ENG_326522.XML
Five different SIMOCRANE Sway Control Systems with varying functionality and focus are available to meet the requirements of different applications. All high‑performance systems can be expanded by the camera measuring system. The camera measuring system comprises a camera and a reflector. The camera system can compensate for disturbances caused by external factors, e.g. wind, or sway caused by load lift at an inclined angle.
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SIMOCRANE SC integrated STS, GSU
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SIMOCRANE CeSAR standalone STS, GSU
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SIMOCRANE SC integrated OHBC, Gantry crane
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SIMOCRANE CeSAR standalone OHBC, Gantry crane
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SIMOCRANE Drive‑Based Sway Control 3)
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Crane type
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STS, GSU
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STS, GSU
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OHBC, Gantry crane
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OHBC, Gantry crane
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OHBC, Gantry crane
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Operating modes
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✓
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✓
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✓
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✓
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✓
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- Manual mode
with Soft Approach (MAN)
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✓
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✓
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–
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–
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–
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✓
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✓
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✓
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✓
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✓
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- Positioning with Detour Control
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–
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–
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–
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✓
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–
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- Sway neutralization (SNL/SND)
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✓
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✓
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✓
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✓
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–
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- Trim, list and skew control (TLS)
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✓
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✓
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–
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–
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–
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✓
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✓
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✓
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–
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–
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- Semi‑automatic mode (SAM)
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✓
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✓
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–
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–
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–
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Axis control
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Hoist/trolley
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Hoist/trolley
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Trolley/gantry and hoist/slewing gear
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Trolley/gantry and hoist
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Trolley or gantry
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Hardware platform
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SIMOTION D 1)
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SIMOTION C
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SIMOTION D 1)
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SIMOTION C
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SINAMICS S 1)
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Camera measuring system
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SIMOCRANE CenSOR 2)
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SIMOCRANE CenSOR 2)
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SIMOCRANE CenSOR 2)
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SIMOCRANE CenSOR 2)
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–
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Retroreflector
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Retroreflector
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Retroreflector
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Retroreflector
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– Not possible
✓ Included in the scope of delivery
1) Hardware not included in scope of delivery. For more information about the scope of delivery, see section "SIMOCRANE Basic Technology".
2) Separately available accessories.
3) With electronic Certificate of License (eCoL).
SIMOCRANE SC integrated Sway Control System
The SIMOCRANE SC integrated sway control system is a software solution that is used on the central SIMOTION D motion controller. The system is currently available in the following variants:
- Overhead bridge cranes/gantry cranes
(application in three axes in direction of trolley, long travel and rotation/hoist)
- Container cranes STS/grab cranes GSU
(application in two axes in trolley and hoist directions)
SIMOCRANE CeSAR standalone Sway Control System
The SIMOCRANE CeSAR standalone Sway Control System is an autonomous system that can be used in any controller and drive landscape. The system has the same functional scope as the integrated solution:
- Overhead bridge cranes/gantry cranes
(application in three axes in direction of trolley, long travel and hoist)
- Container cranes STS/grab cranes GSU
(application in two axes in trolley and hoist directions)
SIMOCRANE Drive‑Based Sway Control
SIMOCRANE Drive‑Based Sway Control is a drive‑based solution for mid‑range crane applications based on SINAMICS for harbor and industry cranes. The system is not possible to be used together with the SIMOCRANE CenSOR camera measuring system. The Certificate of License (CoL) has been changed from paper form to electronic form (eCoL).
SIMOCRANE CenSOR camera measuring system
The SIMOCRANE CenSOR camera measuring system can be used with the SIMOCRANE Sway Control Systems for high performance, depending on the task to be performed and the environmental conditions.
ENG_326523.XML
P_CR01_XX_00054
SIMOCRANE Sway Control System
The SIMOCRANE Sway Control System is based on calculations of a mathematical oscillation model. When a camera is used, the parameters hoisting height, sway angle and skew angle are determined by means of optical contact-free measurement and are incorporated in the calculation model. If the measuring signal of the camera fails, only the states of the oscillation model are used.
Damping of the load sway is performed by influencing the traversing speed for each axis individually. When using the positioning mode, the defined target positions are automatically approached with sway control after enabling. The axis is controlled in such a way that the load sway is eliminated not only when the maximum speed is reached, but also at the target position. All sway resulting from the travel motion is largely eliminated. If a camera is also used, sway resulting from external forces – such as inclined lift or wind – can be almost completely compensated.
Operating modes
The following operating modes and functions are available for the general and automation application areas:
- Manual mode (MAN)
- Soft Approach as option for collision prevention
- Positioning (POS)
- Detour Control with consideration of obstacles as option for OHBC
- Sway neutralization
- Load position (SNL1))
- Trolley position (SND2))
- Trim, list and skew control (TLS)
- Skew damping
- Semi‑automatic mode (SAM)
1)
SNL: Sway neutralization load position
2)
SND: Sway neutralization trolley position
The operating mode is selected (depending on the functional scope) by the PLC by setting the appropriate control bit.
Manual mode (MAN)
In the manual mode, the speed is specified manually from a higher-level controller. The trolley is accelerated or decelerated to the set speed in such a way that the load sway has been eliminated when the set speed is reached.
Sway control is active in manual mode either throughout the complete traverse, or only during at stop.
A new function Soft Approach is added to the manual mode to assist crane drivers for approaching softly the target position with minimal risk of collision. This function can be well applied for smart slow‑down of a trolley and for soft landing of a hoist.
Positioning (POS)
In the positioning mode, the higher-level controller or the internal encoder can specify a target position for each individual axis. This position is approached automatically after enabling. The axes are controlled in such a way that the load sway is eliminated not only when the maximum speed is reached, but also at the target position. The direct path between the current position and the target position must be free of obstacles.
Sway neutralization (SNL/SND)
The sway neutralization mode (only for the version with camera) is used to eliminate swaying movements of the load from standstill.
Sway neutralization is linked to a positioning function. The target position is either the current trolley position (SND) or the load position (SNL) at the time the sway neutralization is activated.
Sway neutralization results in slight travel movements to both sides of the target position.
The position of the load is acquired by the camera measuring system.
Additional functions for ship to shore cranes
Trim, list and skew control (TLS control)
TLS control controls the trim, list and skew positions of a spreader.
The TLS control function assumes that
- the length or
- the pivot points
of the 4 support cables of a spreader can be adjusted by hydraulic cylinders, or an additional electric system with the aid of the camera.
G_CR01_XX_00357
Schematic diagram of TLS movements
Each cylinder can be traversed individually for calibration purposes. Through actuation of these hydraulic cylinders in pairs, the spreader can be tilted to the left or right (trim), inclined towards the waterside or landside (list) or rotated in a clockwise or counterclockwise direction (skew). All of these TLS movements can be carried out simultaneously. The specified positions of all 4 cylinders can be saved as zero positions and approached again. For TLS positioning, either the last TLS position at the landside (LS) and at the waterside (WS) or the last TL position at the LS and at the WS with an externally definable rotational position can be approached.
The TLS control function is subdivided into two categories, each of which requires a separate license:
- TLS Basic modes
- Cylinder inching
- Approach zero position without skew damping
- TLS inching without skew damping
- TLS Advanced modes
- Cylinder inching
- Approach zero position with skew damping
- TLS inching with skew damping
- TLS positioning with skew damping
- Skew damping
Skew damping
Skew damping is an electronic anti‑sway function which eliminates the skewing motion of the spreader by means of the hydraulic cylinder control or an additional electric system. The skewing motions are recorded by the same camera as for sway. In the conventional mechanical design, TLS positioning as well as skew damping is performed via the hydraulic system. In a combined mechanical system using a hydraulic system and an electrical system, TLS positioning is performed via the hydraulic system and only skew damping is performed by the electrical system. This ensures more efficient and more dynamic damping.
Semi‑automatic mode (SAM)
The semi‑automatic mode allows the system to be set up so that the load is traversed along an optimal trajectory. The trajectory is specified to ensure that the spreader or grab does not collide with the crane structure or with containers or other obstacles, and also reaches its target position rapidly and accurately. This operating mode can be used for ship to shore cranes (STS) and ship unloaders (GSU). A seamless switchover between manual mode (MAN) and SAM makes different operation possible.
The obstacles are stored in the system as blocked regions and traversing is only permitted outside these areas. Depending on the starting point and the target position, the fastest possible trajectory is generated from the data about the blocked regions. Both axes (trolley and hoist) must be operated coordinately in the semi‑automatic mode.
The container profile can be specified externally by a 2D/3D laser system or a bay scanner (point laser) connected to the crane controller or acquired internally by learning during the motion.
The trajectory is calculated on the basis of a layout of the working area in which blocked regions are defined. Blocked regions are individual or several combined obstacles or also areas which the crane must not enter for safety reasons to avoid collisions. A distinction is made between fixed and variable blocked regions.
A blocked region is described by two trolley positions and one hoisting position.
The types of blocked regions and their purposes are shown in the following graphic.
G_CR01_XX_00228
Layout of blocked regions
If a bay scanner is used, the signal of the obstacle height is evaluated in addition to the traveled curve. The distance from the scanner to the surface of the container stack is measured (see graphic below, dashed lines).
This value must be converted to a laser value in the PLC which corresponds to the distance from the scanner to the top edge of the container stack at this point (see graphic below; converted laser value). The vertical distance between 2 valid measuring points is set to the height of the highest measuring point.
G_CR01_XX_00229
Measurement of the height of the container stack with the laser scanner
Additional functions in the grab crane application area
Semi‑automatic mode with unloading on the fly
In the ship unloader application (GSU), unloading on the fly utilizes the maximum swaying of a grab when unloading bulk goods and saves turnover time in this way. The trolley is decelerated before reaching the target position while the grab is swinging to the target (e.g. hopper). During swaying over the target area, the grab is opening for unloading. As soon as the grab reaches its target position, the trolley starts to travel back. In this way the trolley eliminates the stop time for unloading over the hopper and the grab remains longer over the hopper area.
P_CR01_XX_00062
Grab crane (GSU)
Additional functions for application OHBC, Gantry crane
This application is designed for industry overhead bridge cranes (OHBC) and gantry cranes with two axes in the plane (trolley, gantry) and an additional axis (hoisting gear).
Either manual mode (MAN: a speed setpoint is set on the master switch) or positioning mode (POS: a target position is set), can be selected. The operating mode of each axis can be switched over on the fly, e.g. from manual mode to positioning mode and vice versa, while the axis is moving.
Each axis can move independently from the other axes without consideration of any obstacles.
The sway neutralization mode (SNL & SND) can be applied to eliminate swaying movements of the load from standstill for both trolley and gantry separately in case of existing camera.
Detour Control
The Detour Control with coordination of trolley and gantry is newly provided inside positioning mode to travel around obstacles for collision prevention. The trajectory can be calculated and optimized by the Sway Control System with given target position and defined obstacles. The path can also be specified by a higher‑level controller via some intermediate targets. In addition, the Detour Control can consider special areas with limited speed for safe operation. Parts of obstacles can be activated or deactivated for flexible usage of the same area. A predefined safety clearance around an obstacle provides a buffer zone for smart slow-down to avoid collisions.
P_CR01_XX_00075
Note:
Various licenses which cover combinations of the operating modes described above are available for the sway control systems (see Selection and ordering data).