2. Content
Crane general function
1. Introduction About Crane Operation
2. Types of motion & Crane Parts
3. Brief about Safety/ Protection & Interlock
4. Types of Protection device/ field Device/
interlock
5. Brief idea about Spreader, Head block.
6. Introduction about General Electrical Hazads
PLC
VVVF Drive
Fundamentals of AC Motors
8. ASI Programming procedure
• Objective: Transmits & receives the signals from field
devices to spreader PLC.
Field Devices: (on the spreader)
Proximity sensor/Solenoid Valve/Container detection
sensor/Positioning sensor.
What is ASI:
AS-I : Actuator Sensor Interface
Connects Input / Out put devices to PLC via a two-wire
flat cable.Eliminates multiple terminations.
9. 4 DI TYPE SLAVE
4 DI + 4 DO TYPE
SLAVE ANALOG TYPE
SLAVE
Type of ASI
Module
10. LED status on slave
LED on
Slave
Healthy
status
Fault status Reason
ASI Power Green Red ASI Power supply &
its cable connection
problem.
Error off Red Slave faulty.
Fault off Red Slave faulty.
Power Green Red ASI Power supply &
its cable connection
problem.
11. 4 DI TYPE SLAVE
4 DI + 4 DO TYPE
SLAVE ANALOG TYPE
SLAVE
LED FOR ASI POWER
12. Flow diagram
Field Device : Proximity sensor/Solenoid Valve/Container
detection sensor/Positioning sensor
ASI Slave Located in junction box Of spreader.
ASI processor which is connected at sp CPU Located
above trolley.
Spreader CPU is connected with master PLC through
profibus and fibreoptic cable.
13. PEPPERL FUCHS
VBP HH1
SLAVE ADDRESS
READER
SLAVE TO
BE
ADDRESS
2 core wire for communication
Programming key
Button
ASI Programmer
14. Procedure
Connection to be done
between P&F
Programmer (VBP-HH1)
with slave module by
using its cable.
Press ADR in
Programmer. The screen
will show previous
address of slave.
In case of error in the
slave during the process
LED on the slave module
will glow.
19. Agenda
• Review brief history of PLCs and
manufacturing control systems
• Introduce the concepts of discrete
control of manufacturing
• Review the various kinds of
instrumentation used for control.
• Overview ladder logic programming
20. Objectives
• To define the basic components of a PLC
• To apply PLC based control to a
manufacturing system
• To be identify instrumentation required to
implement a PLC control system
• To program a PLC
• To implement a PLC control program and
hardware
21. Purpose Of Programmable
Logic Controllers (PLCs)
• Initially designed to replace relay logic
boards
– Sequence device actuation
– Coordinate activities
• Accepts input from a series of switches
• Sends output to devices or relays
23. CONTROL DEVICES
1) mechanical control - cam, governor,
etc.,
2) pneumatic control - compressed air,
valves, etc.
3) electromechanical control - switches,
relays, a timer, counters, etc,
4) electronics control - similar to
electromechanical control, except
uses electronic switches.
5) computer control.
26. What devices does a PLC
interact with?
• INPUT RELAYS-(contacts)These are connected to the outside world.
They physically exist and receive signals from switches, sensors, etc.
Typically they are not relays but rather they are transistors.
• INTERNAL UTILITY RELAYS-(contacts) These do not receive signals
from the outside world nor do they physically exist. They are simulated
relays and are what enables a PLC to eliminate external relays. There
are also some special relays that are dedicated to performing only one
task. Some are always on while some are always off. Some are on only
once during power-on and are typically used for initializing data that
was stored.
• COUNTERS-These again do not physically exist. They are simulated
counters and they can be programmed to count pulses. Typically these
counters can count up, down or both up and down. Since they are
simulated they are limited in their counting speed. Some manufacturers
also include high-speed counters that are hardware based. We can
think of these as physically existing. Most times these counters can
count up, down or up and down.
27. What devices does a PLC interact with?
Continued..
• TIMERS-These also do not physically exist. They come in many
varieties and increments. The most common type is an on-delay
type. Others include off-delay and both retentive and non-retentive
types. Increments vary from 1ms through 1s.
• OUTPUT RELAYS-(coils)These are connected to the outside world.
They physically exist and send on/off signals to solenoids, lights,
etc. They can be transistors, relays, or triacs depending upon the
model chosen.
• DATA STORAGE-Typically there are registers assigned to simply
store data. They are usually used as temporary storage for math or
data manipulation. They can also typically be used to store data
when power is removed from the PLC. Upon power-up they will still
have the same contents as before power was removed. Very
convenient and necessary!!
29. TERMS
Throw - number of states
Pole - number of connecting moving parts (number of individual circuits).
SPDT
DPST
A serial switch box (A-B box) has
two 25 pin serial ports to switch from.
Input
Output
A B
Knob
How is this switch classified?
30. TYPES OF SWITCHES
1. Basic switch, operated by a mechanical level,
2. Push-button switch,
3. Slide switch,
4. Thumbwheel switch,
5. Limit switch,
6. Proximity switch, and
7. Photoelectric switch.
RATING: voltage, current
31. RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"
contact
coil
input
Relay coil Output contact
32. COUNTER
Digital counters output in the form of a relay contact when a
preassigned count value is reached.
Register
Accumulator
contact
input
reset
output
Input
Reset
Output
Count 0 1 2 3 4 5 0 1
5
33. TIMER
A timer consists of an internal clock, a count value register,
and an accumulator. It is used for or some timing
purpose.
Clock
Accumulator
contact
reset
output
Register
Contact
Time 5 seconds.
Clock
Reset
Output
Count 1 2 3 4
0 5
34. AN EXAMPLE OF RELAY LOGIC
L1
LS1 PB1 LS2 R1
R1
R1
TIMER R2
PR=5
For process control, it is desired to have the process start (by turning on a
motor) five seconds after a part touches a limit switch. The process is
terminated automatically when the finished part touches a second limit switch.
An emergency switch will stop the process any time when it is pushed.
LS1
PB1
LS2
R1
TIMER
5
Motor
R2
35. PLC ARCHITECTURE
Programmable controllers replace most of the relay panel
wiring by software programming.
Processor
I/O
Modules
Memory
Power
Supply
Program
Loader
Printer
Cassette
Loader
EPROM
Loader
Switches
Machines
Peripherals External Devices
PC
A typical PLC
36. PLC COMPONENTS
1. Processor Microprocessor based, may allow arithmetic
operations, logic operators, block memory moves,
computer interface, local area network, functions,
etc.
2. Memory Measured in words.
ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electronically Erasable Programmable
ROM),
EPROM (Erasable Programmable Read Only
Memory),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.
37. PLC COMPONENTS
3. I/O Modular plug-in periphery
AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g.., high speed timers,
Stepping motor controllers, etc. PID, Motion
4. Power supply AC power
5. Peripheral Handheld programmer (loader),
CRT programmer,
Operator console,
Printer,
Simulator,
EPROM loader,
Cassette loader,
Graphics processor, and
Network communication interface. MAP, LAN
38. LADDER DIAGRAM
A ladder diagram (also called contact symbology) is a
means of graphically representing the logic required in
a relay logic system.
A
R1
PB1 PB2
R1
R1
start emergencystop
Rail
Rung
39. LOGIC STATES
ON : TRUE, contact closure, energize,
etc.
OFF: FALSE, contact open ,de-energize,
etc.
(In the notes we use the symbol "~" to represent
negation. AND and OR are logic operators. )
Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.
40. AND and OR LOGIC
PB1 R1
PB2
R2
R1 = PB1.AND.PB2
R2 = PB2.AND.~PB4
PB3 PB4
PB1 R1
PB2
R1 = PB1 .OR. PB2
AND
OR
41. RELAY
A Relay consists of two parts, the coil and the contact(s).
Contacts:
a. Normally open -| |-
b. Normally closed -|/|-
c. Off-on transitional -||-
d. On-off transitional -| |-
Coil:
a. Energize Coil -( )-
b. De-energize -(/)-
c. Latch -(L)-
d. Unlatch -(U)-
( )
42. TIMERS AND COUNTERS
Timers:
a. Retentive on delay -(RTO)-
b. Retentive off delay -(RTF)-
c. Reset -(RST)-
Counter:
a. Counter up -(CTU)-
b. Counter down -(CTD)-
c. Counter reset -(CTR)-
RTO counting stop counting
resume
RTF stop counting stop
True False True
Input
RTO reach PR value, output ON
RTF reach PR value, output OFF
PR value in 0.1 second
43. Programming a PLC
Oil is consumed
randomly. The tank
needs to be refilled by
turning on a pump.
Two hydrostatic
switches are used to
detect a high and low
level.
45. What is a VFD?
– Variable Frequency Drive (VFD)
– A VFD can be used to control both the speed and
torque of a standard induction AC electric motor.
– It varies both the frequency and amps of the AC
waveform being delivered to the motor saving
money in electricity.
– Basic components of a VFD:
• Input section, draws AC electric power from the
utility, Rectifier section, converts the AC into DC
power.
• Inverter section, converts DC back into a
controllable AC waveform.
46. • Block diagram of VFD
Motor
L1
L2
L3
C
L
Input Converter
(Diode Bridge)
Output Inverter
(IGBT’s)
DC Bus
(Filter)
+
_
+
_
+
_
+
_
+ +
_ _
1. Converter section ( Rectifier) Convert 3 phase AC power to distorted DC power.
2. DC Bus store & Filter the DC power in larger bank of capacitor.
3. Inverter Invert ( Set of 6 IGBT) the filter DC in to pulsating AC power (PWM)
47. 1. Converter section ( Rectifier) Convert 3 phase AC power to distorted DC power.
2. DC Bus store & Filter the DC power in larger bank of capacitor.
3. Inverter Invert ( Set of 6 IGBT) the filter DC in to pulsating AC power (PWM)
• Woking principle of VFD
To
Motor
RECTIFIER
(AC - DC)
INVERTER
(DC - AC)
AC DC AC
VFD
50/60 Hz
48. Purpose of the VFD
• VFDs help to limit demand and electrical consumption of motors by
reducing the amount of energy they consume. Standard motors are
constant speed and when they are energized they run at a 100% no matter
the load.
– Only use energy you need
– Elimination of expensive mechanical drive components.
– Increased motor longevity.
– Reduced power line disturbances.
– Reduced risk of motor damage during start up and stop.
63. Three Phase Motor Construction
End View
Magnetic
Poles
T1a
T2a
T2a’
T1a’
T1b
T2b
T2b’
T3b
T1b’
T3b’
T3b’
T3b
64. Calculating Motor Rated Speed
Formula to find actual motor RPM
N =
120 f
P
( 1 - s )
Where:
N - RPM of the motor
f - Frequency in Hz
P - Number of poles of the motor
s - (No - N) / No
65. Speed - Torque Curve
(600%)
Locked Rotor
Torque (150%)
Full Load
Torque (100%)
Pull Up Torque
(125%)
Breakdown
Torque
(200-250%)
Rated Speed Synch Speed
SPEED
TORQUE CURRENT
No Load
Current
(30%)
Slip
(300%)
(300%)
(200%)
66. Typical NEMA Design Characteristics
0
100%
SPEED
TORQUE
200%
300%
100%
NEMA Design A
High breakdown torque
Normal starting torque
High starting current
Low full load slip
Used in applications
that require:
Occasional overloads
Better efficiency
67. Typical NEMA Design Characteristics
0
100%
SPEED
TORQUE
200%
300%
100%
Design B
NEMA Design B
Normal breakdown torque
Normal starting torque
Low starting current
Normal full load slip
less than 5%
General Purpose Motor
Design A
68. Typical NEMA Design Characteristics
0
100%
SPEED
TORQUE
200%
300%
100%
Design C
NEMA Design C
Low breakdown torque
High starting torque
Low starting current
Normal full load slip
less than 5%
Used in applications
that require:
high breakaway torque
Design A
Design B
69. Typical NEMA Design Characteristics
0
100%
SPEED
TORQUE
200%
300%
100%
Design D
NEMA Design D
High breakdown torque
High starting torque
Normal starting current
High full load slip
5 - 13%
Used in applications
that require:
high breakaway torque
Design C
Design A
Design B
71. Understanding the Nameplate
Insulation Class
The insulation class
letter designates the
amount of allowable
temperature rise
based on the
insulation system
and the motor
service factor.
72. Insulation Class Information
Most common insulation classes are class B and F
Insulation Class Ambient Temp. Temp. Rise Total Temp.
A 40o
C 65o
C 105o
C
B 40o
C 90o
C 130o
C
F 40o
C 115o
C 155o
C
H 40o
C 140o
C 180o
C
73. Understanding the Nameplate
S.F. - Service Factor
The number by which the
horsepower rating is multiplied to
determine the maximum safe
load that a motor may be
expected to carry continuously
Example - a 10HP motor with a
service factor of 1.15 will
deliver 11.5 horsepower
continuously without exceeding
the allowable temperature rise
of its insulation class
81. Type of motion in RTG
• Gantry
• Main Hoist
• Trolley
• Skew/ Trim
82.
83.
84.
85. RTG gantry Motor directly connected with shaft of gantry wheel.
Features
Direct Driven, No Chain Drive
Gantry travel with load
Wheels hydraulically locked
Motors
4 motors on 16 wheeler
Reduced tyre wear with
differential axles allowing
Wheel turning:
Wheels to rotate during 90° turn
4 motors on 16 wheeler
86. Anti-Sway System:
For controlling the unwanted sway.
Advantages by Design
Minimal spreader positioning times
Anti - Sway: Trolley & Travel direction
Anti - Skew
Trim and Skew spreader positioning
No Additional Ropes or Devices necessary
89. • The Engine
This is typically a diesel engine, much like that in a large vehicle, the bigger
the source of mechanical energy, the more electrical power can come out ‘the
other end’.
• The Alternator
This is the part which turns the mechanical energy (the rotation of the shaft)
into electrical power through induction. The ‘how’ of the alternator is one of the
most fascinating parts of a generator. Faraday discovered (or at least
described) the process of ‘electromagnetic induction’ in the early 1830s. This
principle holds that if you move a wire (or any electrical conductor) through a
magnetic field, an electric current is ‘induced’ in the wire. The same is true if
the wire is still and the magnetic field moves. Simply moving through a
magnetic field causes the electrons to flow through the wire. If the wire moves
north-south, the electrons flow one way, and if it moved back south-north, they
flow into the other. The stronger the field and the longer the wire, the greater
the amount of current induced. Modern generators work by placing several
large, powerful magnets in a cluster around a central, rotating shaft. This is
called the ‘rotor’ or ‘armature’. The magnets might be permanent magnets or
electromagnets, but the point is that they produce a magnetic field, which the
engine causes to turn. The other important sub-component of the alternator is
the ‘stator’, which is essentially a series of tightly bundled coils of wire, all
packed closely around the rotor. When an outside force (such as a diesel
engine) turns the central shaft, the rotor constantly moves the north and south
poles of its magnetic field(s) across the bundles of wire that surround them.
This causes a great deal of electrical current to flow back and forth through the
wires – what we call ‘alternating current’ or ‘AC’ mains power.
90. The Fuel System
This is typically the diesel fuel supply for the engine. The most obvious part is a tank
holding enough fuel for at least 6-8 hours of operation. This tank may be inside the
generator housing for smaller, or portable units, or it may be a separate external structure
for larger, permanently installed units. Other parts of the fuel system involve pipe-work to
get the fuel to the engine, a fuel pump similar to the one in most vehicles, a fuel filter, and
a ventilation pipe or valve for the fuel tank, preventing overpressure or vacuum inside.
There will also be an overflow connection ensuring that if the tank is overfilled, the fuel
ischannelledaway, and not simply splashed over the surface of the engine or alternator.
The Voltage Regulator
This is a fairly complex but important component. Without it, the voltage and amperage of
the AC current provided would vary according to the speed of the engine. As modern
electrical equipment relies on a very steady power supply, something is required to level it
out. The workings of a voltage regulator are quite ingenious and are beyond the scope of
this article. It is probably enough to know what it does, for now.
The Cooling System
Just like in a vehicle, the engine produces a great deal of waste heat in addition to
mechanical energy. The power flowing through the alternator also produces heat via the
electrical resistance of the wires themselves. Again, like in your car, this heat is soaked
up by a coolant fluid, often but not necessarily water, which then runs through a heat
exchanger, dumping its heat typically into the air, or sometimes into a secondary coolant
fluid.
91. The Exhaust System
All internal combustion engines produce exhaust gases. These are toxic and must be
directed away from the engine itself and any nearby people. Exhaust gases are
typicallychannelledthrough pipes, and vented into the outside air. There are typically
health and safety regulations about how and where exhaust systems must
bechannelled, so consult these carefully before installing a new generator.
The Starter & Battery System
Again, just like in a car or lorry, the diesel motor relies on a small electrical motor to
start running. This electrical starter motor is powered by a battery, which is charged by
either a separate charger or the generator output itself.
The Control Panel
The control panel is where the generator is operated. Typical controls & outputs
included on most control panels are:
· Start / shutdown controls (manual, automatic, or both)
· Phase selector switch
· Frequency switch
· Engine mode switch
· Engine fuel
· Engine speed
· Coolant temperature
· Battery charge
· Generator output voltage
· Generator output current (amperage)
· Generator Output in kVA
92. The frame/Housing
Thegensetwill either be contained in a weatherproof housing, an open
structural frame, or a transportable unit. All of these function to keep the
components together and solidly attached. It also ensures that all electrical
components are safely grounded.
The only issue with the alternator powering its own field coils is that it requires
external power to power these coils in order to start. In a combustion engine
vehicle or small diesel generator for example the alternator is connected to a
starter battery whenever the generator is switched on. Usually this battery can
also be switched temporarily to power an engine starter motor.
93. Types of Protection Device In RTG
• Gantry Anticollision, container
collision device.
• Proximity switch for wheel
turning & spreader.
• Load cell for Mainhoist
overload protection.
• CAM switch for Mainhoist Slow
down protection
Source: https://www.osha.gov/Publications/osha3075.pdf
“Most electrical accidents result from one of the following three factors:
• unsafe equipment or installation,
• unsafe environment, or
• unsafe work practices.”
This module provides an operational introduction to the use of Programmable Logic Controllers (PLCs) to manufacturing systems.
The focus here is on the trends towards smaller lot sizes, more frequent change over and higher flexibility required today.
