Transcript Mitsubishi system solution

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Mitsubishi crane solutions
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Introduction
This presentation will help you to sell
more easy to crane applications.
Please find attached:
- Reference customers & applications
- Inverter specific functions
- Necessary Options
- System solutions
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Main crane types
• Tower crane
• Bridge crane
• Gantry / portal crane
• Jib crane
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Additional crane application
information for MEU and partners
• Following some information which
should help to get a better
understanding of the crane market
requirements and where Mitsubishi
has advantages and disadvantages.
• Critical issues for certain crane
types will be mentioned.
• Feel free to use any of these
information for your customers.
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Typical for Cranes
• High overload
(Cranes are often overloaded from user
side, and used outside the manufacturers specification)
• Smooth movement
• Control of mechanical Brake
• Secure magnetization of sliding rotor
motors (Works good with FR-A700)
• Hoist speed 5-25m/min
• Travel speed 15-80m/min
• Brake resistor need high specification
(40-50% power of hoist motor capacity,
for 100% ED, because of long travel distance)
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Typical for Cranes
• 90% of the hoists use an encoder
feedback
• 70% of bigger cranes use
piezo-ceramic load sensor for load
management
• For retrofit you have to take care of
insulation class of the motor and
shaft voltage ( insulated bearings).
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Mitsubishi performance
• High overload capacity
• Easy and precise auto tuning
• High temperature without derating
(temp. under the roof can be 10-20°C higher than on the ground)
• No booksize inverter, standard cabinets for
cranes have mainly 300mm depth
• Robust and dirt resistant design
• Internal structure is built to resist high
vibration levels (which are usual for cranes)
• Steady and precise speed control
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Things to take care of
for tower cranes
• Torsional forces due to wind or load
movement
-> Independent torque limit for each
working quadrant in FR-A700
• Instantaneous power failure
due to brush contacts
-> Instantaneous power failure function in
FR-A700
• Safe working angles
-> Define SW limit switches in inbuilt PLC
function
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Things to take care of
for bridge and portal cranes
• Travel motor can be way bigger than hoist motor (Travel
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•
•
•
structure can be really heavy. E.g. a bridge crane with 3.6 t nominal load and 28 m
wingspan can reach a mass of 25 t)
Often two motor are connected to one inverter.
Combined according to there motor capacity
(Combination 1: hoist with boom hoist and trolley with gantry
combination 2: hoist with gantry and trolley with boom)
A700 overload capacity is meeting the requirements
60s is enough for travel, 150% 60s and 200% 3s is enough for hoist)
(150%
Electrical design of control is more complex
due to safety issues
Mainly brushes are used, due to long moving distance
and existing rail structure
(Voltage dips/spikes should be avoided by using more than one set of pickups. AC
choke and IPF-function helps too)
• Hoist drive for cranes bigger 15 t often have a dual drum
with a single rope (Problem is to have equal amount of rope on the
•
two drums)
For container cranes a teachable positioning is used
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Things to take care of
for Jib cranes
• Easy crane structure,
so only general requirements
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Crane Types Categorisation
• Due to the wide range of crane
types it makes sense to divide the
crane applications into different
groups due to the complexity.
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Crane Types
Low complex
• Controlled manually by joystick /
push buttons in jog operation
• No measurements of speed,
position or load
• Inverter technical features like
s-curve acceleration, brake function
etc. is enough
• Inbuilt PLC is used for speed limit
switches and pendant control
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Crane Types
Mid complex without external PLC
• Controlled manually by joystick in jog operation,
or easy vertical positioning
• Encoder feedback
• Inverter technical features like s-curve
acceleration, brake function etc. is enough
• Adjustment to application by internal PLC
• Load management with external sensor and inbuilt
PLC
• Inbuilt PLC is used for speed limit switches and
pendant control
• Displaying data on HMI or PU07
• Use of regenerative units
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Crane Types
High complex with external PLC
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•
•
•
Control automatically and manually
Encoder feedback
Network communication (Often Profibus and Ethernet)
Positioning vertical and horizontal
High complex functions like safety, load
management, synchronising all moving axis
are realised in the external PLC
• Optimised duty cycle, by automatised
movement
• Displaying data on HMI
• Use of regenerative units
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End of additional internal
information part.
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Dedicated options and functions
• There are a lot of possibilities
to adjust the Mitsubishi
inverters to the application.
Whether standard functions ,
plug in options or dedicated
firmware.
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Torque performance of FR-A740
Output torque (%) (60Hz reference)
Closed-loop vector control (encoder) 200% (150%) torque @ 0.04Hz
Real sensorless vector control 200% (150%) torque @ 0.3Hz
200
150
100
95
70
Maximum torque for short time (0.4K to 3.7K)
Maximum torque for short time (5.5K to 55K)
Continuous torque (0.4K to 3.7K)
50
0
90 180
1800
3600
Speed (r/min)
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Maintenance function and
lifetime display
 Alarm outputs can be activated to
carry out maintenance tasks on the
crane, depending on the number of
hours of operation like:
->
->
->
->
Inrush current limit circuit life
Control circuit capacitor life
Main circuit capacitor life
Cooling fan life
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Dedicated functions in
FR-A740
 Independent torque limit for each working quadrant
(generation/ regeneration)
 Built in PLC function
-> Realise secure working areas
-> Maximum load limiter
 Deceleration ramp can be generated
in the absence of power (not for hoist)
 Instantaneous power failure
 S-pattern acceleration / decelaration
 Speed automatically adjusted depending on the
load
 Brake sequence function (torque proving)
 Digital input functions
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FR-A740-C9
Special crane FW
•
•
•
FCFS first come first serve
2 encoder feedback cards can be mounted
-> Closed loop speed or torque control for 2nd. motor
Dedicated latched encoder feedback pulse register in
inbuilt PLC
-> Semi multi turn positioning for 1st. motor
-> Position tracking for 2nd. motor
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FR-A740-C9
Special crane FW
• Advantages:
-> Closed loop performance in
horizontal and vertical
movement
-> Vibration avoidance
-> Movement tracking and
positioning
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FR-A7AL option card
• Master slave operation
-> Speed control
-> Position control
• Synchronising 2 axis
• Balancing load
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FR-A7AL option card
Master / Slave position control A700
Master
Slave
(Internal Positioning)
(pulse train mode)
A 700
A 700
FR-A7 AL
FR-A7 AP
1
PA
2
PB
1
2
PP
PGP
PA
PAR
NP
PB
PBR
PGN
PZ
PZR
1
PZ 2
M1
PLG
A
B
Z
5 V TTL
Line Driver
M2
PLG
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FR-A740 droop control
• Sharing load of two motors on one
shaft without a connection between
the inverters
FR-A740
FR-A740
M
M
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FR-A740 droop control
In unbalanced situation
inertia M1 > inertia M2
Factor M1 > 1
Factor M2 < 1
Output frequency M1 decreases
Output frequency M2 increases
Factor M1 positive
Factor M2 negative
Load balanced
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Regenerative energy
• Regenerative energy is always
an issue in crane applications.
The decision for a certain
regenerative option is based on
the following application
characteristic.
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Regenerative energy
• How much regenerative energy
do I have to handle?
Calculation of the Brake power :
W pot.  M L * g * h
t Brake 
PBrake 
h
v
W pot.
t Brake
*  Gearbox * Mechanism *  Motor
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Duty cycle
• How often do I have to handle it?
Duty cycle
t1
Ed 
t2
[%]
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Regenerative unit
or brake resistor
• Regenerative unit
-> Circular duty cycle with high
ED and high PBrake
• Brake resistor
-> Non circular duty cycle, even
with high PBrake
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Mitsubishi Regenerative Solution
Too much regenerative energy?
How much energy? For which time?
Continuous regenerative
Short time regenerative
Convert to heat? Regeneration?
For more than one inverter?
more
heat
Internal
brake
chopper
with
internal /
external
brake
resistor up
to 22k
equal
regen
BU-UFS
up to 550k
FR-BU2
up to 750k
(no CE
mark)
Common
DC Bus
FR-CV
up to 55k
(no CE
mark)
FR-HC
up to 55k
FR-RC
up to 55k
MT-HC-S
up to 375k
MT-RC
up to
280k (no
CE mark)
(no CE
mark)
FR-A701
up to
55k
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FR-A701
• FR-A701 is a FR-A700 with active
front end, which allows 100% torque
continuous regeneration and 150%
torque overload regeneration for 60s.
Capacity in kW
A721
3~ 200V
A741
3~ 400V
5 7.5 11 15 18.5 22 30 37 45 55
o
o
o
o
o
o
o
o
o
o
o
o
x= to be realesed, o=released in Japan
o
o
o
o
o
o
o
o
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FR-RC & MT-RC
POWER REGENERATION CONVERTER
• Energy generated at braking operation of the inverter
can be regenerated to the power supply.
Since a converter does not require a discharging resistor,
it is effective in space and energy saving
and it provides a large peak braking torque.
• One inverter connected to one FR/MT-RC.
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FR-CV
POWER REGENERATION
COMMON CONVERTER
• Enables 100%-torque continuous
regeneration to support continuous
regenerative operation for line control.
• Saves energy since regeneration energy is
used for the other inverters and excess
energy is returned to the power supply.
• Up to six inverters connected to one FR-CV.
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FR-HC & MT-HC
HIGH POWER FACTOR CONVERTER
•
•
Substantially suppresses power harmonics. Power
regeneration function featured as standard enables
common converter system operation with multiple
inverters connected.
Up to six inverters connected to one FR/MT-HC
THDI = 0
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Mitsubishi system solution
Mitsubishi frequency inverters
offer a great variety of inbuilt
functions to adjust your system
to the application needs.
Additionally we have system
solutions with high performance
Mitsubishi components.
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Complete Solution
HMI
FX3U
PLC
Modem
Lifting
Rotation
Translation
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Mitsubishi system solution
•
•
•
•
Inverter
Inverter
Inverter
Inverter
HMI
+
+
+
+
FX series PLC
Q series PLC
GOT HMI
Mitsubishi PLC + GOT
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Mitsubishi system solution
Inverter + FX series
• Inverter + FX1N / FX2N / FX3U with RS-485
module
-> Dedicated function blocks for serial
communication to up to 8 inverters
-> Control, read / write parameters and full
monitor function
• Inverter + FX1N (1 axis) / FX3U (3 axis)
pulse train positioning
-> Dedicated function blocks for absolute
positioning, homing, zero return and SW /
HW limit switches
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FX3U inverter
instructions
Configure and control frequency inverters with single commands:
IVCK: Check inverter status
IVDR: Control inverter
IVRD: Read inverter parameters
IVWR: Write inverter parameters
IVBWR: Block write inverter parameters
User-friendly configuration and
control of frequency inverters and
3-phase AC drives
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Safety features with
FR-A700 in CL & FX3U
Maximum torque limiter can be variable depending on
the position the trolley reaches
When this torque limit is
exceeded you can:
Load in kg
4.000
3.600
3.200
2.800
2.400
2.000
1.600
1.200
800
400
Stop the trolley
advance
Stop the raising of
the hook
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 24 35
Reach in meters
etc.
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Mitsubishi system solution
Inverter + Q series
• Inverter + system Q with C24
serial com. module
-> Dedicated function blocks for
serial communication to up to
32 inverters
-> Control, read / write
parameters and full monitor
function
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Mitsubishi system solution
Inverter + Q series (MEU internal)
• Inverter + system Q with Q62DA
and QD62E two motor
positioning
-> Dedicated function blocks for
absolute positioning, homing,
zero return and SW / HW limit
switches
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GOT1000 and inverter
• GOT1000 series is fully compatible to 700
series inverters
-> Control and set parameters of up to 10
inverters with one HMI
-> Use multi language on GOT1000 for inverter
control and alarm history
-> Displaying advanced process data and
alarms
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Mitsubishi Portal Crane Demo
Main Screen
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Mitsubishi Portal Crane Demo
Data Screen
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Mitsubishi Portal Crane Demo
Alarms Screen
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Complete Solution
Further Advantages
FX3U PLC
Managing/ control movements through communications
as master
Connection for the 3rd party products
Event history (Black Box)
Preventive maintenance data base
Modem
Remote monitoring (alarms, event history, etc)
Remote access
HMI (touch screen)
Monitoring by the end user
Web-page
Adjustment of crane parameters
Black Box display (hidden)
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Our strength in crane
applications - proven by many
reference customers.
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Company ZPMC
Shanghai Zhenhua Port Machinery
• World largest seaport crane manufacturer
• FR-A740–C9 special FW for cranes
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Consys
(Russia)
• Company Baltkran
-> All types of container and
bridge cranes (10 to 60t)
-> FR-A700 11 to 160 kW
• Company 55 MOZ
-> All types of container and
bridge cranes (10 to 20t)
-> FR-A700 1.5 to 15 kW
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CSC-Automation
•
(Ukraine)
Company EMZ
-> Bridge crane for steel production
-> 5xFR-A500 30 to 160 kW,
1 MT-RC, Q series PLC, MAC-E600,
CC-link network
-> Automatised movement
-> Power regeneration
-> Optimised duty cycle due to
automation
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MEU-Italy
• Company Gru Benedini
-> Tower cranes
-> FR-A500 and FR-A700
• Company Gru Comedil
-> Tower cranes
-> FX1N, FX3U
-> F940GOT, GT1150/55
Inverter is in discussion
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MEU-Spain
• Company Jaso
-> Tower cranes
-> FR-A700 5.5 to 11 kW
-> For translation
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MEU-Germany
• Company SLR
-> Overhead and bridge cranes
-> FR-A700 22 kW
• Company Aggreko
-> Portal cranes
-> FR-F700 22 kW
• Company Diefenbacher
-> Bridge crane
-> FR-V500 5.5 kW
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Conclusion
Due to the wide range of
inverter standard functions,
dedicated FW and options,
Mitsubishi is the first choice for
your crane application.