Technology Software Module: Simoreg DC - Master 6ra70 and T300

Technology software module
for the
closed-loop control of crane drives
with
SIMOREG DC - MASTER 6RA70 and T300

or
SIMOVERT MASTER DRIVES CUVC and T300
Introduction and overview
Implementation and owner: Information-related services for industrial equipment and systems
ATD TD IT IS
Sales/marketing: Automation & Drives

A & D MC
AL: N
ECCN: N
Statistical product number: 85439080

NOTES
This documentation describes the software implementation of the closed-loop technology control
of crane drives.
The installation, connection and commissioning of the equipment and modules is not described
here. These are provided in sufficient detail in the Instruction Manual of the equipment.
The information on danger, warning notes and cautionary measures should also be taken from
the appropriate Instruction Manuals of the devices.
Further, it is assumed that the equipment is installed, commissioned and serviced by suitably
trained and qualified personnel, who are both knowledgeable about the product itself as well as
the particular industry sector.
This document also doesn’t describe basic and simpler functions related with crane drives.
No part of this publication may be reproduced or transmitted in any form or by any means, elec-
tronic or mechanical, including photocopy, recording, or any information storage and retrieval
system, without permission in writing from the publisher.
Introduction and overview V1.1 2 01.06.1999

Copyright © Siemens AG All Rights Reserved

Structure
1. Description of the concept
1.1. General overview
1.2. Hardware and software components of the T300 technology module
1.3. Overview of the various drives, modules and functions
1.4. Communications between SIMATIC and drive units (Profibus)
1.5. Communications within the drive units (equipment response)
1.6. Communications between 2 drive units (peer-to-peer)
1.7. Overview of communications
1.8. Basic signal characteristics and structure of the closed-loop control
1.9. Connecting-up diagram for the T300
1.10. Necessary basic device parameters for communications
2. Documentation of the software for the individual drives


1. Description of the concept
1.1. General overview
Presently, SIMOREG DC-MASTER 6RA70 devices are being used for the closed-loop control of DC
crane drives and SIMOVERT MASTER DRIVES CUVC for AC drives.
In order to implement the technological closed-loop control tasks and functions, in almost all cases, it is
necessary to use an additional T300 technology processor in the units mentioned above.
The T300 is a freely-configurable technology processor with analog and digital inputs and outputs, two
connections for pulse encoders, serial interfaces etc. On the plant/system side, these connections are
routed to the SE300 terminal block. This is connected to the T300 technology module using screened
round cables. For this application, only the pulse encoder connections and the analog outputs are used
for commissioning purposes.
The sub-modules (Eproms, program memory modules) for the T300 are programmed with the STRUC
programming language from SIMADYN D. However, these are not required for this particular applica-
tion.
The T300 technology module is used in the electronics box of the drive converter units as option mod-
ule. Module T300 is shown on Page 8, the installation on Page 7 as well as a connection example on
page 16.
For the various crane drive types, the necessary and frequently required closed-loop control structures
and functions required for these drives, are combined in drive-specific software modules. These are
listed in the table on Page 9 together with the functions which have been implemented.
If other functions are required, which are not listed in the table on the next page, then these must be
implemented as custom software.
With the software, the open-loop- and closed-loop control tasks are clearly separated. These are exe-
cuted in the systems which have been designed for these purposes, i.e. the implementation of all of the
open-loop control functions in the SIMATIC as well as implementation of all closed-loop control func-
tions which are distributed in the drive control system.
Digital interlocking, e.g. controlling contactors, generating enable signals for the drive must therefore
be implemented in the higher-level open-loop control system. Only the drive-specific closed-loop con-
trol circuits and functions are implemented in the freely-programmable technology modules.
The closed-loop technology control is realized in the technology modules. However, the closed-loop
speed control and the closed-loop current control in the basic drives are fully utilized.


The drive units communication with the SIMATIC via Profibus SINEC L2 DP with PPO type 5 (4 PKW
and 10 PZD words).
The complete control (control words and setpoint-actual values) of the drive converters is realized via
this interface.
The essential signals from the S5 to the drives are four 16-bit control words as well as the setpoints for
the speeds and the position setpoint for a closed-loop position control.
The communications between the technology module and a basic drive is realized through a DPR (dual
port Ram).
The setpoint is entered from the master switch via ET200, SIMATIC and Profibus to the drive unit.
The position actual values must be sensed for the closed-loop position control of a drive. In many
cases, this can be realized using the speed encoder is mounted on the motor.
For the grab position control of a grab crane or for the closed-loop synchronous control of two drives, it
is necessary to sense the position actual values of both drives. This can also be realized using the
pulse encoder, mounted on the motor for the speed actual values.
The pulse encoder signals for the speed actual value sensing are fed to the basic drives and for the
position actual value sensing, to the technology module. It is also possible to mount additional pulse
encoders on the cable drum.
The necessary parameters are defined as technology parameters and these can be set and changed.
They are set via the basic drive operator panel. It is also possible to parameterize the units (basic drive
and technology module) using the SIMOVIS service tool.
An overview of the concept is shown in the following block diagram using as an example, the holding-
and closing gear of a grab crane. The block diagram is also valid for an individual drive or a master-
slave drive.

S5/7
control words
n** status words
n*
s*
ET ET ET
CB CB
peer to peer
TB n*, i* TB
master switch
HW and SW
GG GG
cable drum cable drum

T
HW
M T
HW
M
ET: electrical terminal block

T: pulse encoder
T T HW: holding gear
SW: closing gear
CB: communication board
TB: technology board
GG: basic unit
1 2 3 4 5 6 7 8
overview concept ATD TD IT IS 4 01.06.99 V. 1.1 page 6

1.2. Hardware and software components of the T300 technology module
Memory module
for slot in T300
Basic electronics CUVC

Comm. board CBP,SCB1,SCB2
Technology board
T300
Slot for
memory
module
Backplane
MS3xx
X131 bus LBA
Service PC/PG with
start-up programm
X132 (RS232)
Peer-to-peer-
connection X133 (RS485)
(to other T300
units, to the SCB2 X134 (RS485)
or SIMOREG
6RA24)
X136
SC58 SC60
Length of
1 the round 1
cables: 2 m
1 The shielded round cables, SC58 and

SC60, and terminal block SE300 are
LEDs included with the T300.
X451 X456
Terminal block SE300 The shields of the round cables must be

connected to earth at both ends.
Can be snapped on to a 35 mm mounting rail to DIN EN 50 022-35

Dimensions: W x H x D = 224 x 60 x 60 mm
Hardware- and software components of the T300 technology board


T300 module with memory module


1.3. Overview of the various drives, modules and functions
Hoisting gear
/RDGGHSHQGLQJILHOGZHDNHQLQJ 3RVLWLRQVHQVLQJZLWKV\QFKURQL]DWLRQ(of the position)
+HDY\ORDGRSHUDWLRQUHGXFHGVHWSRLQW &ORVHGORRSSRVLWLRQFRQWUROIRUDXWRPDWLFRU
-RJJLQJ manual operation)
5DPSIXQFWLRQJHQHUDWRUFKDQJHRYHUIRUILHOG 1RQOLQHDUPDVWHUVZLWFKVHWSRLQW
weakening and heavy loads 3UHOLPLWVZLWFK
&KDQJHRYHUWRV\QFKURQRXVRSHUDWLRQFRQWUROZLWK 6WDUWSXOVH
one-only (manual) setting of the position difference 0RQLWRULQJIXQFWLRQV
(slave operation)
&XUUHQWGLVWULEXWLRQPRQLWRULQJ
Holding gear
Constant field weakening (efficiency) 6ODFNURSHFRQWURO
+HDY\ORDGRSHUDWLRQUHGXFHGVHWSRLQW 3RVLWLRQVHQVLQJZLWKV\QFKURQL]DWLRQ(of the position)
&ORVHGORRSSRVLWLRQFRQWUROIRUDXWRPDWLRQRU 1RQOLQHDUPDVWHUVZLWFKVHWSRLQW
manual operation) 3UHOLPLWVZLWFK
-RJJLQJ 6WDUWSXOVH
5DPSIXQFWLRQJHQHUDWRUFKDQJHRYHUIRU 0RQLWRULQJIXQFWLRQV
heavy loads
Closing gear
*UDEDGMXVWPHQW *UDESRVLWLRQVHQVLQJ
6WDUWSXOVH &ORVHGORRSJUDESRVLWLRQFRQWURO
&XUUHQWHTXDOL]DWLRQFRQWUROZLWKSRO\SJUDE -RJJLQJ
operation 0RQLWRULQJIXQFWLRQV
&KDQJHRYHUWRV\QFKURQRXVRSHUDWLRQFRQWUROZLWK
one-only (manual) setting of the position difference
(slave operation)
Slewing gear
1RQOLQHDUPDVWHUVZLWFKVHWSRLQW 3RVLWLRQVHQVLQJZLWKV\QFKURQL]DWLRQ(of the position)
&ORVHGORRSSRVLWLRQFRQWUROIRUDXWRPDWLFRU 3UHOLPLWVZLWFK
manual operation) 0RQLWRULQJIXQFWLRQV
-RJJLQJ ,QIOXHQFLQJWKHUDPSIXQFWLRQJHQHUDWRUGHSHQGHQW
:RUNLQJDQJOHGHSHQGHQWDFFHOHUDWLQJWLPH on the system deviation
:RUNLQJDQJOHGHSHQGHQWVOHZLQJVSHHG
Traversing gear, master
1RQOLQHDUPDVWHUVZLWFKVHWSRLQW 3RVLWLRQVHQVLQJZLWKV\QFKURQL]DWLRQ(of the position)
&ORVHGORRSSRVLWLRQFRQWUROIRUDXWRPDWLRQRU 0RQLWRULQJIXQFWLRQV
manual operation) &XUUHQWGLVWULEXWLRQPRQLWRULQJ
-RJJLQJ &KDQJHRYHUWRV\QFKURQRXVRSHUDWLRQFRQWUROZLWK
3UHOLPLWVZLWFK one-only (manual) setting of the position difference
(slave operation)
Traversing gear, slave
&XUUHQWGLVWULEXWLRQPRQLWRULQJ 3RVLWLRQVHQVLQJZLWKV\QFKURQL]DWLRQ(of the position)
&ORVHGORRSV\QFKURQRXVRSHUDWLRQFRQWUROZLWK 0RQLWRULQJIXQFWLRQV
offset as position difference
-RJJLQJ


Monitoring functions: Closed-loop control monitoring
Speed actual-actual monitoring
Overspeed monitoring
Zero speed signal


1.4. Communications between SIMATIC and the drive units
The communications between these two systems is implemented via Profibus SINEC L2-DP.
This serial peripheral SINEC L2-DP bus system is optimized for extremely fast cyclic master-slave
operation. In this case, the drives are always operated as slaves; the higher-level system has the
master function, which in this case is the SIMATIC.
The CBP module is used as communications module in the drive units.
The net data structure with which a DP master can access the drives is described in the following text.
The SINEC L2-DP transfers the net data with the SRD utility (Send and Request with Data). This
means, that net data are always transferred via the bus, both from the master to the slave as well as in
return telegrams from the slave to the master.
The master formulates a task, the slave processes this task and formulates the appropriate response.
There is precisely one task in each telegram from the master to the slave; there is precisely one re-
sponse in each telegram from the slave to the master.
The length and structure of the net data are permanently specified, and are known as Parameter Proc-
ess data Objects (PPO).
Five types are defined to transfer net data (PPO), with which process data, i.e. control words, status
words, setpoints and actual values can be simultaneously transferred, also parameters from the mas-
ter to the slave and vice versa.
In the following application, only PPO type 5 is used.
The PPOs are sub-divided into two areas: PKW (parameter identification value)
PZD (process data)
The PKW area allows parameter values to be read and written into and parameter descriptions and
texts read. Every drive parameter can be visualized or changed via this mechanism.
The PZD area contains all of the necessary signals which are required for process control. These in-
clude control words and setpoints from the automation to the drive and status words and actual values
from the drive to the automation system.
Both areas together result in the net data block (PPO).
The advantage in this case is that in a telegram, both the cyclically required process data can be
transferred, and it is also possible to simultaneously access parameters (reading/writing). The selected
type is parameterized via the operator control panel of the basic unit. The PPO type, selected at the
basic unit must be registered with the master, when parameterizing the master system.
The configured PPO type must be the same on both the master- and slave sides.


System connector
Fixing screw
LED (green)
LED (yellow)
LED (red)
9-pole Sub D terminal
Fixing srcew
CBP communications board
PKW PZD
PZD1 PZD2
IND PWE STW1 HSW PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10
ZSW1 HIW
1st 2nd 3rd 4th 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
PPO1
PPO2
PPO3
PPO4
PPO5
PWE: Parameter ID value STW: Control word 1

PZD: Process data ZSW: Status word 1
PKE: Parameter ID HSW: Main setpoint
IND: Index HIW: Main actual value
PWE: Parameter value
Net-data structure in the "PROFIBUS Profile for PROFIDRIVE Variable-Speed Drives"


1.5. Communications within the drive units
The data transfer within the "slave modules", i.e. between the drive converter and CB, is realized using
internal SIEMENS data transfer mechanisms, the so-called device response. The data is transferred
between the communications module and drive converter via the DUAL PORT RAM (DPR).
Data transfer between the communications module CB and the basic drive is realized via a dual port
RAM coupling (DPR). Both sides, CB and basic drive can access the memory of the dual port RAM
writing and reading. The dual port RAM chip is provided on the CB.
If an additional TB technology module is provided, then this is switched between the CB and the basic
drive. In this case, the dual port RAM of the CB is the interface to the TB and dual port RAM on the TB
is the interface to the basic drive (configuration TB-CB basic drive).
The initialization data transferred between CB and the basic drive is not influenced by the TB, i.e. the
technology module copies the data from its dual port RAM one-to-one into the dual port RAM of the CB
and vice versa. The function must be appropriately configured in the TB.
16 pieces of process data can be transferred in both directions between the T and basic drive.
1.6. Communications between two drive units
This communications connection is generally used for master-slave drives, where the master setpoint
for the slave drive(s) is (are) entered from the master drive.
This is also the case for holding- and closing gears of a grab crane where the speed setpoint for the
closing gear and the current setpoint for the current equalization control is transferred to the closing
gear via this coupling.
This coupling is realized using a fast peer-to-peer connection between the technology modules.
A maximum of 5 PZD data words can be transferred in both directions via this interface.

S7 CBP T300 unit 1 CU
PROFIBUS converter response 1.word 2.word 3.word 4.word converter response

PKW PKE IND PWE PWE PKW
PROFIBUS converter response converter response

PKW PKW
PROFIBUS converter response converter response

PZD 10 words PZD 16 words
peer
to
peer
T300 5 unit 2
words
1 2 3 4 5 6 7 8
1.7. overview of communications ATD TD IT IS 4 01.06.99 V. 1.1 page 14

2 1
SIMATIC
control word 2
control word 1
IG
control word technology 1
control word technology 2
setpoints
ET200 ET200
functions functions
n* n* ML
2
RFG n-controller i-controller
PROFIBUS i*
SINEC L2 DP
M
technological
control
nist
∆n
1 i* T
nist
monitoring
acknowledge monitoring
sist acknowledge
nist nist
status word technology
status word 1
status word 2
T300 basic unit
1 2 3 4 5 6 7 8
1.8. basic signal characteristics and structure of the closed-loop control ATD TD IT IS 4 01.06.99 V. 1.1 page 15

1.9. Connecting-up diagram T300
2 pulse encoder inputs

+24 V +24 V
Fine HTL-signal level, max.
pulse Input frequency 400 kHz
Coarse
Zero- +15 V Zero-
+15 V Input current per channel:
pulse pulse
pulse 90° 0° 90° 0° 4 mA
X5.538 537535 533 531 540 539 548 547 545 543 541 549
+15V X133
Pulse encoder Pulse encoder
detection 1 detection 2
6
X5
Serial interface 1
7
501 e.g. for service,
+ A RS485, 2-wire
+10
- V 502 - 8
start-up with PC/PG
D
T/Rx+
503
+ A 9
+10
- V 504 - D T/Rx- Either RS232 or RS485
10
505 interface useable!
+ A X132
+10
- V 506 - D RxD 1
TTL
7 analog inputs 507 RxD 2
Differential inputs + A RS232
+10
- V 508 - D 3
11 bits + sign
10 V/ k 4
511
+ A 5
+10
- V 512 - D X134
513 RS485, 4-wire
+ A Tx+ 13
+10 V 514 -
Micro-
- D
processor Tx- 14
515 Serial interface 2
A
CPU:
+ Rx+ 11 (peer-to-peer)
+10
- V 516 - D 80C186
20 MHz Rx- 12
X6
15
+24 V 610
+ 11 bit + VZ X5
601 D 509
602 A
510
603
8 binary inputs D
604 519
24 V DC A
(input current 605 520
4 analog outputs
8 mA typical) 606
D 521
11 bits + sign
607 + 10 V / 10 mA.
A
608 522
D 523
+24 V 630
A
524
+
611 X6
639 +24 V
612
Slot for 631
613 memory
8 binary inputs 632
614 module, e.g.
24 V DC MS 300 633 8 binary outputs
(input current 615
634 24 V DC / max. 100 mA
8 mA typical) 616 Base load 40 mA for
635
617 external P24 infeed which
636
can also come from
618 637 the basic unit
638
640
1/2 LBA 1/2 LBA

Communications MASTERDRIVES
board, e.g. Dual- Dual- basic unit
CBP, SCB1 port- port- (CUVC board)
or SCB2 RAM RAM
X135 X137
Terminals X5, X6: Connect to terminal block SE300.
Terminals X132, X133, X134: Connect to the T300.
VZ = sign
T300 technology board connection diagram


1.10. Basic drive converter parameters required
In order to establish error-free communications and functionality between SIMATIC and the drive unit,
the following parameter settings must be made in the basic drive of the converter or inverter. Depend-
ing on the selected BICO data set, these settings are made in index 1 or 2. These are:
1.10.1. SIMOVERT MASTER DRIVE CUVC
Enter the Profibus address
P60 = 4 select the "module configuration" menu

P918.1 or = ? enter the CB bus address
P60 = 1 return to the parameter menu
Interlocking the receive data
PZD1: Control word 1

The bits assigned by the SIMATIC must be interlocked with the appropriate parameters (refer to
the Compendium Vector Control, function chart 180). The following parameterization must be
made if, for example, all control bits are assigned by the SIMATIC.
P554.1 or 2 = 3100
P555.1 or 2 = 3101
P558.1 or 2 = 3102
P561.1 or 2 = 3103
P562.1 or 2 = 3104
P563.1 or 2 = 3105
P564.1 or 2 = 3106
P565.1 or 2 = 3107
P568.1 or 2 = 3108
P569.1 or 2 = 3109
P571.1 or 2 = 3111
P572.1 or 2 = 3112
P573.1 or 2 = 3113
P574.1 or 2 = 3114
P575.1 or 2 = 3115
Otherwise, the parameters which are to be not controlled from the SIMATIC, should be left in the
factory setting.
PZD2: Speed setpoint

P443.1 or 2 = 3002


The bits assigned by the SIMATIC should be interlocked with the appropriate parameters (refer to
the Compendium Vector Control, function chart 190). The following parameterization must be
made, if for example, all control bits are to be assigned by the SIMATIC.
P576.1 or 2 = 3300
P577.1 or 2 = 3301
P578.1 or 2 = 3302
P579.1 or 2 = 3303
P580.1 or 2 = 3304
P581.1 or 2 = 3305
P582.1 or 2 = 3306
P583.1 or 2 = 3307
P584.1 or 2 = 3308
P585.1 or 2 = 3309
P586.1 or 2 = 3310
P587.1 or 2 = 3311
P588.1 or 2 = 3312
P589.1 or 2 = 3313
P590.1 or 2 = 3314
P591.1 or 2 = 3315
Otherwise, the parameters which are not to be controlled from the SIMATIC, should be left in the
factory setting.
PZD4: Start pulse

P438.1 or 2 = 3004
Interlocking the send data
PZD1: Status word 1

P734.1 = 32
PZD2: Speed actual value

P734.2 = 148
PZD3: Status word 2

P734.3 = 33
PZD4: Current setpoint

P734.4 = 168
PZD5: System deviation

P734.5 = 152


1.10.2. SIMOREG DC MASTER 6RA70
Enter the Profibus address
P51 = 40 access authorization

P918.1 or .2 = ? enter the CB bus address
Interlocking the receive data

The bits assigned by the SIMATIC are interlocked with the appropriate parameters (refer to the In-
struction Manual SIMOREG DC MASTER, function chart 33). The following parameterization must
be made, if for example, all of the control bits are to be assigned by the SIMATIC.
P654.1 or 2 = 3100
P655.1 or 2 = 3101
P658.1 or 2 = 3102
P661.1 or 2 = 3103
P662.1 or 2 = 3104
P663.1 or 2 = 3105
P664.1 or 2 = 3106
P665.1 or 2 = 3107
P668.1 or 2 = 3108
P669.1 or 2 = 3109
P671.1 or 2 = 3111
P672.1 or 2 = 3112
P673.1 or 2 = 3113
P674.1 or 2 = 3114
P675.1 or 2 = 3115
factory setting.
PZD2: Speed setpoint

P443.1 or 2 = 3002


The bits assigned by the SIMATIC are interlocked with the appropriate parameters (refer to the In-
struction Manual SIMOREG DC MASTER, function chart 34). The following parameterization must
be made if, for example, all of the control bits are assigned by the SIMATIC.
P676.1 or 2 = 3300
P677.1 or 2 = 3301
P678.1 or 2 = 3302
P679.1 or 2 = 3303
P680.1 or 2 = 3304
P681.1 or 2 = 3305
P682.1 or 2 = 3306
P683.1 or 2 = 3307
P684.1 or 2 = 3308
P685.1 or 2 = 3309
P686.1 or 2 = 3310
P687.1 or 2 = 3311
P688.1 or 2 = 3312
P689.1 or 2 = 3313
P690.1 or 2 = 3314
P691.1 or 2 = 3315
factory setting.
PZD4: Start pulse

P621 = 3004
Interlocking the send data
PZD1: Status word 1

P734.1 = 32
PZD2: Speed actual value

P734.2 = 167
PZD3: Status word 2

P734.3 = 33
PZD4: Current setpoint

P734.4 = 120
PZD5: System deviation

P734.5 = 165

Technology software module
for the
closed-loop control of crane drives
Module 0: All functions
Functions
Load-dependent field weakening Zero speed signal
Non-linear master switch setpoint Constant field weakening (efficiency)
Heavy load operation (reduced setpoint) Slack rope control
Pre-limit switch Grab position sensing
Jogging Grab adjustment
Start pulse Grab position control
Ramp-function generator changeover for field Closed-loop synchronous operation control for
weakening and heavy loads holding- and closing gear of grab cranes
Position sensing with synchronization Current equalization control with polyp grab
(of the position) operation
Closed-loop position control (for automatic- or Working angle-dependent slewing speed
manual operation) Working angle-dependent accelerating time
Changeover to closed-loop synchronous opera- Influencing the ramp-function generator from
ion control with single (manual) setting of the the system deviation
position difference (slave)
Position offset sensing with synchronization
Current distribution monitoring (of the offset)
Closed-loop control monitoring Closed-loop synchronous operation control with
Speed actual-actual monitoring offset as position difference
Overspeed monitoring

Load-dependent field weakening
For closed-loop controlled drives, for various operating cases, an attempt is made to increase the
speed above the rated speed. This is used, for example, for hoisting gear of cranes at partial loads to
increase the handling performance, i.e. moving more loads in less time.
This function is implemented using the load-dependent field weakening.
Step 1
When field weakening is selected (using the master switch), depending on the load, in addition to the
maximum value for the base speed range, entered from the master switch, a supplementary speed
setpoint, permissible for the actual load, is generated for field weakening.
The load actual value is determined from the torque-generating current and the accelerating torque,
which is determined via the speed actual value. The values for current and acceleration are integrated-
up over several sampling times to obtain a precise determination, and the arithmetic average gener-
ated.
Step 2
When accelerating, the torque-generating current is measured, which, in the base speed range, is
directly proportional to the total torque M provided by the motor. The accelerating torque of the rotating
masses (moment of inertia j) and the accelerating torque of the load is subtracted from this total
torque.
The subsequent torque equation is used to calculate the steady-state load currents:
MM = Mload + MBload + MBrot + Mfriction

Ë
this is required!
Step 3
After the steady-state load actual value has been calculated (steady-state torque ML of the load), the
permissible supplementary speed setpoint is calculated for field weakening. This is dependent on the
calculated torque for P = PN (via the output hyperbole characteristic of the motor, implemented as
parameterizable polygon characteristic).
Step 4
The calculated, load-dependent supplementary speed setpoint is then included in the setpoint input of
the master switch and a total setpoint generated for the speed setpoint input. When accelerating, it is
added with that from the master switch, and when decelerating, can be added or multiplied with that
from the master switch.
Module 0: All functions V1.1 2 01.06.1999

Function description Copyright © Siemens AG All Rights Reserved

M
MM = Mload + MBload + MBrot + Mfriction
MBload
MM : motor total torque
MBrot Mload : steady-state load torque
MBload : acceleration torque
Mfriction of load
MBrot : acceleration torque
Mload of rotating masses
t Mfriction : friction torque
1 2 3 4 5 6 7 8
torques in accelerating and steady-state period at the hoisting process
output motorized
hyperbole potentiometer
i
Mload n**Zus
calculation of load current
i > iN
1 2 3 4 5 6 7 8
calculation of the steady-state load torque during accelerating,

generation and correction of supplementary speed setpoint


Non-linear master switch setpoint
Using this function, the drive can be sensitively operated via the master switch for manual positioning.
Often, the master switch supplies a setpoint, which is directly proportional to its deflection angle. In
order that at low deflection angles, lower speed setpoints are obtained than those which would linearly
correspond to the deflection angle, the master switch setpoint is controlled as a non-linear function.
This means, that when changing the deflection angle at low angles of deflection, this results in speed
changes which are lower than the same change of the deflection angle in the center and higher deflec-
tion range. In practice this means that the drive can be manually and precisely corrected. The non-
linear function is implemented in the I and III quadrants using 3 adjustable straight line sections.
B6
B5
x A1 A2 A3 B4
n** linear n** non-linear
x
y
B3 A4 A5 A6
master switch B2
B1
1 2 3 4 5 6 7 8
conversion of a linear master switch setpoint to a non-linear master switch setpoint


Heavy load operation
This function is required, if the hoisting gear is used to hoist loads which exceed the rated load.
For heavy load operation, loads exceeding the rated load can be hoisted. Generally, however, this is
only permissible at reduced speeds as a result of the mechanical crane design. Thus, for this operating
mode, the master switch setpoint is multiplied by a selectable factor of < 1. This means that the deflec-
tion range can be fully utilized with a reduced setpoint input.
ramp-function
generator
n** n*
100% 0
1
50%
selection
heavy duty
1 2 3 4 5 6 7 8
heavy duty operation


Pre-limit switch
This function prevents the drive approaching the limit switch or entering the buffer zone at full speed.
When a pre-limit switch is passed-over, the speed setpoint in front of the ramp-function generator is
limited to a selectable speed. The position of the pre-limit switch with respect to the limit switch or the
buffer zone is dimensioned, so that the drive is reliably braked via the ramp-function generator from the
maximum speed down to the selectable pre-limit switch speed.
ramp-function
generator
TH TR
0% 0 n**
e.g. nmax. 1
n*
master switch
nmax = +/- 100% 0

1
nVE = +/- 10%
n*
nmax distance covered at

time TR
(vmax - vVE) TR
s= = e.g. 20m
2
nVE
appr. TR
pre-limit switch limit switch buffer
e.g. s=23m s=3m s=2m s=0m s
∆ s = 20m
1 2 3 4 5 6 7 8
pre-limit switch function


Jogging
Using this function, the drive can be moved with small speed setpoint intervals. This is required, for
example, to attach the cable to the hoisting gear.
When jogging, an adjustable jog setpoint is entered as speed setpoint.
ramp-function
generator speed controller
0
1
jogging
setpoint
setpoint direction B 0 command

direction A 1 jogging
command jogging
direction A
command jogging
direction B
command jogging
direction A
command jogging t
direction B
jogging setpoint
direction A
jogging setpoint t
direction B
1 2 3 4 5 6 7 8
jogging


Start pulse for hoisting gear
This function avoids or improves the "load sag" when the hoisting gear is started with a suspended
load.
For hoisting gear, when starting, i.e. when the hoisting gear brake is opened, with a freely-suspended
load, the load can undesirably drop (sag). The reason for this is the torque which is missing when
starting and which is only relatively slowly established after the travel command has been output. Ini-
tially via the processing time of the systems, the time constants of the closed-loop control (ramp-
function generator, integration times) and the time constants of the control loop. However, when start-
ing to hoist with a suspended load, the torque must be quickly established.
In order to prevent this sag, when starting, a constant or a load-dependent start pulse (setpoint) is di-
rectly switched to the setpoint input of the speed controller in the hoisting gear. It then decays after a
specific time. This start-up characteristic corresponds to an inverse exponential function, which is "dis-
charged" when the control is enabled.
This causes the torque to be quickly established, thus preventing "load sag". The start pulse direction
is always in the hoisting direction (torque direction I).
The start pulse is optimized experimentally with pre-optimized closed-loop speed control at the final
load test. When starting from zero speed, with a freely-suspended load, the control lever is set to the
minimum speed setpoint, and the starting behavior of the drive is monitored at the crane hook or at the
cable drum.
When setting a start pulse with constant amplitude, a compromise must be made between starting with
rated load and starting with an empty crane hook (no load), as the selected constant value can only be
optimally set for a single load. Thus, for other loads, there will either be a low amount of load sag of the
empty hook will move in the hoisting direction.
If a load-measuring device is used, the output voltage of this load-measuring device is used as initial
amplitude for the starting pulse. Thus, independent of the load, the drive optimally starts with the cor-
rect height, without the load sagging and without the empty crane hook moving in the incorrect direc-
tion. This is achieved by adapting the value which is received from the load measuring device.
Another possibility is to directly pre-control the I component of the speed controller, dependent on the
adapted value of the load measuring device (without inverse exponential function) or with a constant
value.
Depending on the particular application, a (start pulse) or another version (pre-control) provides the
best result. The actual version which is used, should be decided at the actual crane system by the
commissioning engineer depending on the results obtained.
speed controller
n*
nist i*
adjustable constant value
0
1
selection
enable start
impulse
actual load value

adaption
pre-control value
pre-control
value
1 2 3 4 5 6 7 8
start pulse


Ramp-function generator changeover in the field-weakening range and when selecting heavy
load duty
This function is required for hoisting gear with field weakening in order to prevent the drive going to its
current limit when accelerating in the field-weakening range.
At low loads (steady-state load torque), in order to increase the load handling performance, the speed
is increased to a permissible speed, corresponding to the load, by reducing the field current. This
means, that in the field weakening range, the accelerating torque available is appropriately reduced.
For the steady-state load torque and the accelerating torque of the load, only that lower torque, corre-
sponding to the lower load, is required. The accelerating torque of the rotating masses remains the
same due to the unchanged moment of inertia (this is independent of the load).
For hoisting gear, the ramp-function generator is normally set, so that the drive, when accelerating and
hoisting with rated load, and full motor field, is just about to go into current limiting. This keeps the ac-
celerating- and decelerating travel as short as possible.
If in the field-weakening range, the ramp-function generator is also set to the base speed range values,
when accelerating in the field-weakening range, the drive goes into current limiting as the available
accelerating torque in the field-weakening range is not adequate for the same acceleration of the base
speed range with unchanged moment of inertia (the accelerating torque of the rotating masses is inde-
pendent of the load.
If the ramp-function generator is set, so that the drive when accelerating, even in field weakening,
doesn’t go into current limiting, for constant acceleration in the base speed- and field weakening
ranges, long accelerating- and decelerating distances are obtained.
In order to optimize this, the ramp-up time can be extended at the transition into the field-weakening
range.
For heavy load operation, in order to reduce the accelerating torque, a high accelerating time can be
immediately switched-in when selecting heavy load operation.
n*
nFS
nbase
TH base TH field weakening TH heavy duty t
1 2 3 4 5 6 7 8
ramp-function generator changeover in the field weakening range and when selecting heavy load duty


Position sensing, synchronizing the position actual value
Differential position actual value sensing for synchronous operation control of a slave drive
This function is required, if the drive should be closed-loop position controlled or have closed-loop syn-
chronous operation control.
The position actual value has to be synchronized, if the position actual value of the drive which should
be controlled, should be set to an absolute position at a point on the travel. This corrects erroneous
measurements or erroneous pulses.
The prerequisite for positioning (closed-loop position control) of a drive or closed-loop synchronous
position control of two drives is the ability to sense the actual position. This, in almost all cases, can be
realized using the speed encoder mounted to the motor (pulse encoders are used, analog tachometers
are not suitable).
Technology module T300 has, in the form of its terminal module, pulse encoder sensing inputs 1 and 2
which can be simultaneously read-in from a block.
The pulse encoder signals are routed to the basic drive for actual speed sensing the technology mod-
ule for actual value sensing.
For closed-loop position control of a drive, under certain circumstances, it is necessary to synchronize
the position actual value of the drive at a point along the complete travel. For instance, this is always
required, if errors in the position actual value sensing of the drive occur as a result of the pulse encoder
and the influence of noise and disturbances.
The synchronization function has the task to correct this possibly erroneous position actual value. In
this case, the sensed actual value position is re-referenced to an absolute synchronizing mark.
When the synchronizing point is passed (synchronizing mark), this is sensed per hardware using a
Bero via the zero pulse encoder, and the position actual value is thus synchronized.
Further, it is also possible to sense this synchronizing point via the SIMATIC and to synchronize the
system to a specified value via the control word from the SIMATIC.
In this case, the counter of this actual value sensing is set once at a defined point along the total travel,
to an absolute position actual value corresponding to this specific point. Thus, this corrects possible
wheel slip or erroneous pulses.
This means that synchronization represents a position actual value correction. The synchronization has
nothing to do with the basic closed-loop control structure, as when synchronizing, the position actual
value is only corrected at the synchronizing point.
For closed-loop synchronous position control of two drives, the actual value position difference sens-
ing, implemented for the slave operation, can also be used, if it is sufficient to manually set the position
difference once, to which the system should be controlled.
At changeover, the actual position difference value is saved as setpoint. This is used with the closed-
loop synchronous operation control as setpoint until it is again cancelled.
However, if automatic synchronization is required at certain intervals (e.g. due to the possibility of erro-
neous pulses) at several synchronization points, then the traversing gear slave module must be used.
For the closed-loop position synchronous control for both drives, the position actual values of both
drives must be sensed. The pulse encoder, mounted on the motor for the speed actual values can be
used for this purpose.
The pulse encoder signals are routed to the basic drive for speed actual value sensing and to the tech-
nology board of the second drive for position actual value sensing.
However, the position actual value of the drive must always be connected to pulse encoder sensing
input 1 and that of the master drive to pulse encoder sensing input 2 (for the slave).

S5/7
setpoints setpoints
communication board communication board

n** ramp-function
generator
n**
0
+100% 0 1
<0% 1
peer to peer
-100%
AAT
ramp-function
position control
generator
<0%
WSR2
hw-syn. via 1
index signal WSR1 0 0 hw-syn. via index
input 1
+ signal input
WSAUT -
synchronisation
AAT
SE SE controller
AGL y=x
actual y
x
X5M position X5M position
sist ∆s
value difference
X5N evaluation nist X5N evaluation
synchron nist
WSSYN WSSYN
SYN via nist- SYN via nist-

control word monitoring control word monitoring
technology board technology board
n-controller i-controller n-controller i-controller
n* n*
i* i*
nist nist
basic unit basic unit
M T M T
T T
1 2 3 4 5 6 7 8
hardware- and software structure for position- and synchronization control ATD TD IT IS 4 01.06.99 V. 1.1 page: 11

Closed-loop position control
This function is required if a drive should approach a specified target closed-loop position controlled in
the shortest time.
The demand for ever increasing handling performance has meant that for hoisting drives, the drives
must be able to approach a specified target position as quickly as possible.
By applying the position equations and taking into account limiting conditions, it can be determined that
this can be achieved using the square root function.
v = 2⋅a⋅s
Where: v: speed a: acceleration s: position actual value
If this relationship is implemented, the drive can approach a specified point, closed-loop position con-
trolled, in the optimum time. The master switch enters the speed setpoint. If the drive approaches the
target, then from a calculated initiation point, the speed setpoint from the master switch is limited as a
function of the position. The position actual value is available from a pulse encoder. The SIMATIC
specifies the final target (position setpoint).
When the semi-automatic- or automatic modes are selected, a speed setpoint is automatically entered,
dependent on the position setpoint input (polarity) (from the SIMATIC).
After the optimum speed setpoint has been calculated, dependent on the actual position actual value
difference, this setpoint is conditioned corresponding to the particular operating mode.
For example, in manual operation, only the speed direction is enabled, in which the master switch is
set.
On the other hand, in the automatic mode, both directions of rotation must be enabled, so that the
drive can automatically correct itself, for instance, after it has passed the target position.
Further, it is possible to select a parameterizable crawl speed, if the position controller output has
reached (fallen below) this parameterizable value.

n-controller
speed setpoint
speed setpoint (S7) 0% 0 to CU
speed
0 1
setpoint
1
setpoint
AAT enable
(S7)
+100% 0
1
-100%
x x
y>x y>x
0% y 0% y
master switch
polarity
position setpoint direction 2 (S7)

1
position setpoint direction 1 (S7) 0 0 MIN 0
1 0
+ 1
- 1
switch over point KP
position setpoint automatic mode (S7) position control
AAT
AAT
T
hw-syn. via index signal input pulse sist
synchronization setpoint from S7 encoder x
y>x 0
sw-syn. via control word from S7
evaluation 0% y
1
AAT
1
1 2 3 4 5 6 7 8
signal flow chart position control overview ATD TD IT IS 4 01.06.99 V. 1.1 page: 13

Possibility of changing over to slave operation with closed-loop synchronous operation control
and single (manual) setting of the position difference
This function is required, if two or several hoisting- or traversing drives which are normally operated
closed-loop speed controlled individually and independently of one another, must operate in synchro-
nism with one another for specific operating situations.
This is the case, for example, if trolleys or traversing gears, which are not mechanically coupled, must
hoist or move a common load.
For this operating case, it is necessary to provide closed-loop synchronous position control between
the trolleys or between the hoisting gears. Initially, the drives operate in single-motor operation to con-
nect-up a load, and can then be changed-over at any position to closed-loop synchronous operation
control.
When two drives are operated in synchronism, the slave drive follows the master drive, closed-loop
synchronous position controlled with a position difference setpoint, which should be saved.
At changeover, the actual position difference value is saved as setpoint. This is used as setpoint for the
closed-loop synchronous operating control until it is cancelled again.
For this operating case, the separately speed-controlled drives must also be coupled with one another
through the control system via a synchronous operation control in the slave drive. They must also op-
erate in synchronism (position) even when the load is unevenly distributed.
The synchronous operation controller is superimposed on the closed-loop speed control of the slave
drive. The inputs of the synchronous operation controller are the stored position difference actual value
as setpoint and the actual position difference value as actual value. The output of the synchronous
operation controller acts as supplementary setpoint at the setpoint of the slave drive speed controller.
When closed-loop synchronous operation control is activated, and a position difference develops be-
tween the drives, then the slave drive receives a supplementary speed setpoint via the synchronous
operation controller. This operates this drive with an increased or decreased speed setpoint, until the
position difference is again zero. The supplementary setpoint (the intervention of the supplementary
setpoint from the synchronous operation controller) should in this case be a maximum of 20% to 30%
of the max. drive speed.


Two hoisting gears of a gantry crane are now shown as an example of closed-loop synchronous op-
eration control. Both hoisting gear operate separately, closed-loop speed controlled to accept the load.
Once the load has been accepted and is suspended, aligned at the crane hooks the system is
switched-over to synchronous operation control. The instantaneous actual position difference value of
s = 40 m is now saved as setpoint. With this position difference, both hoisting gear units can be
raised and lowered, closed-loop synchronous operation controlled, and always maintain this position
difference of s = 40 m .
sist = 100m sist = 60m
∆ sist = YDP = 40m
1 2 3 4 5 6 7 8
synchronization control of a hoisting gear

master
n-controller
speed setpoint to
0% 0 basic unit i*
speed setpoint (S7) 1
setpoint
position setpoint (S7)
enable (S7)
actual position
value
position synchronization
value (S7) pulse s1
encoder
T evaluation
peer to peer
synchronize
slave
n-controller
speed setpoint to
speed setpoint (S7) 0% 0 basic unit i*
0 1
1
position setpoint (S7) selection setpoint

synchronism enable (S7)
actual position (S7)
value
selection synchronism (S7) y=x position difference setpoint

y
x
value (S7) s1 0%
pulse W 0
actual position
T encoder
∆s difference value
1
evaluation X
selection
synchronism
enable (S7)
synchronize synchronization
controller (S7)
1 2 3 4 5 6 7 8
signal flow chart synchronization control overview ATD TD IT IS 4 01.06.99 V. 1.1 page: 16

Current distribution monitoring
This function can be used for slave drives (if it is practical). For a master-slave drive, it monitors that
the total torque (current) is evenly distributed over both drives. However, as described above, this is
not always the case.
CBP CBP
ramp-function ramp-function
generator generator
n* peer to peer n*
i* i*
monitoring
status word
- bit 8
+
T300 T300
n* i* n* i*
CU CU
master slave
1 2 3 4 5 6 7 8
current distribution monitoring


Closed-loop control monitoring
This function continually monitors the speed setpoint and speed actual value, which, when the system
is operating correctly, must approximately correspond with one another.
This monitoring function responds, for example, if the closed-loop control goes to its current limit due
to an overload or a stalled drive, as the speed actual value can no longer follow the speed setpoint.
However, if the setpoint is less than the response difference, then there is a no signal output if the ac-
tual value is missing. This fault is detected using the interrupted tachometer monitoring function of the
basic drives.
Speed-actual-actual-monitoring
This function can be used for speed-actual-actual monitoring if a drive is equipped with a speed actual
value- and position actual value encoder.
If a drive has, in addition to a pulse encoder for the speed actual value, also a pulse encoder for the
position actual value, which is not mounted to the motor, but for example, to the drum, then monitoring
can be realized by evaluating the speeds supplied from both encoders. For instance, this can be used
to monitor the gearboxes or couplings for two rigidly coupled drives.
Speed monitoring
This monitoring function represents a software centrifugal switch. Using this monitoring function, a
signal can be generated when a selectable speed is exceeded.
Values of between 110-150% of the maximum permissible operating speed are set for these over-
speed protective devices. When an overspeed monitoring function responds, appropriate shutdown
mechanisms can be initiated.
Zero speed signal
This function monitors the speed and responds if the selected limit is fallen below.
This signal is mainly used to close the brake. It is also used, for example, in the hoisting gear module
to calculate the supplementary speed setpoint for load-dependent field weakening.


speed actual-actual monitoring
actual speed
signal to status word
value from
+ (technology) bit 4
basic unit -
actual speed
value from
technology board
(NAV)
closed-loop control monitoring
system deviation signal to status word

from basic unit (technology) bit 1
overspeed monitoring
actual speed
value from
(technology) bit 2
basic unit
zero speed signal

(technology) bit 3
1 2 3 4 5 6 7 8
monitorings


Constant (efficiency-dependent) field weakening for grab cranes
Generally, load-dependent field weakening for grab cranes is not used for the following reasons:
Mode, grab closed with material

When the grab is closed, this means that generally has its rated load, so that load-dependent field
weakening cannot be used.
Mode, grab closed without material

Hoisting or lowering an empty grab is essentially a mode which is not used in practice and is therefore
not relevant.
Mode, grab open

The weight of several grab types is often already 50% of the total hoisting load of both drives (holding-
and closing gear). To hoist the grab when open (the grab is completely suspended in the holding gear),
means in this case the holding gear draws rated current. When lowering, in this mode, with the same
current drain would mean that it would be faster by the absolute value of the efficiency.
When lowering the grab (open or closed), and field weakening is selected (master switch contact), the
rated hoisting speed when lowering is multiplied by the efficiency factor.
The factor can be set as follows:

Increase the factor, so that when lowering with full load, the rated current for both motors is obtained.
ramp-function
generator
0
1
selection field
weakening
nominal speed
e.g. 90% 0
1
100%
enable field
weakening
1 2 3 4 5 6 7 8
constant field weakening


Slack rope controller
This function is used for every grab crane.
This function does not involve, as could be assumed, a classic closed-loop control with setpoint-actual
value comparison, but a function transmitter, which specifies a speed setpoint, dependent on the cur-
rent actual value (torque) for the grab closing mode.
If the holding gear (the holding winch) is simply braked when closing the grab, then the grab cannot
bury itself in the material and it isn’t sufficiently filled.
On the other hand, if the holding gear brake (the holding winch) is simply opened when closing the
grab, there is the potential danger that through the tensioned cable, the drum of the holding gear will be
accelerated in the lowering direction, thus resulting in an undesirable slack rope condition.
The slack rope control prevents both of these happening. Using the slack rope controller, a slack rope
condition can be avoided when closing the grab. It also ensures that the grab can bury itself into the
material to achieve the maximum filling level.
When closing the grab, the brake is opened, and the holding cable is held under slight tension using
the slack rope control. Any slack rope is drawn-in at a low speed. After this, the drum of the holding
gear is maintained with a residual tension, which, after the slack rope has been drawn-in, holds this
under tension but cannot prevent the grab sagging. The grab sags with tensioned cable. This residual
torque can be set, and must at least compensate the weight of the longest holding cable length.
If the closing operation is initiated with the grab in the air, then the slack rope control additionally pre-
vents the grab sagging quickly with an uncontrolled speed. In this case, the weight of the grab attempts
to accelerate the holding winch in the lowering direction. However, this speed is limited to a maximum
sag speed (lower characteristic) via the slack rope control.
If the grab load is too high, the grab can be prevented from sinking back into the material when closing,
by disabling the slack rope control with a foot switch as long as the pushbutton is actuated.
The speed setpoint input for the holding gear in the "closing" mode is realized using a slack rope func-
tion transmitter, which provides a speed characteristic as shown in the following diagram. Its output
value is entered into the holding gear as speed setpoint.


n*
slack-rope
setpoint
nx ideal take-up speed
LU
n1 max. take-up speed
i1 ix i*HW
i2 = 2 i1
n2
LL max. sag speed
1 2 3 4 5 6 7 8
curve of a slack-rope controller
slack rope controller
0% 0
1
enable slack
rope conroller
(FRZ)
ramp-function
generator n-controller
0% 0 i*
1
nist
disable setpoint
(FWN) by FRZ
1 2 3 4 5 6 7 8
signal flow chart: slack rope control


Sensing the grab opening travel
This function is required for the closed-loop grab position (travel) control.
The prerequisite for the closed-loop grab travel control (positioning) or the closed-loop position syn-
chronous control for the holding- and closing units (e.g. for traversing operation) is that the actual posi-
tion values of the holding- and closing gear have to be sensed (for grab operation, a grab actual value
position).
It is not possible to sense the grab opening position directly at the grab, but is approximately deter-
mined by measuring the cable length difference (holding cable minus the closing cable). This cable
length difference is in turn proportional to the number of revolutions of the cable drum holding gear (or
motor holding gear) minus the number of revolutions of the cable drum, closing gear (or motor closing
gear). This measurement is technologically precise in spite of the elasticity and cable sag.
The position actual value of the holding- and closing gear is measured (or the grab opening travel) in
almost all cases using the speed encoder, mounted at the motor (a pulse encoder must be used, an
analog tachometer is not adequate).
The T300 technology module has, in the form of its terminal module pulse encoder sensing inputs 1
and 2, which can be read-in from a block at the same time.
The pulse encoder signals are connected to the basic drive for the speed actual value sensing and to
the technology module for position actual value sensing.
For a closed-loop synchronous position control of the holding- and closing gear, the position actual
value difference sensing can also be used if it is sufficient that the position difference, which the sys-
tem should control, is set manually once.
The actual (required) position difference actual value when closed-loop synchronous operation control
is selected with “grab closed" must be saved as setpoint. The closed-loop synchronous operation con-
trol is operated with this as setpoint until it is cancelled again.
For closed-loop grab position controls as well as for closed-loop synchronous operation control of
holding- and closing gears, the position actual values of both drives must be sensed in the closing
gear. This can also be implemented using the pulse encoder, mounted at the motor, which is used to
sense the speed actual values.
The pulse encoder signals are routed to the basic drive for speed actual value sensing and to the tech-
nology module of the second drive for position actual value sensing.
The position actual value of a drive must always be connected to pulse encoder sensing input 1 and
that of the master drive to pulse encoder sensing 2 (for the slave).
Adjusting the grab
In order to adjust the grab when changing grabs, the master switch is directly entered as setpoint and
the required end positions for grab open and closed, is approached, closed-loop speed controlled. The
actual values at the end positions, open and closed, are then saved as setpoints at the push of a but-
ton. When the master switch is moved to open or close the grab, the associated signal is switched to
the position controller as setpoint.

S5/7
setpoints setpoints

n** ramp-function
generator
0
+100% 0 1
<0% 1
peer to peer
-100%
>0%
AAT ramp-function
generator position control
hw-syn. via <0%
index signal WSR2
hw-syn. via index
1
input WSR1 0 0 signal input 0%
0
1 1
+ +
WSAUT - KGO
-
AAT
SE SE
position control KGG y=x
y
actual x
X5M X5M position
position sist ∆s
difference
evaluation
X5N X5N evaluation
synchron nist nist
WSSYN
synchronization
controller
SYN via nist- nist-
control word monitoring monitoring
technology board technology board
n* n*
i* i*
nist nist
M T M T
T T
1 2 3 4 5 6 7 8

Closed-loop grab position control
This closed-loop control ensures that the closing operation, when required, is executed at the maxi-
mum speed, and is optimally positioned in the "closed" or "opened" end positions.
The demand for higher material handling performance has meant that crane drives must approach the
specified target as quickly as possible.
State-of-the-art grab cranes with high closing speeds have closing gear equipped with closed-loop
position control, which is effective both in the automatic- as well as in the manual modes.
The closed-loop grab position control ensures that the closing operation, when required, is executed at
the maximum speed, and the grab is optimally braked and positioned in the grab open and grab closed
end positions.
For the closed-loop grab position control, the end points for grab open and grab closed are approached
as quickly as possible corresponding to the principle of the previously described closed-loop position
control. The grab, for example, reaches the precise position closed, without the grab gripping edges
hitting each other.
Also in the manual mode, the closed-loop position control makes it far easier for the crane driver, as
the closing gear drive is precisely and automatically stopped in the grab open and grab closed end
positions by the software.
By applying the position equations and taking into account the limiting conditions, it can be determined
that this is possible using the square-root equation.
v = 2⋅a⋅s
Where: v: speed a: acceleration s: position actual value
By implementing this equation, the drive can approach a specified point as quickly as possible, closed-
loop position controlled.
The closed-loop position control specifies the setpoint for the closed-loop speed controller. If the drive
comes in the direction of the target point, then from a calculated initiation point, the speed setpoint is
reduced as a function of the position. The position actual value is available from a pulse encoder. The
target for the end points (position setpoint) are manually saved at the start of a grab change and
switched-in, dependent on the direction requested from the master switch.
The generated setpoint must then be normalized to the rated speed of the closing gear for closing and
opening.

speed setpoint (S7)
n-controller
speed setpoint
0% 0
to basic unit
speed
1
setpoint
setpoint
enable
(S7)
x
y>x
0% y
master switch
polarity
0%
setpoint grab open 0 MIN 0
1
+ 1
command grab closed y=x

- switch over
y point position KP
x setpoint grab close
control
pulse
T encoder
∆s
evaluation x
y>x
0% y
command grab open ∆s=0
1 2 3 4 5 6 7 8
signal flow chart grab position control closing gear ATD TD IT IS 4 01.06.99 V. 1.1 page: 26

Closed-loop synchronous operation control for holding- and closing gear of grab cranes
This function is required if holding- and closing gear, which normally operate individually and essen-
tially independent of one another in the closed-loop speed controlled mode, must operate in synchro-
nism for specific operating cases.
For grab cranes, which can also be used for multi-function operation (container-, traversing- or normal
hook operation), depending on the application and design of the mechanical system, it may be neces-
sary that the holding- and closing gear operate in synchronism.
For this operating case, it is necessary to have closed-loop synchronous position control between the
holding- and closing gear. When positioning to accept loads the drives first operate individually, and
then can be changed over at any position to closed-loop synchronous operation control.
When the holding- and closing gear operate in synchronism, the closing gear follows the holding gear,
closed-loop position controlled with the position difference setpoint to be saved, from the closed grab
position.
The actual position difference actual value must then be saved as setpoint with the grab closed com-
mand. The closed-loop synchronous control is then operated with this as setpoint..
The drives which are operated separately in the closed-loop speed controlled mode, also in this oper-
ating case, are then coupled through the closed-loop control using a closed-loop synchronous control-
ler in the slave drive. They must then operate with position synchronism, even if the load is unevenly
distributed
The closed-loop synchronous operation controller is superimposed on the closed-loop speed control of
the slave drive. The inputs of the closed-loop synchronous operation controller are the saved position
difference actual value as setpoint and the actual position difference actual value as actual value. The
synchronous controller output acts as supplementary setpoint on the setpoint input of the slave drive
speed controller.
operation controller. The drive is operated with an increased or decreased speed setpoint, until the
position difference is again zero. The supplementary setpoint (the intervention of the supplementary
setpoint from the synchronous operation controller) should in this case be a maximum of 20% to 30%
of the max. drive speed.

holding gear
n-controller
speed setpoint to
0% 0 basic unit i*
setpoint
position setpoint (S7) enable (S7)
actual position
value
value (S7) pulse s1
encoder
T evaluation
peer to peer
synchronize
closing gear
n-controller
speed setpoint to
speed setpoint (S7) 0% 0 basic unit i*
0 1
1
>0% setpoint
selection enable (S7)
synchronism
0%
setpoint grab open 0
(S7)
1
setpoint grab closed

position difference
command grab closed (S7) y=x setpoint
y
x
pulse 0%
T actual position
W 0
encoder 1
evaluation ∆s difference value X
∆s=0 selection
command grab
open (S7) synchronism
enable (S7)
synchronization
controller (S7)
1 2 3 4 5 6 7 8
signal flow chart synchronization control holding and closing gear overview ATD TD IT IS 4 01.06.99 V. 1.1 page: 28
holding gear n-controller
speed setpoint to
0% 0 basic unit i*
position setpoint (S7) setpoint

enable (S7)
actual position
value
value (S7) pulse s1
encoder
evaluation
T
enable slack-rope
controller (S7)
current
speed setpoint
synchronize setpoint
peer to peer peer to peer enable current

closing gear equalization controller
(S7)
n-controller
speed setpoint (S7) speed setpoint to
0% 0 basic unit i*
0 1
1
>0%
selection setpoint
0% enable (S7)
setpoint grab open 0
synchronism
1 (S7)
setpoint grab closed

position difference
command grab closed (S7) y=x setpoint
y
x
pulse 0%
T actual position
W 0
encoder 1
evaluation ∆s difference value

X
∆s=0 selection
command
grab open (S7) synchronism
enable (S7)
synchronization
controller (S7)
1 2 3 4 5 6 7 8
signal flow chart holding and closing gear overview ATD TD IT IS 4 01.06.99 V. 1.1 page: 29

Current equalization controller with polyp grab operation
This function is required for every grab crane.
When raising and lowering the load with the grab closed, the tension levels in the holding- and closing
cable should be approximately equal. The required hoisting power is then optimally distributed over
both hoisting motors This demand is fulfilled by using a closed-loop equalization control between the
two drives.
The current setpoints, generated from the speed controllers of the hoisting gear are compared, and
their difference is added to the speed setpoint of the closing gear via a controller.
The highest cable torque is obtained when the grab has almost closed. The selected closed-loop posi-
tion control is falsified by the unavoidable cable expansion, i.e. the closing operation is automatically
ended before the grab has completely closed.
This "fault" is also corrected by enabling the closed-loop current equalization control when the grab
closed message is received.
For grab cranes, which are also used for multi-functional operation (container-, traversing- or hook
operation) it may be necessary to activate the closed-loop current equalization controller depending on
the application and the mechanical design.
Polyp grab operation
With this operating mode, the grab generally requires a higher tension in the closing cable than in the
holding cable. The current distribution can be unsymmetrically divided with the required ratio by using
additional circuitry in the closed-loop current equalization control.
This is required, for example, when loading scrap, tree trunks and other large objects. Using polyp
grabs, these objects are held with the grab not completely closed at the grab points.
In order that the load doesn’t slip from the grab, the largest possible closing force should be applied.
The closed-loop current equalization controller is used to ensure that the load distribution is non-
symmetrical.


holding gear (HW)

n-controller HW i-controller HW
i*HW
n*HW M
closing gear (SW)

n-controller SW i-controller SW
i*SW
n*SW M
current equalization
controller
n*Zusatz
1 2 3 4 5 6 7 8
overview: current equalization controller
current
equalization
controller
i*HW
nzusatz
to speed
setpoint
K3 closing gear
enable current
equalization
controller
i*SW 0
1
p-droop function
selection
polyp grab
K1
K2
1 2 3 4 5 6 7 8
realization of a current equalization controller


Working angle-dependent slewing speed for slewing gear
This function is required, if, for slewing gear, the speed of the jib head is to be independent of the
working angle.
In order to keep the circumferential speed of the jib head constant for slewing cranes, the speed n
(angular velocity ω) of the slewing gear is adapted using the equation ω = v/r as a function of the work-
ing angle (radius) of the luffing gear.
This is realized using a hyberbolic function with a polygon characteristic.
The setpoint, entered from the master switch, is converted via a function transmitter into a speed set-
point which is dependent on the working angle.
ramp-function
generator
0 n** n*
1
selection
y working angle-
dependent
slewing speed
B1
actual working angle x B2 y

factor working angle-
B3 dependent slewing
B4 speed
B5 B6
A1 A2 A3 A4 A5 A6 x
1 2 3 4 5 6 7 8
working angle-dependent slewing speed


Working angle-dependent accelerating time
This function is required for slewing gear to optimally set the accelerating time as a function of the
working angle (so that it is not too long but the drive still doesn’t go to its current limit).
Slewing gear of cranes is always a pure accelerating drive. The higher the working angle of the luffing
gear, then the higher is also the accelerating torque for the slewing gear. In order to avoid the current
limit being reached, the ramp-up time for the ramp-function generator of the slewing gear should be
generally set for the largest working angle. However, this would result in lost time for lower working
angles. Thus, the ramp-up and ramp-down times of the ramp-function generator are linearly adapted
as a function of the working angle.
The following function is obtained.
max.
ramp-up time B6
B5
B4
B3
actual working angle x B2 working angle-dependent
min. y
ramp-up time B1 ramp-up time
A1 A2 A3 A4 A5 A6 x
min. working max. working
angle angle
1 2 3 4 5 6 7 8
working angle-dependent accelerating time


Influencing the ramp-function generator as a function of the system deviation
This function can be used in addition to the working angle-dependent accelerating time, and also pre-
vents the current limit being reached.
The ramp-function generator for the slewing gear is set to an accelerating time corresponding to the
working angle as described in the function above.
If higher system deviations are obtained when accelerating (the drive reaches its current limit) in spite
of this function (ramp-up time dependent on the working angle), then the accelerating- and decelerat-
ing times of the slewing gear can be continually varied as a function of the actual system deviation.
Using this function, the closed-loop speed control is just on the edge of going into current limiting and
the control monitoring function is active.
However, there is no defined accelerating- or decelerating time.
motorized
potentiometer
setting value motorized potentiometer (to working angle-
dependent accelerating time)
motorized potentiometer
(RUT) raise ramp-up time for
ramp-function generator
system deviation
motorized potentiometer
(RUT) lower
1 2 3 4 5 6 7 8
influencing the ramp function generator as a function of th system deviation


ramp-function
generator
0 n** n*
1
selection working
angle-dependent
slewing speed
actual working angle

motorized
potentiometer
setting value RUT

to working angle- depen-
ramp-up time
dent ramp-up time
for RFG
RUT raise
system deviation
RUT lower
1 2 3 4 5 6 7 8
slewing gear specific functions


Position offset sensing with synchronization (of the offset)
This function is required if a slave drive should precisely follow a master drive, closed-loop position
controlled and the differential position actual value (offset) between the two drives which should be
kept controlled, is to be set to an absolute position actual value at several points along the travel to
correct erroneous measurements or erroneous/missing pulses. The offset must always be determined
if the relative position between two drives with respect to one another regarding their synchronization
marks (Bero) must be sensed and controlled.
The actual position must be sensed for the closed-loop synchronous position control. In almost all
cases, the speed actual value encoder mounted to the encoder can be used (a pulse encoder is re-
quired, analog tachometers are not suitable).
Technology module T300 has, in the form of its terminal module, pulse encoder sensing inputs 1 and 2
which can be read-in from a block at the same time.
For the closed-loop synchronous position control of two drives, the actual positions of both drives must
be sensed. The pulse encoder, mounted to the motor for the speed actual values can be used for this
purpose.
The pulse encoder signals are fed to the basic drive for the speed actual sensing and to the technology
module of the second drive for the position actual value sensing.
The position actual value of the drive must always be connected to pulse encoder sensing input 1 and
that of the master drive to pulse encoder sensing input 2 (for the slave).
For closed-loop position control of a drive, under certain circumstances, it is necessary to synchronize
the position actual value of these drives at shorter or longer intervals depending on the application.
This, for example, always required, if errors in the position actual value sensing of the drive occur as a
result of the pulse encoder and the influence of noise and disturbances.
The synchronizing function has the task to correct this possibly erroneous position actual value. In this
case, the reference to the sensed actual value position is re-referenced an absolute synchronizing
mark.
When the synchronizing point is passed (synchronizing mark), this is sensed per hardware using a
Bero through the zero pulse encoder inputs.
The position actual values of both drives are then set to defined, actual position actual values when
passing-over fixed synchronizing marks. The number of pulses which are received by the master and
slave between passing over the two synchronizing marks is known as the offset.
After the second drive has passed-over its synchronizing mark, the correct offset is determined. This
new offset replaces the old offset actual value which could have been possibly incorrect. It is now used
by the closed-loop synchronous operation control as new offset actual value which must be corrected.
This corrects wheel slip or possible erroneous pulses.
In this case, synchronization means determining the offset. The synchronization has nothing to do with
the actual closed-loop control structure as when synchronizing, only the position difference actual value
has to be corrected from the position of the synchronizing marks.
The synchronization and therefore the availability of synchronizing marks are not required for closed-
loop synchronous position control, and should only be used when actually required.

S5/7
setpoints setpoints

n** ramp-function
generator
n**
0
+100% 0 1
<0% 1
peer to peer
-100%
AAT
ramp-function
position control generator
hw-syn. via <0%
index pulse WSR2
1 hw-syn. via index
input WSR1 0
0 signal input
1 SDP
+
WSAUT - SMA SSL
synchronization
AAT
SE SE controller
WSSYNMA DPS y=x
actual y
x
X5M position X5M position
sist ∆s
value difference
X5N evaluation X5N evaluation
nist nist
synchron
WSSYNSL Sync.
WSSYN
recei.
nist- offset nist-

SYN via monitoring sync. monitoring
control word
technology board Syn1 Syn2
technology board
n* n*
i* i*
nist nist
M T M T
T T
1 2 3 4 5 6 7 8

Closed-loop synchronous operation control with offset as position difference
This function is required in conjunction with the offset sensing which was previously described, in order
to operate two drives in synchronous operation, which are separately closed-loop speed controlled and
to correct the previously determined offset between the two drives.
When 2 drives are in synchronism, the slave drive follows the master drive, closed-loop position con-
trolled in synchronism, with a position difference setpoint which has to be saved.
A position difference, which has to be defined (or a position difference equals 0) can be saved as offset
setpoint.
Initially, the two drives must be optically aligned (the slave drive by jogging). The difference actual
value must then be manually set to 0. The drives can now be manually moved to the required offset
and the offset actual value saved as setpoint. The closed-loop position synchronous control is now
operated with this setpoint.
The separately speed-controlled drives in this operating case must be coupled through the control
system via a synchronous operation controller in the slave drive. They must remain in position syn-
chronism even if the load is unevenly distributed.
The synchronous operation controller is superimposed on the closed-loop speed control of the slave
drive. The inputs of the synchronous operation controller are the stored position difference actual value
as setpoint and the actual position difference value as actual value. The output of the synchronous
operation controller acts as supplementary setpoint at the setpoint input of the slave drive speed con-
troller.
operation controller. This then operates this drive with the increased or decreased speed setpoint, until
the position difference is again zero. The supplementary setpoint (the intervention of the supplemen-
tary setpoint from the synchronous operation controller) should in this case be a maximum of 20% to
30% of the max. drive speed.
The closed-loop synchronous operation control of a crane traversing gear will now be illustrated as
example.

master
n-controller
speed setpoint to
0% 0 basic unit i*
setpoint
position setpoint (S7)
enable (S7)
actual position
value
value (S7) pulse s1
encoder
T evaluation
peer to peer
synchronize
slave
n-controller
speed setpoint to
0% 0 basic unit i*
0 1
offset 1
evaluation
selection setpoint
jogging (S7) enable (S7)
SYNC2 SYNC1
recei. recei. jogging
setpoint selection
offset save (S7) y=x position difference setpoint jogging (S7)
position synchronization s1 y
x
value(SL)(S7)
T pulse s2
encoder W 0% 1
actual position 0
evaluation
position synchronization ∆s difference value X
value(MA)(S7)
synchr. synchr.
enable
SL (S7) MA (S7)
synchronization
controller (S7)
synchr. ∆s (S7)
1 2 3 4 5 6 7 8
signal flow chart synchronization control with synchronization overview ATD TD IT IS 4 01.06.99 V. 1.1 page: 39

Synchronous operation and synchronizing using as an example, a crane traversing gear
The necessity to provide synchronization is shown using an additional example with the traversing gear
of a container crane. Both sides of the crane traversing gear fixed leg and hinged leg should run in
synchronism and be closed-loop position controlled.
Synchronization is required here, as the pulse encoders are mounted on the motor and they therefore
do not represent the actual motion (position actual value) of the wheels. The wheels could slip which
would cause errors in the actual value sensing of the drives and therefore errors in the position differ-
ence as control quantity between the two drives.
The synchronization function has the task to correct this error. The position actual values of the two
drives are set to defined, actual position values when passing-over fixed synchronizing marks. The
difference between the two drives after the second drive has passed-over its mark, is known as the
offset. This offset is now the real position difference between the two drives which must be corrected.
For this purposes, on both side, the position actual value is set to e.g. 30 m when mark 1 is passed-
over using Bero 3. These marks are mechanically and precisely located along the crane track.
If the crane traversing gear gets into an skewed setting (e.g. caused by wheel slip), then, at the marks,
for example, first the position actual value of side 1 and later, the position actual value of side 2 are set
to 30 m. The difference between passing-over mark and passing-over mark 2 is determined by calcu-
lating position actual value 1 (in the meantime, this is greater than 30 m) minus the position actual
value 2 (= 30 m) when passing-over mark 2.
This difference is known as offset. The slave drive must now correct this offset. This is the task of the
offset calculation and closed-loop synchronous operation control.
1 1
3 3
5
master drive slave drive
1 1
5
master drive slave drive
1 synchronization mark
page 1 page 2
3 Bero
1 2 3 4 5 6 7 8
synchronization control of a crane travelling gear


Technology Software Module: Simoreg DC - Master 6ra70 and T300

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Technology software module

closed-loop control of crane drives

SIMOREG DC - MASTER 6RA70 and T300

SIMOVERT MASTER DRIVES CUVC and T300

Introduction and overview

Sales/marketing: Automation & Drives

Introduction and overview V1.1 2 01.06.1999

1. Description of the concept

1.1. General overview

1.2. Hardware and software components of the T300 technology module

1.3. Overview of the various drives, modules and functions

1.4. Communications between SIMATIC and drive units (Profibus)

1.5. Communications within the drive units (equipment response)

1.6. Communications between 2 drive units (peer-to-peer)

1.7. Overview of communications

1.8. Basic signal characteristics and structure of the closed-loop control

1.9. Connecting-up diagram for the T300

1.10. Necessary basic device parameters for communications

2. Documentation of the software for the individual drives

Introduction and overview V1.1 3 01.06.1999

1.1. General overview

Introduction and overview V1.1 4 01.06.1999

Introduction and overview V1.1 5 01.06.1999

cable drum cable drum

ET: electrical terminal block

overview concept ATD TD IT IS 4 01.06.99 V. 1.1 page 6

Basic electronics CUVC

1 The shielded round cables, SC58 and

Terminal block SE300 The shields of the round cables must be

Can be snapped on to a 35 mm mounting rail to DIN EN 50 022-35

Hardware- and software components of the T300 technology board

Introduction and overview V1.1 7 01.06.1999

T300 module with memory module

Introduction and overview V1.1 8 01.06.1999

Introduction and overview V1.1 9 01.06.1999

Introduction and overview V1.1 10 01.06.1999

The CBP module is used as communications module in the drive units.

In the following application, only PPO type 5 is used.

PZD (process data)

Both areas together result in the net data block (PPO).

Introduction and overview V1.1 11 01.06.1999

9-pole Sub D terminal

CBP communications board

PWE: Parameter ID value STW: Control word 1

Net-data structure in the "PROFIBUS Profile for PROFIDRIVE Variable-Speed Drives"

Introduction and overview V1.1 12 01.06.1999

1.6. Communications between two drive units

Introduction and overview V1.1 13 01.06.1999

PROFIBUS converter response 1.word 2.word 3.word 4.word converter response

PROFIBUS converter response converter response

PROFIBUS converter response converter response

1.7. overview of communications ATD TD IT IS 4 01.06.99 V. 1.1 page 14

control word technology 2

RFG n-controller i-controller

status word technology

T300 basic unit

2 pulse encoder inputs

1/2 LBA 1/2 LBA

T300 technology board connection diagram

Introduction and overview V1.1 16 01.06.1999

1.10.1. SIMOVERT MASTER DRIVE CUVC

Enter the Profibus address

P60 = 4 select the "module configuration" menu