Ct & Port Cranes Psa 22jan07


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  • Ct & Port Cranes Psa 22jan07

    1. 1. Control Techniques CK Fong Vice President - Asia Pacific
    2. 2. Founded in 1973 We are a world leader in the ; Design, Manufacture, Marketing and Application of…. AC & DC Drives, Servos and Systems In 1995 we became a member company of Emerson
    3. 3. Control Techniques Mentor II (DC Drives) Commander SK (AC Open Loop) Unidrive SP High Perf. AC Servos & Unimotor
    4. 4. United Kingdom Newtown, Wales London Headquarters R&D Manufacturing Plant
    5. 5. Drive Centres in Europe Finland Holland UK Norway Sweden Hungary Austria Germany Belgium Ireland Denmark Spain Italy Turkey Czech Switzerland Sales via Distributor France Russia Portugal Iceland Poland
    6. 6. Drive Centres in Asia Pacific South Africa Australia Thailand India S. Korea China Indonesia (distributor) Malaysia Singapore Hong Kong Taiwan Vietnam (distributor)
    7. 7. Drive Centres in North America Chicago Toronto Providence Charlotte Cleveland Distributors S.America Minneapolis (Head Office) Dallas
    8. 8. CT CT CT CT CT CT CT CT covers the PSA ports around the world
    9. 9. High Performance , Intelligence and Networking Control Techniques Drives are about ;
    10. 11. Application Software : Constant Power Hoisting, Slewing Control, Load Sharing, Motor Map Swapping, Auto Steering, Cable Reeling, Grab Control etc
    11. 12. Intelligence and Networking UD75 UD75 Unwind Software Index Position Software UD75 CAM Position Software E E E UD75 Unwind Feed Rolls Rotary Shear Take-off Conveyor CTNet Real-time & Sequential Control (<10mS) Supervisory Control (>20mS) E HMI or SCADA Machine Settings Monitoring Logging Trending Alarm Handling Remote I/O PLC Machine Sequencing I/O handling Machine Set-point Fault Handling Gateway SCADA
    12. 13. Networking INFORMATION LAYER Area-Controller Factory level Cycle-time < 1000 ms Peer-Peer/ Multi-master Large Data Transfer DCS VME/PC Peer-Peer/ Multi-master SCADA Sensor CNC PC/VME CONTROL LAYER Cell- level Cycle-time < 100 ms Cell- controller Master/Slave Small Data Transfer Field device Sensor Trans- mitter DEVICE LAYER Remote I/O Field- level Cycle-time < 10 ms PLC
    13. 14. Cranes Fans & Pumps Food and Drink Material Handling Metals & Metal Forming Paper Printing Rubber & Plastics Stage Scenery Textiles Wire Drawing Industry Focus
    14. 15. Steel Industry <ul><li>Corus Steel (UK, Netherlands) </li></ul><ul><li>60 X SP for continous caster process line </li></ul><ul><li>Key Benefits: </li></ul><ul><ul><li>30% increase in strand speed </li></ul></ul><ul><ul><li>Improved load sharing </li></ul></ul><ul><ul><li>Shorter rethread times </li></ul></ul><ul><ul><li>Enhanced reliability </li></ul></ul><ul><ul><li>Superior product quality </li></ul></ul>
    15. 16. Steel Galvanising Line Hot rolled steel 0.8 - 4 mm in Semi-continuous 2 - 4 mm in Push-pull mode 790 - 1330 mm 2.2 MW AC variable speed 23000 N Uncoiler 73500 N Entry to skinpass mill 83300 N Exit from skinpass mill 65000 N Recoiler 150 m/min 170 m/min entry/exit zone 2 months: Material: Strip thickness: Strip width: AC drives installed power: Pulls: Line speed: Commissioning duration: Steel Industry - Italy
    16. 17. Wood Industry <ul><li>Switzerland, Finland Scierie Zahnd SA </li></ul><ul><li>4 X SPM 160kW for driving the 1800rpm milling cutters </li></ul><ul><li>15 X SP 5.5~30kW for line speed, rotation of wood lengths, selection left/right and cut-to-length machines. </li></ul><ul><li>Key Benefits: </li></ul><ul><ul><li>Line speed has been increased from 60 to 80metres per minute </li></ul></ul><ul><ul><li>Cost reduction </li></ul></ul><ul><ul><li>Energy consumption reduced </li></ul></ul><ul><ul><li>Plant Output to Double is double to 200,000 cu metres of cut timber </li></ul></ul>
    17. 18. Rubber Industry - UK <ul><li>630kW for Rubber Mill supplied July 2006 </li></ul><ul><li>AC Drives with SPMD parallel </li></ul>
    18. 19. Food & Beverage <ul><li>Customer name: LEU Anlagenbau AG of Uetendorf, Switzerland </li></ul><ul><li>4.0~7.5kW SP for position control </li></ul><ul><li>0.55~1.5kW SK for pusher (to push the cheese(s) from the board to machine), cheese turner, brush rotation, rotary plate, vertical and lateral movement of the rotary plate, pusher (to extract the cheese), gripper, lateral movement of board, support of board and board centering </li></ul><ul><li>Key Benefits: </li></ul><ul><ul><li>Excellent repeatable positional accuracy (+/- 0.1mm) </li></ul></ul><ul><ul><li>Programmable sequence </li></ul></ul><ul><ul><li>Automatic operation </li></ul></ul><ul><ul><li>540 cheese’s handled/hour </li></ul></ul><ul><ul><li>24hours, 7days a week </li></ul></ul>
    19. 20. <ul><li>CNC pipe cutting (plasma and oxyfuel) </li></ul><ul><li>X/Z-axis : M’ax + SLM-servomotors </li></ul><ul><li>Clamping: Maxi Maestro </li></ul><ul><li>3. CNC => Sigmatek C-IPC + C-SLM modules </li></ul>Machine Tools – The Netherlands
    20. 21. Machine Tools – The Netherlands Polishing Machine
    21. 22. Metal Polishing Machine – Spain (24axes, 4xCNC) – Wrist Watches
    22. 23. Control Techniques SpA Drive Centre Vicenza - Via Ortigara n°13 36051 Creazzo (Vi) Italy Aluminium 20 – 80 microns 800 mm 250kw  0,05mm - linear 300 m/min 2 weeks at EU site Material: Strip thickness: Strip width: SERVO & AC drives installed power: Performances without Register Control Line speed: Commissioning duration: Flexo Stack Printing Machine - Italy <ul><li>New digital drive technology applied to all the cylinders of printing lines instead of a single motor with mechanical trasmission is a “revolution” in the printing and paper converting market, because t he use of electrical digital lock and direct drive motors give very important solutions for the mechanical and electrical problems. </li></ul><ul><li>From the mechanical point of view this solution will remove the gear-box that must be with very low back-slash and so very expensive (this reduction of cost compensate the cost due to the use of the motor for each cylinder). It gives also a very high flexibility for the production with the possibility to adjust the repeat length as desired instead of the use of mechanical transmission where to change the repeat length it is necessary to stretch the material or to change the gear. </li></ul><ul><li>  From the electrical point of view the direct connection between the motor and the cylinder gives to the system a very high rigidity that together with the use of sin-cos encoder for the feedback, give the possibility to increase to a very high level the regulation parameter. This allow to perform a electrical shaft with a very low position error. </li></ul>
    23. 24. Embroidery Machine 20 Axes Servos Embroidery Machine 8 Axes Servos Embroidery Machine Textile Machines - Switzerland
    24. 25. Rolling Dyno Test Rig CT Drives
    25. 26. Gearbox Test Rig - UK 1xSize 5 Regen Front End (170kW) 3xSize5 Motoring(132kW) “ Loss- less” system Gearbox Testing
    26. 27. Test Rig - UK 1200kW Fan Drive for Wind Tunnel (for Jaguar/Red Bull)) Wind Tunnel Fan Drive 6 x Unidrive SPMD 1144kW, 480V, 1800A 1 x LS 455 Frame Motor SP Modular System
    27. 28. <ul><li>Test Rig – UK & Germany </li></ul>Audi (Cosworth) engine dyno
    28. 29. Test Rig Industry – CT Success
    29. 30. Otis (China, HK, Singapore) Shanghai Mitsubishi Escalators Unidrive - Dynamic performance for smooth ride Gearless & Geared Specific Elevator Software Elevators & Escalators
    30. 31. Hoist & Cranes – CT Industry Focus <ul><li>Port & Terminal </li></ul><ul><ul><li>Containers </li></ul></ul><ul><ul><li>Bulk </li></ul></ul><ul><ul><li>Cargo </li></ul></ul><ul><li>Industrial Cranes </li></ul><ul><li>Tower Cranes </li></ul>
    31. 32. Ship Loader/Unloader Thyssen Krupp Germany Site : South China 2006 <ul><li>4 sets of Ship Loader/Unloader mechanical design by Thyssen Krupp, manufactured in China. </li></ul><ul><li>CT Germany supplied the drives control, CT China managed the commissioning in China. 4 quadrant regenerative AC system with SPM’s </li></ul>
    32. 33. <ul><li>Ship Loader Cranes - Australia </li></ul><ul><li>Location: Mackay, Queensland </li></ul><ul><li>Crane Type: Ship Loader </li></ul><ul><li>Capacity: 54 Million tonnes PA </li></ul><ul><li>Industry: Coal Loading Terminal </li></ul><ul><li>Drive Equipment: </li></ul><ul><li>500 kW Regenerative Unidrive (Boom Luffing Winch) </li></ul><ul><li>500 kW Regenerative Unidrive ( Long Travel) </li></ul><ul><li>55 kW Regen Unidrive (Telescopic Winch) </li></ul><ul><li>55 kW Regen Unidrive (Boom Shutle Winch) </li></ul>
    33. 34. <ul><li>Ship Unloader Cranes – S.Korea </li></ul><ul><li>Location: Taean Power Plant </li></ul><ul><li>CSU (Continuous Ship Unloader) </li></ul><ul><li>Capacity: 2000 T/H (2 cranes) </li></ul><ul><li>Industry: Coal Unloading </li></ul><ul><li>Drive Equipment: </li></ul><ul><li>110KW x 4 Unidrive Bucket Elevator </li></ul><ul><li>160KW Unidrive Traveling Gantry </li></ul><ul><li>18.5KW x 4 Unidrive Boom Slewing </li></ul><ul><li>11KW Unidrive Bucket Elevator Slew </li></ul>
    34. 35. <ul><li>Tower Cranes – S.Korea </li></ul><ul><li>Location: Suwon </li></ul><ul><li>Crane Type: Tower Crane </li></ul><ul><li>Capacity: 16 T </li></ul><ul><li>Industry: Construction </li></ul><ul><li>Drive Equipment: Unidrive </li></ul><ul><li>64KW Hoist </li></ul><ul><li>30KW Luffing </li></ul><ul><li>Brake control with DBR </li></ul>
    35. 36. Tower Cranes - Germany <ul><li>NTK Technik GmbH </li></ul><ul><li>1 X 55kW SP for internal torque measurement to eliminate the need for static weighing by a load cell after the initial lift </li></ul><ul><li>1 X 30kW SP to lift the jib from horizontal (0 0 ) up to 89 0 . </li></ul><ul><li>1 X 30kW for 360 0 slewing movement of the crane </li></ul><ul><li>Key Benefits: </li></ul><ul><ul><li>Increased productivity- by eliminating the load weighing time </li></ul></ul><ul><ul><li>Optimising the maximum hoist speed depending on load </li></ul></ul><ul><ul><li>Unidrive SP provides advanced PC functionality </li></ul></ul>
    36. 37. Automatic Positioning Cranes - Australia <ul><li>Location: Port Kembla, NSW </li></ul><ul><li>Crane Type: Overhead Crane </li></ul><ul><li>Features : Driveless Wireless </li></ul><ul><li>Capacity: 30 tones </li></ul><ul><li>Industry: Coil Handling </li></ul><ul><li>Drive Equipment: </li></ul><ul><li>1x132 kW Unidrive (Main Hoist) </li></ul><ul><li>2x37kW Unidrive ( Long Travel) </li></ul><ul><li>2x11kW Unidrive (Cross Travel) </li></ul><ul><li>3x2.2kW Unidrive (Tong Control) </li></ul>
    37. 38. Port Cranes – The Netherlands STEINWEG, C. (HANDELSVEEM B.V.) – ROTTERDAM 50T Container Stacker Crane IGMA B.V. – AMSTERDAM (CARGILL) 16-TONNES AND 25-TONNES FLOATING GRAB CRANES (4 in total)
    38. 39. Sintermar Port Crane - Italy
    39. 40. <ul><li>CT Italy – Project References </li></ul><ul><li>SINTERMAR (Refurbishment) N. 1 STS Crane </li></ul><ul><li>OMG / LSCT (New) N. 2 STS Cranes + CMS </li></ul><ul><li>OMG / LSCT (Refurbishment) N. 3 STS Cranes + CMS </li></ul><ul><li>LSCT (Refurbishment) N. 4 STS Cranes + CMS </li></ul><ul><li>LSCT (Refurbishment) N. 8 RMG Cranes + CMS + DGPS </li></ul><ul><li>LSCT (Refurbishment) N. 3 RTG Cranes + CT-RIS.GA. + DGPS </li></ul><ul><li>LSCT (Refurbishment) N. 1 MHC GOTTWALD Crane </li></ul><ul><li>TDT (Refurbishment) N. 4 STS Cranes </li></ul><ul><li>TDT (New) N. 2 RTG FULL AC + CMS + ANTISWAY </li></ul><ul><li>REEFER TERMINAL (Refurbishment) N. 2 STS Cranes </li></ul><ul><li>TCR Ravenna (Refurbishment) N. 3 STS Cranes </li></ul><ul><li>TCR Ravenna (Refurbishment) N. 4 RMG Cranes </li></ul><ul><li>CICT Cagliari (Refurbishment) N. 2 STS Cranes </li></ul><ul><li>CICT Cagliari (Refurbishment) N. 4 RTG + CT-RIS.GA. + DGPS </li></ul><ul><li>SAPIR (Refurbishment) N. 1 Refuse Quay Crane </li></ul><ul><li>VTE N. 10 CT-RIS.GA. </li></ul>
    40. 41. <ul><li>N. 3 RTG Cranes Refurbishment </li></ul><ul><li>Electric and Operator cabins </li></ul><ul><li>Drives MENTOR II </li></ul><ul><li>PLC + CMS + DGPS (GPS positioning) </li></ul>
    41. 42. <ul><li>N. 4 STS Cranes Refurbishment </li></ul><ul><li>Drives MENTOR II </li></ul><ul><li>PLC + HMI </li></ul><ul><li>Operator cabin </li></ul>
    42. 43. <ul><li>2 no. NEW RTG FULL AC </li></ul><ul><li>Drives UNIDRIVE SPM </li></ul><ul><li>PLC + CMS + DGPS (GPS positioning) </li></ul><ul><li>CT-RIS.GA. (energy saving) </li></ul>
    43. 44. DC solution AC solution Diesel Generator Motors Auxiliaries Lights Heating/Cooling Devices Ris-Ga – Fuel saving function for RTG
    44. 45. These are the graphs with the Voltage and Frequency values using the Ris-Ga functionality Ris-Ga – Fuel saving function Ris-Ga output side Ris-Ga input side Voltage Frequency
    45. 46. THE BEST COOPERATION <ul><li>HIGH LEVEL QUALITY in SYSTEMS and PRODUCTS </li></ul><ul><li>AFTER SALES SERVICE </li></ul><ul><li>ENGINEERING PARTNERSHIP </li></ul><ul><li>INNOVATION TECHNOLOGY (Drives, Software, Solutions, etc.) </li></ul>+ PAOLO MUSSI LSCT Technical Director Customer Reference
    46. 48. CT China DC Crane Upgrades
    47. 49. <ul><li>Qingdao Port : DC M-G STS Retrofit </li></ul><ul><li>M1200R / M350R / MD29 / FXM5 / M45 </li></ul><ul><li>M1200R for Hoist and Gantry </li></ul><ul><li>M350R for Trolley and Boom </li></ul>DC Retrofit STS Crane
    48. 50. <ul><li>ShanTou : Gantry Crane ( 2sets ) </li></ul><ul><li>Unidrive Classic </li></ul><ul><li>2*UNI5401 </li></ul><ul><li>UNI3405 </li></ul><ul><li>UNI3403 </li></ul><ul><li>UD51 </li></ul><ul><li>UD70 </li></ul><ul><li>Digital lock </li></ul>AC Jib Crane
    49. 51. CT China AC Crane (New)
    50. 52. CT China’s 1 st AC STS Crane – ZPMC <ul><li>Shanghai Longwu Port </li></ul><ul><li>ZPMC constructed it in 1998 </li></ul><ul><li>Unidrive Size 5 </li></ul><ul><li>DB resistor system </li></ul><ul><li>Hoist/Gantry share one drive </li></ul><ul><li>Trolley/Boom share one drive </li></ul><ul><li>Digital Lock for two hoist motors in tandem </li></ul>
    51. 53. Port Cranes – Hong Kong Hutchisons International Terminal
    52. 54. <ul><li>Xiamen International Containter Terminal (a Joint Venture with Hutchisons) </li></ul><ul><li>“ No.1/2QC” : (2sets) </li></ul><ul><li>Old M-G set Quayside crane </li></ul><ul><li>(Upgraded with DC Mentor II) </li></ul><ul><li>OEM Changzhou GT </li></ul><ul><li>“ No.5~8QC”: (4sets) </li></ul><ul><li>AC full sinewave 4Q STS crane </li></ul><ul><li>(Unidrive Classic Size5) </li></ul><ul><li>OEM SPMP </li></ul><ul><li>“ No.24/25 RTG” (2sets) </li></ul><ul><li>Old M-G set RTG crane </li></ul><ul><li>(upgraded with DC Mentor II) </li></ul><ul><li>OEM Changzhou GT </li></ul><ul><li>“ No.16~20 RTG” (5sets) </li></ul>CT China’s Key Customer – XICT
    53. 55. <ul><li>61T Full sinewave regeneration </li></ul><ul><li>Front End IGBT : 1000kW </li></ul><ul><li>Hoist : 2 * 350kW </li></ul><ul><li>Trolley : 2*110kW </li></ul><ul><li>Boom : 250kW </li></ul><ul><li>Gantry : 16*11kW </li></ul><ul><li>HV cable reel : 4kW </li></ul><ul><li>Elevator : 7.5kW </li></ul><ul><li>Drive : Unidrive Classic Size 5 </li></ul><ul><li>Feature : Regeneration system, Common DC Bus , Profibus-DP field bus. CPHC program, Host load sharing. Drive sharing, SP+onboard PLC to control HV cable reel </li></ul>AC STS Crane - XICT
    54. 56. <ul><li>41T AC RTG ( 5Sets ) </li></ul><ul><li>Hoist : 210KW </li></ul><ul><li>Trolley : 45KW </li></ul><ul><li>Gantry : 4*45KW </li></ul><ul><li>Hoist : Unidrive Classic Size 5 </li></ul><ul><li>Gantry /Trolley : Unidrive SP </li></ul><ul><li>Feature : ProfibusDP, CPHC application program </li></ul>AC RTG Crane - XICT
    55. 57. <ul><li>A SP1406 + DB resistor as close loop mode </li></ul><ul><li>Standalone system with onboard SyptLite program (No PLC) </li></ul>SPMP-1578 Project – HV Cable Reeler
    56. 58. AC Crane – HV Cable Reeler Application <ul><li>Unidrive SP – 4 kW </li></ul><ul><li>Onboard-PLC , 4K RAM </li></ul><ul><li>Simple centre winder ladder logic </li></ul><ul><li>Coiler and recoiler torque offset </li></ul>
    57. 59. SPMP-1578 Project – Spreader Cable Reeler <ul><li>Two 7.5KW Motor in Parallel </li></ul><ul><li>A SP3403 +DB resistor </li></ul><ul><li>Point to point control by hoist PLC </li></ul><ul><li>Different Torque offset when wind or rewinder </li></ul>
    58. 60. Current Project Ship-to-Shore (STS) & RTG Crane Project – Xiamen China OEM: Shanghai Port Machinery Plant (SPMP) Project: 6sets STS & 6sets RTG Project A = 4STS Project B = 2STS & 6RTG Project A Ship-to-Shore(STS) Crane Total Power Rated per crane =1,972kW: Hoist Motor (2sets x 560kW) Trolley Motor (1 set x 250kW) Boom Motor (1 set x 250kW) Gantry Motor (16 sets x 22kW) Project B Ship-to-shore (STS) Crane Total Power Rated per crane =2,015kW: Hoist Motor (2 sets x 560kW) Trolley Motor (2 sets x 110kW) Boom Motor (1set x 315kW) Gantry Motor (24 sets x 15kW) Project B RTG Crane Total Power Rated per crane =360kW: Hoist Motor (1set x 210kW) Trolley Motor (4sets x 30kW) Gantry Motor(1set x 30kW)
    59. 61. SPMP- 1594 Project
    60. 62. SPMP- 1595 Project - RTG’s
    61. 63. Container Crane MG Set Revamp - China <ul><li>Shanghai Container Terminal </li></ul><ul><li>Revamp in 1998, completed in 55 days </li></ul><ul><li>GE PLC 90 - 30 </li></ul><ul><li>Control Techniques Mentor DC Drive replacing the Motor Generator Set. </li></ul><ul><li>Xiamen Port – October 2000 </li></ul><ul><li>Shenzhen Port – March 2001 </li></ul><ul><li>Revamp projects </li></ul><ul><li>GE PLC </li></ul><ul><li>CT Mentor DC Drive </li></ul>
    62. 64. Container Crane Revamp Analogue DC Drives at Xiamen Port <ul><li>Project started 1999 </li></ul><ul><li>GE PLC 90 - 30. </li></ul><ul><li>Control Techniques Mentor DC Drive to replace the existing Japanese Analogue Drive. </li></ul><ul><li>The crane has been running efficiently and reliably since commissioning. </li></ul>
    63. 65. Port Cranes - Singapore Port of Singapore (PSA) Rubber Tyre Gantry Cranes
    64. 66. Control Techniques A Drives Specialist Worldwide Company With Port Cranes Know How !
    65. 67. How Can We Meet Your Needs ? <ul><li>Emerson Industrial Automation divisions provides package solutions for port cranes (drives, motors, gears). </li></ul><ul><li>CT drives are high performance, intelligent and networking. Proven DC drives (Mentor 2) and latest advanced Unidrive SP AC drives including regeneration capability. </li></ul><ul><li>Local Support - CT Drive Centres are present where PSA ports are located. We understand the needs of busy ports. </li></ul><ul><li>We have vast experience in crane upgrades (DC & AC). </li></ul><ul><li>We have developed port crane application software for drives and CMS. </li></ul><ul><li>We work with crane OEM makers and System Integrators assisting with selection, design and commissioning. </li></ul>