Technology software module. closed-loop control of crane drives. SIMOREG DC - MASTER 6RA70 and T300. SIMOVERT MASTER DRIVES CUVC and T300

Transcription

1 Technology software module for the closed-loop control of crane drives with SIMOREG DC - MASTER 6RA7 and T3 or SIMOVERT MASTER DRIVES CUVC and T3 Introduction and overview Implementation and owner: Industrial Solutions and Services Information Technology Plant Solution I&S IT PS Erl 35 Sales/marketing: Automation & Drives A & D MC AL: N ECCN: N Statistical product number: 4999

2 Notes/FAQ s (frequently Asked Questions): T3 with SIMOREG DC MASTER 6RA7 Current values of DC drives (SIMOREG DC MASTER 6RA7) are referred to the device current. In opposition to the DC drives, the current values of AC drives (SIMOVERT MASTERDRIVES CUVC) are referred to the motor current. With SIMOREG DC MASTER 6RA7 % is not equivalent to the motor current, but to the device current of the SIMOREG DC MASTER 6RA7. With load-dependent field weakening you must pay attention to the input of output hyperbole characteristic (P527-P538). The output hyperbole characteristic must be either normalised to the device current or the current of the SIMOREG DC MASTER 6RA7 (to the T3/pcd 4) must be scaled to the motor current. (module hoisting gear) Closed-loop position control When automatic mode is selected, the maximum speed setpoint (+/-%) is automatically entered (with the correct sign), dependent on the difference between the actual position and the position setpoint. When semi-automatic mode is selected, the master switch enters the maximum speed setpoint. Depending on the speed setpoint polarity the position setpoint or position setpoint 2 is selected. A positive speed setpoint needs a position setpoint, which is larger than the actual position, to approach the target position. A negative speed setpoint needs a position setpoint2, which is smaller than the actual position, to approach the target position. (module hoisting gear, holding gear, slewing gear and traversing gear)

3 Changes Version Date Changes V V Type transformation of parameter (H7-H74): Nominal pulse number for % position (H7, H73 transformed; H72, H74 deleted) V Parameter for factory setting added - Max. process data of the communication board have been increased to 6 process data words - free process data has been connected with the basic drive / communication board - Allocation of digital inputs and digital outputs has been changed for commissioning purposes - Allocation of the alarm display has been changed Introduction and overview V

4 NOTES This documentation describes the software implementation of the closed-loop technology control of crane drives. The installation, connection and commissioning of the equipment and modules is not described here. These are provided in sufficient detail in the Instruction Manual of the equipment. The information on danger, warning notes and cautionary measures should also be taken from the appropriate Instruction Manuals of the devices. Further, it is assumed that the equipment is installed, commissioned and serviced by suitably trained and qualified personnel, who are both knowledgeable about the product itself as well as the particular industry sector. This document also doesn't describe basic and simpler functions related with crane drives. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage and retrieval system, without permission in writing from the publisher. Introduction and overview V

5 STRUCTURE Description of the concept General overview Hardware and Software components of the T3 technology module Overview of the various drives, modules and functions....4 Communications between SIMATIC and drive units Communications within the drive units Communications between 2 drive units Overview of communications Basic signal characteristics and structure of the closed-loop control Connecting-up diagram for the T Necessary basic device parameters SIMVOVERT MASTER DRIVE CUVC SIMOREG DC MASTER 6RA Introduction and overview V

6 Description of the concept. General overview Presently, SIMOREG DC-MASTER 6RA7 devices are being used for the closed-loop control of DC crane drives and SIMOVERT MASTER DRIVES CUVC for AC drives. In order to implement the technological closed-loop control tasks and functions, in almost all cases, it is necessary to use an additional T3 technology processor in the units mentioned above. The T3 is a freely-configurable technology processor with analog and digital inputs and outputs, two connections for pulse encoders, serial interfaces etc. On the plant/system side, these connections are routed to the SE3 terminal block. This is connected to the T3 technology module using screened round cables. (For this application, only the pulse encoder connections, the analog inputs and outputs and the serial interfaces are used. The digital inputs and outputs are only used for commissioning purposes.) The sub-modules (Eproms, program memory modules) for the T3 are programmed with the STRUC programming language from SIMADYN D. However, these are not required for this particular application. The T3 technology module is used in the electronics box of the drive converter units as option board (slot 2). Module T3 is shown on Page 9, the installation on Page 8 as well as a connection example on page 6. For the various crane drive types, the necessary and frequently required closed-loop control structures and functions required for these drives, are combined in drive-specific software modules. These are listed in the table on Page together with the functions which have been implemented. If other functions are required, which are not listed in the table on the next page, then these must be implemented as custom software. With the software, the open-loop- and closed-loop control tasks are clearly separated. These are executed in the systems which have been designed for these purposes, i.e. the implementation of all of the open-loop control functions in the SIMATIC as well as implementation of all closed-loop control functions which are distributed in the drive control system. Digital interlocking, e.g. controlling contactors, generating enable signals for the drive must therefore be implemented in the higher-level open-loop control system. Only the drive-specific closed-loop control circuits and functions are implemented in the freely-programmable technology modules. The closed-loop technology control is realized in the technology modules. However, the closed-loop speed control and the closed-loop current control in the basic drives are fully utilized. Introduction and overview V

7 The drive units communication with the SIMATIC via Profibus SINEC L2 DP with PPO type 5 (4 PKW and PZD words). (Alternative a free configuration of the cyclical data (no PPO type) with the Engineering tool DriveES is possible, when a communication board CBP2 is used. There are up to 6 process data words configurable. A parameter area (PKW) is configurable,.independent on the amount of process data. However the allocation of the process data (Chapter 3) has to be noticed while usage. The complete control (control words and setpoint-actual values) of the drive converters is realized via this interface. (The communication board CBP/CBP2 has to be inserted in slot G via the adaption board ADB (slot 3)). The essential signals from the automation system to the drives are four 6-bit control words as well as the setpoints for the speeds and the position setpoint for a closed-loop position control. The communications between the technology module and a basic drive is realized through a DPR (dual port Ram). The setpoint is entered from the master switch via ET2, SIMATIC and Profibus to the drive unit. The position actual values must be sensed for the closed-loop position control of a drive. In many cases, this can be realized using the speed encoder is mounted on the motor. For the grab position control of a grab crane or for the closed-loop synchronous control of two drives, it is necessary to sense the position actual values of both drives. This can also be realized using the pulse encoder, mounted on the motor for the speed actual values. The pulse encoder signals for the speed actual value sensing are fed to the basic drives and for the position actual value sensing, to the technology module. It is also possible to mount additional pulse encoders on the cable drum. The necessary parameters are defined as technology parameters and these can be set and changed. They are set via the basic drive operator panel. It is also possible to parameterize the units (basic drive and technology module) using the SIMOVIS service tool. (The database of the T3 technology module is included in delivery.) An overview of the concept is shown in the following block diagram using as an example, the holdingand closing gear of a grab crane. The block diagram is also valid for an individual drive or a masterslave drive. Introduction and overview V

8 S5/7 ET ET ET n** s* control words status words n* CB CB master switch HW and SW TB peer to peer n*, i* TB GG GG T cable drum HW M T cable drum HW M T T ET: electrical terminal block T: pulse encoder HW: holding gear SW: closing gear CB: communication board TB: technology board GG: basic unit overview concept I&S IT PS Erl 35.. V.2 page 7

9 .2 Hardware and software components of the T3 technology module Memory module for slot in T3 Service PC/PG with start-up programm Technology board X3 Basic electronics CUVC Comm. board CBP,SCB,SCB2 Slot for memory module MS3xx T3 Backplane bus LBA Peer-to-peerconnection (to other T3 units, to the SCB2 or SIMOREG 6RA24) X32 (RS232) X33 (RS485) X34 (RS485) X36 SC58 SC6 Length of the round cables: 2 m X45 LEDs X456 Terminal block SE3 The shielded round cables, SC58 and SC6, and terminal block SE3 are included with the T3. The shields of the round cables must be connected to earth at both ends. Can be snapped on to a 35 mm mounting rail to DIN EN Dimensions: W x H x D = 224 x 6 x 6 mm Hardware- and software components of the T3 technology board Introduction and overview V

10 T3 module with memory module Introduction and overview V

11 .3 Overview of the various drives, modules and functions Hoisting gear Load-depending field weakening Heavy load operation (reduced setpoint) Jogging Ramp-function generator changeover for fieldweakening and heavy loads Changeover to synchronous operation control with one-only (manual) setting of the position difference (slave operation) Holding gear Constant field weakening (efficiency) Heavy load operation (reduced setpoint) Closed-loop position control (for automation- or manual operation) Jogging Ramp-function generator changeover for heavy loads Closing gear Grab adjustment Start pulse Current equalization control with polyp grab operation Changeover to synchronous operation control with one-only (manual) setting of the position difference (slave operation)) Slewing gear Non-linear master switch setpoint Closed-loop position control (for automatic or manual operation) Jogging Working angle-dependent accelerating time Working angle-dependent slewing speed Traversing gear, master Non-linear master switch setpoint Closed-loop position control (for automation- or manual operation) Jogging Changeover to synchronous operation control with one-only (manual) setting of the position difference (slave operation) Traversing gear, slave Current distribution monitoring Closed-loop synchronous operation control with offset as position difference Position sensing with synchronization (of the position) Closed-loop position control (for automatic- or manual operation) Non-linear master switch setpoint Pre-limit switch Start pulse Monitoring functions Current distribution monitoring Braking with constant distance Slack rope control Position sensing with synchronization (of the position) Non-linear master switch setpoint Pre-limit switch Start pulse Monitoring functions Grab position sensing Closed-loop grab position control Jogging Monitoring functions Position sensing with synchronization (of the position) Pre-limit switch Monitoring functions Influencing the ramp-function generator dependent on the system deviation Position sensing with synchronization (of the position) Pre-limit switch Monitoring functions Current distribution monitoring Jogging Position sensing with synchronization (of the position) Monitoring functions Introduction and overview V.2..2

12 Monitoring functions: Closed-loop control monitoring Speed actual-actual monitoring Overspeed monitoring Zero speed signal Introduction and overview V.2..2

13 .4 Communications between SIMATIC and the drive units The communications between these two systems is implemented via Profibus SINEC L2-DP. This serial peripheral SINEC L2-DP bus system is optimized for extremely fast cyclic master-slave operation. In this case, the drives are always operated as slaves; the higher-level system has the master function, which in this case is the SIMATIC. The CBP/CBP2 module is used as communication module in the drive units. The net data structure with which a DP master can access the drives is described in the following text. The SINEC L2-DP transfers the net data with the SRD utility (Send and Request with Data). This means, that net data are always transferred via the bus, both from the master to the slave as well as in return telegrams from the slave to the master. The master formulates a task, the slave processes this task and formulates the appropriate response. There is precisely one task in each telegram from the master to the slave; there is precisely one response in each telegram from the slave to the master. The length and structure of the net data are permanently specified, and are known as Parameter Process data Objects (PPO). Five types are defined to transfer net data (PPO), with which process data, i.e. control words, status words, setpoints and actual values can be simultaneously transferred, also parameters from the master to the slave and vice versa. In the following application, only PPO type 5 is used. The PPOs are sub-divided into two areas: PKW (parameter identification value) PZD (process data) The PKW area allows parameter values to be read and written into and parameter descriptions and texts read. Every drive parameter can be visualized or changed via this mechanism. The PZD area contains all of the necessary signals which are required for process control. These include control words and setpoints from the automation to the drive and status words and actual values from the drive to the automation system. Both areas together result in the net data block (PPO). The advantage in this case is that in a telegram, both the cyclically required process data can be transferred, and it is also possible to simultaneously access parameters (reading/writing). Cyclical data can be freely-configured by using the communication board CBP2 with the Engineering Tool DriveES (no PPO-type). There are up to 6 process data words configurable. Independent from the amount of process data a parameter area (PKW) is configurable. So you are not dependent on the 5 predetermined PPO types. Introduction and overview V

14 System connector Fixing screw LED (green) LED (yellow) LED (red) 9-pole Sub D terminal Fixing srcew CBP communications board IND PKW PWE PZD STW ZSW PZD2 HSW HIW PZD PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD st 2nd 3rd 4th st 2nd 3rd 4th 5th 6th 7th 8th 9th th PPO PPO2 PPO3 PPO4 PPO5 PWE: Parameter ID value PZD: Process data PKE: Parameter ID IND: Index PWE: Parameter value STW: Control word ZSW: Status word HSW: Main setpoint HIW: Main actual value Net-data structure in the "PROFIBUS Profile for PROFIDRIVE Variable-Speed Drives" Introduction and overview V

15 .5 Communications within the drive units The data transfer within the "slave modules", i.e. between the drive converter and CB, is realized using internal SIEMENS data transfer mechanisms, the so-called device response. The data is transferred between the communications module and drive converter via the DUAL PORT RAM (DPR). Data transfer between the communications module CB and the basic drive is realized via a dual port RAM coupling (DPR). Both sides, CB and basic drive can access the memory of the dual port RAM writing and reading. The dual port RAM chip is provided on the CB. If an additional TB technology module is provided, then this is switched between the CB and the basic drive. In this case, the dual port RAM of the CB is the interface to the TB and dual port RAM on the TB is the interface to the basic drive (configuration TB-CB basic drive). The initialization data transferred between CB and the basic drive is not influenced by the TB, i.e. the technology module copies the data from its dual port RAM one-to-one into the dual port RAM of the CB and vice versa. The function must be appropriately configured in the TB. 6 pieces of process data can be transferred in both directions between the TB and basic drive..6 Communications between two drive units This communications connection is generally used for master-slave drives, where the master setpoint for the slave drive(s) is (are) entered from the master drive. This is also the case for holding- and closing gears of a grab crane where the speed setpoint for the closing gear and the current setpoint for the current equalization control is transferred to the closing gear via this coupling. This coupling is realized using a fast peer-to-peer connection between the technology modules. A maximum of 5 PZD data words can be transferred in both directions via this interface. Introduction and overview V

16 S7 CBP T3 unit CU PROFIBUS PKW converter response.word PKE 2.word IND 3.word PWE 4.word PWE converter response PKW PROFIBUS converter response converter response PKW PKW PROFIBUS PZD max. 6 words converter response converter response PZD 6 words peer to peer T3 5 words unit overview of communications I&S IT PS Erl 35.. V.2 page 5

17 SIMATIC 2 control word 2 control word control word technology IG control word technology 2 setpoints ET2 ET2 2 functions n* n* functions ML RFG n-controller i-controller PROFIBUS SINEC L2 DP i* M technological control n ist n i* T n ist s ist n ist monitoring acknowledge nist monitoring acknowledge status word technology status word status word 2 T3 basic unit basic signal characteristics and structure of the closed-loop control I&S IT PS Erl 35.. V.2 page 6

18 .9 Connecting-up diagram for the T3 Introduction and overview V

19 . Basic drive converter parameters required In order to establish error-free communications and functionality between SIMATIC and the drive unit, the following parameter settings must be made in the basic drive of the converter or inverter. Depending on the selected BICO data set, these settings are made in index or 2. These are:.. SIMVOVERT MASTER DRIVE CUVC Enter the Profibus address P6 = 4 select the "module configuration" menu P98. or.2 =? enter the CB bus address P6 = return to the parameter menu Interlocking the receive data PZD: Control word The bits assigned by the SIMATIC must be interlocked with the appropriate parameters (refer to the Compendium Vector Control, function chart 8). The following parameterization must be made if, for example, all control bits are assigned by the SIMATIC. P554. or 2 = 3 P555. or 2 = 3 P558. or 2 = 32 P56. or 2 = 33 P562. or 2 = 34 P563. or 2 = 35 P564. or 2 = 36 P565. or 2 = 37 P568. or 2 = 38 P569. or 2 = 39 P57. or 2 = 3 P572. or 2 = 32 P573. or 2 = 33 P574. or 2 = 34 P575. or 2 = 35 Otherwise, the parameters which are to be not controlled from the SIMATIC, should be left in the factory setting. PZD2: Speed setpoint P443. or 2 = 32 Introduction and overview V

20 PZD3: Control word 2 The bits assigned by the SIMATIC should be interlocked with the appropriate parameters (refer to the Compendium Vector Control, function chart 9). The following parameterization must be made, if for example, all control bits are to be assigned by the SIMATIC. P576. or 2 = 33 P577. or 2 = 33 P578. or 2 = 332 P579. or 2 = 333 P58. or 2 = 334 P58. or 2 = 335 P582. or 2 = 336 P583. or 2 = 337 P584. or 2 = 338 P585. or 2 = 339 P586. or 2 = 33 P587. or 2 = 33 P588. or 2 = 332 P589. or 2 = 333 P59. or 2 = 334 P59. or 2 = 335 Otherwise, the parameters which are not to be controlled from the SIMATIC, should be left in the factory setting. PZD4: Start pulse P56. or 2 = 34 2 Interlocking the send data PZD: Status word P734. = 32 PZD2: Speed actual value P734.2 = 48 PZD3: Status word 2 P734.3 = 33 PZD4: Current setpoint P734.4 = 68 PZD5: System deviation P734.5 = 52 The remaining available process data can be connected and used individually. 2 The start pulse has to be parameterized just for hoisting gear, holding gear and closing gear (modules -3) because it is only relevant for these gears Introduction and overview V

21 ..2 SIMOREG DC MASTER 6RA7 Enter the Profibus address P5 = 4 access authorization P98. or.2 =? enter the CB bus address Interlocking the receive data PZD: Control word The bits assigned by the SIMATIC are interlocked with the appropriate parameters (refer to the Instruction Manual SIMOREG DC MASTER, function chart 33). The following parameterization must be made, if for example, all of the control bits are to be assigned by the SIMATIC. P654. or 2 = 3 P655. or 2 = 3 P658. or 2 = 32 P66. or 2 = 33 P662. or 2 = 34 P663. or 2 = 35 P664. or 2 = 36 P665. or 2 = 37 P668. or 2 = 38 P669. or 2 = 39 P67. or 2 = 3 P672. or 2 = 32 P673. or 2 = 33 P674. or 2 = 34 P675. or 2 = 35 Otherwise, the parameters which are not to be controlled from the SIMATIC, should be left in the factory setting. PZD2: Speed setpoint P433. or 2,3,4 = 32 Introduction and overview V

22 PZD3: Control word 2 The bits assigned by the SIMATIC are interlocked with the appropriate parameters (refer to the Instruction Manual SIMOREG DC MASTER, function chart 34). The following parameterization must be made if, for example, all of the control bits are assigned by the SIMATIC. P676. or 2 = 33 P677. or 2 = 33 P678. or 2 = 332 P679. or 2 = 333 P68. or 2 = 334 P68. or 2 = 335 P682. or 2 = 336 P683. or 2 = 337 P684. or 2 = 338 P685. or 2 = 339 P686. or 2 = 33 P687. or 2 = 33 P688. or 2 = 332 P689. or 2 = 333 P69. or 2 = 334 P69. or 2 = 335 Otherwise, the parameters which are not to be controlled from the SIMATIC, should be left in the factory setting. PZD4: Start pulse P5 = 34 3 Interlocking the send data PZD: Status word U734. = 32 PZD2: Speed actual value U734.2 = 67 PZD3: Status word 2 U734.3 = 33 PZD4: Current setpoint U734.4 = 2 PZD5: System deviation U734.5 = 65 The remaining available process data can be individually connected and used. 3 The start pulse has to be parameterized just for hoisting gear, holding gear and closing gear (modules -3) because it is only relevant for these gears Introduction and overview V

23 Technology software module for the closed-loop control of crane drives module 6: traversing gear slave Description of the functions Jogging Current distribution monitoring Closed-loop control monitoring Speed actual-actual monitoring Overspeed monitoring Zero speed signal Position offset sensing with synchronization (of the offset) Closed-loop synchronous operation control with offset as position difference

24 STRUCTURE 2 Description of the functions Jogging Current distribution monitoring Closed-loop control monitoring Speed-actual-actual-monitoring Overspeed monitoring Zero speed signal Position offset sensing with synchronization (of the offset) Closed-loop synchronous operation control with offset as position difference Synchronous operation and synchronizing using as an example, a crane traversing gear... module 6: traversing gear slave V Descriptions of the functions

25 2 Description of the functions This application of the T3 module works with a speed scaling of % for maximum speed. 2. Jogging Using this function, the drive can be moved with small speed setpoint intervals. This is required, for example, to attach the cable to the hoisting gear. When jogging, an adjustable jog setpoint is entered as speed setpoint. ramp-function generator speed controller jogging setpoint setpoint direction 2 direction command jogging command jogging direction command jogging direction 2 command jogging direction command jogging direction 2 t jogging setpoint direction jogging setpoint direction 2 t jogging module 6: traversing gear slave V Descriptions of the functions

26 2.2 Current distribution monitoring This function can be used for slave drives (if it is practical). For a master-slave drive, it monitors that the total torque (current) is evenly distributed over both drives. However, as described above, this is not always the case. ramp-function generator CBP ramp-function generator CBP n* peer to peer n* i* i* monitoring - + status word bit 8 T3 T3 n-controller i-controller n-controller i-controller n* i* n* i* CU CU master slave current distribution monitoring module 6: traversing gear slave V Descriptions of the functions

27 2.3 Closed-loop control monitoring This function continually monitors the speed setpoint and speed actual value, which, when the system is operating correctly, must approximately correspond with one another. This monitoring function responds, for example, if the closed-loop control goes to its current limit due to an overload or a stalled drive, as the speed actual value can no longer follow the speed setpoint. However, if the setpoint is less than the response difference, then there is a no signal output if the actual value is missing. This fault is detected using the interrupted tachometer monitoring function of the basic drives. 2.4 Speed-actual-actual-monitoring This function can be used for speed-actual-actual monitoring if a drive is equipped with a speed actual value- and position actual value encoder. If a drive has, in addition to a pulse encoder for the speed actual value, also a pulse encoder for the position actual value, which is not mounted to the motor, but for example, to the drum, then monitoring can be realized by evaluating the speeds supplied from both encoders. For instance, this can be used to monitor the gearboxes or couplings for two rigidly coupled drives. 2.5 Overspeed monitoring This monitoring function represents a software centrifugal switch. Using this monitoring function, a signal can be generated when a selectable speed is exceeded. Values of between -5% of the maximum permissible operating speed are set for these overspeed protective devices. When an overspeed monitoring function responds, appropriate shutdown mechanisms can be initiated. 2.6 Zero speed signal This function monitors the speed and responds if the selected limit is fallen below. This signal is mainly used to close the brake. It is also used, for example, in the hoisting gear module to calculate the supplementary speed setpoint for load-dependent field weakening. module 6: traversing gear slave V Descriptions of the functions

28 speed actual-actual monitoring actual speed value from basic unit + - signal to status word (technology) bit 4 actual speed value from technology board (NAV) closed-loop control monitoring system deviation from basic unit signal to status word (technology) bit overspeed monitoring actual speed value from basic unit signal to status word (technology) bit 2 zero speed signal signal to status word (technology) bit 3 monitorings module 6: traversing gear slave V Descriptions of the functions

29 2.7 Position offset sensing with synchronization (of the offset) This function is required if a slave drive should precisely follow a master drive, closed-loop position controlled and the differential position actual value (offset) between the two drives which should be kept controlled, is to be set to an absolute position actual value at several points along the travel to correct erroneous measurements or erroneous/missing pulses. The offset must always be determined if the relative position between two drives with respect to one another regarding their synchronization marks (Bero) must be sensed and controlled. The actual position must be sensed for the closed-loop synchronous position control. In almost all cases, the speed actual value encoder mounted to the encoder can be used (a pulse encoder is required, analog tachometers are not suitable). Technology module T3 has, in the form of its terminal module, pulse encoder sensing inputs and 2 which can be read-in from a block at the same time. For the closed-loop synchronous position control of two drives, the actual positions of both drives must be sensed. The pulse encoder, mounted to the motor for the speed actual values can be used for this purpose. The pulse encoder signals are fed to the basic drive for the speed actual sensing and to the technology module of the second drive for the position actual value sensing. The position actual value of the drive must always be connected to pulse encoder sensing input and that of the master drive to pulse encoder sensing input 2 (for the slave). For closed-loop position control of a drive, under certain circumstances, it is necessary to synchronize the position actual value of these drives at shorter or longer intervals depending on the application. This, for example, always required, if errors in the position actual value sensing of the drive occur as a result of the pulse encoder and the influence of noise and disturbances. The synchronizing function has the task to correct this possibly erroneous position actual value. In this case, the reference to the sensed actual value position is re-referenced an absolute synchronizing mark. When the synchronizing point is passed (synchronizing mark), this is sensed per hardware using a Bero through the zero pulse encoder inputs. The position actual values of both drives are then set to defined, actual position actual values when passing-over fixed synchronizing marks. The number of pulses which are received by the master and slave between passing over the two synchronizing marks is known as the offset. After the second drive has passed-over its synchronizing mark, the correct offset is determined. This new offset replaces the old offset actual value which could have been possibly incorrect. It is now used by the closed-loop synchronous operation control as new offset actual value which must be corrected. This corrects wheel slip or possible erroneous pulses. In this case, synchronization means determining the offset. The synchronization has nothing to do with the actual closed-loop control structure as when synchronizing, only the position difference actual value has to be corrected from the position of the synchronizing marks. The synchronization and therefore the availability of synchronizing marks are not required for closedloop synchronous position control, and should only be used when actually required. module 6: traversing gear slave V Descriptions of the functions

30 S5/7 setpoints setpoints communication board communication board n** +% <% -% peer to peer n** ramp-function generator hw-syn. via index pulse WSR2 input WSR SE X5M X5N WSSYN WSAUT actual position value evaluation synchron s ist n ist AAT + - <% AAT position control ramp-function generator hw-syn. via index signal input SE X5M X5N WSSYNMA WSSYNSL SMA SDP SSL position difference evaluation DPS s n ist Sync. recei. y=x y x synchronization controller SYN via control word n ist - monitoring technology board Syn offset sync. Syn2 n ist - monitoring technology board n-controller i-controller n-controller i-controller n* i* n* i* n ist n ist basic unit basic unit M T M T T T hardware- and software structure for position- and synchronization control I&S IT PS Erl 35.. V.2 page: 8

31 2.8 Closed-loop synchronous operation control with offset as position difference This function is required in conjunction with the offset sensing which was previously described, in order to operate two drives in synchronous operation, which are separately closed-loop speed controlled and to correct the previously determined offset between the two drives. When 2 drives are in synchronism, the slave drive follows the master drive, closed-loop position controlled in synchronism, with a position difference setpoint which has to be saved. A position difference, which has to be defined (or a position difference equals ) can be saved as offset setpoint. Initially, the two drives must be optically aligned (the slave drive by jogging). The difference actual value must then be manually set to. The drives can now be manually moved to the required offset and the offset actual value saved as setpoint. The closed-loop position synchronous control is now operated with this setpoint. The separately speed-controlled drives in this operating case must be coupled through the control system via a synchronous operation controller in the slave drive. They must remain in position synchronism even if the load is unevenly distributed. The synchronous operation controller is superimposed on the closed-loop speed control of the slave drive. The inputs of the synchronous operation controller are the stored position difference actual value as setpoint and the actual position difference value as actual value. The output of the synchronous operation controller acts as supplementary setpoint at the setpoint input of the slave drive speed controller. When closed-loop synchronous operation control is activated, and a position difference develops between the drives, then the slave drive receives a supplementary speed setpoint via the synchronous operation controller. This then operates this drive with the increased or decreased speed setpoint, until the position difference is again zero. The supplementary setpoint (the intervention of the supplementary setpoint from the synchronous operation controller) should in this case be a maximum of 2% to 3% of the max. drive speed. The closed-loop synchronous operation control of a crane traversing gear will now be illustrated as example. module 6: traversing gear slave V Descriptions of the functions

32 master n-controller speed setpoint (S7) % speed setpoint to basic unit i* position setpoint (S7) setpoint enable (S7) actual position value position synchronization value (S7) T pulse encoder evaluation s peer to peer synchronize slave n-controller offset evaluation % speed setpoint to basic unit i* selection jogging (S7) setpoint enable (S7) T position synchronization value(sl)(s7) position synchronization value(ma)(s7) SYNC2 recei. pulse encoder evaluation SYNC recei. s s 2 s offset save (S7) y=x y x position difference setpoint actual position difference value jogging setpoint W X % selection jogging (S7) synchr. SL (S7) synchr. MA (S7) synchr. s (S7) enable synchronization controller (S7) signal flow chart synchronization control with synchronization overview I&S IT PS Erl 35.. V.2 page:

33 2.9 Synchronous operation and synchronizing using as an example, a crane traversing gear The necessity to provide synchronization is shown using an additional example with the traversing gear of a container crane. Both sides of the crane traversing gear fixed leg and hinged leg should run in synchronism and be closed-loop position controlled. Synchronization is required here, as the pulse encoders are mounted on the motor and they therefore do not represent the actual motion (position actual value) of the wheels. The wheels could slip which would cause errors in the actual value sensing of the drives and therefore errors in the position difference as control quantity between the two drives. The synchronization function has the task to correct this error. The position actual values of the two drives are set to defined, actual position values when passing-over fixed synchronizing marks. The difference between the two drives after the second drive has passed-over its mark, is known as the offset. This offset is now the real position difference between the two drives which must be corrected. For this purposes, on both side, the position actual value is set to e.g. 3 m when mark is passedover using Bero 3. These marks are mechanically and precisely located along the crane track. If the crane traversing gear gets into an skewed setting (e.g. caused by wheel slip), then, at the marks, for example, first the position actual value of side and later, the position actual value of side 2 are set to 3 m. The difference between passing-over mark and passing-over mark 2 is determined by calculating position actual value (in the meantime, this is greater than 3 m) minus the position actual value 2 (= 3 m) when passing-over mark 2. This difference is known as offset. The slave drive must now correct this offset. This is the task of the offset calculation and closed-loop synchronous operation control. 3 3 master drive 5 slave drive 3 3 master drive 5 slave drive synchronization mark page page 2 3 Bero synchronization control of a crane travelling gear module 6: traversing gear slave V.2..2 Descriptions of the functions

34 Technology software module for the closed-loop control of crane drives module 6: traversing gear slave process data, parameter, etc.

35 STRUCTURE 3 process data, parameter, etc allocation of process data allocation and description of the control bits allocation and description of the status bits parameter list faults and alarms used abbreviations of function plans... 2 module 6: traversing gear slave V process data, parameter, etc.

36 3 process data, parameter, etc. 3. allocation of process data This application of the T3 is provided for 6 receive and send process data from or to the Communication Board. The process data words -6 could only be configured and used with the Engineering Tool DriveES and the Communication Board CBP2. The following tables show the allocation of the process data words. Further on the tables show the goal or source of the process data words, i.e. the connection of the process data (T3, base unit CU or Communication Board CB). process data from automation system to T3 goal PCD control word STEU T3 / base unit PCD2 free T3 PCD3 control word 2 STEU2 base unit PCD4 control word (technology) STEU_TB T3 PCD5 control word 2 (technology) STEU_TB2 T3 PCD6 PCD6_Empf PZD6_Emp base unit PCD7 PCD7_Empf PZD7_Emp base unit PCD8 PCD8_Empf PZD8_Emp base unit PCD9 position synchronization value slave WSSYNSL T3 PCD position synchronization value master WSSYNMA T3 PCD PCD_Empf PZD_Emp base unit PCD2 PCD2_Empf PZD2_Emp base unit PCD3 PCD3_Empf PZD3_Emp base unit PCD4 PCD4_Empf PZD4_Emp base unit PCD5 PCD5_Empf PZD5_Emp base unit PCD6 PCD6_Empf PZD6_Emp T3 / base unit process data from T3 to automation system source PCD status word ZUST base unit PCD2 actual speed value XNGG base unit PCD3 status word 2 ZUST2 base unit PCD4 status word (technology) ZUST_TB T3 PCD5 actual position value (slave) XSSL T3 PCD6 actual position value (master) XSMA T3 PCD7 PCD7_Send PZD7_Send base unit PCD8 PCD8_Send PZD8_Send base unit PCD9 PCD9_Send PZD9_Send base unit PCD PCD_Send PZD_Send base unit PCD PCD_Send PZD_Send base unit PCD2 PCD2_Send PZD2_Send base unit PCD3 PCD3_Send PZD3_Send base unit PCD4 PCD4_Send PZD4_Send base unit PCD5 PCD5_Send PZD5_Send base unit PCD6 PCD6_Send PZD6_Send base unit module 6: traversing gear slave V process data, parameter, etc.

37 This application of the T3 is provided for 6 receive and send process data from or to the base unit. The process data, which aren t used in this application, are connected between the base unit and the Communication Board. The following tables show the allocation of the process data words. Further on the tables show the goal or source of the process data words, i.e. the connection of the process data (T3, base unit CU or Communication Board CB). process data from T3 to base unit Source PCD control word STEU CB PCD2 speed setpoint WNGG T3 PCD3 control word 2 STEU2 CB PCD4 free T3 PCD5 free T3 PCD6 PCD6_Empf PZD6_Emp CB PCD7 PCD7_Empf PZD7_Emp CB PCD8 PCD8_Empf PZD8_Emp CB PCD9 free T3 PCD free T3 PCD PCD_Empf PZD_Emp CB PCD2 PCD2_Empf PZD2_Emp CB PCD3 PCD3_Empf PZD3_Emp CB PCD4 PCD4_Empf PZD4_Emp CB PCD5 PCD5_Empf PZD5_Emp CB PCD6 PCD6_Empf PZD6_Emp CB process data from base unit to T3 goal PCD status word ZUST CB PCD2 actual speed value XNGG T3 / CB PCD3 status word 2 ZUST2 CB PCD4 current setpoint ZUST_TB T3 PCD5 setpoint-actual value difference XS T3 PCD6 free T3 PCD7 PCD7_Send PZD7_Send CB PCD8 PCD8_Send PZD8_Send CB PCD9 PCD9_Send PZD9_Send CB PCD PCD_Send PZD_Send CB PCD PCD_Send PZD_Send CB PCD2 PCD2_Send PZD2_Send CB PCD3 PCD3_Send PZD3_Send CB PCD4 PCD4_Send PZD4_Send CB PCD5 PCD5_Send PZD5_Send T3 / CB PCD6 PCD6_Send PZD6_Send T3 / CB module 6: traversing gear slave V process data, parameter, etc.

38 3.2 allocation and description of the control bits The allocation of the control words for the technology board in this application are appropriately the following tables. The tables show the level (high- (H) or low-active (L)) of the commands. A description of each control bit follows the tables. control word technology Bit command jogging direction (H) KTA Bit command jogging direction 2 (H) KTB Bit 2 free Bit 3 free Bit 4 free Bit 5 free Bit 6 free Bit 7 free Bit 8 enable synchronization controller (H) FGR Bit 9 free AAT Bit free Bit free Bit 2 free Bit 3 synchronize position difference value (H) SDP Bit 4 synchronize actual position value (master) (H) SMA Bit 5 synchronize actual position value (slave) (H) SSL control word 2 technology Bit 6 offset save (H) DPS Bit 7 free Bit 8 free Bit 9 free Bit 2 free Bit 2 free Bit 22 free Bit 23 free Bit 24 free Bit 25 free Bit 26 free Bit 27 free Bit 28 free Bit 29 free Bit 3 free Bit 3 free module 6: traversing gear slave V process data, parameter, etc.

39 Bit : command jogging direction (H jogging direction / L jogging direction off ) A high-signal sets the speed setpoint to the base unit to the value, parameterized via the parameter H333.The setpoint should be for example positive for the direction. A low-signal doesn t select a speed setpoint for jogging. Bit : command jogging direction (H jogging direction / L jogging direction off ) A high-signal sets the speed setpoint to the base unit to the value, parameterized via the parameter H332.The setpoint should be for example negative for the direction 2 (reverse to direction ). Command jogging direction has priority, if command jogging direction and command jogging direction 2 are set together (high). A low-signal doesn t select a speed setpoint for jogging. Bit 8: enable synchronization controller (H enable synchronization controller / L disable ) A high-signal enables the synchronization controller. A low-signal disables the synchronization controller. Bit 3: synchronize position difference value (H synchronize / L no synchronize ) A high-signal sets the position difference value to. Bit 4: synchronize actual position value (master) (H synchronize / L no synchronize ) A high-signal sets the actual position value of the master drive to the position synchronization value (PZD ) given via automation system. Bit 5: synchronize actual position value (slave) (H synchronize / L no synchronize ) A high-signal sets the actual position value of the slave drive to the position synchronization value (PZD 9) given via automation system. Bit 6: offset save (H offset save ) A High-Signal saves the actual position difference value. This value is given as position difference setpoint for the closed-loop synchronous, if parameter H28 is set to. module 6: traversing gear slave V process data, parameter, etc.

40 The allocation of the control words and 2 are appropriately the operating instruction of the base unit (6SE7 or 6RA7). The following tables show the level (high- (H) or low-active (L)) of the commands. A description of each control bit you find in the operating instruction of the base unit. control word Bit OFF (L) EIN Bit OFF2 (L) AUS2 Bit 2 OFF3 (L) AUS3 Bit 3 inverter enable (H) FWR Bit 4 ramp-function generator enable (H) FHG Bit 5 ramp-function generator start (H) SHG Bit 6 setpoint enable (H) FWN Bit 7 acknowledge ( ) QUITT Bit 8 jogging bit (H) TIPP Bit 9 jogging bit (H) TIPP2 Bit control requested (H) FAG Bit clockwise phase sequence enable (H) RDF Bit 2 counter-clockwise phase sequence enable (H) LDF Bit 3 motorized potentiometer raise (H) MOPOH Bit 4 motorized potentiometer lower (H) MOPOT Bit 5 external fault (L) STOEX control word 2 Bit 6 selection function data set bit (H) ANW FDS Bit 7 selection function data set bit (H) ANW FDS Bit 8 selection motor data set bit (H) ANW MDS Bit 9 selection motor data set bit (H) ANW MDS Bit 2 select fixed setpoint bit (H) ANW FSW Bit 2 select fixed setpoint bit (H) ANW FSW Bit 22 synchronizing enable (H) FSYN Bit 23 enable flying restart (H) FFANG Bit 24 enable droop, speed controller (H) FSTAT Bit 25 enable speed controller (H) FDREH Bit 26 external fault 2 (L) STOEX2 Bit 27 master drive (speed control) (L) LEIT Bit 28 external alarm (L) WARNEX Bit 29 external alarm 2 (L) WARNEX2 Bit 3 select BICO data set (L) ANW BICO Bit 3 no MC checkback signal (L) HS RUECK module 6: traversing gear slave V process data, parameter, etc.

41 3.3 allocation and description of the status bits The allocation of the status word of the technology board in this application is appropriately the following table. The table shows the level (high- (H) or low-active (L)) of the signals. A description of each status bit follow the table. status word technology Bit signal fault encoder (L) FIGS Bit signal speed setpoint-actual value diff. saved (L) MXNDS Bit 2 signal overspeed saved (L) MXNGS Bit 3 signal speed = (H) MXN Bit 4 signal fault speed actual-actual value difference FIGNSS (L) Bit 5 signal fault coupling T3 to base unit (L) FKGERS Bit 6 signal fault coupling to automation system (L) FKS5S Bit 7 free Bit 8 signal fault current distribution difference (L) FIVERS Bit 9 signal fault coupling peer to peer (L) FKPPS Bit free Bit free Bit 2 free MXNFS Bit 3 signal RFG-output = RFG-input (H) KQE Bit 4 signal fault offset evaluation (L) FVES Bit 5 free AWR Bit : signal fault encoder (H no fault / L fault ) A low-signal shows a configuring error of the encoder. The bit is just reset to high-level via the acknowledge command. Bit : signal speed setpoint-actual value difference saved (H no speed setpoint-actual value difference saved / L speed setpoint-actual value difference saved ) A low-signal shows a deviation of the actual speed compared to the speed setpoint, which is larger than the value parameterized via H456/H457. A larger deviation is saved and the bit is just reset to high-level via the acknowledge command. Bit 2: signal overspeed saved (H no overspeed / L overspeed ) A low-signal shows, if the actual speed is greater than the limit parameterized via H459/H46. A greater actual speed is saved and the bit is just reset to high-level via the acknowledge command. Bit 3: signal speed = (H speed = / L speed <> ) A high-signal shows a deviation of the actual speed compared to speed, which is larger than the value parameterized via H46/H462. module 6: traversing gear slave V process data, parameter, etc.

42 Bit 4: signal fault speed actual-actual deviation (H no fault / L fault ) A low-signal shows a deviation of the actual speed (T3) compared to the actual speed from the base unit, which is larger than the value parameterized via H466/H467. A larger deviation is saved and the bit is just reset to high-level via the acknowledge command. Bit 5: signal fault coupling T3 to base unit (H no fault / L fault ) A low-signal shows an error between the coupling T3 / base unit. The bit is just reset to high-level via the acknowledge command. Bit 6: signal fault coupling to automation system (H no fault / L fault ) A low-signal shows an error between the coupling T3 / automation system (Communication Board). The bit is just reset to high-level via the acknowledge command. Bit 8: signal fault current distribution difference (H no fault / L fault ) A low-signal shows a deviation of the current setpoint/slave compared to the current setpoint/master, which is larger than the value prameterized via H469/H47. A larger deviation is saved and the bit is just reset to high-level via the acknowledge command. This monitoring is only active if synchronism is selected (control word (technology) bit 2) (slave drive). Bit 9: signal fault coupling peer to peer (H no fault / L fault ) A low-signal shows an error between peer-to-peer-coupling. The bit is just reset to high-level via the acknowledge command. Bit 3: signal RFG-output = RFG-input (H RFG-output = RFG-input / L RFG-active or locked ) A high-signal shows, if the ramp-function generator output is equal to the ramp-function generator input (the ramp-function generator isn t active.). A low-level shows, if the RFG is active or locked. Bit 4: signal fault offset evaluation (H no fault / L fault ) A low-signal shows an error of the offset evaluation or the evaluated offset is larger than the value parameterized via H89. A larger offset or an error is saved and the bit is just reset to high-level with the acknowledge command module 6: traversing gear slave V process data, parameter, etc.

43 The allocation of the status words and 2 are appropriately the operating instruction of the base unit (6SE7 or 6RA7). The following tables show the level (high- (H) or low-active (L)) of the signals. A description of each status bit you find in the operating instruction of the base unit. status word Bit signal ready to switch on (H) EINBE Bit signal ready (H) BETRBE Bit 2 signal run (H) BETRIEB Bit 3 signal fault (H) STOERUNG Bit 4 signal OFF2 (L) KEINAUS2 Bit 5 signal OFF3 (L) KEINAUS3 Bit 6 signal switch-on inhibit (H) EINSPERR Bit 7 signal alarm (H) WARNUNG Bit 8 signal setpoint-actual value deviation (L) KEINWXAB Bit 9 signal PcD control requested (H) FAGGEF Bit signal comparison value reached (H) VGWER Bit signal low voltage fault (H) STOEUSP Bit 2 signal request to energize main contactor (H) HSANGEST Bit 3 signal ramp-function generator active (H) HLGAKT Bit 4 signal positive speed setpoint (H) RECHTDF Bit 5 signal kin. buf./ flex. response active (H) KIPAK status word 2 Bit 6 signal flying restart or excitation active (H) FANGAK Bit 7 signal synchronism reached (H) SYNCER Bit 8 signal overspeed (L) KEIUED Bit 9 signal external fault (H) STOEEX Bit 2 signal external fault 2 (H) STOEEX2 Bit 2 signal external alarm (H) WARNEX Bit 22 signal converter overload alarm (H) WARNI2T Bit 23 signal converter overtemperature fault (H) STOEUTMP Bit 24 signal converter overtemperature alarm (H) WARNUTMP Bit 25 signal motor overtemperature alarm (H) WARNMTMP Bit 26 signal motor overtemperature fault (H) STOEMTMP Bit 27 reserve Bit 28 signal motor pulled out/blocked fault (H) STOEMBLK Bit 29 signal bypass contactor energized (H) UEBSAN Bit 3 signal synchronizing error (H) FBSYN Bit 3 signal pre-charging active (H) VORLAK module 6: traversing gear slave V.2..2 process data, parameter, etc.