Mitsubishi crane solutions

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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 10-20C 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
• -gt Independent torque limit for each working
  quadrant in FR-A700
• Instantaneous power failure due to brush
  contacts
• -gt Instantaneous power failure function in
  FR-A700
• Safe working angles
• -gt 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 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

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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

• 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

• Closed-loop vector control (encoder) 200 (150)
  torque _at_ 0.04Hz
• Real sensorless vector control 200 (150) torque
  _at_ 0.3Hz

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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
• -gt Inrush current limit circuit life
• -gt Control circuit capacitor life
• -gt Main circuit capacitor life
• -gt 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
• -gt Realise secure working areas
• -gt 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-C9Special crane FW

• FCFS first come first serve
• 2 encoder feedback cards can be mounted
• -gt Closed loop speed or torque control for 2nd.
  motor
• Dedicated latched encoder feedback pulse register
  in inbuilt PLC
• -gt Semi multi turn positioning for 1st. motor
  -gt Position tracking for 2nd. motor

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FR-A740-C9Special crane FW

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

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FR-A7AL option card

• Master slave operation
• -gt Speed control
• -gt Position control
• Synchronising 2 axis
• Balancing load

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FR-A7AL option card Master / Slave position
control A700
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FR-A740 droop control

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

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FR-A740 droop control
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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
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Duty cycle

• How often do I have to handle it?

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Regenerative unit or brake resistor

• Regenerative unit
• -gt Circular duty cycle with high ED and high
  PBrake
• Brake resistor
• -gt Non circular duty cycle, even with high PBrake

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Mitsubishi Regenerative Solution
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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.

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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-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.

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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

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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
Translation
Rotation
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Mitsubishi system solution

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

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Mitsubishi system solutionInverter FX series

• Inverter FX1N / FX2N / FX3U with RS-485 module
• -gt Dedicated function blocks for serial
  communication to up to 8 inverters
• -gt Control, read / write parameters and full
  monitor function
• Inverter FX1N (1 axis) / FX3U (3 axis) pulse
  train positioning
• -gt Dedicated function blocks for absolute
  positioning, homing, zero return and SW / HW
  limit switches

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FX3U inverterinstructions
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 andcontrol of
  frequency inverters and3-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 Stop
the trolley advance Stop the raising of the
hook etc.
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Mitsubishi system solutionInverter Q series

• Inverter system Q with C24 serial com. module
• -gt Dedicated function blocks for serial
  communication to up to 32 inverters
• -gt Control, read / write parameters and full
  monitor function

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Mitsubishi system solutionInverter Q series
(MEU internal)

• Inverter system Q with Q62DA and QD62E two
  motor positioning
• -gt 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
• -gt Control and set parameters of up to 10
  inverters with one HMI
• -gt Use multi language on GOT1000 for inverter
  control and alarm history
• -gt Displaying advanced process data and alarms

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Mitsubishi Portal Crane DemoMain Screen
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Mitsubishi Portal Crane DemoData Screen
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Mitsubishi Portal Crane DemoAlarms Screen
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Complete SolutionFurther Advantages

• FX3U PLC
• Managing/ 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)

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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-A740C9 special FW for cranes

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Consys (Russia)

• Company Baltkran
• -gt All types of container and bridge cranes (10
  to 60t)
• -gt FR-A700 11 to 160 kW
• Company 55 MOZ
• -gt All types of container and bridge cranes (10
  to 20t)
• -gt FR-A700 1.5 to 15 kW

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CSC-Automation (Ukraine)

• Company EMZ
• -gt Bridge crane for steel production
• -gt 5xFR-A500 30 to 160 kW, 1 MT-RC, Q series
  PLC, MAC-E600, CC-link network
• -gt Automatised movement
• -gt Power regeneration
• -gt Optimised duty cycle due to automation

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MEU-Italy

• Company Gru Benedini
• -gt Tower cranes
• -gt FR-A500 and FR-A700
• Company Gru Comedil
• -gt Tower cranes
• -gt FX1N, FX3U
• -gt F940GOT, GT1150/55
• Inverter is in discussion

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MEU-Spain

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

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MEU-Germany

• Company SLR
• -gt Overhead and bridge cranes
• -gt FR-A700 22 kW
• Company Aggreko
• -gt Portal cranes
• -gt FR-F700 22 kW
• Company Diefenbacher
• -gt Bridge crane
• -gt 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.