crane control made with siemens s7 p.l.c. · crane, and that solves the serious problem of...

AUTOMAZIONE E CONTROLLO

TEKNA AUTOMAZIONE E CONTROLLO s.r.l.

Stabilimento e Uffici commerciali: S.P. 115 Km. 1,200 - 71122 FOGGIA (Italy) Tel. +39 0881/750570 r.a. - fax +39 0881/750552 - E - mail: tekna@ teknautomazione.com

CRANE CONTROL MADE WITH SIEMENS S7 P.L.C.

MOBILE PORT CRANE REVAMPING MHC FANTUZZI ‐REGGIANE

gru_mobile_mhc fantuzzi reggiane_revamping_inglese_1.doc 2


Mobile port crane offer flexible solutions for cargo handling in ports, from container handling, to bulk products management and heavy cargo handling

Fantuzzi Reggiane MHC mobile port crane, in different models and load capacities, allow to meet all the needs required by the market.

Their robust mechanical structure and the complete optimal movements control with the use of hydraulic motors (hoist, rotation, boom and translation) make them particularly flexible machines and particularly interesting in cranes global market

Crane original control system is entrusted to a specialist electronics, managed by a master-slave structure microprocessor, which uses input/output remote peripheral terminals and specialized terminal operators

Control system heart consists of a management computer, so-called Monitor, on which software is visible, realized in "C" pseudo language, for crane management; such a software is not accessible to the end user

Although they are reliable mobile cranes and present on the market for years, but now out of production for some time, there is the problem of spare electronic components become unavailable and in particular of the control part, consisting of:

• Monitor complete with operator panel, is made up of custom microprocessor equipment that manages crane automation

• Electronic Keyboard (one or two keyboards in function of the presence or absence of the second operator's cab) with on board main command buttons for the operator

• Mobile Button Panel, for Jog commands for crane working at low speeds.

• Slave, input/output peripheral, for signal acquisition and seats activation, mounted inside the electrical panel

The installation of this opened system of MHC Fantuzzi Reggiane cranes makes the client independent from suppliers of specific equipment and allows, in fact, reducing downtime and extending the useful life of the crane: the final client can provide for system maintenance purchasing equipment on the market directly

Tekna Automazione e Controllo, thanks to its twenty years of experience in industrial automation using PLC and as a provider of complete equipment for cranes and machines in the port sector for the leading Italian cranes manufacturers, has developed a new control system based on Siemens S7 PLC, which is able to replace the original control system of MHC Fantuzzi Reggiane crane, and that solves the serious problem of unavailability of spare parts, improving the processing speed and crane diagnostics.

Tekna Automazione e Controllo is able to supply, install and commission the complete system, with "turnkey" formula, for all models of MHC Fantuzzi Reggiane mobile cranes and anywhere in the world.



TEKNA AUTOMAZIONE E CONTROLLO CONTROL SYSTEM

MHC FANTUZZI REGGIANE MOBILE CRANE

Tekna Automazione e Controllo control system for MHC Fantuzzi Reggiane mobile crane automation is made up of an open system based on a standard SIEMENS S7 PLC and Siemens Operator Panels, replacing the obsolete closed system developed on sophisticated electronics

With the development of its automation system TEKNA Automazione e Controllo wants to provide to its customers an open system to give them an economic management of MHC Fantuzzi Reggiane crane maintenance, features restoration time reduction after a fault and to delete the existing monopoly for spare parts supply

CONTROL SYSTEM STRUCTURE

The used P.L.C. is Siemens S7-300, with a central rack (that replaces the Monitor of the current system) and remote racks ET200 for input/output management (that replace the SLAVES of the current system). The central and remote rack are configured and planned to be installed inside the existing cabinet and in the same positions of the Slaves, after their removal

The supply includes, in particular:

• A pre-wired plate, with the main PLC rack S7-300 on board and other electromechanical equipment, which is installed inside the existing electrical panel, in the position currently occupied by the current system SLAVE

• An ET200 remote rack, wired inside the button panel to be installed in the operator's cab. The new button panel, included in the supply, fully replaces the existing one, and replicates all the controls and alarms using buttons, lamps and industrial selectors. On the button panel board is installed, in addition, stabilizers joystick

• A second remote rack ET200, wired inside a control panel perfectly identical to the one of the previous point, to be installed in the lower operator's cab, if present

• A third remote rack ET200, wired into the button panel for the JOG commands, attached to the connector on the side of the cabinet. The JOG button panel, included in the supply, completely replaces the existing one, and replicates all the controls and alarms using buttons, lamps and industrial selectors.

Profibus-DP net connects P.L.C. to remote ET200 units: the supply includes the cable, its installation and its connection

The new automation system, with its interface cards, is perfectly compatible with the sensors installed on crane board, such as pressure switches, pressure gauges, load cells, encoders, manipulators, etc.., and doesn’t require, therefore, their replacement



OPERATOR INTERFACE

User interface has been implemented using standard industrial Operator Panels, color Touch Screen size 10 "or 12"

Operator panels are installed inside the cabins and allow to manage all the machine functions, from parameters setting to crane diagnosis.

Profibus-DP net connects P.L.C. to remote ET200 units: the supply includes the cable, its installation and its connection

Additional features have been implemented compared to those on the current Monitor, and in particular:

• crane diagnostics has been enhanced by useful additional information that help to reduce time troubleshooting

• video pages have been implemented to duplicate commands on the button panel operator: the operator, acting directly on the touch screen monitor, may require all the commands implementing without using the button panel

• video pages have been implemented to display if the conditions that enable the movements are active; such information are very useful to quickly identify the causes of crane non-operation



SUPPLY, INSTALLATION AND COMMISSIONING

CONTROL SYSTEM IMPELEMENTED IN SIEMENS S7 P.L.C.

Crane automation is carried out by a specialized electronics, controlled by a microprocessor with a master-slave structure, which use remote input/output units and specialized operator terminals, obsolete and hard to find on the market

The system developed by Tekna Automazione e Controllo provides for the replacement of obsolete equipment with new commercial one such as Siemens S7 PLC and market operator terminals, complete of specific software for crane automation

Remote devices

remote units, for sensor acquisition, installed inside the

electrical panels

CURRENT SITUATION TEKNA CONTROL OBJECT OF SUPPLY

Remote devices

remote units for sensors acquisition, installed inside the

operator cab



Operator cab

Supply, installation and control unit programming, display, monitor, central processing unit and

manipulators for crane management

Operator Cab

Crane parameters preset

Device Configuration Crane input/output channels

preset and devices configuration



NEW ADVANCED OPERATOR INTERFACE



COMPLEMENTARY ACTIVITY GRU MHC FANTUZZI REGGIANE REVAMPING

Tekna Automazione e Controllo, thanks to its experience in crane industry, is able to perform the complete revamping of MHC Fantuzzi Reggiane cranes, which includes the supply of all equipment (whether mechanical, hydraulic and electrical), their installation, their adaptation with equivalent devices (if any were needed) and their starting and testing to load

Perkins diesel engine crane government

Supply of new motor 850kw, complete with muffler, silencer and mechanical adaptations to its installation in the available space in the cab diesel

Electric Motor Siemens crane government Supply of the new engine 560kW, complete with inverter cabinet, the power supply to the crane when in operation

Reducer coupler pumps, diesel engine and electric motor

Supply of coupler pumps, supply and installation of all hydraulic pumps to the government of the movements of the machine, including the implementation of a new high‐pressure hydraulic oil



Oil tank and plumbing supply pumps

Supply of new oil tank 3000 liters, complete with all the hydraulic circuit for the connection of pumps, motors and hydraulic users of the machine

Automation switchboards

Providing all the automation frameworks in crane control, complete with remote units to interface the sensors of the crane

Replacing control stabilizers with Siemens PLC

Supply, installation, software and commissioning of a PLC Siemens S7 for the management of groups stabilizers of the crane, in replacement of the obsolete unit components

Inspection and testing of the crane to load

Evidence against the crane with sample weights and verification capacities and speeds

crane control made with siemens s7 p.l.c. · crane, and that solves the serious problem of...

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