Siemens AG Getting Started 01/2012

Getting Started
SIMOCRANE Basic Technology
CAUTION
Please pay attention to the polarity rules :

Hoist:
Hoisting velocity is POSITIVE, with ascending position values.
Lowering velocity is NEGATIVE, with descending position values.

Gantry:
Motion to right, POSITIVE velocity with ascending position values.
Motion to left, NEGATIVE velocity with descending position values.

Trolley:
Motion towards ship, POSITIVE velocity with ascending position values.
Motion towards shore, NEGATIVE velocity with descending position values.

Boom:
Hoisting velocity is POSITIVE, with ascending position values.
Lowering velocity is NEGATIVE, with descending position values.

Holding Gear:
Hoisting velocity is POSITIVE, with ascending position values.
Lowering velocity is NEGATIVE, with descending position values.

Closing Gear:
Closing, velocity is POSITIVE, with ascending position values.
Opening, velocity is NEGATIVE, with descending position values. (Position "zero",
grab is fully open.)

Slewing Gear:
Slewing right, velocity is POSITIVE, with ascending position values.
Slewing left, velocity is NEGATIVE, with descending position values.

Luffing Gear:
Hoisting velocity is POSITIVE, with ascending position values.
Lowering velocity is NEGATIVE, with descending position values.

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The Simocrane Basic Technology is based on the new platform Simotion / Sinamics.
To simplify the introduction of the new platform several standard projects for the
“Ready – To – Run” solution will be delivered on the CD. The appropriate standard
project must be selected, downloaded to the SIMOTION D435 and then the
commissioning can be started. In this Chapter the commissioning main line of the
“Ready – To – Run” solution will be described.

The following diagram provides an overview regarding the commissioning sequence.

Figure 1-1 Commissioning overview

Prerequisites:

WARNING
The system must be in a no-voltage state during checking the subsequently
described prerequisites for commissioning.

• All DRIVE-CLiQ nodes must be connected with one another exactly as was
created in project (reference and actual topology must match).
• The commissioning engineer is responsible for ensuring that the motors are
actually correctly connected.
• The encoder must be correctly connected.
• To connect only in parallel the drives of the same type and from same
manufacturer in order to guarantee identical drive data and symmetrical load
distribution.

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Step 1. General
The scope of delivery is described in the Chapter System Overview of the
SIMOCRANE Basic Technology documentation. On the CD there are a setup and
several standard projects available for the different types of cranes. Before starting
with the engineering, the ‘Setup’ must be executed.

After that the user should open the applicable standard project with SIMOTION
Scout. The following data have to be checked and if it is necessary then also
changed.

Step 2. SINAMICS:
Note:
The parameterization must be done for each drive data set.

Select control mode

p1300[0] = 21 Speed control (with encoder)
p1300[1] = 20 Speed control (sensorless) only for Trolley and Gantry applications

Select power unit

Configure the drive properties:

Standard: IEC – motor (e. g. 50Hz, SI units)

Connection voltage: p210

Drive filter type, motor side: p230

Power unit overload response: p290

Configure the motor:

Motor type p300[0]

Rated motor voltage p304[0]

Rated motor current p305[0]

Rated motor power p307[0]

Rated motor power factor p308[0]

Rated motor frequency p310[0]

Rated motor speed p311[0]

Motor cooling type p335[0]

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Motor data, Induction motor rotary (optional)

Motor rated magnetization current / short – circuit current p320[0]

Maximum motor speed p322[0]

Motor moment of inertia p341[0]

Ratio between the total and motor moment of inertia p342[0]

Motor weight p344[0]

Cable resistance p352[0]

Motor series inductance p353[0]

Calculation of Motor / Control parameters

Automatic calculation of motor / control parameters p340[0]

0: No calculation
1: Complete calculation (recommended)
5: Calculation of technological limits and threshold values

Motor holding brake configuration p1215 (Extended Brake control recommended)

0: No motor holding brake being used

1: Motor holding brake acc. to sequence control
3: Motor holding brake like sequence control, connection via BICO

Note:
p1215 = 1 is depending on power block

Configuration of the encoder data

Standard No standard
Enc type selection p400[0] Enc type selection = [9999] User-defined
Track A/B sq-wave p404[0].3
Equidistant zero mark p404[0].12
Voltage level 5V p404[0].20
Voltage level 24V p404[0].21
Remote sense (only SMC30) p404[0].22
Signal p405[0].0
Level p405[0].1
Track monitoring p405[0].2
Zero pulse p405[0].3
Switching threshold p405[0].4
Rotary encoder pulse No. p408[0]
SUB-D p420[0].0
Terminal p420[0].1
Encoder, rotary zero mark distance
p425[0]

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Set the values for the most important parameters:

Current limit p640[0]

(Important: In synchronous operation mode or Master – Slave operation the current
limit for the Master and Slave must be parameterized with the same value.)

Minimum speed p1080[0] = 0 (Important)

Maximum speed p1082[0]

(Important: In synchronous operation mode or Master – Slave operation the
maximum speed for the Master and Slave must be parameterized with the same
value.)

Ramp – up time p1120[0] (no influence in Simocrane Basic Technology)

Ramp – down time p1121[0] (be in force only in operation if OFF1 deactivated)

Ramp – down time with OFF3 p1135[0] (be in force only in operation if OFF3
deactivated)

Torque limit upper p1520[0]

(Important: In synchronous operation mode or Master – Slave operation the torque
limit for the Master and Slave must be parameterized with the same value.)

Torque limit lower p1521[0]

(Important: In synchronous operation mode or Master – Slave operation the torque
limit for the Master and Slave must be parameterized with the same value.)

Reference data

Reference speed reference frequency p2000

Reference voltage p2001

Reference current p2002

Reference torque p2003

Important: In synchronous operation mode or Master – Slave operation the reference

data must be parameterized with the same value.)

At the first commissioning the standstill identification must be done

Motor data identification and rotating measurement p1900

[1] Motor data identification for rotating motor (recommended)

[2] Motor data identification at standstill

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Speed controller

Speed controller with encoder

Speed controller P gain p1460[0]

Speed controller integral time p1462[0]

Speed controller (sensorless) only for Gantry or Trolley

Speed controller sensorless operation P-gain p1470[1]

Speed controller sensorless operation integral time p1472[1]

Sampling time settings (optional, if problems with synchronization appears)

Further Information, refer to FAQ in Internet address

http://support.automation.siemens.com/WW/view/en/44027119

Sampling times pre-setting: p112 = [0] Expert

Sampling times for Current controller p115[0]

Sampling times for Speed controller p115[1]

Scripting

For each main drive script file is available, with this file the complete communication
connection in the SINAMICS will be automatically done. The script file is under the
folder ‘scripts’ on each drive.

Step 3 SIMOTION:
Setting of the mechanics data of the Technology object

Distance per spindle revolution LeadScrew.pitchVal

Mounting of encoder
TypeOfAxis.NumberOfEncoders.Encoder_1.AssemblyBase.assemblyBase

Measuring gear
Number of motor revolutions
TypeOfAxis.NumberOfEncoders.Encoder_1.AdaptDrive.numFactor

Number of encoder revolutions

TypeOfAxis.NumberOfEncoders.Encoder_1.AdaptDrive.denFactor

Load gear
Number of motor revolutions

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TypeOfAxis.NumberOfDatasets.DataSet_1.Gear.numFactor

Number of load revolutions

TypeOfAxis.NumberOfDatasets.DataSet_1.Gear.denFactor

Limits in Technology object

Position and velocity

Maximum velocity TypeOfAxis.MaxVelocity.maximum

Here the formula to calculate the maximum velocity:

Speedreference must be the same value as in p2000

Dynamic response
Acceleration TypeOfAxis.MaxAcceleration.maximum

Jerk TypeOfAxis.MaxJerk.maximum

Monitoring in Technology object

Positioning and standstill

Positioning monitoring
Positioning window TypeOfAxis.PositionMonitoring.tolerance
Positioning tolerance time TypeOfAxis.PositionMonitoring.posWinTolTime
Minimum dwell time (in positioning window)
TypeOfAxis.PositionMonitoring.posWinToDelayTime

Standstill monitoring
Standstill window TypeOfAxis.StandStillMonitoring.stillStandTolerance
Tolerance time (when leaving standstill window)
TypeOfAxis.StandStillMonitoring.delayTimeToActivate

Following error
Maximum permitted following error
TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicFollowing.maxPositionTolerance

Constant following error

TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicFollowing.minPositionTolerance

Minimum velocity for dynamic following error monitoring

TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicFollowing.minVelocity

Maximum velocity
TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicFollowing.maximum

Standstill signal
Velocity threshold standstill signal TypeOfAxis.StandStillSignal.maxVeloStandStill

Signal output delay time TypeOfAxis.StandStillSignal.delayTimeToActivate

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Encoder data in Technology object

Encoder type: TypeOfAxis.NumberOfEncoders.Encoder_1.encoderType

Encoder mode: TypeOfAxis.NumberOfEncoders.Encoder_1.encoderMode

Measuring system: TypeOfAxis.NumberOfEncoders.Encoder_1.encoderSystem

Encoder pulses per revolution:

TypeOfAxis.NumberOfEncoders.Encoder_1.IncEncoder.incResolutionMultiplierCyclic

Fine resolution:
TypeOfAxis.NumberOfEncoders.Encoder_1.IncEncoder.incResolution
Standard value is zero.

Tolerate the encoder failure when it is not involved in the closed – loop control:
TypeOfAxis.NumberOfEncoders.Encoder_1.SensorControlConfig.tolerateSensorDef
ect (Important)

Optimize of the position controller

More information refer to in Ref. 2, Chapter 2.12

Static controller data

Servo gain factor
TypeOfAxis.NumberOfDataSets.DataSet_1.ControllerStruct.PV_Controller.kv = 1.0

Note:
Following kv settings are empirical values:
Gantry and Trolley in the range from 0.7 to 2.0
Hoist in the range from 1.0 to 5.0

Precontrol On
TypeOfAxis.NumberOfDataSets.DataSet_1.ControllerStruct.PV_Controller.preCon

Weighting factor
TypeOfAxis.NumberOfDataSets.DataSet_1.ControllerStruct.PV_Controller.kpc =
100.0% (recommend )

Balancing filter
TypeOfAxis.NumberOfDataSets.DataSet_1.ControllerStruct.PV_Controller.balanceFil
terMode = [1] MODE_1 (Balancing filter active)

Fine interpolation
TypeOfAxis.FineInterpolator._type = [2] CUBIC_MODE (Constant-acceleration
interpolation)

Dynamic controller data

Speed control loop equivalent time
TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicData.velocityTimeConstant

Position control loop equivalent time

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TypeOfAxis.NumberOfDataSets.DataSet_1.DynamicData.positionTimeConstant

Reference data

Specification of the maximum speed

TypeOfAxis.SetPointDriverInfo.DriveData.maxSpeed

Maximum torque of the drive TypeOfAxis.SetPointDriverInfo.DriveData.maxTorque

Specification of the reference speed

TypeOfAxis.SetPointDriverInfo.DriveData.nominalSpeed

Selection setting for the normalization: reference speed or maximum speed

TypeOfAxis.SetPointDriverInfo.DriveData.speedReference

Step 4 Crane DCC Baustein:

Using
DCC_Masterswitch?
Yes No
Enable of the Master-switch function Disable the Master-switch function
Parameterize the polygon curve
(Deflection and Velocity setpoint)

Gantry or Trolley
Using No
DCC_Tractioncontrol?
Yes No
Enable Traction-control function Disable Traction-control function
Parameterize the velocity settings
Parameterize the acceleration
settings

Using
DCC_PreLimitSwitch?
Yes No
Parameterize the velocity limits -

Hoist / Holding Gear

Yes No
Using Gantry or Trolley
DCC_ChangeOverHDFW?
Yes No Yes No
Parameterize the - Using -
Ramp-up and DCC_ChangeOverHDFW?
Ramp-down time Yes No

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in heavy duty Parameterize the -

Ramp-up and
Ramp-down time in
field weakening

Hoist / Holding Gear

Yes No
Using NominalVelocity
DCC_LoadDependingFieldWeak? must be the
Yes No same value as
Parameterize the Load value and the velocity - MaximumVelocity
Commissioning notes,
refer to [Ref. 1] Chapter 8.9
Setting connections before commissioning

rFact_AccCurrent_Load Rough order of magnitude 5%-

10%

rFact_AccCurrent_RotMass Rough order of magnitude:

20 % - 40 %

rFrictionCurrent Rough order of magnitude: 1 % - 3 %

rEfficiency_eta Rough order of magnitude: 110 % - 120

%

rLoadNormFactor Load[t] = measured value *

rLoadNormFactor +
rAddCurrentBeforePLI

rAddCurrentBeforePLI Load [t] = measured value *

rLoadNormFactor +
rAddCurrentBeforePLI

rLowLimitMeasRange = 40.0 %

rUpLimitMeasRange = 90.0 %

rSmoothTime_dn_dt Rough order of magnitude: 0 ms –

150 ms

rCurrentSmoothTime Rough order of magnitude: 0 ms –

200 ms

Note
The specified values in the above table are guide values.

Hoist / Holding Gear

Yes No
Using -
DCC_HeavyDuty

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Yes No
Parameterize the factor of -
heavy duty
Using constant field weakening
Yes No
Parameterize the factor of -
constant field weakening

Hoist / Holding Gear / Boom

Yes No
Using
DCC_StartPulse?
Method 1 Method 2 Method 3
Parameterize the Parameterize the Parameterize this
factors of the method, factors of the method, method, refer to
refer to [Ref. 1] refer to [Ref. 1] [Ref. 1]
Chapter 5.2.11 Chapter 5.2.11 Chapter 8.11

Hoist / Holding Gear

Yes No
Using -
DCC_ContLoadMeasurement?
Yes No
Parameterize the load values and the velocity setpoint -
Commissioning notes,
refer to [Ref. 1] Chapter 8.10
Setting connections prior to commissioning for gear stage 1

rFact_AccTorque_Load1 Rough order of magnitude: 5 %- 10 %

rFact_AccTorque_RotMass1 Rough order of magnitude: 20 % - 40

%

rY1_Friction_SGST1 bis rY10Friction_SGST1

Rough order of magnitude: 1 % - 3 %

rEfficiency_eta_lift = 100%

rEfficiency_eta_drop = 100%

rLimitToStartSawToothGen = 10 %

rLimitToStopSawToothGen = 30 %

rLoadNormFactor Load [t] = measured value * rLoadNormFactor

rStartMeasurement = 2.0

rStopMeasurement = 30.0

rIntegrationTimeSawTooth = 1.0

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Hoist / Holding Gear

Yes No
Using -
DCC_OverSpeed?
Yes No
Enable OverSpeed detecting -
Yes No
Parameterize Offset Enable Setpoint
and delay time Actualvalue detection
Yes No
Parameterize -
Offset and delay
time

Slewing Gear
Yes No
Using -
DCC_VelocityChangeSlewGear?
Yes No
Parameterize the settings -
of the velocity

Slewing Gear
Yes No
Using -
DCC_AccelChangesSlewGear
Yes No
Parameterize the settings -
of the accelerations

Holding Gear
Yes No
Using -
DCC_SlackRopeControl?
Yes No
Using Polygon curve? -
Yes No
Parameterize Parameterize
the polygon gain factor
cruve

Holding Gear
Yes No
DCC_SlackRopeControl or DCC_SlackRopeControl_1 -
Method 1 Method 2 Method 3
P – controller, refer Polygon curve, refer Torque limit, refer to
to [Ref. 1] Chapter to [Ref. 1] Chapter [Ref. 1] Chapter 5.2.13

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5.2.13 or 5.2.14 5.2.13 or 5.2.14 or 5.2.14

Function Easy Closing Torque limit is send by
boEnableEasyClosing only with the plc S7
DCC_SlackRopeControl_1
Yes No
Polygon curve, refer to -
[Ref. 1] Chapter 5.2.14
Adapting to material or gripper types
boEnableMaterialFactor only with
DCC_SlackRopeControl_1
Yes No
Factor will be send -
from the plc S7

Slewing Gear
Yes No
Using -
DCC_CurrentEqualControl?
Yes No
Parameterize gain factor -
Parameterize factor for
current setpoint Holding Gear
and Closing Gear
Using orange – peel bucket
mode?
Yes No
Parameterize -
factor for
current
setpoint
Holding Gear
and Closing
Gear in
orange – peel
bucket mode

Slewing Gear
Yes No
Using -
DCC_Grapmonitor
Yes No
Parameterize Interval limit -

Synchronous operation mode and Master Slave Torque control mode

Yes No
Using by the Slave drive the -
DCC_CurrentDistribution?
Yes No
Parameterize deviation -
threshold and delay time

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Step 5 MCC settings

The variables will be available in the Units of the main drives, for example Hoistp_1,
Gantryp_1, etc.

Using MinimumVelocity?
Yes No
Parameterize override for Minimum Velocity for the -
switchover from normal positioning to minimum
velocity movement.
Using
Operation mode Automatic?
Yes No
Parameterize positive direction -
MinimumVelocityAutoPositive
Parameterize negative direction
MinimumVelocityAutoNegative
Using
Operation mode Manual?
Parameterize positive direction -
MinimumVelocityManualPositive
Parameterize negative direction
MinimumVelocityManualNegative

Velocity limit in operation mode SENSORLESS EMERGENCY

r64VelocitySensorlessEmergency (recommended 10% - 15% from maximum

velocity)

Reference data are strongly required

Nominal velocity nominalVelocity = p2000, if Loaddepending Fieldweaking is not

used, then the value of the maxVelocity must be written.

Reference voltage nominalVoltage = p2001

Reference current nominalCurrent = p2002

Reference torque nominalTorque = p2003

Important data:

Jerk and minimum Ramp – Up and Ramp – Down time:

Start jerk of the acceleration r64positiveAccelerationStartJerk

End jerk of the acceleration r64positiveAccelerationEndJerk

Start jerk of the deceleration r64negativeAccelerationStartJerk

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End jerk of the deceleration r64negativeAccelerationEndJerk

Minimum Ramp – Up time minimumRampUpTime

Minimum Ramp – Down time minimumRampDownTime

The minimum Ramp Up and Ramp Down Time must be set correct, otherwise
smaller values from high level PLC will not be accepted.

Extend Ramp – Down time r64DecelerationFactor

For Closing Gear refer to Ref. 1 in Chapter 8.3.12

Homing

Fixed homing-value Homingwert HomingFixValue

Homing position will be send by the plc S7 or fixed homing value. HomingValuePLC

Monitoring time of the telegram failure

Monitoring time of the telegram failure S7 to Simotion MonitoringTimeS7

Monitoring (the most variables are in the Slave)

Position tolerance between Master and Slave ToleranceMasterSlavePosition

In synchronous control mode (speed control) or Master Slave Torque control the
maximum velocity difference value ToleranceVelocityMonitoring

In synchronous control mode (position control) the maximum position difference

value TolerancePositionMonitoring

Delay time for velocity or position difference ToleranceDelayTime

Gear factor (Motor encoder / external encoder) Gearratio

Permitted velocity tolerance between motor encoder and external encoder

Gearspeedtolerance

In synchronous or master-slave operation, the maximum current difference [A] is set.

ToleranceCurrentMonitoring.

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Step 6 Control
The Chapter 8.4 of the manual of SIMOCRANE Basic Technology includes
application examples for the plc S7. On the SIMOCRANE Basic Technology CD
these examples are included.
The interface is described in the Ref. 1, Chapter 6.2.

Information:
All warnings and alarm messages will be sent in the process data 4 from Simotion to
PLC. In Chapter 7 of Ref.1 the warnings and alarm messages are described. The
area of the warning and alarm numbers are in the Chapter 7 of Ref. 1. The warning
and alarm numbers are also available in the header of the function block (source
code).

The commissioning is described in Chapter 8.5 to 8.8. and for Grab it is described in
the Chapter 8.13.

Reference:
1. SIMOCRANE Basic Technology, Operating Instructions, Edition 10. 2010
2. SIMOTION Motion Control, TO Axis Electric / Hydraulic, External Encoder,
Function Manual, Edition 05/2009

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