Transcript
Degree project
Design of a Quay Crane Training Simulator
Author: Boyang Chen, Mingyi Xu Supervisor: Göran Ewing, Pieternella Cijvat Examiner: Pieternella Cijvat Date: 15-06-2015 Course code: 2ED14E, 15hp Topic: Electrical Engineering Level: Bachelor of Science Department of Physics and Electrical Engineering Faculty of Technology
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Summary This thesis describes the whole process of crane training simulator designing. First the console control system scheme was made based on the functions of the crane training simulator. A PLC was chosen to achieve the goal of controlling the system. Secondly we decided to use a Siemens PLC S7-300 to evaluate the amount of inputs and outputs. Thirdly the functions were analyzed which the crane training simulator needs. Then the amount of inputs and outputs were counted and an I/O address distribution table was made. Next programming with the software STEP7 was done. The result was shown in a watch table for every function with the software S7-PLCSIM. A simplified experiment was finally done with the S7-200 unit and an HMI unit. The limit of the project is that we didn’t make a full-scale physical demonstration due to equipment and economy reasons.
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Abstract Nowadays, port enterprises pay more attention to train operators of heavy machinery, by mean of a simulator. An example is a quay crane training simulator. A perfect control simulator system can achieve the function of crane training better, make it more perfect, improve the efficiency of training operators and enhance the port management. This will promote the development of the port. This thesis mainly focuses on PLC implementation of a simulator system. The logical relationship between buttons on the console and input and output signals are presented and the information exchange between seat console and computer is achieved by programming with PLC.
Keywords: Quay crane, Training simulator, Control system, PLC, Seat console, Programming.
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Preface This project is made within the framework of the innovation project we have in Shanghai Maritime university. We make it a more complete base on the framework, but the project still have a limit that we don’t make it a perfect physical stuff. But we have tried our best in the experiment of PLC S7-200, hope to do more physical connection with PLC. We deeply appreciate our supervisor Göran Ewing’s support, all the experiment is under your help. Thanks to our supervisor Ellie Cijvat, giving us a lot of help with the report and design, your patient comment make this project more complete and logical.
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Table of Contents S u m m a r y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I Abstract........................................................ IV Preface.........................................................V Ta b l e o f C o n t e n t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V I I 1. Introduction 1.1
Problem statement................................................1
1.2
Problem background................................................1
1.3
Aim of the work...................................................1
2. Crane simulator system 2.1
Description of a quay crane.........................................3
2.2
D e s c r i p t i o n o f a q u a y c r a n e t r a i n i n g s i m u l a t o r. . . . . . . . . . . . . . . . . . . . . . 5
3. M a t h e m a t i c a l m o d e l o f a q u a y c r a n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 4. PLC signal acquisition setup 4.1
Choice of PLC model....................... ........................21
4.2
I/O address distribution..........................................21
5. Implementation and experiment 5.1
Programming .......................................................25
5.2
Simulation on software .............. ..............................26
5.3
Experiment with PLC S7 -200....................... ..................28
6. Discussion and conclusion...................................... 33 7. References...................................................... 35 Appendix.......................................................37
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1. Functions of the operation panel.....................................3 8 2. Input I/O address distribution........ ..............................47 3. Output I/O address distribution....... .............................54 4. M address distribution................ ..............................57 5. The full instruction...............................................62
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1 Introduction 1.1 Problem statement To meet the needs for the continued rapid development of China’s port economy, the throughput of container ports are growing. Newer and higher requirements on the process of container port handling and container handling technology and equipment are enforced. Port container lifting equipment is developing towards the direction of high-speed, large-scale and automated direction. Training for operators has become increasingly important in that the cost of port container equipment is getting higher. The technical proficiency of operators plays a decisive role in safety, equipment service life and economic benefits of the port. Container cranes simulation training systems based on virtual reality have widely been used in many countries, as they have the advantages of safety, cost saving, better function and high training efficiency. Thus, it is of vital importance to research and develop the container crane training simulator that is in line with China’s national conditions and with independent intellectual property rights.
1.2 Background Nowadays, a quay crane is the main equipment for loading the cargo of the containers. The ability and speed it works at have a direct relation to the port economy. With the development of overseas shipping trade and port trade, the amount of cargo becomes larger. So the crane needs to be larger and high-speed. A more safe and high efficiency training method is needed urgently. As a result, training simulator is becoming popular. It is a system which contains dynamics simulation technology, real-time 3D visual simulation technology, sensor and control technology, computer interface and communication technology, artificial intelligence and knowledge engineering. It is safe, high-efficiency and low cost,booming.
1.3 Aim of the work The aim of the project is to describe a crane training simulator system and implement a program for signal acquisition and processing with PLC, building the control system for a quay crane training simulator. The program is implemented using a Siemens S7-PLC. More over a simplified program is implemented using an S7-200 unit and evaluated.
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2. Crane simulator system 2 .1 Description of a quay crane A quay crane is a specialized kind of crane which is used to load and unload containers in front of the container terminal. There are thousands of quay crane in the world, these quay cranes have different appearance because of suppliers. The most common quay crane is made up with a door frame, tension member and bridges supported by the gantry. A trolley moves along the track on the beam, loading the containers by using a technical spreader. The gantry moves parallel to the shoreline so as to be easier to calibrate the lifting position and container position. For the convenience of the ship to moor and leave the dock, the part of the bridge which is out of shoreline can do the pitching movement up and down. There are several types of quay crane according to different classification methods, see the table below. Table 1. Quay crane classification.
Main beam structure
Single box-girder bridge structure Twin box-girder bridge structure Plate girder and truss structure Truss structure
Trolley shape
Loading trolley Self propelled trolley Used trailed trolley
Height restriction
Pitching main beam Stretching main beam
Quay crane
Bending main beam Trolley work mode
Single trolley Twin trolleys Double 40-inch single trolley
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Double 40-inch twin trolleys Type of cargo ship
Panama quay crane Post-panama quay crane
Figure 2.1 A quay crane of gantry crane
The main steps of unloading containers Typical steps performed when loading or unloading containers are: [2] (1) Before the cargo ship mooring, move the quay crane along the track to the quay line. (2) After the cargo ship mooring, move the quay crane to the accurate place. (3) According to the cargo situation, move the trolley along the track to above the container which is going to be unloaded, put the spreader off.
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(4) Make sure that the spreader and the container have been locked, lift the container on the ship. (5) Move the trolley to the land along the track, hang the containers directly to the transport machine (such as a container truck) (6) Detach the spreader and container. (7) Lift up the spreader, move the trolley to the seaside. This is an unloading circle, again and again until all the containers have been unloaded.
Figure 2.2 Crane unloading sketch
2.2 Description of a crane training simulator It is important that all steps can be performed in a training simulator, with an experience as close to real work as possible. A crane training simulator is based on virtual reality. It is a system which contains dynamics simulation technology, real-time 3D visual simulation technology, sensor and control technology, computer interface and communication technology, artificial intelligence and knowledge engineering. It is for training the operators to be familiar with the crane. The PLC control system is the main focus of this work and will be discussed further in chapter 3. The cab system, providing the inputs to the PLC system, and the mathematical model will be briefly described below.
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Structure of a crane training simulator A quay crane training simulator may be made up with the following modules Cab System Instructor Station Control System 3D Imaging Visual System Dynamic Mathematical Model Motor Drive PLC Control System Video System Teaching Projection System Network Communication System
Cab
Trainee
operating
console
Signal acquisition PLC
Vision
Instructor Station Control Sound
System including Mathematical Model
Seat vibration
Teaching Projection System Instructor
Figure 2.3 Crane training simulator schematic diagram. 6
The training system can be represented as shown in figure 2.3 *the PLC control system is responsible for the signal acquisition and mathematical model. ? *3D Imaging Visual System is responsible for the vision. *Network Communication System is for the connection between the models as well as communication between instructor and trainee.. *Dynamic Mathematical Model is the mathematical description of crane movement including containers movement and spreader movement and so on. *Teaching projection system is the guide showed on the screen which can help the trainee to be familiar with the operation.
2.2.2 Cab System The cab system includes Operation Console, Seat Simulation Vibration System, Windows system, Indoor Video System and interior Photographic Surveillance System. The simulator works through the virtual environment, the result of controlling the visual system and sound system. The PLC need to collect signals from the switches, input signal buttons. It also sends output signals to go through the address Q to guiding lights and buzzers at the panel directly. Other output signals need to go through the address M to communicate with the PC, to control the visual environment system and sound system for the corresponding action. The PC also needs some of the signals. These signals come through the PROFIBUS cable from the PLC to simulate the operating process of the various conditions and the current state of the crane, to achieve the effect of the simulation of real work.
As for this project, the PLC program is programmed on Step-7. The cab simulation environment is shown in figure 2.4.
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Vision software communicates with PLC access OPC server.
PROFIBUS cable
Address：I
Address：M
Address：Q
For collecting all input
Use to communicate to
For collecting all output
signals from panel
OPC server on PC
signals to panel
Input signals from panel
Input signals to
such as buttons
panel
such
light,buzzer.
Figure 2.4 Structure of the PLC system
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as
Figure 2.5 Cab system of a training simulator
The crane seat has two operating panels, one on the left side of the seat and the other is on the right side. The layouts of these panels are shown in the figures below.
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Figure 2.6 Right operation panel.
The button functions of the right panel from left to right are: Row1: Unlock, lock (switch); stop (knob) Row2: Guide plate rise or down (switch) ; relative position of two spreader (switch) Row3: Overload ( light); overload alarm ( light); emergency stop (light) Row4: Control connect (light+self reset button); anchor rise in high wind (light+self reset button); gantry anchor rise ( light+self reset button); wind speed 30m/s (light) Row5: On or off (two way switch); spreader pump on (light+self hold button); wind speed 20m/s (light) Row6: Head block cylinder manual rise or down (self reset button); head block cylinder choose left ,all or right (three way switch); automatic adjust (self reset button)
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Row7: Spreader reset position1 (self reset button); position2 (self reset button); spreader position set position1,stop or position2 (three way switch); spreader anchor choose seaside, stop or land side (three way switch); Row8: Silencing (self reset button); electrical fault (light) Row9: Beam move allowed (light+self reset button); beam stop moving (light+self reset button); beam goes up (light+self reset button); beam goes down (light+self reset button)
Figure 2.7
Left operation panel.
The button functions of the left panel from left to right are: Row1: Seaside left guide plate (light+self hold button); seaside right guide plate (light+self hold button);
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Row2: Land side left guide plate (light+self hold button); land side right guide plate (light+self hold button); Row3: Boom movement allowed (light+self reset button) Row4: Trolley automatic stop (light+self reset button); trolley stop (light+self reset button); Row5: 20 feet (light+self hold button); 40 feet (light+self hold button); 45feet (light+self hold button); 2×20feet (light+self hold button); Row6: Van or trailer (two way switch); hook or spreader (two way switch); button);
Lock shrink (self reset
lock stretch (self reset button);
Row7:Lock memory stop or automatic or manual (three way switch);Seaside lock position set (light+self reset button); land side lock position set (light+self reset button); Row8: Spreader choose sea, all or land (three way switch); head block pump on or off (self hold button); head block cylinder stretch, stop or shrink (three way switch); Row9: Spreader link (self reset button); spreader detach (self reset button); head block connect automatic or manual (two way switch).
2.2.3 Cab console units The following units are present on the operation console: Push buttons
Guiding light: Give information to the trainee about what is going on, red, yellow, green are available.
Self reset button: The button will reset after pressing.
Self hold button: The Button will hold on after pressing. 12
Two-way or three-way switch
Maximal contact load: 24VDC-2A. Minimal contact load: 5VDC-1mA.
Figure 2.8 Joystick. A four-way joystick is used to start, control the speed and rotating direction of crane motors, to control different crane motors simultaneously. The joysticks on the right operation panel and the left panel are the same kind of joystick shows in figure 2.8. The one on the right panel is a single axis joystick which controls the movement of trolley. The one on the left panel is a dual axis joystick. Its X axis represents the movement of the gantry and its Y axis represents the up and down movement of the spreader.
Working conditions : - Rated supply frequency AC 50Hz (60Hz) - Rated voltage 380V (440V) or lower
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Comfort seat, mechanical suspension with weight adjustment. 50-130kg with height adjustment 0-30-60-80-mm.
2.2.4 Cab operation panel functions The table below shows the functions of the operation panel. The full table is in shown in appendix 1.
For example, when the overload is more than 100%, the red overload light will turn on and the trainee can see that light on the right operation panel. It is an output. When the trainee chooses spreader reset position1 on the right operation panel, an input signal is sent to the PC.
Table 2. Some of the function of the operation panel.
Name
Type of signal
Function Descriptions
DI Power General
switch
(Digital signal
Control power
input) control Control connect
DI
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Controller is connected
DO Light of connection
(Digital signal
Light of connection turns on
output) Emergency
DI
stop
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Stop every processes
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3 Mathematical model of a quay crane As an illustration of crane movement, a simple model for two dimensions is presented here.[3] The model used in the simulator is more complicated, but is outside the scope of this thesis.
Figure 3.1 A 2-D model of the crane.
M is the mass of the trolley, m is the mass of the container. The length of the cable carrying the container is L. X is the position of the trolley. According to the actual condition of the crane, it has the following assumptions: (1) The displacement of the crane is ignored. (2) The air resistance is ignored. (3) The weight of the steel cable is ignored. (4) The rotation of the container is ignored.
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From the force diagram we can get the two equations below. .. .. . 2 . ( M m ) x ml cos ml F u x .. .. x cos l g sin
Here F is the force in the direction of X and g is gravity. u is the friction of the trolley wheels. Usually
is smaller than in 5 this model. So cos 1 , sin , and we can get
u mg 1 .. x M x M M F .. u x (m M ) g 1 F Ml Ml Ml Transfer the equations to state-space representation . x(t ) A(t ) x(t ) B(t )u (t ) y (t ) C (t ) x(t ) D(t )u (t )
x [ x, x , , ] And with u(t)=F ,Y=[x] we get
0 u M A 0 u Ml
1
0 m 0 g M 0 0 ( M m) g 0 Ml
0 0 1 0
0 1 BM 0 1 Ml C 1 0 0 0
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So we give constant values to g, u, m, M and l from the data of a real crane. g=9.81 m/s2 u=0.05; m=100000 kg; M=40000 kg; l=8 m;
Figure 3.2 Simulation result. A math model used in a full-scale simulator would be more complicated for 3D. The model used here is an illustration. The math model can run on a PC, where combined with input from the instructor, suitable vision, hearing and seat vibration signals for the training system can be provided.
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4. PLC signal acquisition setup 4.1 Choice of PLC There are 39 inputs and 15 outputs on the control panel at the right side, and 49 inputs and 16 outputs on the left control panel. So the PLCS7 - 200 can not meet the requirements of the access number, and therefore PLCS7-300 is selected as core [6]. According to the S7-300 Instruction Manual, 6ES7321-1BL00-0AA0
(DI32×24VAC)
is
selected
as
input
module. The
output
module
is
6ES7322-1HH01-0AA0 (DO16×DC24VDC/0.5A). Both sides of the control panels have two input modules and one output module.
4.2 I/O address distribution Table 3.
I/O address distribution, as an example of the list of inputs. Input Module
6ES7321-1EL00-0AA0. The full table is shown in appendix 2. This is module No.1 of 4 input modules. I/O address
Function
Condition
Received
signal
Send signal to PC
Not spreader reaches
M0.5 spreader reach
M5.0 Spreader
Spreader pump
the limit signal, not
es the limit signal,
pump on signal
on button
spreader fault signal
M0.6 spreader fault
from PC I0.0
mute button
I0.1
signal I0.2
Spreader unlock
Spreader pump on
M0.7 container in
M5.1 Spreader
signal, container in the
the right place signal
unlock signal
Spreader pump on
M1.0 spreader in the
M5.2 Spreader lock
signal, spreader in the
right place signal
signal
Seaside right guide
M1.1 container
M5.3 Guide plate go
plate choose signal,
shipment signal
up signal
right place signal I0.3
Spreader lock
right place signal I0.4
Guide plate go up
seaside left guide plate
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choose signal,land side left guide plate choose signal,land side right guide plate choose signal I0.5
Guide plate go
M5.4 Guide plate go
down
down signal
I0.6 I0.7
I1.0
I1.1
Spreader left
Spreader pump on
M5.5 Spreader left
leans
signal
leans signal
Spreader right
M5.6 Spreader
leans I1.2
right leans signal
Spreader
M5.7 Spreader
forward I1.3
forward signal
Spreader
M6.0 Spreader
backward
backward signal
I1.4
M6.1 record
Spreader position
spreader position 1
1
signal
I1.5
M6.2 record
Spreader position
spreader position 2
2
signal
I1.6 I1.7
Table 4. Output Module 6ES7322-1BH01-0AA0. The full table is shown in appendix 3. This is module No1 of 2 output modules.
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I/O address
Function
Condition
Received
signal
Send signal to PC
from PC Q0.0
Red overload
overload 100% signal,
M0.0 overload
lights on with
100% signal
lights Q0.1
blinking,interval1s.
Yellow overload
overload 75% signal
lights
75% signal
Q0.2
wind velocity30
wind velocity30 Warning lights
M0.1 overload
M0.2 wind velocity30
warning signal, lights on
alarm
signal
with blinking,interval1s.
Q0.3
wind velocity20 Warning lights
wind velocity20
M0.3 wind velocity20
warning signal alarm signal
Q0.4 Q0.5 Q0.6 Q0.7
Address M distribution Table 5. Address M distribution. The full table is shown in appendix 4. This is the first byte of the M-memory.
I/O address
Function
M0.0
overload 100%
M0.1
overload 75%
M0.2
wind velocity 30 alarm
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M0.3
wind velocity 20 alarm
M0.4
Electrical fault warning
M0.5
spreader reaches the limit
M0.6
spreader fault
M0.7
container in the right place
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5. Implementation and experiment 5.1 Programming The program is divided into nine parts, as the following image shows. Each function handles one part of the crane. The full instruction is shown in appendix 5.
OB1 is a Cyclic Program and it is executed continuously until OB1 is interrupted by others. It is available to call other function blocks in OB1 (FB, FC).
FC1 is designed to control the alarm system. FC2 is designed to control the spreader system. FC3 is designed to control the guide board. FC4 is designed to control the boom movement. FC5 is designed to permit the pitching control. FC6 is designed to control the trolley. FC7 is designed to control the crane movements. FC8 is designed to control the head block movements. FC9 is designed for other control signals.
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5.2 Simulation on software After the PLC program is written, software S7-PLCSIM is used to debug. S7-PLCSIM is a software which is developed by Siemens Company. The software is used to simulate and test S7-300. S7-PLCSIM and STEP7 is integrated together, and for simulation, it is not needed to be connected to any PLC hardware. It provides ports for monitoring and modifying programs.
S7-PLCSIM can be opened from the SIMATIC Manager. Because there are so many inputs and outputs, as well as M memory address communicating with the PC, this chapter will not show every function of PLC, just show some result of watch table and explain them.
Example1: Input overload signal（M0.0), the overload alarm（Q0.0）is energized and flashing，and a buzzer （Q1.6）is energized.
Example2: When you turn on the spreader motor (I0.1), the “Spreader motoe on” light turns on（Q0.5).
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Example 3: Input strong wind signal（M0.2，the wind alarm（Q0.2）is energized and flashing，a buzzer （Q1.6）is energized. The pitching operation is canceled (Q2.4).
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5.3 Experiment with PLC S7-200 [4] [5] Serial communication is when data is transmitted one bit at a time. A data word has to be separated into its constituent bits for transmission and then reassembled into the word when received. Serial communication is used for transmitting data over long distances. This might be used for the connection between a computer and a PLC. The possibilities for serial communication between PLC and PC are shown below.
PPI communication: The PPI interface is used for the S7-200 PLC. It is a point to point interface. - OPC server - The additional module CP243 can be used in order to enable the S7 protocol communication via the PmS7 driver - The S7-200 CPU226 devices support also the communication interfaces MPI and PROFIBUS. - The designer can implement simple ASCII protocol into the PLC S7-200 and then to use the PmChar- Driver for communication by user defined ASCII/BIN protocol in the PROMOTIC system.
MPI communication: The MPI interface is a "Derivation" of the PROFIBUS-DP. It is I is Multi Point Interface. The communication line is RS485, the speed rate is preset to 187.5kb/sec. The speed rate can be decreased to 19.2kb/sec and according to the device (CPU300, OP, CP6511) it can be even increased to 12Mb/sec. - PmS7 - Driver for communication by S7-TCP/IP protocol. The driver can be used only together with the Netlink converter. - OPC server - Communication using the PRODAVE or Soft NET-S7 libraries is considered obsolete and is not recommended.
PROFIBUS communication: PROFIBUS is a physical interface that cannot be directly connected to the PC. The connection is managed by additional PROFIBUS PC card. - PmS7 - Driver for communication by S7-TCP/IP protocol. The driver can be used together with the Netlink converter. - OPC server. In our experiment PROFIBUS was used.
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The OPC server: Virtually all mentioned communication types can be executed through the OPC server. It is supplied by default with PLC programming environment or it can be purchased in its software package SOFTNET. The OPC server supports virtually all protocols required for the communication with the PLC of the Simatic type (serial link, MPI, PROFIBUS, PROFINET, PPI, etc.).
Figure 5.1 Setup of the experiment.
Figure 5.2 The PLC-200
HMI is the abbreviation of Human Machine Interface. It is the medium of exchange between human and a technological system. HMI can connect PLC or similar of industrial control equipment, and show information and operate by screen. It is made up of two parts, software and hardware. Using HMI, it is more convenient to operate systems and more easy to get information from a machine. In this thesis, the KTP 600 DP is selected as HMI device to connect human and the PLC system. After finishing the programming, we made a HMI project by using TIA Portal V12. Both KTP 600 and TIA portal are developed by Siemens. This HMI project is based on some functions we selected from the complete crane training simulator. It can explain the function of the simulator clearer and easier to understand.
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When someone opens the HMI project, the root screen is shown on the screen. Then the root screen button can be touched and the screen is shown as below.
Click Start to turn on the simulator
Press alarm to enter to the alarm part.
Switch on wind 20 signal resulting in the yellow light alarm and switch wind 30 signal resulting in the red light alarm.
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For the trolley part, we can give the analog signal value to control the movement of the trolley on the X axis by the knob. The position of the trolley will also be shown on the right side of the screen.
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6 Discussion and conclusion A crane training simulator occupies an important position when the port enterprise is training their staff because of its safety and economical efficiency. Every simulator has its special control system, different control systems give simulators different functions. This thesis aimed to design a console control system fit for a crane simulator. This thesis described the whole process of crane training simulator designing. Firstly the console control system scheme was made based on the functions of a crane training simulator. PLC was chosen to achieve the goal of controlling the system. Secondly, we decided to use PLC S7-300 to evaluate the amount of inputs and outputs. Thirdly, the functions was analyzed which the crane training simulator needs and then the amount of input and output was counted and a I/O address distribution table was made. At last, programming with the software STEP7 was done and a simplified experiment was done with the S7-200 unit. The limit of the project is that we didn’t make a full-scale physical demonstration due to equipment and economy reasons. To improve the result, a 3D mathematical model can be made by matlab to simulate the movement of the crane. But a 3D mathematical model is complicated to make so we simplified it into a two dimensional model. The technique of simulation is now emerging in the port management and training. We can use the model and the method of making the model for the other kinds of cranes. The success of simulator applications to the port provides new risks and bigger development space. With the perfection of training simulators, the training of operators will be more efficient and formal. More and more skilled operators will be sent to the port to meet the need of development of port trade and container shipping industry.
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7.References [1] Wilson, B.H., Mourant, R.R., Li, M., et all. “A Virtual Environment for Training Overhead Crane Operators: Real-Time” in IIE Transaction 1998, Page 589-595 [2] DONG Haoming; XU Guifang, CHEN Dingfang. “Research on Overhead Crane Training System and its Construction Based on Virtual Reality”, In ICAIE 2010, Page 197-208 [3] G.F Franklin, J. D. Powell, and A. Emami-Naeini. Feedback Control of dynamic systems. Pearson, seventh edition, 2014. [4] SIMATIC HMI HMI device KTP400 Basic, KTP600 Basic, KTP1000 Basic, TP1500 Basic Operating Instructions, Siemens, 2007 [5] SIMATIC S7-200 Programmable controller System Manual, Siemens, 2008 [6] PLC S7-300, CPU Specifications CPU 312 IFM to CPU 318-2 DP, Siemens, 2001
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Appendix Appendix 1: Functions of the right and left control panel Appendix 2: Input I/O address distribution Appendix 3: Output I/O address distribution Appendix 4: M address distribution Appendix 5: The full instruction
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Appendix 1 Functions of the operation panel
Right control panel Type of
Name
signal
Function Descriptions
DI(Digital Power switch
signal
Control power
input) Control connect
Controller is connected
DO
General control
DI
Light of
(Digital
connection
signal
Light of connection turns on
output) Emergency stop Emergency stop light Red overload light Yellow overload light Alarm
DI
Stop every processes
DO
Light turns on when emergency stop runs
DO
DO
The wind speed 30 red alarm
DO
light The wind speed 20 yellow
DO
alarm light
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Light turns on when overload is more than 100% Light turns on when overload more than 75%
Red light turns on when wind speed is more than 30
Yellow light turns on when wind speed is more than 30
Mute button
DI
Error alarm
DO
light
the crane
DO
Buzzer alarm rings when any fault occurs
Spreader pump
DI
Spreader pump open/close
DO
Light turns on when spreader pump open
DI
Spreader Container open
Spreader lock
DI
Spreader Container to close
Guide plate rise
DI
light
movement
Alarm light turns on when a fault occurs on
Buzzer alarm
Spreader pump
Spreader
Mute the buzzer
Spreader unlock
Control Direction of guide plate
Guide plate
DI
drop Spreader lean left Spreader lean right
DI
Control spreader lean left
DI
Control spreader lean right
DI
Control spreader lean forward
DI
Control spreader lean backward
DI
Setting spreader position 1
DI
Setting spreader position 2
Spreader operation
Spreader Lean Forward Control spreader lean backward Spreader
Spreader
position 1
reset signal
Spreader position 2
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Spreader stop Reset position 1 Reset position 2 Sea side Anchor Spreader anchor
Land side anchor Stop Anchor rise in high wind
Spreader anchor in special Situation
---
DI Press the button,spreader moves to the specific location DI
DI
Sea side spreader anchor
DI
Land side spreader anchor
---
DI
Light of Anchor rise in
DO
high wind Gantry anchor rise
DI
Rise the spreader to specific location when there has high wind alarm.
Light turns on when Anchor rise in high wind
Press the bottom, move the gantry to specific location
Head Head block
block cylinder
DI
Select head block cylinder
DO
Lights turns on when gantry anchor rise
left select Light of Truck anchor rise Head block Cylinder right
DI
select Select all
---
Manual rising
DI
Manual downing Automatic adju
Head block Cylinder up/down movement DI
DI
40
Automatic lifting position of Head block
stment
Cylinder
Movement
DI
permit Light of movement
DO
permit Movement stop Boom
Light of
movement
movement s Boom up Light of boom up Boom down Light of boom down Trolley moves
Trolley moves
Forward
right
Light turns on when permitting boom movement works
DI
Stop boom movement
DO
Light turns on when movements stop
DI
Control boom up
DO
Light turns on when boom up
DI
Control boom down
DO
Light turns on when boom down
DI
left Trolley
Permit boom movement
DI
Trolley’s speed
DI
(8)
41
Trolley handle
Left control panel Type of
Name
signal
Function Descriptions
Choose left guild board at
DI
Choose left guild board at seaside
seaside Choose left guild board at
DO
seaside light
Light turn on when someone choose left guild board at seaside
Choose left guild board at
DI
Choose left guild board at seaside
seaside Choose left guild board at
DO
seaside light
Guild board
Light turn on when someone choose left guild board at seaside
Choose left guild board at
DI
Choose left guild board at seaside
seaside Choose left guild board at
DO
seaside light
Light turn on when someone choose left guild board at seaside
Choose left guild board at
DI
Choose left guild board at seaside
seaside Choose left guild board at
DO
seaside light Pitching permit light Trolley
Trolley stop
Light turn on when someone choose left guild board at seaside
DO
Light turns on when pitching is permit
DI
Trolley stop at specific position
42
control
automatically button Light of trolley stop
DO
automatically Trolley stop button Light of trolley stop button Container selection
TTDS
Select 20 feet container Select 20 feet container light Select 40 feet container Select 40 feet container light Select 45 feet container Select 45 feet container light
Light turns on when trolley stop automatically
DI
Trolley stop movement
DO
Light turns on when trolley stop
DI
DI
DO
DI
DO
DI
DO
Twin-twenty detection system
Mode for 20 feet container
Light turns on when someone select 20 feet container
Mode for 40 feet container
Light turns on when someone select 40 feet container
Mode for 45 feet container
Light turns on when someone select 45 feet container
Select double 20 feet
DI
Mode for double 20 feet containers
containers Select double 20 feet
DO
containers light Select Trolley
DI
43
Light turns on when someone select double 20 feet containers
Trolley/ Truck mood select
Select truck
DI
Select hook
DI
Select hook
DI
Lock shrink
DI
Lock shrink
Lock stretch
DI
Lock stretch
DI
Adjust lock position manually/automatic
Hook/ Spreader mood select
Lock memory-manua lly Lock memory-autom
DI
atic Lock memory-stop
--
Set lock position at sea
DI
Set lock position at sea side
side Spreader and headline
Light of set lock position at
DO
sea side
Light turns on when someone set lock position at sea side
Set lock position at land
DI
Set lock position at land side
side Set lock position at land
DO
side light
Light turns on when someone set lock position at land side
Select spreader-seasid
DI
e Select spreader-land
DI
side
44
Select spreader seaside/land side/both
Select spreader-
--
all Head block pump on/off
DI
Guiding light of head block
DO
pump on/off Head block cylinder stretch Head block cylinder shrink
DI
DI
Guiding light of spreader
works.
Head block movement stretch/shrink/stop
--
cylinder stop
button
Light turns on when head block pump
DI
Head block
Spreader link
Head block pump on/off
DO
connect
Two spreader connect together
Light turns on when two spreader connect together
Spreader disconnect
DI
Two spreaders separate
button Guiding light of spreader
DO
disconnect
Light turns on when two spreader disconnect
Head block connect-manual
DI
ly Head block connect-automa
--
tic
45
Head block connect manually/automatic
Crane goes forward Crane goes backward
DI
DI
Crane speed (8)
DI
Spreader up
DI
Spreader down
DI
Spreader speed (8)
4 way joystick
DI
46
4 way joystick
Appendix 2 Input I/O address distribution Input Module 6ES7321-1EL00-0AA0 I/O address
Function
Condition
Received
signal
Send signal to PC
from PC I0.0
Mute button
I0.1 Spreader pump on button
Not spreader
M0.5 spreader reach
M5.0 Spreader pump
reach the limit
the limit signal,M0.6
on signal
signal, not
spreader fault signal
spreader fault signal
I0.2 Spreader unlock
Spreader pump on
M0.7 Container in
M5.1 Spreader
signal,container in
the right place signal
unlock signal
Spreader pump on
M1.0 Spreader in the
M5.2 Spreader lock
signal,spreader in
right place signal
signal
Seaside right
M1.1 Container
M5.3 Guide plate go
guide plate
shipment signal
up signal
the right place signal
I0.3 Spreader lock
the right place signal
I0.4
choose signal, seaside left guide plate choose Guide plate go up
signal,land side left guide plate choose signal, land side right guide plate choose signal
I0.5
Guide plate go
M5.4 Guide plate go
down
down signal
47
I0.6 - I0.7
I1.0
I1.1
Spreader left
Spreader pump on
M5.5 Spreader left
leans
signal
leans signal
Spreader right
M5.6 Spreader
leans I1.2
right leans signal
Spreader
M5.7 Spreader
forward I1.3
I1.4
forward signal
Spreader
M6.0 Spreader
backward
backward signal M6.1 Record
Spreader position
spreader position 1
1
I1.5
signal M6.2 Record
Spreader position
spreader position 2
2
I1.6
signal
Position 2 reset
Spreader pump on
M6.3
Spreader
signal
return to position 1 signal
I1.7
Position 2 reset
M6.4
Spreader
return to position 2 signal I2.0
I2.1
Spreader sea side
Spreader pump on
M6.5 Spreader sea
anchors
signal
side anchors signal
Spreader
land
side anchors I2.2
Wind velocity30 Strong wind
alarm signal or
anchor rise
strong wind anchor button
48
M6.7 Strong wind anchor signal
pressed Spreader pump on signal I2.3
M7.0 Crane anchor
Crane anchor rise
I2.4 Left head block
rise signal 2*20 Inch
M7.1 Signal of Left
container choose
head block
signal I2.5
Right head block
M7.2 Signal of right head block
I2.6
I2.7
I3.0
M7.4 Signal of Head
Head block up
block up M7.5 Signal of Head
Head block down
block down
M7.6 Signal of
Automatic adjust
I3.1 Front beam move
Automatic adjust Interlock with
M1.4 Trolley in the
M7.7 Front beam
front beam stop
initial position signal
move allowed signal
signal I3.2 Front beam stop
Inter lock with
M8.0 Front beam
front beam move
stop signal
signal I3.3
I3.4
Beam goes up
Beam goes down
Front beam move
M8.1 Front beam
signal
goes up signal
Front beam move
M8.2 Front beam
allowed signal
goes down signal
I3.5 -I3.7 I4.0-I4.7 I5.0
Trolley speed Trolley goes left
M1.5 Trolley track
49
M12.1 Trolley goes
no obstacle signal I5.1
Trolley goes
M1.5 Trolley track
right
no obstacle signal
left signal M12.2 Trolley goes right signal
I5.2 - I5.7
I8.0
Seaside
right
Seaside
right
M8.3
guide
plate
guide
plate
seaside
choose
choose,
seaside
Choose left
guide
plate signal
right guide plate choose, land side left guide plate choose, land side right guide plate choose,
four
signal interlock I8.1
Seaside
right
M8.4 Seaside right
guide
plate
guide plate choose
choose I8.2
Land
signal side
guide
I8.3
left
M8.5 Land side left
plate
guide plate choose
choose
signal
Land side right
M8.6 Land side right
guide
guide plate choose
plate
choose I8.4
signal
Trolley automatic stop button
I8.5
I8.6
M1.2 Trolley move
M8.7 Trolley move
to the right place
to the right place
signal
signal
Trolley stop
M9.0 Trolley stop
button
signal
TTDS
I8.7 I9.0
20 Inch container
Spreader pump on signal,spreader 50
M1.6
Spreader
M9.1 container
20
Inch choose
choose
unlock
signal,
without load signal
signal
40 Inch container
M1.6
M9.2
choose
without load signal
four choose mode interlock I9.1
Spreader
40
container
Inch choose
signal I9.2
45 Inch container
M1.6 Spreader
choose
without load signal
M9.3
45
container
Inch choose
signal I9.3
2*20
Inch
M1.6
container choose
Spreader
without load signal
M9.4 2*20 Inch container choose signal
I9.4 - I9.7 I10.0
2*20 Lock shrink
Inch
M10.1 Signal of
container choose
lock shrink
signal I10.1
I10.2
I10.3
I10.4
M10.2 Signal of
Lock stretch
lock stretch
Lock
M10.3 Signal of
memory-manuall
Lock
y
memory-manually
Lock
M10.4 Signal of
memory-automati
Lock
c
memory-automatic
set lock position
M10.5 Signal of set
at sea side
lock position at sea side
I10.5
Set lock position
M10.6 Signal of Set
at land side
lock position at land side
I10.6 - I10.7
51
I11.0
M10.7 Spreader
Spreader
choose-seaside
choose-seaside
I11.1
signal M11.0 Spreader
Spreader choose-
choose- land side
land side
I11.2
signal
Head block pump on/off
I11.3
I11.5
head block
head block pump
M11.3 Signal of
Head block
Head block cylinder stretch
Head block
M11.4 Head block
cylinder shrink
cylinder shrink
Spreader link button
I11.6
M11.2 Signal of turning on
cylinder stretch
I11.4
M1.3 Fault signal of
Spreader
Spreader pump on
M11.5 Spreader link
signal, 2 status
signal
interlock
detach
M11.6
button
Spreader
detach signal
I11.7 I12.0-I12.7 I13.0
I13.1
I13.2
I13.3
Crane speed M12.3 Crane go
Crane go ahead
ahead signal M12.4 Crane retreat
Crane retreat
Spreader go up
Spreader go down
signal Spreader pump on
M12.5 Spreader go
signal
up signal
Spreader pump on
M12.6 Spreader go
signal
down signal
I13.4 - I13.7 I14.0 - I14.7
Spreader speed
52
53
Appendix3 Output I/O address distribution Output Module 6ES7322-1BH01-0AA0 I/O address
Function
Condition
Q0.0
Red overload lights Q0.1
Received signal from PC
Overload 100% signal,
M0.0 Overload 100% signal
lights on with blinking,interval1s.
Yellow overload
Overload 75% signal
M0.1 Overload 75% signal
lights Q0.2
Wind velocity30 Warning lights Q0.3
Wind velocity30
signal warning signal, lights on with blinking,interval1s. Wind velocity20
M0.3 Wind velocity20
Warning lights
warning signal
alarm signal
Electrical fault warning
M0.4 Electrical fault warning
Electrical fault
signal,
signal
warning lights
lights on with blinking,interval1s
Spreader pump on lights
Q0.6 - Q0.7
Q1.0
Strong wind anchor rise lights
Q1.1
Crane
anchor
rise light Q1.2
Front
beam
move light Q1.3
alarm
Wind velocity20
Q0.4
Q0.5
M0.2 Wind velocity30
Front beam stop light 54
Q1.4
Beam goes up light
Q1.5
Beam goes down light
Q1.6
Overload 100% signal or
M0.0 Overload 100% signal,
overload 75% signal or
M0.1 overload 75% signal,
wind velocity30
M0.2 wind velocity30
alarm
signal, M0.3 wind velocity20 Warning buzzer
warning signal or wind velocity20
alarm signal
warning signal or Electrical fault warning signal. Q1.7
Q2.0
Seaside left guide
Seaside right guide plate
plate choose light
choose, seaside right guide plate choose, land side left guide plate choose, land side
right
guide
plate
choose, four signal interlock Q2.1
Seaside
right
guide
plate
choose light Q2.2
Land side left guide plate choose light
Q2.3
Land side right guide plate choose light
Q2.4
Pitching
Not wind velocity30
operation allowed
alarm , trolley stop signal,
light
gantry stop signal, spreader
55
stop signal Q2.5
Trolley automatic stop lights
Q2.6
Trolley stop light
Q2.7
Light of head block pump on
Q3.0
Light of set lock
2*20 Inch container choose
position at sea
signal
side Q3.1
Light of set lock position at land side
Q3.2
Spreader pump on signal, 2 Spreader link
status interlock
lights
Q3.3
Spreader detach lights
Q3.4 - Q3.7
56
Appendix 4: M address distribution Address M distribution I/O address
Function Description
M0.0.
Overload 100%
M0.1.
Overload 75%
M0.2.
Wind velocity30 alarm
M0.3.
Wind velocity20 alarm
M0.4.
Electrical fault warning
M0.5
Spreader reach the limit
M0.6.
Spreader fault
M0.7
Container in the right place
M1.0
Spreader in the right place
M1.1
Container shipment signal
M1.2
Trolley move to the right place
M1.3.
Head block fault
M1.4
Trolley in the initial position
M1.5
Trolley track no obstacle
M1.6
Spreader without load
M1.7
57
M5.0
Spreader pump on
M5.1
Spreader unlock
M5.2
Spreader lock
M5.3
Guide plate go up
M5.4
Guide plate go down
M5.5
Spreader left leans
M5.6
Spreader right leans
M5.7
Spreader forward
M6.0
Spreader backward
M6.1
Record spreader position 1
M6.2
Record spreader position 2
M6.3
Spreader return to position 1
M6.4
Spreader return to position 2
M6.5
Spreader sea side anchors
M6.6
Spreader land side anchors
M6.7
Spreader land side anchors
M7.0
Crane anchor rise
M7.1
Left head block
M7.2
Right head block
M7.3
Choose all head block
M7.4
Head block up
M7.5
Head block down
M7.6
Automatic adjust
58
M7.7
Front beam move allowed
M8.0
Front beam stop
M8.1
Front beam goes up
M8.2
Front beam goes down
M8.3
Choose seaside left guide plate
M8.4
Choose right guide plate
M8.5
Choose land side left guide plate
M8.6
Choose land side right guide plate
M8.7
Trolley move to the right place
M9.0
Trolley stop
M9.1
20 Inch container
M9.2
40 Inch container
M9.3
45 Inch container
M9.4
2*20 Inch container
M9.5
Van carrier choose
M9.6
Choose trailer
M9.7
Choose hook
59
M10.0
Spreader choose
M10.1
Lock shrink
M10.2
Lock stretch
M10.3
Lock memory-manually
M10.4
Lock memory-automatic
M10.5
Set lock position at sea side
M10.6
Set lock position at land side
M10.7
Spreader choose-seaside
M11.0
Spreader choose- land side
M11.1
Choose both side of spreader
M11.2
Head block pump turning on
M11.3
Head block cylinder stretch
M11.4
Head block cylinder shrink
M11.5
Spreader link
M11.6
Spreader detach
M11.7
Head block connect-manually
M12.0
Head block connect-automatic
M12.1
Trolley goes left
M12.2
Trolley goes right
M12.3
Crane go ahead
M12.4
Crane retreat
60
M12.5
Spreader go up
M12.6
Spreader go down
M12.7
61
Appendix 5:The full instructions
The function is divided into nine parts: FC1: Faults
Network1:
Red
overload
62
light
Network2 : Red overload light
Network3: Yellow overload light
Network4: Wind speed 30 alarm
63
Network5: Wind speed 30 alarm
Network6: Wind speed 20 alarm
Network7: Error alarm
64
Network8: Error alarm
Network9: Buzzer
65
Network10: Mute
66
Network11: Mute
FC2: Spreader Network1: Pump of spreader
Network2: Spreader lock
67
Network3: Spreader lock
Network4: Spreader leans left
68
Network5: Spreader leans right
Network6: Spreader leans forward
Network7: Spreader leans backward
69
Network8: Spreader position 1
Network9: Spreader position 2
Network10: Spreader position 1 reset
Network11: Spreader position 2 reset
70
Network12: Spreader anchor at seaside
Network13: Spreader anchor at land side
Network14: Anchor in wind
71
Network15: Select spreader for 20 foot container
Network16: The spreader for 40 foot contain
72
Network17: The spreader for 45 foot contain
Network18: The spreader for 20 foot contain
73
Network19: Lock shrink
Network20: Lock stretch
Network21: Select spreader at seaside
74
Network22: Select spreader at land side
Network23: Select all spreader
Network24: Connect spreader
75
Network25: Disconnect spreader
FC3: Guild Board Network1: Guild board up
Network2: Guild board down
76
Network3: Left guide board at seaside
Network4: Right guide board at seaside
77
Network5: Left guide board at land side
Network6: Right guild at land side
78
FC4: Boom Network1: Permit boom movement
Network2: Stop boom movement
79
Network3: Boom up
Network4: Boom down
80
FC5: Pitching Network1: Permit pitching
FC6:Trolley Network1: Trolley stop automatically
81
Network2: Trolley stop manually
FC7: XYZ Network1: Trolley toward to left
82
Network2: Trolley toward to right
Network3: Crane move forward
Network4: Crane moves back
83
Network5: Spreader up
Network6: Spreader down
Network7: Trolley speed
84
Network8: Crane speed
Network9: Crane speed
85
FC 8: Head block Network1: Head block cylinder toward left
Network2: Head block cylinder toward right
Network3: Select all head block
86
Network4: Head block cylinder up
Network5: Head block cylinder down
Network 6: Head block cylinder automatic adjust
87
Network7: Turn on head block pump
Network8: Head block stretch
88
Network9: Head block shrink
FC 9: Others Network 1: Select carrier
Network 2: Select trailer
89
Network 3: Select spreader
Network 4: Select hook
Network 5: Lock shrink
Network 6: Lock stretch
90
Network 7: Manual lock memory
Network 8: Automatic lock memory
Network 9: Set lock at seaside
91
Network 10: Set lock at land side
92
93
