC integrated OHBC, Gantry crane
182 Operating Instructions, 02/2014
9.4.2.9
Step 7: Change communication addresses
You can change the communication addresses in the screen illustrated below (see also
Chapter Setting addresses (Page 211)).
Figure 9-6 Setting communication addresses
9.4.2.10
Step S: Saving parameters
All parameter sets are saved.
Commissioning
9.5 Operation mode "manual" with sway control
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 183
9.5
Operation mode "manual" with sway control
9.5.1
Preparation
Once you have completed all the commissioning steps, proceed as follows to activate the
sway control system:
● Set the control bit "SC_On" 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.
9.5.2
Test runs without boosted camera 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 camera measuring signal. The advantage of this approach is that you
can record a signal trace in the SIMOCRANE CeCOMM diagnostic program and use it to
compare the pendulum deflection measured by the camera with the pendulum deflection
of the mathematical oscillation 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 oscillation 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
oscillation model. If this is not the case, calculation of the effective pendulum length or
the correctness of the communicated hoist height must be verified because the
mathematical model calculates the frequency as follows:
(T = period duration of the oscillation; l = effective pendulum length)
Commissioning
9.5 Operation mode "manual" with sway control
SC integrated OHBC, Gantry crane
184 Operating Instructions, 02/2014
● 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 oscillation 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 oscillation 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
9.5 Operation mode "manual" with sway control
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 185
9.5.3
Test runs with boosted camera 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 oscillation
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 is largely depends on the controlled system as a whole. Settings
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.
9.5.4
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 160).
Test the travel behavior in the prelimit switch range
● Start with a small setpoint.
● 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 diagnostic program).
● Test the function of the prelimit switches at all hoist heights occurring in normal operation.
Testing with long pendulum lengths is especially important.
Commissioning
9.6 Checking and fine-tuning the sway control system
SC integrated OHBC, Gantry crane
186 Operating Instructions, 02/2014
9.6
Checking and fine-tuning the sway control system
9.6.1
General
This chapter discusses all the settings required for the "manual" operation mode which have
not been made during the commissioning phase.
The parameters can be set manually in the Parameters menu of the SIMOCRANE CeCOMM
diagnostic program.
9.6.2
Correction of the effective pendulum length
9.6.2.1
Application
If the application involves the use of different load carrying devices and/or variable loads, the
center of gravity of the load and thus also the pendulum length can vary.
For this reason, digital and analog functions for correcting the effective pendulum length are
provided for the trolley and the 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 in screen 1 (kinematics).
9.6.2.2
Digital correction of the effective pendulum length for the trolley and the gantry
Precondition
● 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, it must be calculated. This is done by performing the relevant
commissioning steps (see Step 2: Determine parameters of effective pendulum length in
the trolley direction (Page 180) or Step 3: Determine parameters of effective pendulum
length in the gantry direction (Page 180)).
Commissioning
9.6 Checking and fine-tuning the sway control system
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 187
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.
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 as follows:
Formula 1:
Formula 2:
The relationship between "T" and "I" (formula 1) known from the field of physics can
be resolved according to "I" (formula 2) and the effective pendulum length can thus be
determined from the results of the oscillation measurement.
– 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 SIMOCRANE 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.
Commissioning
9.6 Checking and fine-tuning the sway control system
SC integrated OHBC, Gantry crane
188 Operating Instructions, 02/2014
9.6.2.3
Digital correction of the effective pendulum length for the slewing gear
Precondition
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) so that it can be detected by 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) and 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 about commissioning, Step 4: Determine parameters of effective pendulum
length for slewing gear (Page 181).
9.6.2.4
Analog correction of the effective pendulum length
Precondition
● 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.
This value is interpreted as the total load by the AddOn sway control. 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, it must be calculated. This is done by performing the relevant
commissioning steps (see Step 2: Determine parameters of effective pendulum length in
the trolley direction (Page 180) or Step 3: Determine parameters of effective pendulum
length in the gantry direction (Page 180)).
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
Commissioning
9.6 Checking and fine-tuning the sway control system
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 189
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 SIMOCRANE CeCOMM
diagnostic program.
Example
Total load:
60 t
Weight of load carrying device:
20 t
Effective pe
ndulum length
without load:
30 m
Effective pendulum length with
load:
32 m
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:
2,000 mm : 40,000 kg = 0.05 mm/kg
Commissioning
9.6 Checking and fine-tuning the sway control system
SC integrated OHBC, Gantry crane
190 Operating Instructions, 02/2014
9.6.2.5
Additional information
● If the crane control system
– does not have any information about the load weight,
– does not have any information about setting of bit "DigitalLiftCorrection",
– but, depending on the load and / or the load carrying device in use, is detecting
differences between pendulum lengths combined with a deterioration of the control
quality of the sway control system,
it will be necessary to find a compromise.
One option is to vary the offset parameter used to calculate the effective pendulum
length (P23, P63, P153).
● If the digital correction function and the analog correction function for the effective
pendulum length are both active, both correction values will be added to the original
effective pendulum length.
● In cases where the load is relatively constant (e.g. coils or slabs), it may be more
meaningful to use the analog correction instead of the digital correction. If you are using
the digital correction function, you must set the bit "DigitalLiftCorrection" in the crane
control system after the correction value for the effective pendulum length has been
calculated.
9.6.3
Setting the permissible residual sway
The parameters 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 not be set lower
than the minimum required value. Excessively low values extend the stopping time
("Pos_completed" and "SC_completed") and under certain circumstances can lead to sway
after stopping as a result of dead times.
Commissioning
9.6 Checking and fine-tuning the sway control system
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 191
9.6.4
Setting the velocity for zero speed detection
The parameters for the zero speed detection function can be separately set for each drive.
● Trolley: P19
● Gantry: P59
● Slewing gear: P149
● Hoist: P149
The parameters are a condition for setting the status bit "Pos_Completed" (see Chapter
Interface description (Page 107)).
Excessively high values cause the crane to stop quickly, but with a jerking motion.
Very low values allow the crane to stop very smoothly, but increase the time until it reaches
a standstill.
Settings values of between 1 % and 3 % have proven satisfactory in practice.
9.6.5
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 is only applicable
for the "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.
9.6.6
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 boosting to zero (depending on drive P21, P61, P151).
● Start the trace in the SIMOCRANE CeCOMM diagnostic program, record pendulum
deflections from the mathematical oscillation model and from the camera.
● Begin to move in "manual" operation mode with pendulum deflection close to zero.
● Set the ON delay time in such a way that the start of the pendulum deflections from the
mathematical oscillation model and from the camera correspond as closely as possible.
● Set the camera boosting back to the original value.
Commissioning
9.6 Checking and fine-tuning the sway control system
SC integrated OHBC, Gantry crane
192 Operating Instructions, 02/2014
Without camera:
● Start the trace in the SIMOCRANE CeCOMM diagnostic program, 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.
9.6.7
Defining the activation velocity of the sway control
Using parameters P20, P60 and P150, it is possible to define a minimum velocity as a % of
the maximum output velocity for each drive in order to activate the sway control system. 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 load to be precisely positioned over short distances,
without disturbing neutralizing motion by the sway control. Pendulum deflection is still slight
in the lowest travel stage. If the crane driver 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.
Commissioning
9.6 Checking and fine-tuning the sway control system
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 193
9.6.8
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:
When the set velocity and output velocity have opposite signs, the deceleration rate is
increased in accordance with the settings in parameters P18 (P48, 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 during fine positioning:
If the set and actual velocities equal less than 30 % of the maximum velocity, the
acceleration and braking ramps are reduced to the values from P94 and P95. This allows
the crane operator to finely position his crane. Sway motion is only excited to a low
degree.
● Ramp alignment:
The acceleration/deceleration rates for operation without sway control are adjusted so
that the acceleration and braking times are similar to those in operation with sway control.
9.6.9
Pendulum length from SIMATIC S7 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 oscillation model can only be used to
a limited extent, or not at all.
If the 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 mean
s that using the distance measured between the reflector and camera only
represents a compromise solution.
Commissioning
9.7 Commissioning positioning
SC integrated OHBC, Gantry crane
194 Operating Instructions, 02/2014
9.7
Commissioning positioning
9.7.1
Conversion of the actual position S_ACTUAL and the target position
S_TARGET
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 calculate these parameters:
The following values must be recorded at two different positions:
x1:
Position 1 in mm
x2:
Position 2 in mm
s1:
S_ACTUAL (actual position) at position 1
s2:
S_ACTUAL (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 "Factor" and "Offset" for the specific drive into the parameters stated above.
Note
Checking the actual position
The AddOn sway control system requires precise position values. It is not therefore sufficient
to determine the positions purely by calculation. The relevant location must be measured
directly during commissionin
g in order to verify that the displayed positions are correct.
Correct functioning of the position sensing and position monitoring systems must be verified
before the positioning operation mode can be commissioned.
We recommend the use of identical reference systems in the crane control and the sway
control systems. This ensures that the position values are the same in both systems and are
therefore easier to manage. The factor set is then 1 and the corresponding offset is 0 mm.
Commissioning
9.7 Commissioning positioning
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 195
9.7.2
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 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. Slight
differences result through the deactivated position controller.
Higher deviations might be caused by a maximum output velocity error or limits in the
drive system.
For delimiting the error, the sway control system can be deactivated by resetting
control bit "SC_On" or by zeroing the damping factors P16, P56, P146 (operation
without sway control only).
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, be
fore
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
9.7 Commissioning positioning
SC integrated OHBC, Gantry crane
196 Operating Instructions, 02/2014
9.7.3
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 between 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.
Influences on the sway from other disturbance variables are not determined and therefore
also cannot be corrected. 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 shut down in the case of small
pendulum lengths, i.e. if the distan
ce between the camera and the reflector is very small, as
for various reasons the sway angle measured may no longer be detected correctly in some
cases (e.g. if the reflector fills the camera's entire field of vision).
Commissioning
9.8 Testing the sway neutralization modes
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 197
9.8
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."
Precondition
● The SIMOCRANE CenSOR camera measuring system must be used
● The actual position (S_ACTUAL) 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 165) and Operation mode "sway neutralization
drive position" (Page 166).
Testing the "sway neutralization load position" operation mode
1. Cause the load to sway. Start the first tests with very small amounts of sway.
2. Set the control bit "OM_SC_LO" (see Interface description (Page 107)) in order to select
the "sway neutralization load position" operation mode.
3. Start the travel motion by setting the control bit "Travelling".
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_ACTUAL + pendulum deflection.
Note
If the sway motion is not properly corrected, then you must check the previous
commissioning steps to identify the error.
Note
We recommend that you use the SIMOCRANE CeCOMM diagnostic program to record
signal traces so
that you can assess the test results more accurately.
4. When the status bit "Pos_completed" is set, then 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
9.8 Testing the sway neutralization modes
SC integrated OHBC, Gantry crane
198 Operating Instructions, 02/2014
Testing the "sway neutralization drive position" operation mode
1. Cause the load to sway. Start the first tests with very small amounts of sway.
2. Set the control bit "OM_SC_DR" (see Operation mode "sway neutralization load position"
(Page 165)) in order to select the "sway neutralization drive position" operation mode.
3. Start the travel motion by setting the control bit "Travelling".
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_ACTUAL" 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 identify the error.
Note
We recommend that you use the SIMOCRANE CeCOMM diagnostic program to record
signal traces so t
hat you can assess the test results more accurately.
4. When the status bit "Pos_completed" is set, then 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
9.8 Testing the sway neutralization modes
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 199
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
9.9 Stability test and monitoring functions
SC integrated OHBC, Gantry crane
200 Operating Instructions, 02/2014
9.9
Stability test and monitoring functions
9.9.1
Stability test
With maximum, medium and minimum pendulum lengths, set the load into a heavy sway
motion in "manual" operation mode without sway control, 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 201)) 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
9.9 Stability test and monitoring functions
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 201
9.9.2
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
9.9 Stability test and monitoring functions
SC integrated OHBC, Gantry crane
202 Operating Instructions, 02/2014
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 203
SIMOCRANE CeCOMM diagnostic program
10
10.1
General
The SIMOCRANE CeCOMM diagnostic program can be utilized for the following purposes:
● Editing parameter sets (see Chapter Parameter sets (Page 153))
● Functions for monitoring crucial data
● File manager function, for example, to exchange parameter files
● Diagram function for tracing curves
● Integrated Primary Setup Tool for determining the communication addresses of
connected nodes
● Assistance with commissioning
● Readout of error messages (current messages and error messages stored in the error
history)
● Tool for calculating the effective pendulum length (in systems without a camera)
● Additional functions such as version information, calculation of position and velocity
parameters, web browser
German or English can be selected as the user interface language for the diagnostic
program.
A general description of the key functions of the SIMOCRANE CeCOMM diagnostic program
is given below.
SIMOCRANE CeCOMM diagnostic program
10.2 Installing
SC integrated OHBC, Gantry crane
204 Operating Instructions, 02/2014
10.2
Installing
The SIMOCRANE CeCOMM ("Setup_CeCOMM.exe") diagnostic program which provides
commissioning assistance is available on the DVD. The program must be installed on the
commissioning PC (Windows). The software is installed by running "Setup_CeCOMM.exe".
An IP address which matches the SIMOTION D435-2 DP/PN address must be set on the
commissioning PC. The default settings are:
IP address:
192.168.1.X
(X = freely selectable)
Subnet mask:
255.255.255.0
Figure 10-1 Setting a fixed IP address
Note
The program can run under the "WINDOWS 200
0", "WINDOWS XP" or "WINDOWS 7"
operating system. This requires that the user is logged on to the PC as administrator.
Note
This requires that the user is logged on to the PC as administrator.
Any personal firewalls (e.g. Windows Firewall for Microsof
t XP) should be deactivated or
specific exceptions permitted.
SIMOCRANE CeCOMM diagnostic program
10.3 Searching the network for SIMOTION D435-2 DP/PN
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 205
10.3
Searching the network for SIMOTION D435-2 DP/PN
Figure 10-2 Calling the primary setup tool from the SIMOCRANE CeCOMM diagnostic program
When the SIMOCRANE CeCOMM diagnostic program 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 D435-2 DP/PN and the
SIMOCRANE CenSOR camera measuring system can be scanned in this way.
The IP address can only be changed temporarily using the PST. The old address is effective
again after SIMOTION D435-2 DP/PN is restarted. To permanently change the IP address,
this must be set using the SIMOCRANE CeCOMM diagnostic program (commissioning
menu, step 7, or "I" in the parameter menu)
Note
The IP address of the commissioning PC must be set so that it matches the SIMOTION
D435
-2 DP/PN address, with the same subnet.
SIMOCRANE CeCOMM diagnostic program
10.4 Establishing the connection
SC integrated OHBC, Gantry crane
206 Operating Instructions, 02/2014
10.4
Establishing the connection
The symbols for establishing a communication link are arranged below the menu bar:
After the program has started, one of these icons must be used to establish the connection
to the SIMOTION D435-2 DP/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
10.5 Monitoring functions
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 207
10.5
Monitoring functions
10.5.1
Display and operating information
After the connection has been established, all the available keyboard commands are
displayed when the space bar is pressed.
The basic monitor functions can be divided into three groups:
● Screens,
● Parameterization menus,
● Additional functions.
Figure 10-3 Monitor functions
SIMOCRANE CeCOMM diagnostic program
10.5 Monitoring functions
SC integrated OHBC, Gantry crane
208 Operating Instructions, 02/2014
The display for the prelimit switch command in display screen [3] "Status of drives" has the
following meaning (selection):
Table 10- 1 Explanation of the "Prelimit switch" command in 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 10- 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 209)
"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.
It is also possible to answer the prompt from the SIMOCRANE CeCOMM diagnostic
program "Y/N" with "Y" instead of the "Enter" key. Both procedures are of equal value.
SIMOCRANE CeCOMM diagnostic program
10.5 Monitoring functions
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 209
3. Enter the new value.
4. Confirm twice using the "Enter" key.
10.5.2
The parameter menu
Figure 10-4 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 270), 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
10.5 Monitoring functions
SC integrated OHBC, Gantry crane
210 Operating Instructions, 02/2014
Table 10- 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 a parameter set
"L"
Display a parameter list
"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
10.6 Setting addresses
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 211
10.6
Setting addresses
10.6.1
General
Each device must have its own IP address for communication in the Ethernet network.
Note
The IP address of the SIMOTION D435
-2 DP/PN must not be used for another device within
the network
.
10.6.2
Default settings
IP address SIMOTION D435-2 DP/PN:
192.168.1.158
Subnet mask SIMOTION D435-2 DP/PN:
255.255.255.0
PROFIBUS DP address:
45
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 D435-2 DP/PN for
communication with the camera.
The following IP addresses saved in the project are then used:
IP address SIMOTION D435-2 DP/PN:
192.168.0.2
Subnet mask SIMOTION D435-2 DP/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
10.6 Setting addresses
SC integrated OHBC, Gantry crane
212 Operating Instructions, 02/2014
10.6.3
Setting addresses
You can set the Ethernet address of the camera in the parameter menu of 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 the SIMOCRANE CeCOMM diagnostic program.
Addresses can also be set via the commissioning menu by pressing the "I" key and calling
the function "7 - Change communication addresses".
Figure 10-5 Setting communication addresses
Note:
● IP address of camera
Precondition: P115 Without Camera = OFF
Note
The
address information is saved in the text file "IP_Addresses.txt" in the "SwayControl"
directory on the CF card and is loaded when the SIMOTION D435
-2 DP/P is booted.
(Exception: The PROFIBUS transmission rate is not stored.)
SIMOCRANE CeCOMM diagnostic program
10.6 Setting addresses
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 213
10.6.4
Searching for the changed IP address
If you have changed the IP address of the SIMOTION D435-2 DP/PN and have forgotten its
new address, you can search for it using the Primary Setup Tool (see Searching the network
for SIMOTION D435-2 DP/PN (Page 205)).
SIMOCRANE CeCOMM diagnostic program
10.6 Setting addresses
SC integrated OHBC, Gantry crane
214 Operating Instructions, 02/2014
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 215
Alarm, error, and system messages
11
11.1
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
"ERROR_BITS" (see Chapter Output data, general (Page 130)).
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 11- 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
E12
12
Reserved
E13
13
Sway control temporarily reduced, trolley
E14
14
Sway control temporarily reduced, gantry
E15
15
Sway control temporarily reduced, slewing gear
Alarm, error, and system messages
11.1 General
SC integrated OHBC, Gantry crane
216 Operating Instructions, 02/2014
Table 11- 2 Warnings
Warnings
Meaning
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
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
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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 217
11.2
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
Reaction on switchover between parameter sets
When error message E0 is issued,
the consequences are as follows:
•
If the cause of the problem is not in the active parameter set, the error message will have
no effect and the drive continues to operate normally.
•
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 operation mode bit per drive.
Alarm, error, and system messages
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
218 Operating Instructions, 02/2014
E2 Fieldbus error
The telegram counter for the receiving telegram is not receiving any data.
Display:
● In the SIMOCRANE CeCOMM diagnostic program: Value "received" in display screen 2
(PROFIBUS interface)
● In the PLC: Value "trailer" (telegram counter) in send block SC_DB_SEND_BT)
Error bit:
2
Error type:
Error
Remedy:
Investigate the causes listed below.
Possible causes:
● No sample blocks available in the SIMATIC S7
● Connection with the crane control system faulty (e.g. cable disconnected)
● Incorrect PROFIBUS address
● Faulty hardware configuration, configured addressing ranges do not correspond with
those in the FC SC_MAIN_BT
● 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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 219
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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
220 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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 221
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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
222 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
Remed
y:
Stop the oscillation manually and check cause of the problem in Chapter
Stability test and monitoring functions (Page 200).
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 200).
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 200).
E16 Parameter file not found
A parameter file cannot be opened when the SIMOTION D435-2 DP/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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 223
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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
224 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 restart the SIMOTION D435-2 DP/PN (stop/run).
E22 Language file not loaded
It was not possible to load the current language file.
Language file not on the CF card 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 CF card.
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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 225
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.
Error bit:
-
Error type:
Alarm
Remedy:
Reset the control bit.
Alarm, error, and system messages
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
226 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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 227
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
11.2 List of alarm, error, and system messages
SC integrated OHBC, Gantry crane
228 Operating Instructions, 02/2014
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 229
Parameter list
12
12.1
Overview
Table 12- 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 SIMOCRANE 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 CF card and
are loaded after a restart.
Parameter list
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
230 Operating Instructions, 02/2014
12.2
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
This value corresponds to the maximum attainable 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 set acceleration is a guide value 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 mathematical 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
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 231
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_ACTUAL + P6
Target position = P5 · S_TARGET + 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_ACTUAL + P6
Target position = P5 · S_TARGET + P6
Default: 0 [mm]
Min: -100,000 [mm]
Max: 100,000 [mm]
Access code: 2
Parameter list
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
232 Operating Instructions, 02/2014
P7 Minimum position for trolley positioning
Target p
osition
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
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 233
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 107)). 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 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 manual operation mode.
P11 Not used
Parameter list
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
234 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 operative 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
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 235
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 manual operation mode.
Parameter list
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
236 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 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 with small velocity setpoints without sway control
Default: 0 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 2
Note
Only relevant for manual operation mode.
P21 Boosting of camera measuring signal in trolley dir.
Value to boost the measured deflection to the mathematical oscillation model.
The camera measuring system has no effect for zero.
Default: 0.1
Min: 0
Max: 1
Access code: 3
Parameter list
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 237
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
current 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 effective 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 current 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
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
238 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. To take this delay into account when activating the mathematical 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 oscillation 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 mathematical
oscillation model.
Default: 1
Min: 0
Max: 10000
Access code: 2
Parameter list
12.2 Trolley parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 239
P31 Not used
P32 Target position offset trolley
Offset of the current position: S_ACTUAL:=S_ACTUAL+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 releva
nt 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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
240 Operating Instructions, 02/2014
P35 Normalization value, trolley
● The following applies when control bit "V_SET_MM_S" = 1 (default):
This parameter is not used and is not displayed in the parameter menu of the
SIMOCRANE CeCOMM diagnostic program.
● The following applies when control bit "V_SET_MM_S" = 0:
This value denormalizes the set velocity V_set and the current velocity V_ACTUAL and
normalizes the output velocity V_norm specified by the sway control.
Default: 16384
Min: 100
Max: 32767
Access code: 2
12.3
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
This value corresponds to the maximum attainable velocity.
Default: 1,000 [mm/s]
Min: 10 [mm/s]
Max: 4,000 [mm/s]
Access code: 2
Parameter list
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 241
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 set acceleration is a guide value 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 mathematical 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_ACTUAL + P46
Target position = P45 · S_TARGET + P46
Default: 1
Min: -100
Max: 100
Access code: 2
Parameter list
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
242 Operating Instructions, 02/2014
P46 Position conversion offset, gantry
Offset for the actual and target positions of the gantry.
Actual position = P45 · S_ACTUAL + P46
Target position = P45 · S_TARGET + 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 bit
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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 243
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 107)). 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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
244 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 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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 245
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 operative 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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
246 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 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 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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 247
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 with small velocity setpoints without sway control
Default: 0 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 2
Note
Only relevant for manual operation mode.
P61 Boosting of camera measuring signal in gantry dir.
Value to boost the measured deflection to the mathematical 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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
248 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
current 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 current 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. To take this delay into account when activating the mathematical 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 oscillation 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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 249
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 mathematical
oscillation model.
Default: 1
Min: 0
Max: 10000
Access code: 2
P72 Target position offset, gantry
Offset of the current position: S_ACTUAL:=S_ACTUAL+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
12.3 Gantry parameters
SC integrated OHBC, Gantry crane
250 Operating Instructions, 02/2014
P73 Permitted residual sway when stopping, gantry
Maximum permissible pendulum deflection
If the pendulum velocity 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
● The following applies when control bit "V_SET_MM_S" = 1 (default):
This parameter is not used and is not displayed in the parameter menu of the
SIMOCRANE CeCOMM diagnostic program.
● The following applies when control bit "V_SET_MM_S" = 0:
This value denormalizes the set velocity V_set and the current velocity V_ACTUAL and
normalizes the output velocity V_norm specified by the sway control.
Default: 16384
Min: 100
Max: 32767
Access code: 2
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 251
12.4
Parameters for third drive
12.4.1
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: 4,000 [c°/s]
Access code: 1
Note
Only relevant for the positioning operation mode.
P131 Maximum output velocity, slewing gear
This value corresponds to the maximum attainable velocity.
Default: 500 [c°/s]
Min: 10 [c°/s]
Max: 4,000 [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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
252 Operating Instructions, 02/2014
P133 Setpoint acceleration, slewing gear
The set acceleration is a guide value for accelerating and decelerating with sway control
activated in all operation modes. The acceleration value is not constant. It varies depending
on the state of the mathematical 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_ACTUAL + P136
Target position = P135 · S_TARGET + 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_ACTUAL + P136
Target position = P135 · S_TARGET + P136
Default: 0 [c°]
Min: -100,000 [c°]
Max: 100,000 [c°]
Access code: 2
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 253
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 posit
ion
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: 36,000 [c°]
Min: -200,000 [c°]
Max: 200,000 [c°]
Access code: 1
Note
Only relevant for the positioning operation mode.
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
254 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 107)). 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 positionin
g 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 re
levant for manual operation mode.
P141 Not used
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 255
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
Deceleration of slewing gear when the prelimit switch responds.
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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
256 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 manual operation mode
.
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 257
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 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 with small velocity setpoints without sway control
Default: 0 [%]
Min: 0 [%]
Max: 100 [%]
Access code: 2
Note
Onl
y relevant for manual operation mode.
P151 Boosting of camera signal in slewing gear dir.
Value to boost the measured deflection to the mathematical oscillation model.
The camera measuring system has no effect for zero.
Default: 0.05
Min: 0
Max: 1
Access code: 3
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
258 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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 259
P156 Time constant current rise, slewing gear
The current rise and therefore the change in acceleration over time are often limited by the
converter. To take this delay into account when activating the mathematical 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 oscillation 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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
260 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).
I
f the parameter 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 mathematical
oscillation model.
Default: 1
Min: 0
Max: 10000
Access code: 2
P161 Target position offset, slewing gear
Offset of the current position: S_ACTUAL:=S_ACTUAL+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 mode.
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 261
P162 Not used
P163 Permitted residual sway when stopping, slewing gear
Maximum permissible rotation
If the pendulum velocity 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
● The following applies when control bit "V_SET_MM_S" = 1 (default):
This parameter is not used and is not displayed in the parameter menu of the
SIMOCRANE CeCOMM diagnostic program.
● The following applies when control bit "V_SET_MM_S" = 0:
This value denormalizes the set velocity V_set and the current velocity V_ACTUAL and
normalizes the output velocity V_norm specified by the sway control.
Default: 16384
Min: 100
Max: 32767
Access code: 2
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
262 Operating Instructions, 02/2014
12.4.2
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
This value corresponds to the maximum attainable 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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 263
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_ACTUAL + P136
Target position = P135 · S_TARGET + 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_ACTUAL + P136
Target position = P135 · S_TARGET + P136
Default: 0 [mm]
Min: -100,000 [mm]
Max: 100,000 [mm]
Access code: 2
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
264 Operating Instructions, 02/2014
P137 Minimum position for hoist positioning
Targ
et 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 E03 (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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 265
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 107)). 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 positioning operation mod
e.
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 manual operation mode.
P141 Not used
Parameter list
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
266 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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 267
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 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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
268 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_ACTUAL:=S_ACTUAL+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
12.4 Parameters for third drive
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 269
P162 Not used
P163 Not used
P164 Not used
P165 Normalization value hoist
● The following applies when control bit "V_SET_MM_S" = 1 (default):
This parameter is not used and is not displayed in the parameter menu of the
SIMOCRANE CeCOMM diagnostic program.
● The following applies when control bit "V_SET_MM_S" = 0:
This value denormalizes the set velocity V_set and the current velocity V_ACTUAL and
normalizes the output velocity V_norm specified by the sway control.
Default: 16384
Min: 100
Max: 32767
Access code: 2
Parameter list
12.5 General parameters
SC integrated OHBC, Gantry crane
270 Operating Instructions, 02/2014
12.5
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 178)).
•
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
12.5 General parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 271
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 weig
ht "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 the SIMOCRANE CeCOMM
diagnostic prog
ram 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 does not depend on the direction. The sway control is
dea
ctivated if the value for "S_Hoist" or "Distance" is outside the limits of P84 and P85.
Parameter list
12.5 General parameters
SC integrated OHBC, Gantry crane
272 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 and P85 does not depend on the direction. The sway contr
ol 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
12.5 General parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 273
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 reflector," the sway angle for the gantry
and trolley wil
l 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 reflector, but not the camera," a zero position of
-
S_A
CTUAL (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 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
12.5 General parameters
SC integrated OHBC, Gantry crane
274 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 releva
nt for the manual 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 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
12.5 General parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 275
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
12.5 General parameters
SC integrated OHBC, Gantry crane
276 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 i
s 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 dista
nce 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
12.5 General parameters
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 277
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
Note
Settings 1 and 2 are required if either a slewing gear is activated or no third drive is used.
Settings 3 and 4 are required for a configuration with a hoist.
P111 Not used
P112 Not used
P113 Not used
P114 Not used
Parameter list
12.5 General parameters
SC integrated OHBC, Gantry crane
278 Operating Instructions, 02/2014
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
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
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 279
Notes on servicing and maintenance
13
13.1
General information
This chapter provides only selected notes on servicing and maintenance. Please refer to the
following operating instructions for comprehensive information:
● SIMOTION D435-2 DP/PN,
● SIMOCRANE CenSOR.
13.2
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.
13.3
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 measuring system.
13.4
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
13.4 Check of the position sensing functions for the hoist after rope changing
SC integrated OHBC, Gantry crane
280 Operating Instructions, 02/2014
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 281
Appendix
A
A.1
Diagrams showing SIMOTION D435-2 DP/PN connections
The diagrams below provide a general overview of the connections on the SIMOTION D435-
2 DP/PN (with and without the CBE30-2 module)
Appendix
A.1 Diagrams showing SIMOTION D435-2 DP/PN connections
SC integrated OHBC, Gantry crane
282 Operating Instructions, 02/2014
Figure A-1 SIMOTION D435-2 DP/PN without communication module CBE30-2
Appendix
A.1 Diagrams showing SIMOTION D435-2 DP/PN connections
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 283
Figure A-2 SIMOTION D435-2 DP/PN with communication module CBE30-2
Appendix
A.2 Interconnection of DCC blocks in DCC SwayControl (when BT is used)
SC integrated OHBC, Gantry crane
284 Operating Instructions, 02/2014
A.2
Interconnection of DCC blocks in DCC SwayControl (when BT is
used)
Appendix
A.2 Interconnection of DCC blocks in DCC SwayControl (when BT is used)
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 285
Appendix
A.2 Interconnection of DCC blocks in DCC SwayControl (when BT is used)
SC integrated OHBC, Gantry crane
286 Operating Instructions, 02/2014
Appendix
A.3 List of abbreviations
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 287
A.3
List of abbreviations
The following abbreviations are used in this document:
Abbreviation
Meaning
BT
Basic Technology
c°
Centigrade
CFC
Control Flow Chart
CF card
CompactFlash card
CPU
Central Processing Unit
LS
Limit Switch
DB
Data Block
DCC
Drive Control Chart
DP/PN
Distributed I/Os / PROFINET
FAQ
Frequently Asked Questions
FB
Function Block
FC
Function
I/O
Input/Output
IP
Internet Protocol
IT
Information Technology
OB
Organization Block
OHBC Overhead Bridge Crane
OM
Operation Mode
MCC Chart Motion Control Chart
MCC source file
Motion Control source file
MPI
Multi-Point Interface
PD
Pendulum
PLC
Programmable Logic Control
PCS
Pre-Limit Switch
RMG
Rail-Mounted Gantry Crane
PS1 (2, 3, 4)
Parameter Set 1 (2, 3, 4)
RTG
Rubber-Tired Gantry Crane
SC
Sway Control
PLC
Programmable logic controller
ST
Structured Text
TO
Technology Object
TP
Technology Package
UDP
User Datagram Protocol
Appendix
A.4 References
SC integrated OHBC, Gantry crane
288 Operating Instructions, 02/2014
A.4
References
1.
SIMOCRANE Basic Technology V3.0; Operating Instructions, 06/2012 Edition
2.
SIMOCRANE CenSOR Camera Measuring System; Operating Instructions, 08/2012
Edition
3.
SIMOTION D4x5-2; Manual, 02/2012 Edition
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 289
Glossary
AddOn
An
AddOn
is an optional module which can be installed in order to expand the existing
hardware or software. The existing libraries of the relevant application are used for this
purpose and also expanded by new functions. To use a simple analogy, an AddOn is
installed "backpack style" on top of the main application and can be uninstalled at any time
without impairing the proper functioning of the main application.
AddOn sway control system
The product name of the AddOn sway control system is SIMOCRANE SC integrated OHBC,
Gantry crane. It refers to the entirety of all the software components that are needed to
operate the sway control system.
The main application for this AddOn is the product SIMOCRANE Basic Technology (user
project).
Crane control system (PLC)
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. The crane control system
does not include the SIMOTION D with SIMOCRANE Basic Technology.
Data is exchanged between the AddOn sway control system and the crane control system
via PROFIBUS, but can also be exchanged via PROFINET.
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.
Glossary
SC integrated OHBC, Gantry crane
290 Operating Instructions, 02/2014
FB library
An FB library consists of individual ST source files.
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.
MCC charts
MCC charts are flow charts which represent the logical execution sequence in visual form.
They must be integrated into the execution levels of the execution system. They are stored
under the MCC source file in the project navigator.
The individual elements of these flow charts are called "modules".
MCC source files
MCC source files contain a collection of MCC charts. MCC source files are stored in the
SIMOTION SCOUT project navigator under the SIMOTION device in the "Programs" folder.
Modules
Modules are used to structure MCC charts. Modules comprise a number of interrelated
commands that are joined to make one single command.
One module command can contain all types of command (e.g. system functions, program
branches, subroutine calls, variable assignments, etc.)
You can also nest modules and copy them for multiple use in different charts.
OHBC
OHBC is an overhead bridge crane.
RMG
RMG is a rail-mounted gantry crane.
RTG
RTG is a rubber-tired gantry crane.
Glossary
SC integrated OHBC, Gantry crane
Operating Instructions, 02/2014 291
Sample project
SIMOTION SCOUT project which is supplied as standard with the AddOn sway control
system. This sample project includes all the required AddOn sway control system
components. These components can be copied into the user project.
SIMOCRANE CeCOMM
Diagnostic program for the AddOn 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,
● the distance between the camera and reflector.
SIMOTION SCOUT
The SCOUT engineering system is a holistic environment for SIMOTION automation
applications and is integrated into the SIMATIC environment in accordance with TIA. SCOUT
is the common frame for all tools of the engineering system. This workbench is thus the
navigation center for the individual engineering steps. It is used to create and manage
SIMOTION projects and provides a uniform view of all data and programs. It also provides
access to all commissioning and test functions.
ST source files
An ST source file is a collection of several functions or function blocks that are executed in
the Structured Text programming language.
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".
Glossary
SC integrated OHBC, Gantry crane
292 Operating Instructions, 02/2014
User project
Fully functional SIMOTION SCOUT project with integrated SIMOCRANE Basic Technology,
version V3.0 or higher, for which a suitable standard application has been used. This project
provides the basis for expansion with the AddOn sway control system.
