Cargotec technology forum - Kalmar Global · Unrestricted / © Siemens AG 2016. All Rights...

Unrestricted / © Siemens AG 2016. All Rights Reserved. siemens.com/cranes

Cargotec technology forum

Siemens AG – Siemens Cranes, October 20th, 2016

Crane modernization

Presenter: Abdessalam El Azzouzi

Unrestricted / © Siemens AG 2016. All Rights Reserved.

October 2016 Cranes and Terminal Technology Conference

Agenda

• Siemens Cranes portfolio

• Phase-out Masterdrives

• Modernization market

• Comparison Masterdrives vs. Sinamics

• Modernization concept

• Add-on functionality



SIMOCRANE

Portfolio and Modular Architecture

Full Automation

Advanced Technology

Basic Technology

Hoist Slew Boom Grab Gantry Trolley

Ship profiling

Skew control Sway control

Stack

positioning

Remote

control

Collision prevention

Crane Management System Optimum path

Stack profiling

Container No.

Recognition

Truck positioning

Auto landing

Increase the safety level of terminals by TÜV and SIL certified

SIMOCRANE subsystems

TÜV certified collision prevention system (LCPS) for RTG

expected by Sept 2016

See Siemens Cranes

product catalog



Functional blocks in focus for modular automation

Truck

Rail

Water-side

BMS, BCS

HT interface

Land-side Storage yard

STS

cranes

TT/SC/

AGV

Horizontal

transport

(HT)

TT/SC/

AGV

Terminal Operating System

Yard cranes

HT

Container Terminal

Function Block View



Modular Automation

Safe working

height

Bay

scanner

Trim,

List,

Skew

Sway/

Skew

camera

Sway/Skew

Reflector

Position

scanning

system

Semi

automatic

move

Yard with targeted crane productivity of 30 moves/hour

- analysis of cycle time and contributing factors

- optimum path trajectory

- profile scanning

- truck positioning - final landing system

Block management system

Vessel interface with targeted crane productivity of 40 moves/hour - analysis of cycle time and contributing factors

- semi automatic operation/sway & skew control

- profile scanning

- truck positioning

- remote control interface



Crane operating cycle

Page 6

Gantry to slot

Identify Terminal Truck (TT)

Identify Container

Trolley pre-positioning

Position TT

Trolley above TT

Hoist down above TT

Auto landing on container

Lock Hoist up to lift protection

Hoist up to safe height

Trolley to target row

Stack profile scan

Hoist down to

above target

Auto landing at target pos.

Micro motion

Unlock

Micro motion

Hoist up to safe height

OCR/

RFID

OCR

TPS

FLS

LCP

FLS

Receive TT type & expected container position on trailer

3D scan of lane

Verify container pos.

Guide TT to set pos.

RCOS



SIMOCRANE Sway Control

SIMOCRANE

Sway Control

Crane control

Guiding user application SW

Drive System

SINAMCIS S120

Functions:

• Control of the load sway angle

• Positioning of the load

• (semi) automatic crane operation

• Smooth operation

• Trim, list and skew control

Benefits:

• Control of load trajectory

• Pre-requisite for remote control

• Reduction of the stressing on mechanical transmission

elements

SC



Skew Control as Part of Simocrane SC

Hydraulic system in combination with an additional electrical system

PLC

Crane

sequence

Sway Controller

camera

Hydraulic system

D

A B

C

D C BA

Waterside

Lanside

S1-in

S2-out

S3-in

S4-out

S5-in

S6-out

S7-in

S8-out

Profibus

Profinet

Ethernet

Profinet

BT

SC

DCC-TLS

Electric axis

Skew damping



SIMOCRANE Truck Positioning System

Traffic

direction

Crane contol


Delta-X

Position data

Delta-X (OPC)

SIMOCRANE TPS

Functions:

• Scan max. 2 working lanes

• Recognize parameterized objects

• Provide high precision position data of parameterized

objects in 2D and 3D.

• Automatic system calibration

Benefits:

• Productivity boost (up to 10%)

• Increase safety, less interaction with personnel in the

container hand-over zone

TPS



Final Landing System

Functions:

• Auto landing empty spreader on container

• Auto placing containers on ground markers

• Auto stacking of containers in stack

• Auto loading of containers on trucks/AGVs

Benefits:

• Productivity boost

• Safety improvement

• Maintenance friendly sensor

Crane contol


SIMOCRANE FLS

FLS



Simocrane Product Portfolio

Motion Controller

Drive Controller

Drives

Cranes Technology CMS

Advanced

Technology Sway Control

Skew Control

Booksize Chassis Crane

Cabinet

Modules

(Remote) Crane Management System

Motors 1PH8 1LP4/6

BT V3.0

SIMOTION D435-2

CU320-2

ECO Technology

Truck Position System

Basic

Technology

1LG4/6 1LA8/

1LL8

S I M

O C

R A

N E

1LP1/

1LQ1

Dri

ve

Sy

ste

m



Forecast by Drewry

Excellent value offering (productivity, safety, availability) to customer by modernization of existing cranes – low investment



Phase-out of Masterdrives

• SIMOVERT MASTERDRIVES is in the process of being phased out since October 2010.

• The following will be available until approx. 2020:

- Spare parts

- Repair and service support

However:

Expansion of existing MASTERDRIVES systems is not possible any more!

Replacing of existing MASTERDRIVES systems by new MASTERDRIVES

chassis is not possible any more!

• For expansion / replacement the current series of SINAMICS devices is available.

Basically the following scenarios are possible:

- Expansion of MASTERDRIVES systems by SINAMICS chassis

- Successively replacement of MASTERDRIVES systems by SINAMICS chassis

Complete replacement of MASTERDRIVES systems by SINAMICS chassis



Harbor Cranes > 10 years – Modernization/retrofit

Container cranes:

- Total Harbor Cranes in operation

18,500 cranes

-Approx. 11,000 older than 10years

Note, grab unloaders and industrial

cranes are not included in the

analysis.

Source: Siemens CRANES IBase 2014

Masterdrives Sinamics

Opportunities

for Retrofit

DC/AC drives DC drives



Overview Siemens Installed Base and Kalmar modernization offices

Kalmar presence



Overview harbor cranes installed base > 10 years

South America QTY Supplier QTY

Cranes > 10 years = 437 Siemens 59

Total QSG: 181 13

Total RMG: 10 0

Total RTG: 246 46

Asia & Australia QTY Supplier QTY


Total QSG: 1191 126

Total RMG: 276 9

Total RTG: 2495 235

Middel East QTY Supplier QTY


Total QSG: 243 165

Total RMG: 55 3

Total RTG: 377 135

Europe QTY Supplier QTY


Total QSG: 929 213

Total RMG: 552 118

Total RTG: 490 130

> 10 years

North America QTY Supplier QTY


Total QSG: 459 15

Total RMG: 19 0

Total RTG: 581 22

Africa QTY Supplier QTY


Total QSG: 87 15

Total RMG: 24 0

Total RTG: 81 21



Comparison MASTERDRIVES ─ SINAMICS

MASTERDRIVES SINAMICS

Both series MASTERDRIVES and SINAMICS

- are covering the same voltage levels - are covering comparable power ranges

- have a similar basic structure

MASTERDRIVES can basically be replaced by SINAMICS or be combined with SINAMICS!

Preferred solution is complete replacement of Masterdrives- by Sinamics chassis



Main common features


Line supply

voltage

Compact units, Chassis

units and cabinet units 3AC 380 V – 480 V 3AC 500 V – 600 V

3AC 660 V – 690 V

Restriction for MASTERDRIVES Compact units

3AC 380 V – 480 V 3AC 500 V – 600 V

SINAMICS S, Chassis units

and cabinet units 3AC 380 V – 480 V 3AC 500 V – 690 V

Restriction for SINAMICS S, Booksize units 3AC 380 V – 480 V

Line freq. 50/60Hz 50/60Hz

Infeed units

(rectifier)

- Line-commutated 2Q

(rectifier units) - Line-commutated 4Q (rectifier/regenerative

units) - Self-commutated 4Q

(Active Front End / AFE)

- Line-commutated 2Q

(Basic Infeed / Basic Line Module) - Line-commutated 4Q

(Smart Infeed / Smart Line Module)

- Self-commutated4Q (Active Infeed / Active Line Module)


DC link

voltages

- Identical overvoltage shutdown thresholds

- Identical operating ranges of the braking units

- Very similar undervoltage shutdown thresholds

Inverter - 2-level IGBT inverter

- Similar overload capability (standard load cycle „High overload“)

Take in account power cycling factor k-IGBT!

- Similar stress on the motor with respect to:

- Voltage stress on the winding in converter

operation

- Bearing currents in converter operation

Pulse

frequency of the inverter (factory

setting)

2,5 KHz 2,0 kHz or 1,25 kHz

(device-specific) Lower converter losses Slightly increased losses

in the motor Increased motor noise is

possibe (motor-specific)



Replace Masterdrives by Sinamics S120 chassis

- Main focus on modernization of STS, RMGs and RTGs by chassis exchange concept.

- Replacement of AFE/Masterdrives chassis by ALM/Sinamics S120 chassis. All cubicles and cabling remain unchanged.

- All other main drive parts; MV-switchgear, transformer, ACBs, motors, external cabling, etc.. remain unchanged.



Replace Masterdrives by Sinamics S120 chassis

CU32

0

SIM

OTIO

N D

D4x5

-2

SINA

MIC

S

DRIVE-CliQ

DC BUS

SMC3

0

ALM

INFEED

PLC

Hoist 1

SMC3

0

SMC3

0

Gantry 1

SMC3

0

SMC3

0

Gantry 2

Mot

or M

odul

es

Trolley 1 Boom 1

Hoist 2

MA

ST

ER

DR

IVE

S

DC BUS

AFE

INFEED

PLC

Hoist 1

Gantry 1

Gantry 2

Trolley 1 Boom 1

Hoist 2

MA

ST

ER

DR

IVE

S

MA

ST

ER

DR

IVE

S

Tec

hn

olo

gy

Car

d T

300

Tec

hn

olo

gy

Car

d T

300

CU

320-2

Sinamics technology

Masterdrive technology

Update PLC program

Update CMS (if possible)

Main scope of work:

- Replace Masterdrive chassis by Sinamics S120 chassis

- Update PLC <->Sinamics communications

- Integrate Crane functions in new system

- Update PLC program

- Update CMS system (if possible)

- Integrate any add-on features for productivity improvement

(sway control, truck positioning, TPS, etc..)

Note, in case T300 software is in PLC. Only a CU320-x will be added.



Modernization concept from 6SE70 to 6SL33 – Control Section

Remove existing

noise filters

Install adapters between

chassis and existing

cables

Install adapters between

chassis and existing DC-

bus

• Advantages of the concept:

• Keep existing cubicles

• Keep existing cabling to motors and cable

• No main mechanical work required (remove E-house roof, cubicle mountings, etc…)

• Minimum downtime

• low costs – upgrade only what’s important

• Harvest spare parts for remaining cranes

Replace masterdrives chassis by

Sinamics S120 chassis

• Main activities:

• Re-calculate the drives

• Replace Masterdrive chassis by

Sinamics chassis

• Adapt connection

DC-bus to chassis

• Adapt connection

Chassis incoming/outgoing cables

• Replace

• AFE filter ALM filter

• Re-wire the communication PLC/drive

• ……



Modernization concept from 6SE70 … to 6SL33..

AFE/Masterdrives ALM/Sinamics



Comparison mechanical Dimensions 6SE vs. 6SL (chassis)

Infeed

-Line connection module (LCM) will be not change

- Line contactors stay in the LCM space in the Clean Power Filter Cabinet is sufficient for the AIM

Sinamics chassis fit all existing cubicles with Masterdrives

Sinamics lay-out Masterdrives lay-out

http://www.dict.cc/englisch-deutsch/contactor.html



Additional semi-automation features

3D laser scanner:

• Target Positioning

System.

• Ship profile

scanning

• Vehicle positioning

Load control:

• Sway control.

• Skew control

CMS:

Information system

for fast diagnose and

trouble shooting



Summary modernization from Masterdrives to Sinamics

Advantages Disadvantages

Minimal costs for modernization due to:

- Keeping existing cubicles

- Keeping existing cabling between motors and cubicles

- No mechanical work required (mounting new cubicles)

- Minimal downtime

- Low modernization costs – replace only what is important

drives

Onsite downtime may influence operation

Harvest spare parts for remaining cranes (reduces

investment in new spares for remaining cranes)

Modernization of the installed base takes time, needs on

time planning and budgeting to assure minimal downtimes.

Higher availability of Sinamics spare parts and lower costs

State of the art technology and higher availability of service

engineers for Sinamics

Upgrade cranes to higher level of automation and productivity



Crane courses Simocrane/Sinamics and solution partners

http://w3.siemens.com/mcms/mc-solutions/en/mechanical-engineering/crane-solutions/pages/crane-solutions.aspx



Questions ?



Abdesselam El Azzouzi

Manager modernization Crane projects

Department: PD LD Cranes

Cellular: +31 6 55844839

E-Mail: [email protected]

Thank you for your attention!

siemens.com/cranes

Cargotec technology forum - Kalmar Global · Unrestricted / © Siemens AG 2016. All Rights...

Documents

Transcript of Cargotec technology forum - Kalmar Global · Unrestricted / © Siemens AG 2016. All Rights...