SmartCrane Anti-Sway. Crane Control. Initialization Manual

Transcription

1 SmartCrane Anti-Sway Crane Control Initialization Manual

2 2009, 2010 SmartCrane, LLC All rights reserved The owner, authorized user, or dealer of a SmartCrane software or hardware product may reproduce this document for the purposes of installing, using, or maintaining the software or hardware. No other reproduction or commercial uses are permitted. We have made every effort to ensure this document is up to date and accurate. However, there are numerous SmartCrane products in production that have not been updated to the latest version. In those cases, previous manual versions will still apply. SmartCrane, LLC is not responsible for printing or clerical errors. We encourage customers and users to provide comments and corrections to SmartCrane, LLC for the purpose of improving the accuracy and usefulness of this and related documents. The SmartCrane logo and the name SmartCrane are trademarks of SmartCrane, LLC.

3 About This Manual This manual describes the details of the SmartCrane Initialization File. This file allows the same basic software product to be installed for different crane classes, crane types, lifting mechanisms, and crane response characteristics. In This Manual This Initialization manual includes instructions for editing and maintaining the initialization file require for operation of the SmartCrane anti-sway control program. The file consists of data lines identified by key words, blank lines, and comment lines. Some entries are mandatory and others define optional features. The data table gives complete information on each type of input line in the file. SmartCrane Anti-sway is computer-controlled operation of the trolley speed, gantry speed, and hoist speed for the purpose of decreasing the time required to move a suspended load between destinations and improving the safety of operations. The SmartCrane software runs on a computer that shares or can exchange data with the customerʼs crane drive in real time and responds, through the drive or directly, to operatorʼs commands. The patented SmartCrane Anti-sway Control uses an open-loop algorithm that eliminates load sway induced by trolley accelerations and decelerations. It operates in three modes: Manual Anti-sway, Automatic Move, and Suspend. In Manual mode, the control responds to the operator's trolley stick demands and completely inhibits sway no matter what demands the operator gives.

4 Other SmartCrane documents may be useful to operators, installers, PLC programmers, and maintenance personnel. These documents are in pdf format and are available for download free of charge from PLC Interface Specifications This manual describes detailed data interfaces required to allow the anti-sway software to work with a craneʼs PLC to control sway during both manual and automatic moves. Two configurations are addressed, where the primary operator interface is provided either by the PLC or by the SmartCrane touch screen. Operator Quick Guide This two-page document contains short descriptions of operator use of the SmartCrane touch panel, using mostly pictures rather than words. Installation and Maintenance Manual This document describes the steps to install a SmartCrane system under various installation options. It also provides critical data for maintenance personnel to diagnose and correct problems, and how a customer can set up remote access to equipment and receive SmartCrane support. Operator Guide This document provides description and operator instructions the SmartCrane Anti-sway Control for overhead traveling cranes, rail mounted gantry cranes, and other cranes whose lift point height remains constant.

5 About the Initialization File SmartCraneInitx.txt (where x is a number containing one or more digits) is a text file residing in /Library/Application Support/SmartCrane/. This file contains all the important configuration values for the customer site and the crane(s) to be controlled. Data sections begin with special keywords in capital letters and understrokes, followed by data elements separated by spaces. Data elements may follow in succeeding new lines if desired. Follow these important rules when editing this file: The file may contain blank lines between entries The file may also may contain comment lines beginning with # Comment lines must have at least one space after the # mark Data elements defined as INT must have whole numbers Data elements defined as REAL must have a decimal point and at least one digit after the decimal Data elements defined as unquoted text must not contain spaces or non-alphanumeric characters other than _ (underscore) or - (hyphen) Data for a single entry may be continued on multiple new lines, but with no intervening blank lines or comments.

6 SmartCrane Initialization File Table of Values KEY WORD Example Data BEGIN INT This line signifies the beginning of the problem. The number following defines a date in seconds, which for most applications except simulation need not be changed. Do not delete this value. LICENSEE "For use only on XYZ Customer Crane 12" This keyword must be present and must be followed by license restrictions enclosed by quotation marks. The manufacturer supplies this license restriction, which may not be changed in any way and the user agrees to the restriction. Also, the license key in the license.txt file is keyed to the text and the application program will not start if the two do not match exactly. Again, do not make any changes in this text field. DEFINE_YARD Number of columns Number of rows This section defines the area managed by all the cranes in the system. The area is divided into rows (perpendicular to crane rails) and columns (stacks, parallel to crane rails) of fixed size blocks. Blocks are numbered and measured from the origin as displayed in the Plan View, with columns counted from right to left and rows counted from top to bottom. The values are as follows: INT (columns are measured in the crane direction) INT (rows are measured in the trolley direction) Row Spacing

7 Column spacing DEFINE_YARD (Continued) Column Origin location, usually 0.0 Row Origin location Yard Orientation, REAL In compass degrees, usually 0.0 NEW_CRANE_ TYPE Maximum stack height Pier above sea level Rail row boundaries (ten pairs) SLAB INT For applications where objects may be stacked for marine container applications only INT For applications controlling multiple cranes on different sets of rails. These values must be smaller than number of rows, above. Ten pairs of INT must be entered in all cases. The Crane type entry supplies basic information about each crane type in the system.

8 NEW_CRANE_ TYPE (Continued) Type ID Crane Class Maximum trolley speed Maximum crane (gantry) speed Maximum trolley acceleration Maximum crane (gantry) acceleration Maximum hoist acceleration Minimum hoist rate Maximum hoist rate Minimum hoist height INT Any number greater than zero. If there are multiple crane types every ID must be unique. INT These classes are defined as follows, 0 rail mounted gantry crane with extended boom; 1 small transfer crane with trolley motion only and no extended booom; 2 Large container (quay) crane; 3 electric overhead cranes having motion in two dimensions, with either elevated or floor level beams or rails and without extended trolley booms. REAL (meters/minute) REAL (meters/minute) REAL (meters/minute 2 ) REAL (meters/minute 2 ) REAL (meters/minute 2 ) REAL (meters/minute) REAL (meters/minute)

9 Twistlock activation delay Gantry Response Lag Trolley Response Lag Minimum Crane Speed Fraction Minimum Trolley Speed Fraction Kill Sway Mode Gantry Kill Sway Mode Trolley Kill Sway Phase Gantry Kill Sway Phase Trolley Kill Sway Gain Gantry Kill Sway Gain Trolley REAL Seconds(maritime container spreaders only) REAL Seconds REAL Seconds REAL fraction > 0.0 REAL fraction > Suspended 1 Full time 2 Stopped only 3 One time 4 Moving only 5 Beginning of move 6 End of move (recommended mode) Same as Gantry code REAL Seconds, for sway kill tuning REAL Seconds, for sway kill tuning REAL fraction near 1.0, for sway kill tuning REAL fraction near 1.0, for sway kill tuning

10 Max Final Sway Gantry Max Final Sway Trolley Early Stop Gantry Early Stop Trolley Name REAL Meters REAL Meters REAL Meters REAL Meters Any text string not separated by spaces or commas COORDINATE_ TRANSFORM This entry defines how the SmartCrane program will transform PLC measurements to SmartCrane internal measurements. XY values in this file are in SmartCrane internal coordinate system, which is positive right (gantry) and positive down (trolley), as viewed by operator looking down from the cab. See entries in the next DATA line for "sign" and "offset" in x and y To create new items with XY values, use the following: internal value = sign * PLC position + offset; Gantry Sign INT 1 or -1 Gantry Offset Trolley Sign INT 1 or -1 Trolley Offset

11 COORDINATE_ TRANSFORM (Continued) Hoist Sign INT 1 or -1 Hoist Offset Load Scale NEW_ CRANE 0 EOT Crane ID Name Crane type Minimum X boundary Maximum X boundary Minimum Y boundary Maximum Y boundary Y position of rail 1 REAL To scale load to Metric tonnes (when load cell is present) or to scale motor current to acceleration (meters/minute 2 ) This entry defines one crane of a particular type. INT Any positive number (>0), but each must be unique if there are multiple cranes. Any text string not separated by spaces or commas INT Must match a define crane type, above

12 Y position of rail 2 CRANE Crane ID Time Starting X position of crane Starting Y position of trolley Status This entry defines the starting status of a particular crane. INT Must match a defined crane ID, above INT (in seconds, only used in simulation applications) will be immediately replaced by PLC values will be immediately replaced by PLC values INT status codes: 0 Inoperative 1 Operational 2 Busy 3 Safety Suspend 4 Being Pushed 5 External_Control Monitor Port INT port to establish monitor server (for remote monitoring), > 8000 Operating mode INT 0=clamp, where lifting device is lowered to the position of the load or

13 Hook Offset X 1=ladle, where load is not lowered below the destination height as specified by the operator horizontal distance to allow hook to move clear of ladle handles CRANE (Continued) Hook Offset Y Hook Offset Z Load Lane Discharge Lane horizontal distance to allow hook to move clear of ladle handles vertical distance to allow hook to lift ladle handles INT (default lane for quay cranes only, use 0 otherwise) INT (default lane for quay cranes only, use 0 otherwise) Tuning Type INT use -1 Tuning cr1 REAL 0.0 Tuning cr1 REAL 0.0 Tuning tr1 REAL 0.0 Tuning tr1 REAL 0.0 PIER_LANE "LANE 1" Defines a pier lane, for container terminal use only Lane ID INT, Code for default use 0 None 1 Discharge Lane 2 Load Lane

14 Y position Height Default INT, 0 or 1 PIER_LANE (Continued) NEW_SHIP Label SHIP1 <and much more> ID Number of hatches Name Hatch boundary 1 Hatch boundary 2 Number of stacks Number of cells Number of hatch covers Hold depth Text, in double quotes ( My Label ) Defines a ship layout in detail, stacks, hatches, cells, for container terminal use only INT, 701 and above INT Text, no spaces or commas REAL, For each Hatch, the distance from the bow to the front of the hatch REAL, For each Hatch, the distance from the bow to the front of the hatch INT, For each Hatch, the number of stacks (above decks) across INT, For each Hatch, the number of cells (below decks) across INT, For each Hatch, the number of hatch convers REAL, the vertical distance from the deck to the bottom of the hold in this hatch

15 Freeboard Hold capacities Stack capacities SHIP_VISIT ID Ship ID Early arrival time Expected arrival time Stay time Berth Number of Quay cranes Hatch sequence REAL, the nominal distance from the waterline to the deck INT, for each hatch and stack, the maximum number of containers below deck INT, for each hatch and stack, the maximum number of containers above deck Defines the expected visit of a specific ship, where the ship will berth, the number of quay cranes to be assigned, and the preferred sequence of working the hatches. INT, a unique visit ID INT, must match a ship above INT, seconds UNIX time INT, seconds UNIX time INT, hours INT, must match a berth ID, above INT, the maximum number of quay cranes to be assigned to this ship visit INTs, all the hatches on the ship, in the order to be worked. Every hatch must be represented, even if there are no containers. Empty hatches should be entered last, in any order. BERTH Defines a berth for docking a ship for container loading.

16 ID INT, a unique number >0 Start Position X Start Position Y TRUCK ND , usually 0, assuming the Y origin of the yard is at the waterʼs edge. Defines one truck delivering or picking up cargo ID INT, beginning at 1201 DEFINE_ CONTAINER Maximum length Speed Driver ID ICCNo State Registration REAL, in meters, defining the longest cargo that can be loaded REAL, in meters/minute INT, installation specific INT ICC Code Text, 2-letter state abbreviation Text, registration on license plate This entry allows for the definition of any kind of load to be lifted, be it a shipping container, ladle, slab, coil, or pallet. ID INT Number > 0

17 Shape INT code for shape: 0 Rectangle or box shape (container, slab) 1 Vertical cylinder shape (ladle) 2 Front cylinder shape (coil) 3 Side cylinder shape DEFINE_ CONTAINER (Continued) Height Length Width Handle Height Weight Early gate arrival Late gate arrival Estimated gate arrival Actual arrival time, measured parallel to crane direction when stored, measured parallel to trolley direction when stored, distance from the bottom of the load to the bottom of the handles REAL (metric tons) INT Seconds, Container terminals only, UNIX time INT Seconds, Container terminals only, UNIX time INT Seconds, Container terminals only, UNIX time INT Seconds, Container terminals only, UNIX time Import/Export INT code, Import = 0, Export =1 Hazardous cargo Location code INT code, no hazard = 0; otherwise installation specific INT code, 0 = unspecified row and stack under crane

18 Current row position Current stack position Current level INT, 0 = bottom position, 1+ higher position DEFINE_ CONTAINER (Continued) Ship ID 1 INT, Container terminals only, otherwise -1 On deck 1 INT, Container terminals only, otherwise 0 Hatch 1 INT, Container terminals only, otherwise 0 Stack 1 INT, Container terminals only, otherwise 0 Cell 1 INT, Container terminals only, otherwise 0 Sequence 1 INT, Container terminals only, otherwise 0 Ship ID 2 INT, Container terminals only, otherwise -1 On deck 2 INT, Container terminals only, otherwise 0 Hatch 2 INT, Container terminals only, otherwise 0 Stack 2 INT, Container terminals only, otherwise 0 Cell 2 INT, Container terminals only, otherwise 0 Sequence 2 INT, Container terminals only, otherwise 0

19 Level 2 INT, Container terminals only, otherwise 0 CONTAINER Updates the location of a load item CONTAINER (Continued) SAVED_ DESTINATION ID Truck assignment Current row Current stack Precise position T3A INT, must match a container ID, above INT, must match a truck ID INT, code 0 = not precise, 1 = precise. Only precisely located loads can be picked up automatically. This entry defines a saved location to be displayed on the operator screen. There are a limited number of buttons but more than one saved destination can be assigned to the same button. ID INT, a unique identifier >0 Button ID X (crane) position Y (trolley) position Tolerance INT, Buttons start at 1 and the total number of buttons is installation specific, defines how close an automatic move must come to the XY position before the move is complete.

20 Text label DEFINE_OBJECT Maximum 7 letters, no spaces permitted (use hyphen to separate into two words if desired) This entry defines an object to be displayed on the operator screen and perhaps aligned to a saved location. At most fifty of these may be defined. DEFINE_OBJECT (Continued) X position Y position Width Length Shape defines the corner to the left defines the corner away from the cab INT (0 = rectangle, 1 = ellipse) Destination INT Link to saved destination (1-50) DEFINE_ OBSTACLE Floor height Approach distance X Approach distance Y Obstacle height REAL (+ or in meters) REAL (meters, when automatic lowering can begin) REAL (meters, when automatic lowering can begin) This entry defines an obstacle that must be avoided.

21 Standard horizontal clearance Number of points in polygon INT (maximum 10) DEFINE_ Corner X OBSTACLE (Continued) Corner Y PILLAR Position X Position Y Size X Size Y Size Z Defines a pillar as background for display only. Helps visualize motion in vertical display windows. DEFINE_ CAMERA 0a IP Address This entry defines a SmartCamera on the Ethernet network. The values are as follows: Four INTs, Converted to hexadecimal notation. There are 4 separate numbers in an IP address, for example : convert each separate number to a 2-digit hexadecimal notation, so 10 is 0a, 0 is 00, 1 is 01, and 71 is 47, yielding 0a

22 DEFINE_ CAMERA (Continued) Port number Mounting Monitor Port Offset X Offset Y Offset Z INT, Defined in the SmartCamera, always Data is exchanged through this port. INT, code for mounting: 0 same view as operator looking down 1 rotate right 90 degrees 2 rotate 180 degrees 3 rotate left 90 degrees INT, Defined in the SmartCamera, always This port is used for resetting the camera in case of a communications failure on the main port. REAL, distance in meters from center of target reflector to center of camera, direction parallel to crane motion (+ right). REAL, distance in meters from center of target reflector to center of camera, direction parallel to trolley motion (- away from cab). REAL, distance in meters from center of hoist drum to camera lens, (+ up) DEFINE_PLC 0a This entry defines a PROFIBUS connection to a PLC on the Ethernet network. The values are as follows: IP Address Port number Of PLC or converter equipment converted to hexadecimal notation defined in the PLC or converter equipment documentation (Softing FG-100 is always 2357)

23 Slave address of the converter on the PROFIBUS network (must agree with settings in the PLC and should avoid numbers smaller than 3) DEFINE_ REMOTE_CRANE 16 0a Defines another crane sharing the same rails. Allows one crane to monitor another directly, or through a server. If defined, the other craneʼs position and intentions will appear on the control window (and 3D window if available). Also, automatic moves will be restricted so as not to interfere with the other crane. Crane ID IP Address Port number INT, must match a crane defined above with status not Operational INT, used if communications with the other crane is direct, not through a server. INT, used if communications with the other crane is direct, not through a server. END This entry defines the end of the input. Values after this line will be ignored