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Mitsubishi crane solutions

Mitsubishi crane solutions. Introduction. This presentation will help you to sell more easy to crane applications. Please find attached: Reference customers & applications Inverter specific functions Necessary Options System solutions. Main crane types. Tower crane Bridge crane

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Mitsubishi crane solutions

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  1. Mitsubishi crane solutions

  2. Introduction This presentation will help you to sell more easy to crane applications. Please find attached: • Reference customers & applications • Inverter specific functions • Necessary Options • System solutions

  3. Main crane types • Tower crane • Bridge crane • Gantry / portal crane • Jib crane

  4. Additional crane application information for MEU and partners • Following some information which should help to get a better understanding of the crane market requirements and where Mitsubishi has advantages and disadvantages. • Critical issues for certain crane types will be mentioned. • Feel free to use any of these information for your customers.

  5. Typical for Cranes • High overload (Cranes are often overloaded from user side, and used outside the manufacturers specification) • Smooth movement • Control of mechanical Brake • Secure magnetization of sliding rotor motors (Works good with FR-A700) • Hoist speed 5-25m/min • Travel speed 15-80m/min • Brake resistor need high specification(40-50% power of hoist motor capacity, for 100% ED, because of long travel distance)

  6. Typical for Cranes • 90% of the hoists use an encoder feedback • 70% of bigger cranes use piezo-ceramic load sensor for load management • For retrofit you have to take care of insulation class of the motor and shaft voltage ( insulated bearings).

  7. Mitsubishi performance • High overload capacity • Easy and precise auto tuning • High temperature without derating (temp. under the roof can be 10-20°C higher than on the ground) • No booksize inverter, standard cabinets for cranes have mainly 300mm depth • Robust and dirt resistant design • Internal structure is built to resist high vibration levels (which are usual for cranes) • Steady and precise speed control

  8. Things to take care of for tower cranes • Torsional forces due to wind or load movement -> Independent torque limit for each working quadrant in FR-A700 • Instantaneous power failure due to brush contacts -> Instantaneous power failure function in FR-A700 • Safe working angles -> Define SW limit switches in inbuilt PLC function

  9. Things to take care of for bridge and portal cranes • Travel motor can be way bigger than hoist motor (Travel structure can be really heavy. E.g. a bridge crane with 3.6 t nominal load and 28 m wingspan can reach a mass of 25 t) • Often two motor are connected to one inverter. Combined according to there motor capacity (Combination 1: hoist with boom hoist and trolley with gantrycombination 2: hoist with gantry and trolley with boom) • A700 overload capacity is meeting the requirements (150% 60s is enough for travel, 150% 60s and 200% 3s is enough for hoist) • Electrical design of control is more complex due to safety issues • Mainly brushes are used, due to long moving distance and existing rail structure (Voltage dips/spikes should be avoided by using more than one set of pickups. AC choke and IPF-function helps too) • Hoist drive for cranes bigger 15 t often have a dual drum with a single rope (Problem is to have equal amount of rope on the two drums) • For container cranes a teachable positioning is used

  10. Things to take care of for Jib cranes • Easy crane structure, so only general requirements

  11. Crane Types Categorisation • Due to the wide range of crane types it makes sense to divide the crane applications into different groups due to the complexity.

  12. Crane TypesLow complex • Controlled manually by joystick / push buttons in jog operation • No measurements of speed, position or load • Inverter technical features like s-curve acceleration, brake function etc. is enough • Inbuilt PLC is used for speed limit switches and pendant control

  13. Crane TypesMid complex without external PLC • Controlled manually by joystick in jog operation, or easy vertical positioning • Encoder feedback • Inverter technical features like s-curve acceleration, brake function etc. is enough • Adjustment to application by internal PLC • Load management with external sensor and inbuilt PLC • Inbuilt PLC is used for speed limit switches and pendant control • Displaying data on HMI or PU07 • Use of regenerative units 

  14. Crane TypesHigh complex with external PLC • Control automatically and manually • Encoder feedback • Network communication (Often Profibus and Ethernet) • Positioning vertical and horizontal • High complex functions like safety, load management, synchronising all moving axis are realised in the external PLC • Optimised duty cycle, by automatised movement • Displaying data on HMI • Use of regenerative units 

  15. End of additional internal information part.

  16. Dedicated options and functions • There are a lot of possibilities to adjust the Mitsubishi inverters to the application. Whether standard functions , plug in options or dedicated firmware.

  17. Maximum torque for short time (0.4K to 3.7K) Maximum torque for short time (5.5K to 55K) Continuous torque(0.4K to 3.7K) Output torque (%) (60Hz reference) Speed (r/min) Torque performance of FR-A740 Closed-loop vector control (encoder) 200% (150%) torque @ 0.04Hz Real sensorless vector control 200% (150%) torque @ 0.3Hz

  18. Maintenancefunction and lifetime display • Alarm outputs can be activated to carry out maintenance tasks on the crane, depending on the number of hours of operation like: -> Inrush current limit circuit life -> Control circuit capacitor life -> Main circuit capacitor life -> Cooling fan life

  19. Dedicated functions in FR-A740 • Independent torque limit for each working quadrant (generation/ regeneration) • Built in PLC function -> Realise secure working areas -> Maximum load limiter • Deceleration ramp can be generated in the absence of power (not for hoist) • Instantaneous power failure • S-pattern acceleration / decelaration • Speed automatically adjusted depending on the load • Brake sequence function (torque proving) • Digital input functions

  20. FR-A740-C9Special crane FW • FCFS first come first serve • 2 encoder feedback cards can be mounted -> Closed loop speed or torque control for 2nd. motor • Dedicated latched encoder feedback pulse register in inbuilt PLC -> Semi multi turn positioning for 1st. motor -> Position tracking for 2nd. motor

  21. FR-A740-C9Special crane FW • Advantages: -> Closed loop performance in horizontal and vertical movement -> Vibration avoidance -> Movement tracking and positioning

  22. FR-A7AL option card • Master slave operation -> Speed control -> Position control • Synchronising 2 axis • Balancing load

  23. FR-A7AL option cardMaster / Slave position control A700

  24. FR-A740 FR-A740 M M FR-A740 droop control • Sharing load of two motors on one shaft without a connection between the inverters

  25. Factor M1 positive Factor M2 negative In unbalanced situation inertia M1 > inertia M2 Factor M1 > 1Factor M2 < 1 Output frequency M1 decreasesOutput frequency M2 increases Load balanced FR-A740 droop control

  26. Regenerative energy • Regenerative energy is always an issue in crane applications. The decision for a certain regenerative option is based on the following application characteristic.

  27. Regenerative energy • How much regenerative energy do I have to handle? Calculation of the Brake power :

  28. Duty cycle [%] Duty cycle • How often do I have to handle it?

  29. Regenerative unit or brake resistor • Regenerative unit -> Circular duty cycle with high ED and high PBrake • Brake resistor -> Non circular duty cycle, even with high PBrake

  30. Too much regenerative energy? How much energy? For which time? Continuous regenerative Short time regenerative Convert to heat? Regeneration? For more than one inverter? more equal heat regen Internal brake chopper with internal / external brake resistor up to 22k BU-UFSup to 550kFR-BU2up to 750k(no CE mark) CommonDC Bus FR-CVup to 55k (no CE mark) FR-HCup to 55kMT-HC-Sup to 375k (no CE mark) FR-RCup to 55k MT-RCup to 280k (no CE mark) FR-A701 up to 55k Mitsubishi Regenerative Solution

  31. FR-A701 • FR-A701 is a FR-A700 with active front end, which allows 100% torque continuous regeneration and 150% torque overload regeneration for 60s.

  32. FR-RC & MT-RCPOWER REGENERATION CONVERTER • Energy generated at braking operation of the inverter can be regenerated to the power supply. Since a converter does not require a discharging resistor, it is effective in space and energy saving and it provides a large peak braking torque. • One inverter connected to one FR/MT-RC.

  33. FR-CVPOWER REGENERATIONCOMMON CONVERTER • Enables 100%-torque continuous regeneration to support continuous regenerative operation for line control. • Saves energy since regeneration energy is used for the other inverters and excess energy is returned to the power supply. • Up to six inverters connected to one FR-CV.

  34. THDI = 0 FR-HC & MT-HCHIGH POWER FACTOR CONVERTER • Substantially suppresses power harmonics. Power regeneration function featured as standard enables common converter system operation with multiple inverters connected. • Up to six inverters connected to one FR/MT-HC

  35. Mitsubishi system solution Mitsubishi frequency inverters offer a great variety of inbuilt functions to adjust your system to the application needs. Additionally we have system solutions with high performance Mitsubishi components.

  36. Complete Solution HMI FX3U PLC Modem Lifting Translation Rotation

  37. Mitsubishi system solution • Inverter + FX series PLC • Inverter + Q series PLC • Inverter + GOT HMI • Inverter + Mitsubishi PLC + GOT HMI

  38. Mitsubishi system solutionInverter + FX series • Inverter + FX1N / FX2N / FX3U with RS-485 module -> Dedicated function blocks for serial communication to up to 8 inverters -> Control, read / write parameters and full monitor function • Inverter + FX1N (1 axis) / FX3U (3 axis) pulse train positioning -> Dedicated function blocks for absolute positioning, homing, zero return and SW / HW limit switches

  39. FX3U inverterinstructions Configure and control frequency inverters with single commands: IVCK: Check inverter status IVDR: Control inverter IVRD: Read inverter parameters IVWR: Write inverter parameters IVBWR: Block write inverter parameters User-friendly configuration andcontrol of frequency inverters and3-phase AC drives

  40. Safety features with FR-A700 in CL & FX3U Load in kg 4.000 3.600 3.200 2.800 2.400 2.000 1.600 1.200 800 400 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 24 35 Reach in meters Maximum torque limiter can be variable depending on the position the trolley reaches When this torque limit is exceeded you can: Stop the trolley advance Stop the raising of the hook etc.

  41. Mitsubishi system solutionInverter + Q series • Inverter + system Q with C24 serial com. module -> Dedicated function blocks for serial communication to up to 32 inverters -> Control, read / write parameters and full monitor function

  42. Mitsubishi system solutionInverter + Q series (MEU internal) • Inverter + system Q with Q62DA and QD62E two motor positioning -> Dedicated function blocks for absolute positioning, homing, zero return and SW / HW limit switches

  43. GOT1000 and inverter • GOT1000 series is fully compatible to 700 series inverters -> Control and set parameters of up to 10 inverters with one HMI -> Use multi language on GOT1000 for inverter control and alarm history -> Displaying advanced process data and alarms

  44. Mitsubishi Portal Crane DemoMain Screen

  45. Mitsubishi Portal Crane DemoData Screen

  46. Mitsubishi Portal Crane DemoAlarms Screen

  47. Complete SolutionFurther Advantages FX3U PLC Managing/ control movements through communicationsas master Connection for the 3rd party products Event history (Black Box) Preventive maintenance data base Modem Remote monitoring (alarms, event history, etc)Remote access HMI (touch screen) Monitoring by the end user Web-page Adjustment of crane parameters Black Box display (hidden)

  48. Our strength in crane applications - proven by many reference customers.

  49. Company ZPMC Shanghai Zhenhua Port Machinery • World largest seaport crane manufacturer • FR-A740–C9 special FW for cranes

  50. Consys (Russia) • Company Baltkran -> All types of container and bridge cranes (10 to 60t) -> FR-A700 11 to 160 kW • Company 55 MOZ ->All types of container and bridge cranes (10 to 20t) -> FR-A700 1.5 to 15 kW

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