03_ACS880_CraneControl_TechnicalPresentation_ AntiswayControl.pptx

manual ACS880 ABB

1. ACS880 Crane control program Anti-sway control © ABB Group October 8, 2015 | Slide 1

2. Anti-sway control Anti-sway control principle Swing of the load causes problems when a crane is being operated in manual control, particularly if the operator has only little experience that may cause dangerous situations and serious damage for equipment . The Anti-sway control program gives the crane operator better control of the crane, cutting the time of movements by higher speed and shorter acceleration and deceleration times SAFETY LESS MAINTENANCE HIGHER PRODUCTIVITY

3. ACS880 Anti-sway control Anti-sway control principle

4. ACS880 Anti-sway control Anti-sway control principle The Anti-sway adjusts the operator given speed reference in a way that it will not cause sway of the load. The A nti-sway controls the load sway without additional Anti-sway sensors. Sensorless Anti-sway cannot compensate the effect of external disturbances such as wind or u ndirect lifting. Also wrong time constant of a swinging pendulum arm causes unwanted behavior . Wrong parameter settings in the Anti-sway drive result in wrong values.

5. ACS880 Anti-sway control Anti-sway control principle Anti-sway core needs to know pendulum arm time constant to calculate correct acceleration/deceleration rates Time constant is defined by pendulum arm length Total pendulum arm length is the sum of: The hook position (=rope length) comes from the hoist drive Position calculation in the hoist system (either in the drive or a PLC) Pendulum arm offset Offset can be varied because there are many different types of loads and lifting devices There are a couple of methods to determine offset: Step offset logic, load sensitive method, direct offset from a PLC or through AI, Auto- determination Anti-sway is mainly targeted for process cranes . Why? Total pendulum arm OFFSET= Distance between hook and center of mass of lifted object Hook position =rope length t= time constant

6. ACS880 Anti-sway control Anti-sway control principle Anti-sway function is meant only for trolley and long travel movements (x/y directions) The hoist drive transmits hook position and load data to the Anti-sway drives through D2D-link, or PLC/Fieldbus. Anti-sway needs those values to determine the right value of pendulum arm length. Hoist drive Trolley drive Long travel drive Hook distance and load Hook distance and load ACS880 Crane control program (+N5050) ACS880 Crane control program (+N5050) ACS880 Crane control program (+N5050) D2D-link D2D-link

7. Master/follower communication Basics M/F communication as well as the anti-sway communication based on D2D-link as following setup. Total number of drives in the whole link is 11. Main master of the whole communication link is MAIN HOIST which must exist in the link. In each drive define: CRANE DRIVE TYPE

8. Master/Follower communication Basics Physical link.

9. Master/Follower communication Communication supervision Communication supervision in the link is set in MAIN HOIST drive with parameter 60.201 : Crane drives construction. Supervision is activated by setting drive bit 0  1 in the parameter. In the MAIN HOIST (MAIN TROLLEY & MAIN LONG TRAVEL) define: Supervised drives

10. ACS880 Anti-sway control Functionality Main part of Anti-sway control Anti-sway on/off logic Anti-sway on/off through DIx , pointer Min speed logic Pendulum arm min/max length Hook position Select source: D2D, pointer, AIx … Scaling hook position to pendulum arm length Offset determination Step reference logic with actual hoist load, DIx , pointers… Anti-sway core Modify speed reference ramp avoiding load swaying when total pendulum arm length is known (hook position + offset)

11. ACS880 Anti-sway control Functionality Scaling hook position to be pendulum arm length Because a real pendulum arm length are not same as length of the rope (mechanic, friction…) During start-up a swaying test , where the length of rope and real pendulum arm length are set coincide to each others, is executed. How? By measuring the time constant of one swaying cycle of the empty hook in two points. Then entering measured times and length value from the hoist system into the Anti-sway control. The Anti-sway control calculates real pendulum arm length by itself.

12. Anti-sway control Start-up procedure © ABB Group October 8, 2015 | Slide 12

13. ACS880 Anti-sway control Start-up procedure summarized Basic trolley and long travel drives start-up with interlocking and supervisions If the hook position is calculated inside hoist drive, do the scaling in the hoist. Also take care of position counter resetting function. Define the source of hoist position and load in the Anti-sway (if needed) D2D, AIx , FB, PTR… If using the D2D-link communication, do the settings and check communication. Do the swaying test with empty hook/lifting device to set the hook position and pendulum arm length to meet each others. Activate Anti-sway and do the trial run with empty hook Define and set offset functions if needed.

14. ACS880 Anti-sway control Functionality Anti-sway ON/OFF logic On/off Selected DI, CW bit or PTR controls the Anti-sway Most commonly used Min speed logic If speed reference is above set min speed then Anti-sway is ON Pendulum arm max/min length If pendulum arm length is between set min and max length then Anti-sway ON Working time out If time has not been elapsed then Anti-sway is ON. Time is set from stop command (RUN->0) to normal safety zero speed and brake closed situation Run command from operator ANTI-SWAY CORE COMP ON/OFF PENDULUM ARM SP REF IN SP REF OUT MIN SPEED SPEED REF IN1 IN2 IN2>IN1 COMP MIN PENDULUM PENDULUM ARM ACT IN1 IN2 IN2>IN1 COMP MAX PENDULUM IN1 IN2 IN2<IN1 AND TOFF TIME OUT IN1 TIME AND SR R S Start command from operator SEL DIx, PTR… 1 2 3 4 EN ENABLE AUTO ON EN ENABLE AUTO ON 77.02 77.02 77.05 77.04 77.05 77.11

15. ACS880 Anti-sway control Start-up procedure fro both antisway drives Take the hook up position (25% from top most position) Execute swaying test , measure time of one cycle . Enter both position and time to the antisway control. The control will calculate the real pendulum arm length . Repeat the test in a low position. During normal operation Anti-sway interpolate s rest of the values between two points. © ABB Group October 8, 2015 | Slide 15 Test point (from top) Reading from hoist 77.21 Measured time [s] Calculated arm length [m] 1. 25% -212 3.40 2.89 2. 75% -807 5.80 8.41 t=3.40ss t=5.80s

16. ACS880 Anti-sway control Start-up procedure: Anti-sway ON/OFF and scaling ON/OFF logic and tuning parameters Hoist position and pendulum arm length scaling

17. ACS880 Anti-sway control Start-up procedure: Offset STEP OFFSET Step logic consists of three offset values Selection by DIx , pointer (PTR), hoist load LINEAR OFFSET according to lifted load By setting MIN LOAD-MIN OFFSET and MAX LOAD-MAX OFFSET pairs DIRECT OFFSET Direct offset value from FB, AIx or PTR AUTO OFFSET Can be used if load is lifted always from same level, for example from floor When hoist load > min load then load is lifted. Offset=max length-actual hook position Final offset is summed with pendulum arm length (from hoist) to be final value to the Anti-sway core 5

18. ACS880 Anti-sway control Start-up procedure: Offset parameters STEP OFFSET LINEAR OFFSET ( Lifted load -Offset) AUTO OFFSET ( when lifted from same level ) DIRECT OFFSET

19. ACS880 Anti-sway control Start-up procedure: Core Anti-sway core controls speed reference so that swaying of load is avoided. Incoming signals are speed reference from the operator, total pendulum arm length and some setting parameters: SWAY TRACKING If sway tracking is ON, the Anti-sway core calculates speed reference. Meanwhile function itself is off. RAMP TIME When Anti-sway is on, speed reference follows Anti-sway ramp times ( acceleration and deceleration times), otherwise crane control ramp times are active. RAMP TIME IN SLOW DOWN Behavior in case of slowdown: Normal or Anti-sway BRAKE COMMAND When Anti-sway is active, it also controls the mechanical brake. When Anti-sway corrections h ave been made, then brake close command is given. ANTI-SWAY CORE ANTI-SWAY ON/OFF LOGIC ON/OFF PENDULUM ARM Speed ref from operator SP REF IN SP REF OUT GAIN From offset calculation GAIN-parameter RAMP TIME ANTI-SWAY RAMP-parameter ANTI-SWAY IN SLOWDOWN-parameter SLOWDOWN RAMP

20. ACS880 Anti-sway control Start-up procedure: Settings ON/OFF logic and tuning parameters

21. ACS880 Anti-sway control Start-up procedure: Status signals IN HOIST DRIVE (77.80): Select the load value to Anti-sway drives: Calculated from torque From Hoist speed optimization Speed reference to and from Anti-sway Total p endulum arm offset and total pendulum arm lenght

22. ACS880 Anti-sway control Parameter set-up example Hoist drive Long travel drive Hook distance and load ACS880 Crane control program (+N5050) ACS880 Crane control program (+N5050) D2D-link Settings in the main hoist: 60.200 Crane drive type Main hoist (D2D master ) 77.1 Antisway enable Enable 77.20 Pendulum length source P.90.5 77.80 Load to antisway selection Internal Settings in the long travel : 60.200 Crane drive type Main long travel 77.1 Antisway enable DI5 77.2 Enable auto on function Disable 77.6 Antisway enable in slowdown Normal ramp 77.7 Sway tracking enable Disable 77.8 Antisway ramp time 5.00 77.9 Antisway gain 1.00 77.10 Short rope mode enable Enable 77.11 Antisway timeout 77.20 Pendulum length source D2D 77.22 Up position swing time 3.40 77.23 Up position length value -2.12 77.24 Down position swing time 5.80 77.25 Down position length value -7.95 77.26 Maximum pendulum length 10.000 77.30 Load signal source D2D 77.33 Step 1 source Load step 1 77.36 Load step 1 15.00 77.39 Step offset 1 1.00 77.70 Total pendulum arm length 1.73 (actual value :final and total length)

23. ACS880 Anti-sway control How does it work? Main part of Anti-sway control Anti-sway on/off logic Anti-sway on/off through DIx , pointer Min speed logic Pendulum arm min/max length Hook position Select source: D2D, pointer, AIx … Scaling hook position to pendulum arm length Offset determination Step reference logic with actual hoist load, DIx , pointers… Anti-sway core Modify speed reference ramp avoiding load swaying when total pendulum arm length is known (hook position + offset) ANTI-SWAY CORE ANTI-SWAY ON/OFF LOGIC HOOK POSITION OFFSET PENDULUM ARM length ON/OFF PENDULUM ARM Speed ref from operator SP REF IN SP REF OUT D2D, AIx , PTR.. DIx , AIx , LOAD, PTR… TOPIC: Functionality