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21 no Gantries Synchronous Movement for handling 260M long rails

BY-M/S REVA INDUSTRIES LIMITED FARIDABAD

Project : DDFC - Tata Aldesa - Bhadan, Kanpur and Aliargh

Commissioning date -December 2014

Project Requirement:

Tata Aldesa was awarded order for dedicated freight corridor. The requirement was that
260M long rails would have to be unloaded from BFR and loaded onto Track Laying
Machine.

For this application 21 nos of Gantries each with 2t hoist, lifting beam were required.
these gantries were spaced @12.5M apart.
The application required all 21nos of gantries or group of 7 or 4 or individual to be
operated as per application use.

Handling area Span: 260m X 20 m
Height of Lift: Approx. 6.0 meters.
Lifting Capacity: 2 tons per Hoist
Hoist Speed: 0.3 - 3 mpm
Cross Traverse Speed:1.6 to 16 mpm.
Scope of Supply
Mechanical:
21 nos of gantries
2t hoists - 21 nos
lifting beams - 21 nos
Rail Clamps - 42 nos
cage : 21 nos
cross members - 42 nos

civil :
foundation of each gantries
control room.

Electrical:
PLCs, wired Control Pendants ,wireless Radio Remote, L&T-Yaskawa drives, Control
desk (in control room), HMIs, Local control panel, Yard lighting, Cameras.

Rail Handling Arrangement

Fixed 21 nos gantries of 8m height and 20 m width are provided at an 12.5m distance
along the length of the rail in handling area. On each of these gantries one hoist of 2t
capacity is provided, with lifting beam and 2 sets of lifting rail clamps. These are used to
unload the rails in synchronous from the BFR, to the adjacent storage area and then from
the storage area back to the rail track laying machine.
The hoists are equipped with VVVF Drives which can provide stepless speed in hoisting
as well as cross travel motion. This is required for the precise movement of the hoist.
PLC's are installed in each hoist control panel, further grouping is done in pair for 4 such
stations and these are connected to the Master PLC installed in the control room.
Master PLC is attached to HMI for operation - control and display.
The gantries are numbered and the status of the individual is shown on the HMI. PLC
detects any failure in any of the gantries and displays the same on the HMI.
There are options of Grouping N number of hoists and control them together in
synchronization as per operator need.
Radio remote option is given where in the complete system can also be operated through
radio remote.

Control philosophy:

Each AC Drive control panel of hoist will be connected to each other via Ethernet
Modbus communication for which one no. PLC will be used for every SLAVE
panel. further 4 stations are made to connect with 21 no. of hoist panels PLC.
And
These 4 PLC station will be inter-connected via ETHERNET communication
while using a master PLC with HMI to control and operate complete system in a
user friendly manner..
Advantages of the system

1) individual PLC and the VVVF drive combination provides 2 way communication,
feedback of any limit switch failure and the torque generated by the individual motor is
received by the master PLC in real time.
2) In case of any overloading in a particular hoist, the system will show alarm.
3) In case any of the hoists is not working then the system will show alarm.
4) In case limit switches are activated on any one of the hoists then alarm will be shown.
5) In case brake of one of the hoists is loose then also alarm will be displayed.
6) In case of power phase loss in any phase then alarm will generate and stop working.
7) radio remote operation is provided, where in the user is free to move around.
8) cameras are provided on each of the gantry and this can be viewed from the control
room.
9) for operation at night, sufficient lightning is provided.
10) each gantry is provided with cage for maintenance of the hoist and the control panel.
11) Individual local control pendants provided for use of a particular crane in local mode.