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Mitsubishi crane solutions


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


Main crane types

• Tower crane

• Bridge crane

• Gantry / portal crane

• Jib crane


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.


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)


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).


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


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


Things to take care of for bridge and portal cranes

• Travel motor can be way bigger than hoist motor (Travel 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 gantrycombination 2: hoist with gantry and trolley with boom)

• A700 overload capacity is meeting the requirements (150% 60s is enough for travel, 150% 60s and 200% 3s is enough for hoist)

• 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


Things to take care of for Jib cranes

• Easy crane structure, so only general requirements


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.


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


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


Crane Types High complex with external PLC

• 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


End of additional internal information part.


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.


Torque performance of FR-A740

Closed-loop vector control (encoder) 200% (150%) torque @ 0.04HzReal sensorless vector control 200% (150%) torque @ 0.3Hz

50

7095

100

150

200

0 90180 1800 3600

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)

Out

put t

orqu

e (%

) (6

0Hz

refe

renc

e)

Speed (r/min)


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

Maintenance function and lifetime display


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


FR-A740-C9Special 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


FR-A740-C9Special crane FW

• Advantages:-> Closed loop performance in horizontal and vertical movement-> Vibration avoidance-> Movement tracking and positioning


FR-A7AL option card

• Master slave operation-> Speed control-> Position control

• Synchronising 2 axis• Balancing load


FR-A7AL option card Master / Slave position control A700Master / Slave position control A700

Master(Internal Positioning)

Slave(pulse train mode)

A 700 A 700

FR-A7 AP

FR-A7 AL

M1 PLG

PA

PB

PZ

PP

PGP

NP

PGN

PA

PAR

PB

PBR

PZ

PZR

1

2

1

2

1

2

M2 PLG

BA

Z

5 V TTLLine Driver


FR-A740 droop control

• Sharing load of two motors on one shaft without a connection between the inverters

M

FR-A740

M

FR-A740


FR-A740 droop control

In unbalanced situation inertia M1 > inertia M2

Factor M1 > 1Factor M2 < 1

Factor M1 positive Factor M2 negative

Output frequency M1 decreasesOutput frequency M2 increases

Load balanced


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.


Regenerative energy

• How much regenerative energy do I have to handle?

MotorMechanismGearboxt

WP

v

ht

hgMW

Brake

potBrake

Brake

Lpot

***

**

.

.

Calculation of the Brake power :


Duty cycle

Duty cycle

2

1

t

tEd [%]

• How often do I have to handle it?


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


Mitsubishi Regenerative SolutionToo much regenerative energy?

Short time regenerative Continuous regenerative

FR-RCup to 55k

MT-RCup to 280k

(no CE mark)

FR-CVup to 55k

(no CE mark)

FR-HCup to 55k

MT-HC-Sup to 375k

(no CE mark)

FR-A701 up to 55k

Internal brake

chopper with

internal / external

brake resistor up

to 22k

BU-UFSup to 550k

FR-BU2up to 750k

(no CE mark)

How much energy? For which time?

Convert to heat? Regeneration? For more than one inverter?

CommonDC Bus

more equal

heat regen


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.

5 7.5 11 15 18.5 22 30 37 45 55A721 3~ 200V o o o o o o o o o o

A741 3~ 400V o o o o o o o o o o

Capacity in kW

x= to be realesed, o=released in Japan


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.


FR-CVPOWER REGENERATIONCOMMON 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.


FR-HC & MT-HCHIGH 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


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.


Lifting

Rotation

Translation

HMI

FX3UPLC Modem

Complete Solution


Mitsubishi system solution

• Inverter + FX series PLC• Inverter + Q series PLC• Inverter + GOT HMI• Inverter + Mitsubishi PLC + GOT

HMI


Mitsubishi system solutionInverter + 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


FX3U inverterinstructions

Configure and control frequency inverters with single commands:

IVCK: Check inverter statusIVDR: Control inverterIVRD: Read inverter parametersIVWR: Write inverter parametersIVBWR: Block write inverter parameters

User-friendly configuration andcontrol of frequency inverters and3-phase AC drives


Maximum torque limiter can be variable depending on the position the trolley reaches

Safety features with FR-A700 in CL & FX3U

When this torque limit is exceeded you can:

Stop the trolley advance

Stop the raising of the hook

etc.

Load in kg

4.0003.6003.2002.8002.4002.0001.6001.200

800400

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 24 35

Reach in meters


Mitsubishi system solutionInverter + 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


Mitsubishi system solutionInverter + 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


• 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

GOT1000 and inverter


Mitsubishi Portal Crane DemoMain Screen


Mitsubishi Portal Crane DemoData Screen


Mitsubishi Portal Crane DemoAlarms Screen


FX3U PLCManaging/ control movements through communicationsas 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)

Complete SolutionFurther Advantages


Our strength in crane applications - proven by many

reference customers.


Company ZPMC Shanghai Zhenhua Port Machinery

• World largest seaport crane manufacturer• FR-A740–C9 special FW for cranesFR-A740–C9 special FW for cranes


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


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


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


MEU-Spain

• Company Jaso-> Tower cranes-> FR-A700 5.5 to 11 kW-> For translation


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


Conclusion

Due to the wide range of inverter standard functions, dedicated FW and options, Mitsubishi is the first choice for your crane application.

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