Simocrane Tps 082012 en en-us

8/21/2019 Simocrane Tps 082012 en en-us

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ruck Positioning System (TPS)

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SIMOCRANE

Truck Positioning System (TPS)

Operating Instructions

applies toSIMOCRANE TPS Version 1.1

08/2012

Preface

Introduction

1

Description

2

Application planning

3

Mechanical installation

4

Electrical installation

5

Operator interface (HMI)

6

Preparation of the sensor

controller

7

Coordinates, dimensions,

parameters

8

Interface to the crane

controller

9

The TPS START

commissioning tool

10

Commissioning

11

Troubleshooting / FAQs

12

Appendix

A


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Siemens AGIndustry SectorPostfach 48 4890026 NRNBERGGERMANY

08/2012 Technical data subject to changeCopyright Siemens AG 2008 - 2012.All rights reserved

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to preventdamage to property. The notices referring to your personal safety are highlighted in the manual by a safety alertsymbol, notices referring only to property damage have no safety alert symbol. These notices shown below aregraded according to the degree of danger.

DANGER

indicates that death or severe personal injurywill

result if proper precautions are not taken.

WARNING

indicates that death or severe personal injurymay

result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger willbe used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating toproperty damage.

Qualified Personnel

The product/system described in this documentation may be operated only bypersonnel qualified

for the specifictask in accordance with the relevant documentation, in particular its warning notices and safety instructions.Qualified personnel are those who, based on their training and experience, are capable of identifying risks andavoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technicaldocumentation. If products and components from other manufacturers are used, these must be recommendedor approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation andmaintenance are required to ensure that the products operate safely and without any problems. The permissibleambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by are registered trademarks of Siemens AG. The remaining trademarks in this publicationmay be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and softwaredescribed. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, theinformation in this publication is reviewed regularly and any necessary corrections are included in subsequent

editions.


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Operating Instructions, 08/2012 3

Preface

This document is aimed at readers who are interested in the SIMOCRANE Truck PositioningSystem and at engineers who are tasked with commissioning the system. To understand thecontent of this manual, you will require a basic knowledge of procedures and technical termsassociated with hoisting gear as well as a basic knowledge of automation systemterminology.

For an overview of the most important information contained in this manual, refer to thechapter titled Introduction(Page 13).

Prerequisite (range of validity)

This manual is valid for the application with SIMOCRANE TPS V1.1 in conjunction withSIMATIC NET IE SOFTNET 2008.

Scope of supply

The SIMOCRANE Truck Positioning System (TPS) comprises the following components:

Sensor controller

SIMATIC IPC for DIN-rail mounting, e.g. in the switchgear room of a crane, installed andpreconfigured for plug and play, contains:

SIMATIC NET OPC server

TPS START

TPS Runtime

3D sensor

3D sensor (Lase GmbH type 3D-LMS221), consisting of:

Laser scanner LMS221-30206 (outdoor) (SICK AG)

Servo drive (Schunk)

Weather protection hood for the LMS221 (special design for this application) HARTING plugs for the connection of power supply cables and data leads

Order numbers

Package

Order No.

SIMOCRANE TPSsensor controller 6GA7220-1AA00-0AB0

SIMOCRANE TPS3D sensor 6GA7221-1AA21-0AB0


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Preface


4 Operating Instructions, 08/2012

Versions

The system must be operated with the software versions specified below or later versions.

Sensor controller:

Component Subcomponent Version number

SIMATIC IPC 427C (Microbox PC) 427C

Microsoft Windows operating system XP Professional SP3

SIMOCRANE TPS Runtime V1.1

SIMOCRANE TPS START V1.1

SIMATIC NET IE SOFTNET-S7 Lean 2008 Edition

SIMATIC NET IE SOFTNET-S7 Basic 2008 Edition

3D sensor:

Component Subcomponent Version number

Schunk servo motor PDU 110 Software/firmware V5.3 / FW 1.3.1

SICK, laser scanner LMS221-30206

Firmware X01.46

Device identification data

Enter the identification data of the various devices so that we can assist you more quickly ina service case.

Sensor controller

Order number:6GA7220-1AA00-0AB0

Microsoft Windows Product Key(You will find the Certificate of Authenticity (COA) label in the device.)

.

Ethernet address 1

In the BIOS setup ( key) under Main Hardware Options Ethernet Address

Ethernet address 2

In the BIOS setup ( key) under Main Hardware Options Ethernet Address


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Preface



3D sensor_0(You will find the type label in the device.)

Order number of the device:6GA7221-1AA21-0AB0

Serial number:

.

CAN device ID:

.

3D sensor_1(You will find the type label in the device.)

Order number of the device:6GA7221-1AA21-0AB0

Serial number:

.

CAN device ID:

.

Hotline and Internet addresses

If you have any technical questions, please contact our hotline (worldwide):

A&D Technical Support:

Phone.: +49 (180) 50 50 222

Fax: +49 (180) 50 50 223

Email: [email protected]

Internet:(https://support.automation.siemens.com/WW/llisapi.dll?aktprim=5&lang=en&referer=%2f

WW%2f&func=cslib.csinfo&siteid=csius&groupid=4000002&extranet=standard&viewreg=WW&nodeid5=38718979&objaction=csopen)

If you have any questions, suggestions or corrections regarding the documentation, pleasefax or e-mail them to:

Fax: +49 (9131) 98 2176

Email: [email protected]

Siemens Internet address

The latest information about SIMOCRANE products and product support can be found in theInternet at: (http://www.siemens.com/cranes)
https://support.automation.siemens.com/WW/llisapi.dll?aktprim=5&lang=en&referer=%2fWW%2f&func=cslib.csinfo&siteid=csius&groupid=4000002&extranet=standard&viewreg=WW&nodeid5=38718979&objaction=csopenhttps://support.automation.siemens.com/WW/llisapi.dll?aktprim=5&lang=en&referer=%2fWW%2f&func=cslib.csinfo&siteid=csius&groupid=4000002&extranet=standard&viewreg=WW&nodeid5=38718979&objaction=csopenhttps://support.automation.siemens.com/WW/llisapi.dll?aktprim=5&lang=en&referer=%2fWW%2f&func=cslib.csinfo&siteid=csius&groupid=4000002&extranet=standard&viewreg=WW&nodeid5=38718979&objaction=csopenhttp://www.siemens.com/craneshttp://www.siemens.com/craneshttps://support.automation.siemens.com/WW/llisapi.dll?aktprim=5&lang=en&referer=%2fWW%2f&func=cslib.csinfo&siteid=csius&groupid=4000002&extranet=standard&viewreg=WW&nodeid5=38718979&objaction=csopenhttps://support.automation.siemens.com/WW/llisapi.dll?aktprim=5&lang=en&referer=%2fWW%2f&func=cslib.csinfo&siteid=csius&groupid=4000002&extranet=standard&viewreg=WW&nodeid5=38718979&objaction=csopenhttps://support.automation.siemens.com/WW/llisapi.dll?aktprim=5&lang=en&referer=%2fWW%2f&func=cslib.csinfo&siteid=csius&groupid=4000002&extranet=standard&viewreg=WW&nodeid5=38718979&objaction=csopen


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Preface



Application notes

Available in the Internet at:

(http://support.automation.siemens.com/WW/view/en/48342008/136000)

Latest information about SIMOCRANE products

Available in the Internet at:(http://support.automation.siemens.com/WW/view/en/10807397/130000)

Further assistance

We offer training courses to help you get started with the Truck Positioning System (TPS).For further information, contact:

Siemens Industry DT MC Cranes application supportEmail: [email protected]
http://support.automation.siemens.com/WW/view/en/48342008/136000http://support.automation.siemens.com/WW/view/en/10807397/130000http://support.automation.siemens.com/WW/view/en/10807397/130000http://support.automation.siemens.com/WW/view/en/48342008/136000


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Contents

Preface ...................................................................................................................................................... 3

1 Introduction.............................................................................................................................................. 13

2 Description............................................................................................................................................... 15

2.1 Impetus for system development.................................................................................................15

2.2 Positioning sequence...................................................................................................................16

2.3 System components ....................................................................................................................172.3.1 Sensor controller..........................................................................................................................182.3.2 3D sensor.....................................................................................................................................192.3.3 Crane controller............................................................................................................................202.3.4 Signaling system..........................................................................................................................21

2.4 How it works.................................................................................................................................21

3 Application planning................................................................................................................................. 23

3.1 Ambient conditions.......................................................................................................................23

3.2 Number of 3D sensors .................................................................................................................233.2.1 Coverage calculation ...................................................................................................................243.2.1.1 Coverage area and range ............................................................................................................253.2.1.2 Coverage area and angle ............................................................................................................26

3.2.1.3 A summary of the coverage calculation principles.......................................................................273.2.2 3D distance calculation ................................................................................................................273.2.3 Calibration....................................................................................................................................293.2.4 Accuracy ......................................................................................................................................303.2.5 Calculating the number of 3D sensors in the example ................................................................303.2.6 Number and positions of the 3D sensors.....................................................................................31

4 Mechanical installation............................................................................................................................. 33

4.1 Assembly safety device lug..........................................................................................................33

4.2 Assembly swivel angle limitation..................................................................................................33

4.3 Mounting the 2D laser scanner ....................................................................................................33

4.4 Mounting the 3D sensor...............................................................................................................34

4.5 Sensor controller..........................................................................................................................384.5.1 Mounting positions .......................................................................................................................384.5.2 Types of installation .....................................................................................................................40

5 Electrical installation ................................................................................................................................ 43

5.1 Power supply................................................................................................................................445.1.1 3D sensor.....................................................................................................................................455.1.2 SIMOCRANE sensor controller....................................................................................................465.1.2.1 Connection elements ...................................................................................................................465.1.2.2 On/Off switch................................................................................................................................475.1.2.3 Connecting the 24 V DC power supply........................................................................................47


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5.1.2.4 Connection for equipotential bonding ......................................................................................... 48

5.2 Data interfaces ............................................................................................................................ 49

5.2.1 3D sensor.................................................................................................................................... 495.2.2 CAN interface.............................................................................................................................. 505.2.3 RS 422 interface ......................................................................................................................... 525.2.4 Summary of data cables ............................................................................................................. 53

6 Operator interface (HMI).......................................................................................................................... 55

6.1 Requirements of the Truck Positioning HMI ............................................................................... 556.1.1 Data to be supplied by the Truck Positioning HMI...................................................................... 556.1.2 Link to the Truck Positioning System.......................................................................................... 56

6.2 The Truck Positioning HMI in SIMOCRANE CMS...................................................................... 56

6.3 Operating modes......................................................................................................................... 576.3.1 System Off................................................................................................................................... 576.3.2 Calibration ................................................................................................................................... 586.3.3 Truck positioning ......................................................................................................................... 596.3.4 Cold restart.................................................................................................................................. 60

7 Preparation of the sensor controller......................................................................................................... 63

7.1 Restoring the basic setting of the SIMOCRANE sensor controller............................................. 63

7.2 Connection with the service PC .................................................................................................. 65

8 Coordinates, dimensions, parameters ..................................................................................................... 71

8.1 The coordinate systems.............................................................................................................. 718.1.1 The TPS coordinate system........................................................................................................ 71

8.1.2 The OPC coordinate system for data exchange with the crane controller ................................. 738.1.3 Coordinate systems of trucks and container trailers................................................................... 74

8.2 Crane (calibration)....................................................................................................................... 74

8.3 Lanes........................................................................................................................................... 78

8.4 Working area of the 3D sensor ................................................................................................... 80

8.5 Vehicles....................................................................................................................................... 818.5.1 Trucks.......................................................................................................................................... 828.5.2 Container trailer........................................................................................................................... 84

8.6 Container..................................................................................................................................... 86

9 Interface to the crane controller ............................................................................................................... 87

9.1 Data assignment with scores7.txt ............................................................................................... 87

9.2 Configuring the SIMATIC NET OPC server ................................................................................ 889.2.1 Adapting the hardware configuration Ethernet......................................................................... 889.2.2 Adapting the hardware configuration PROFIBUS.................................................................... 899.2.3 Configuring the network Ethernet............................................................................................. 919.2.4 Configuring the component configurator..................................................................................... 949.2.5 Checking the connection............................................................................................................. 95

9.3 Input data TPS ............................................................................................................................ 979.3.1 Lane Number Words ................................................................................................................... 999.3.2 Sensor Modus words ................................................................................................................ 1009.3.3 Crane Status words................................................................................................................... 102


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9.3.4 Crane handshake.......................................................................................................................1039.3.5 Actual Hoist Position ..................................................................................................................1049.3.6 Actual Trolley Position ...............................................................................................................1049.3.7 Actual Gantry Position ...............................................................................................................1049.3.8 Actual Slew position...................................................................................................................1049.3.9 General spreader status words..................................................................................................1059.3.10 Spreader Status Landside words...............................................................................................1069.3.11 Spreader Status Waterside words .............................................................................................107

9.4 Output data TPS ........................................................................................................................1089.4.1 Sensor Status word....................................................................................................................1099.4.2 Servo Status word......................................................................................................................1109.4.3 Sensor mode status word ..........................................................................................................1129.4.4 Truck Positioning System status word.......................................................................................1139.4.5 Truck Positioning System Handshake .......................................................................................1149.4.6 Calibration status word ..............................................................................................................1149.4.7 Lane status words......................................................................................................................1159.4.8 Landside / Waterside Vehicle Type ...........................................................................................1169.4.9 Landside/waterside actual position............................................................................................1169.4.10 Landside/waterside status cold restart ......................................................................................116

9.5 Control of the TPS system.........................................................................................................1179.5.1 Mode calibration.........................................................................................................................1189.5.2 Positioning mode .......................................................................................................................1189.5.2.1 Flowchart for positioning ............................................................................................................1199.5.3 Cold restart mode ......................................................................................................................124

10 The TPS START commissioning tool..................................................................................................... 125

10.1 Overview of the user interface ...................................................................................................12610.2 Menu Bar....................................................................................................................................126

10.3 The command bar......................................................................................................................127

10.4 The Navigator.............................................................................................................................127

10.5 The working area .......................................................................................................................12810.5.1 The "Overview" tab ....................................................................................................................12810.5.2 The "Parameter list" tab .............................................................................................................13010.5.3 The "3D View" tab......................................................................................................................13210.5.3.1 The "Calibration / Lanes" tab .....................................................................................................13310.5.3.2 The "Vehicle models" tab...........................................................................................................13410.5.3.3 The "Position monitoring" tab.....................................................................................................134

10.6 The detail display .......................................................................................................................13510.6.1 The "Faults and alarms" tab.......................................................................................................13510.6.2 The "Control panel" tab..............................................................................................................13610.6.3 The "Symbol browser" tab .........................................................................................................13710.6.4 The "Recording" tab...................................................................................................................13810.6.5 The "Logging" tab.......................................................................................................................13810.6.6 The "Output TPS START" tab....................................................................................................13910.6.7 The "Output TPS Runtime" tab ..................................................................................................139

10.7 The Status Bar ...........................................................................................................................140

11 Commissioning...................................................................................................................................... 141


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11.1 Sample configuration ................................................................................................................ 141

11.2 Preconditions ............................................................................................................................ 142

11.3 Checklists.................................................................................................................................. 142

11.4 Procedure.................................................................................................................................. 143

11.5 Activate online operation: TPS START via Ethernet ................................................................ 14311.5.1 Starting the Program................................................................................................................. 14311.5.2 Connection to TPS Runtime...................................................................................................... 14411.5.3 Ending the connection with TPS Runtime................................................................................. 144

11.6 Connection to the crane controller ............................................................................................ 14511.6.1 Configuring and parameterizing the OPC server...................................................................... 14511.6.2 Checking the exchanged data .................................................................................................. 14611.6.3 Parameterization of the OPC server used by TPS Runtime..................................................... 14611.6.4 Check the connection to the crane controller............................................................................ 147

11.7 Commissioning the terminals for communication with the crane controller.............................. 14811.7.1 2D laser scanner ....................................................................................................................... 14811.7.1.1 RS422 interface settings........................................................................................................... 14811.7.1.2 2D laser scanner settings.......................................................................................................... 14911.7.1.3 Checking the settings................................................................................................................ 14911.7.2 Servo motors............................................................................................................................. 15111.7.2.1 Settings for the CAN interfaces................................................................................................. 15111.7.2.2 Settings for CAN Channel and ESD CAN Channel .................................................................. 15111.7.2.3 Device settings.......................................................................................................................... 15211.7.2.4 Checking the settings................................................................................................................ 15311.7.3 3D sensor.................................................................................................................................. 154

11.7.3.1 Checking the assignment of the 2D laser scanner to servo motor ........................................... 15411.8 Automatic calibration of the 3D sensor ..................................................................................... 15611.8.1 Preparations for calibration ....................................................................................................... 15611.8.2 Visual inspection of the set parameters .................................................................................... 15811.8.3 Example: Adapting the sill beam size ....................................................................................... 16111.8.4 Checking the mounting angle of the 3D sensors ...................................................................... 166

11.9 Lanes......................................................................................................................................... 16711.9.1 Determining and marking the y origin ....................................................................................... 16811.9.2 Configuring the lanes ................................................................................................................ 16811.9.3 Working area of the 3D sensors ............................................................................................... 17111.9.4 Coordinate conversion between crane controller and TPS ...................................................... 17211.9.4.1 Single spreader or tandem spreader? ...................................................................................... 173

11.9.5 Checking the lane settings........................................................................................................ 173

11.10 Truck models............................................................................................................................. 17411.10.1 Creating truck models ............................................................................................................... 174

11.11 Container trailer models ............................................................................................................ 17911.11.1 Creating container trailer models .............................................................................................. 179

11.12 Positioning................................................................................................................................. 18211.12.1 Check the position calculation................................................................................................... 18311.12.2 Checking the coincidence signal............................................................................................... 184

11.13 Alternate system configurations................................................................................................ 185

12 Troubleshooting / FAQs......................................................................................................................... 187


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12.1 General problems ......................................................................................................................187

12.2 No connection to the crane controller ........................................................................................191

A Appendix................................................................................................................................................ 193

A.1 List of abbreviations ...................................................................................................................193

A.2 Installation checklist for the Truck Positioning System..............................................................194

A.3 STS calibration parameter values form .....................................................................................198

A.4 STS lanes parameter values form .............................................................................................199

A.5 Glossary.....................................................................................................................................200

A.6 ESD information.........................................................................................................................201


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Introduction

1

The Truck Positioning System is primarily intended for installation on ship-to-shore containercranes. It is designed to provide better protection for operators and to increase the efficiencyof container handling procedures. In principle, the system can also be used on other types ofcrane where pre-identified trucks need to be positioned. The conditions of application withrespect to installation and design must be evaluated when the system is used on other cranetypes.

These instructions describe the entire Truck Positioning System step by step. They start witha description of its operating principle and go on to provide instructions on crane installation,commissioning of individual components, and finally commissioning of the system as awhole.

If you want some initial information about the system's design, operating principle, andsuitability for your requirements, please read Chapters Description(Page 15), Applicationplanning(Page 23), and Operator interface (HMI)(Page 55).

If you are looking for details on the mechanical and electrical installation of the TruckPositioning System, please read Chapters Mechanical installation(Page 33) to Electricalinstallation(Page 43).

Section Coordinates, dimensions, parameters(Page 71) is particularly relevant aspreparation for commissioning. Checklists for the commissioning can be found in theAppendix (Installation checklist for the Truck Positioning System(Page 194)) as well asforms for the acquisition of the parameter values (STS calibration parameter values form(Page 198) and STS lanes parameter values form(Page 199)).

If you wish to commission the system with a sensor controller that has the necessarysoftware installed but the operating system settings deviate from the preconfigured values,please also read Preparation of the sensor controller(Page 63).

To restore your sensor controller configuration to the shipped state, please contact thesupport line. To save system-specific data, use the "Save parameter list" command; seeChapter The command bar(Page 127) and Figure 10-8 Versions of the parameter list(Page 131).


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Introduction




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Description

2

This chapter describes the purpose, design and basic operating principle of the system. It isdesigned to give you a general understanding of the Truck Positioning System.

2.1

Impetus for system development

Ship-to-shore cranes are used in numerous ports around the world to handle containers.Containers are transported from the crane to the storage area by various types of vehicle.

Manually operated truck-trailer combinations are frequently used for this purpose.Positioning the truck trailer correctly under the crane is particularly challenging, as the craneis lined up with the container row on the ship and must not move along the quay wall whilecontainers are being loaded/unloaded.

Loading and unloading containers frequently involves numerous different combinations oftruck and container trailer. This means that there is no clearly defined position at which adriver of a truck can stop to ensure easy loading or unloading of a container. Since the drivercannot determine the optimum stop position from the vehicle's cabin, he needs to be directedinto the correct position.

Until now, the driver was directed into position by an instructor (or "checker") movingbetween the lanes giving manual positioning instructions. The system described in this

document can perform this task fully automatically which means that operators are no longerrequired to work in the danger area under cranes.

Other advantages of an automatic positioning system is that it allows a continuous flow ofvehicles, thereby minimizing the wear on trucks (gear unit wear is reduced, for example) andtrailers, and it largely eliminates the risk of damage to trailers and trucks caused by loadingin the wrong position. What is more, efficient use speeds up container handling.


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Description

2.2 Positioning sequence



Figure 2-1 Positioning a truck with trailer

2.2 Positioning sequence

The truck travels under the crane for loading or unloading along a lane specified by the user(e.g. crane operator). As the vehicle approaches, the system detects the truck and trailer and

automatically determines the optimum stop position. It continuously reads the currentposition of the truck trailer, calculates its distance from the target stop position and transfersthese data to the crane controller via Ethernet or PROFIBUS (via OPC).

A user program evaluates the transferred data and generates signals that indicate to thedriver of the truck when to decelerate and when to stop. These instructions can be visualizedby visual signals, such as "traffic lights" with special switching sequences, a large display onthe crane or a small display in the truck. Alternatively, an acoustic signal can be used which,similar to acoustic reversing sensors on cars, "bleeps" intermittently at increasing frequencyas the vehicle approaches the target position until the acoustic signal becomes continuous inthe vehicle's end position.


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Description

2.3 System components



2.3

System components

The TPS consists of two basic components:

1 SIMOCRANE TPS sensor controller

2 SIMOCRANE TPS 3D sensors

Note

The components may be bundled differently in the order.

Other essential components are:

1 crane controller (PLC)

1 connection to the crane controller (PROFIBUS or Ethernet)

1 user interface (HMI; e.g. SIMOCRANE CMS Lite or SIMOCRANE CMS)

1 signal system

1 service PC for commissioning (Windows XP Professional SP3 and higher)

Figure 2-2 Schematic diagram of a Truck Positioning System


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Description




Note

A virus scan cannot be run while the TPS Runtime is running. A system virus scan wouldcause a performance impairment of the system and thus also of the TPS Runtime. Thismeans no virus scanner is available on the SIMOCRANE sensor controller.

We strongly recommend that you check the sensor controller for viruses at regularintervals, e.g. during the maintenance of your IT, and protect your company network witha firewall.

2.3.1 Sensor controller

The sensor controller is based on a SIMATIC IPC 427C. The controller performs the

following functions:

Controls the 2D laser scanners and the servo motors

Collects raw scanner data and recognizes scanned objects

Calculates the positions of recognized objects

Provides a command and data interface to the crane controller and for operator inputs

The sensor controller must be connected to the crane controller via Ethernet or PROFIBUS.It is installed either in a control cubicle in the crane's switchgear room or in a cubicle in thechecker cabin. It is advisable to install the sensor controller as close as possible to the 3Dsensors to minimize the length of supply cables. The sensor controller is shipped with pre-installed software so that software installation and configuration is a very quick process. Thesensor controller also offers reserve capacity for future applications with a functional scopebeyond the SIMOCRANE Truck Positioning System.

Figure 2-3 SIMOCRANE sensor controller (SIMATIC IPC 427C)

The SIMOCRANE sensor controller is connected to the SIMOCRANE 3D sensor via twointerfaces:

RS422 interface for the 2D laser scanner

CAN interface for the servo motor


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Description




2.3.2 3D sensor

The 3D sensors are mounted on support platforms attached to the crossbeams (portal

beams) of the crane. The scanners face downwards onto the loading/unloading lanes belowthe crane.

A 3D sensor consists of one 2D laser scanner, a servo motor, and a swiveling platform. The2D laser scanner can be swiveled by the servo motor in order to extend its scan range by thethird dimension. The servo motor and 2D laser scanner are mounted on the swivelingplatform which connects both components mechanically so that the 2D laser scanner isrotatable. The two components are wired inside the platform in such a way that the powerconnections and communications interfaces of the individual components are each broughtout to a common connector.

The 2D laser scanner measures the distance to objects by emitting a pulsed laser beamwhich is reflected by objects within range.

The (2D) polar coordinates of the individual measuring points are transferred in real time tothe sensor controller for evaluation. In 3D operation, the second angle required for a 3Dpolar coordinate is defined by the servo motor setting.

The scan range of the 2D laser scanners covers the length of the loading/unloading lanes.The dimensional extension provided by the servo motors enables the laser scanners to bealigned for positioning on different lanes.


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Description




Swiveling platform

2D laser scanner Servo motor with housing

Figure 2-4 Components of the 3D sensor

2.3.3

Crane controller

Note

The scope of supply of SIMOCRANE TPS does not include a crane controller.

The crane controller provides TPS data about the state of the crane and itself receives dataabout the status of the TPS and the positioning status. Data exchange between the sensorcontroller and the crane controller is platform-neutral and handled by an OPC server on thesensor controller using Ethernet or PROFIBUS.

The crane controller is also responsible for controlling the signaling system for the driver ofthe truck.

To solve these two tasks, a program which is capable of initializing transfer of crane data tothe OPC interface and controlling the signaling system must be implemented in the cranecontrol.


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Description

2.4 How it works



2.3.4 Signaling system

Note

The scope of supply of TPS does not include a signaling system.

The signaling system provides the interface between the TPS and the driver of the truck. Inits simplest form, it consists of a traffic lights display with special signal sequences that isdriven by the crane controller.

The user is responsible for planning and implementing the signaling system.

2.4

How it works

Laser beams (scan area)

Figure 2-5 Diagram showing laser scanning

When the TPS is switched on for the first time, the operator must first select an operatingmode (Positioning, Calibration, or Cold Restart). In Calibration mode, all the 3D sensorssearch for a prominent position by which they can orient. The zero point of the coordinatesystem is determined in the course of calibration. This is generally a point centered belowthe crane (see The TPS coordinate system(Page 71)).

In Positioningmode, the system continuously checks a defined lane in a defined approachdirection for the presence of trucks and / or container trailers. For this, the 3D sensor isaligned with the defined lane and 2D scans are continuously recorded and evaluated.

If a truck is detected, the TPS can calculate an initial target position and start the checkingprocedure. As it approaches, the system detects the truck, the container trailer, and thecontainer (model recognition) with which it determines the precise position.

Once the system has recognized a container or trailer, it derives the exact target positionplus the deviation of the actual position from the target. The crane controller can thenevaluate this distance and drive the signaling system for the driver of the truck accordingly.


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Description

2.4 How it works



When the truck leaves the monitored area again, either because it has been successfullypositioned or because it has moved sideways into the next lane (e.g. if the truck has simplyused the lane to maneuver), the system detects this and continues searching for otherapproaching trucks.


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3

Carefully prepare commissioning of the TPS. Only in this way can you ensure fastcommissioning and smooth functioning of the system.

3.1

Ambient conditions

For the Truck Positioning System to work successfully, a variety of local ambient conditionsmust be parameterized.

The following dimensions are required for parameter settings:

Height of the portal beam of the crane above the lanes or mounting height of the 3Dscanners

Distance of the 3D laser scanners from the sill beams of the crane gantry (waterside andlandside)

Number and positions of lanes under the crane (referred to the center point between thesill beams of the crane gantry)

Maximum spreader hoisting height (above the lanes) at which the 3D sensors will stillhave an unobstructed view.

These dimensions can either be taken from the crane construction drawing or measured insitu.

Furthermore, the TPS requires a reference coordinate with the coordinate system that isvalid on the OPC interface, see Coordinate conversion between crane controller and TPS(Page 172).

3.2

Number of 3D sensors

The number of 3D scanners required depends on the features of the individual installation. Itmust be ensured that the TPS functions on every lane.


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3.2 Number of 3D sensors



The calculations are based on the information given in Sections Coverage calculation(Page 24) and 3D distance calculation(Page 27). These are explained below. The impact ofcrane color on the accuracy of the test reference process is described in Calibration(Page 29) and the accuracy calculation is described in Accuracy(Page 30).

Note

In the current edition, the TPS is configured for use of two 3D sensors. In future versions, itwill be possible to scale the number of 3D sensors.

Using the calculations described below, you will be able to verify whether the currentsoftware version with two 3D laser scanners will meet your requirements.

For an approximate guide value, please refer to Number and positions of the 3D sensors(Page 31) .

3.2.1

Coverage calculation

The coverage calculation determines how many lanes can be covered by a single 3D sensormounted at a specific height. This calculation is based on simple trigonometric featureswhich can be determined using tangent or Pythagoras' theorem.

Figure 3-1 Spot diameter

The above diagram shows that the spot diameter increases as a function of the distancebetween laser and object. As soon as the spot diameter becomes larger than the object, the3D sensor will have problems recognizing objects; see diagram below.


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Figure 3-2 Spot diameter larger than object

The 3D sensor must detect the entire profile of the container trailer in order to be able todistinguish between different types of container trailer. The more container trailer types thatare in use around the cargo handling area, the more details will be required for safedetection. For a maximum of four vehicle types, the scanner can be mounted at a maximum

height of 19 m, for more than four vehicle types the maximum mounting height is 15 m.It must also be taken into account that the 3D sensor can cover the lanes below up to amaximum angle of 35 to the left and to the right. At an angle greater than 35, the beamwould hit the objects at too shallow an angle and the accuracy of the reflected beam wouldbe impaired. Furthermore, obstacles (such as another truck) would be more likely to obscurethe truck in the adjacent lane.

3.2.1.1 Coverage area and range

Figure 3-3 Geometric analysis


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The diagram above shows the scanner range of the 3D sensor over individual lanes. In thiscase, the laser is mounted on the portal beam of the crane and aligned downward."DistanceSpot" expresses the range of the 3D sensor within which the spot emitted by the 3Dsensors is still small enough to recognize sufficient detail on the trailer. This variable is thus15 m for areas with more than four vehicle types and 19 m for less than four vehicle types.The trailer height of 1.5 m is subtracted from the mounting height of the 3D sensor. On thebasis of the triangle shown, the following relation can be defined using Pythagoras' theorem:

We will continue working with the equation above, but will replace the variable "Area" with thewidth of the lanes and the gaps between the lanes. Remember that there is always one lane

gap less than the number of lanes, i.e. where there are 10 lanes, there will only be 9 gaps.Furthermore, the variable "Area" above covers only half the lanes in the diagram above. Allthese factors are taken into account in the following formula.

The variable "Area" is now applied in the formula above and solved according to variable"MaskedLanes". The result of this calculation is the formula below. The rounded resultspecifies the number of lanes that can be covered by one 3D sensor.

3.2.1.2 Coverage area and angle

If the 3D sensor is mounted too low, the 3D sensor with its range of 15 m or 19 m covers anangle greater than 35 to the left and right over the lanes below. In this case, not the angle ofcoverage of the 3D sensor is used for calculation, but the 35 angle. Based on the triangleshown in the diagram "Geometric analysis" (see above), the following relation which takesthe angle into account can be defined:

We will now develop the formula above further so as to include the geometric dimensions of

the lanes in place of the variable "Area." The resulting formula is as follows:

The rounded result specifies the number of lanes that can be covered by one 3D sensor.


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3.2.1.3 A summary of the coverage calculation principles

To summarize the basic rules: To ensure reliable recognition of all vehicles, the following

conditions apply, depending on the height at which the 3D scanner is mounted:1. Range of the 3D sensor

The scanner-to-object distance must not exceed 15 m (with more than 4 vehicle types) or19 m (with fewer than 4 vehicle types).

2. Angle of rotation of the 3D sensorThe 3D sensor must not be swiveled by more than 35.

The swivel angles or ranges of the 3D sensor thus act as limiting factors which call fordifferent calculation variants:

Calculation 1 (example)

(limiting factor: range of the 3D sensor)

Mounting height 15 m and fewer than 4 vehicle types(range of 3D sensor 19 m)or

Mounting height 12.2 m and more than 4 vehicle types(range of 3D sensor 15 m)

Calculation 2 (example)

(limiting factor: swivel angle of the 3D sensor)

Mounting height < 15 m and less than 4 vehicle typesor

Mounting height < 12.2 m and more than 4 vehicle types

3.2.2

3D distance calculation

Here, the general range is used to recognize the truck or trailer at a certain distance for thefirst time without any disinction between details. The range of laser LMS221 is maximum 30m (in the case of black objects).

This calculation is based on the outermost lane that the 3D laser still manages to cover. The3D sensor must detect the truck for the first time at a distance of 15 m on this outermost laneif it is to identify and position the truck within the defined time. If trucks can enter the cranearea from both sides, the 3D sensor must be capable of recognizing the truck at a distanceof 20 m. This distance (15 m or 20 m) is represented by the variable "Direction".


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Figure 3-4 3D analysis

In the diagram above, the scan range of the 3D sensor is shown in red. The z axis describesthe mounting height of the 3D sensor (14 m). The x axis extends along the lanes at groundlevel. The coverage calculation (see Coverage calculation(Page 24) ) may have determined,for example, that the laser can cover a total of seven lanes to the left and right of itsmounting position. However, the 3D distance calculation now needs to ascertain whether the3D sensor can read far enough forward and backward along the x axis on each lane to beable to detect trucks in good time. In this example, it would take the 3D sensor too long todetect the full profile of the two trucks on the outermost lanes. It is the function of the 3Ddistance calculation to check this range of the laser.

The following two formulas are applied to calculate the 3D distance. The variable"MaskedLanes" is obtained from the coverage calculation (see Coverage calculation(Page 24)). It is used in the 3D distance calculation.

If the value calculated for variable "Distance" is < 30 m, then the variable "MaskedLanes"obtained previously from the coverage calculation is the final result.

If, however, the value calculated for the variable "Distance" is > 30 m, it is outside thetolerance range. In such cases, the number of lanes monitored ("MaskedLanes" variable)needs to be reduced. Keep reducing the variable "MaskedLanes" by 1 until you get a result< 30 for "Distance".


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The result in the variable "MaskedLanes" specifies the number of lanes which can be coveredby one 3D sensor. This can be used as the basis for calculating how many 3D sensors areneeded to cover a particular number of lanes.

3.2.3

Calibration

For calibration (see How it works(Page 21)), the angle of incidence and the distancebetween the laser beam of the outer 3D sensor and the crane foot opposite are key factors.The greater the distance, the better the laser beam needs to be reflected. Reflectivity isdependent on the color of the crane or, to be more precise, on the color of the crane surfacewhich the laser beam scans to self-calibrate. In cases where the color needs to be changed,it is necessary to repaint only the inside faces of the crane uprights and only at the height atwhich the laser beam hits the uprights.

The calibration process references either the positions of the sill beams (beams alongsidethe lanes) or the crane feet. The following formula is used to calculate the distance betweenthe laser and crane upright (LaserPosition) at sill beam (Sillbeam) height:

SICK has published a table in compliance with Kodak standard in which a remission value isassigned to each color. The brighter a color, the better the laser beam is reflected and thusthe better the remission value. The greater the distance between the crane upright and 3Dsensor, therefore, the better the remission value must be.

Table 3- 1 Crane colors

Distance between 3D sensor and crane

upright

Remission values Crane color

Up to 22 m 10 % Black or lighter

Up to 30 m 20 % Dark gray or lighter

Up to 52 m 55 % Light gray or lighter

> 52 m >55 % White

To ensure calibration is highly accurate, the distance values in this table are set at arelatively low level.


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3.2.4 Accuracy

The accuracy is calculated using the following formula:

The result specifies accuracy in cm. The complexity factor ranges from 1 to 2, where "1"indicates very good conditions and "2" very poor conditions in the cargo terminal. Theparameters for estimating the complexity factor are specifically the ground surface condition,environment, vehicle types and crane color. The better the surface condition of the ground,the clearer the air, the simpler the vehicle types and the brighter the crane color, the lowerthe complexity factor will be.

3.2.5

Calculating the number of 3D sensors in the example

The values needed to perform the calculation must also be entered in the "env" file.

Width of the lanes: 2.8 m

Distance between the lanes: 0.8 m

Mounting height of the 3D sensor: 14 m

Both directions: Yes

More than four vehicle types: No

Apply in formula for coverage calculation 2:

Coverage calculation 2 is selected because the laser is mounted at a height of 14 m and lessthan 4 different types of vehicle are employed in the cargo handling area. The coveragecalculation is performed with the formula for coverage calculation 2 (see above). In ourexample, the rounded intermediate result indicates that one 3D sensor will be able to cover

five lanes.Now perform the sample 3D distance calculation. Since we want vehicles to approach thecrane from both directions, the variable "Direction" is set to 20 m. We obtain a result of27.3 m. The distance is < 30 m and the intermediate result obtained from the coveragecalculation is therefore the end result, i.e. one 3D sensor can cover seven lanes. If this resultwere > 30 m, the variable "MaskedLanes" would be reduced by 1 and the 3D distancecalculation would have to be performed again.


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3.2.6 Number and positions of the 3D sensors

The table below defines the required quantity of 3D sensors as a function of the number of

lanes and the selection of single-spreader or tandem-spreader mode. The table alsospecifies the crane color based on the distance between the last 3D sensor and the oppositecrane upright at sill beam height (approximately 6 m).

The table below assumes a lane width of 3 meters and a distance between lanes of 0.8meters.

Table 3- 2 Number of 3D sensors

Number of 3D sensors forumber of lanes

1)

Single spreader Tandem

spreader

Distance

3D sensor > crane

upright

Crane color

4(14.4 m)

1 2 11 m Black or lighter

5(18.2 m)


6(22 m)


7(25.8 m)


8(29.6 m)


9(33.4 m)

2 - 23 m Black or lighter

10(37.2 m)

2 - 25.5 m Black or lighter

1) The values in brackets specify the operating range underneath the crane.

The values in this table provide the basis for determining how many 3D sensors arerequired. Please also take extreme weather and environmental conditions into account (e.g.sandstorms, heavy fog, high levels of air pollution). To incorporate these environmentalrequirements, it may be necessary to increase the number of 3D sensors or to reduce thenumber of lanes.

As the table above shows, two 3D sensors are needed for ten lanes in tandem-spreadermode, because one 3D sensor cannot scan two lanes at the same time. An alternative

method of reducing the number of 3D sensors would be to park trucks sequentially. In otherwords, they would be positioned under the crane one after the other, although this wouldslow the cargo handling process. The number of 3D sensors would then be calculated inexactly the same way as for single-spreader mode.


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Figure 3-5 Positions of the 3D sensors

The diagram above illustrates how 3D sensors can be positioned for ten lanes in single-spreader mode. 3D sensor ID0 covers lanes 6 to 10 and 3D sensor ID1 covers lanes 1 to 5.

As we have selected the option "Both directions," the 3D lasers can be mounted offset onthe front and rear portal beams to provide better cargo terminal coverage.


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4

Note

Before you start with actual installation: Check whether all required parts were included inthe scope of supply.

4.1

Assembly safety device lug

The 3D sensor is prevented from falling from its mounting position by a securing lug. A chainor a strong wire rope is fastened to the securing lug for this. The products should bedelivered with the securing lug already mounted on the side flange of the 3D sensor.

If the securing lug is supplied with the 3D sensor as a separate item:

Mount the securing lug on the 3D sensor as described in the installation guide of the 3Dsensor. Also observe the figures in Section Mounting the 2D laser scanner(Page 33).

4.2

Assembly swivel angle limitation

The 2D laser scanner features limit stops to protect it from mechanical damage. These limitstops prevent the laser scanner from accidentally exceeding the maximum swivel angle. thusensuring that the laser scanner's housing does not collide with the catwalks of the baseplate, which, if allowed to happen, could result in serious mechanical damage. If thepositions of these limit stops need to be changed, refer to the operating instructions for the3D sensor.

4.3

Mounting the 2D laser scanner

The 2D laser scanner device for the 3D sensor is delivered in a separate box and must bemounted on the swiveling unit's support plate. The scope of delivery includes screws (hexscrews M8 x 16) and washers which are suitable for attaching the scanner.


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4.4 Mounting the 3D sensor



A detailed description is provided in the manual supplied with the laser scanner by LaseGmbH.

NOTICE

Damage to the laser scanner

The maximum reach of screw on the scanner is 9 mm. If this maximum reach of screw isexceeded, the laser scanner will be damaged.


Figure 4-1 Mounted 3D sensor

The 3D sensors are designed for mounting on the inside of the crane's portal beam. A guideto determining the exact mounting location is given below. For mounting purposes, a supportplatform must be attached to the crane to hold the swiveling platform.

Note

Ensure that the laser scanner is mounted in the correct position in the swiveling unit. Theopening for the drying agent cartridge (see arrow) must be on the side facing away from themotor housing.


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Fixing points

The 3D sensor base plate features six fastening holes ( = 10.5 mm) for fixing the laser

scanner in position at the mounting location. The following figure shows the positions of thefastening holes on the base plate.

Figure 4-2 Mounting drawing for the 3D sensor

NOTICE

Safe mounting of the 3D sensor

Suitably strong stainless steel screws, e.g. M10 x 60-8.8, must be used to fix the 3Dsensor in position.

The mounting surface must be totally flat.

When mounting the 3D sensor, make sure that there are no obstacles blocking thepivoting range in any direction. You must observe a sufficient safety clearance aroundthe laser scanner's pivoting range.

Note

It is advisable to drill elongated fixing holes in the support platform so that it is easy to adjustthe mounting angle of the laser scanner in relation to the lane.


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Aligning the laser scanner

Please particularly observe the following when aligning the 2D laser scanner:

Mounting angle with respect to the lane

Mounting the weather protection hood

NOTICE

Damage to the laser scanner when mounting the weather protection hood

You must use the screws supplied to mount the weather protection hood.

The maximum reach of screw on the scanner is 9 mm. If this maximum reach of screwis exceeded, the laser scanner will be damaged.

Guarantee that the scanner can swivel freely Avoid any visual obstacles

CAN ID number (see label on the 3D sensor):

ID 16 for the 3D sensor on the land side

ID 17 for the 3D sensor on the water side


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Mounting the 3D sensor as close as possible to the center of the portal beamFigure 4-3 Diagrammatic representation of mounting a 3D sensor


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4.5 Sensor controller



4.5

Sensor controller

The sensor controller is designed for mounting either in a control cubicle in the switchgearroom or in a control cubicle in the checker cabin. In any case, the components of the sensorcontroller should be installed in close proximity, that is, in the same control cubicle. Tominimize the lengths of the connecting cables to the 3D sensors, it is best to install thesensor controller in a cubicle as close as possible to the 3D sensors.

4.5.1

Mounting positions

NOTICE

Safe mounting of the sensor controller

The sensor controller is approved for operation in closed rooms only.

Minimum clearances to other components or the walls of a housing must be maintained

in order to ensure adequate ventilation of the sensor controller: downward: Minimum, 100 mm

upward: Minimum, 50 mm

Failure to observe these minimum clearances can cause overheating of the sensorcontroller.

Mounting position Permitted temperatures

Horizontal (preferred position)

Operation with hard disk:

with up to 3 expansion modules(max. load 9 W): +5 to +40C

Operation with CompactFlash card and/or SSD:

with up to 3 expansion modules(max. load 9 W): 0 to +45C

with up to 3 expansion modules(max. load 9 W) in RAL*: 0 to +50C

Operation with Compact Flash cards:

without expansion modules in RAL*: 0 to +55C


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Mounting position Permitted temperatures

Vertical (power supply at the top)Operation with hard disk:


Operation with CompactFlash card:

Without expansion modules: 0 to +45C





Note

:When mounted on a DIN rail, the device should be secured toprevent shifting (e.g. with a DIN rail ground terminal).

Suspended

Operation with CompactFlash card and/or SSD and withoutexpansion modules:0 to +40C

Note

:Mounting brackets are required if the device is suspended.

Upright mounting

Operation with hard disk:


Operation with CompactFlash card:

Without expansion modules: 0 to +45C





*RAL= Restricted Access Location(installation of device in operating facilities with restricted access, for example, a locked controlcabinet)


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4.5.2 Types of installation

The SIMOCRANE sensor controller can be mounted on DIN rails, with mounting brackets

and in an upright position (portrait installation).

Mounting on DIN rails

1 Set the device inclined on the upper DIN rail.

2 Swing the device fully onto the rails until bothclamps completely latch.


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Wall mounting (on mounting brackets)

1 Remove the four screws and the two mountingclamps from the back of the device.

2 Install two mounting brackets with eight oval-head screws on the device (mounting brackets andscrews are included in the accessory kit).

Note

Examples for mounting and materials can be found in the operation instructions.

Note

Information on portrait installation is available in the supplement of the mountingaccessories.


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5

This chapter describes the electrical connections of all system components. The powersupply connection and data interface connections are explained in separate subchapters.Diagrams of connector pin assignments show the terminal end of the connector. "Terminalend" in this case means the side on which cables are attached to the connector.

Recommended cable types

Power supply cable 2 x 0.75 to 2.5 mm Ethernet connecting cable, CAT 5 or higher Cable for connection between RS 422 and 2D laser scanner

Recommended: UNITRONIC Li2YCY (TP) 3 x 2 x 0.5

Cable for connection between CAN and 3D sensorRecommended: UNITRONIC BUS CAN UL/CSA 2 x 2 x 0.5 Power supply cable to the 3D laser scanner

Recommended: lflexClassic 110 CY 7 x 4 mm

Figure 5-1 Diagrammatic representation of the electrical installation of a SIMOCRANE TPS system

Note

The connection cables are not part of the scope of supply!


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5.1 Power supply



5.1

Power supply

Two different voltages are required to supply power to the individual components of theTruck Positioning System. Power supply units with the following voltage and current supplycapacity values must be installed in the control cubicle for this purpose:

Voltage Permitted deviation Current

demand

Device

Sensor controller

2D laser scanner (electronic circuits)

24 V DCelectronics

3%,max. 0.5 V ripple

4 A

Servo motor (electronic circuits)

24 V DC heating max. 6 V ripple 6 A 2D laser scanner (heater)

48 V DC 3% 30 A Servo motor (drive)

The elecctronics connections for the laser scanner and the servo motor converge in thehousing of the 3D sensor and do not have to be connected separately. This line requires ahigh-quality, stabilized power supply unit with low ripple. We recommend one of the unitsfrom the Siemens SITOP series.

Connect the 24 VDC and 48 VDC power supplies as shown in the figure below.

Note

When connecting the 24 V DC and 48 V DC power supplies, do not ground the negativeterminal on the infeed side; the resulting ground loop would cause faults to occur in theoperating sequence.

Figure 5-2 24 VDC and 48 VDC infeeds


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5.1 Power supply



Note

When dimensioning safety equipment (fuses, circuit-protective devices), please ensure thatthe rated output, response characteristics and selectivity comply with local safetyregulations.

Note

When installing and connecting up the power supply cables, please select suitable cables(i.e. cable type and cross section) and an installation method which complies with localsafety regulations.

5.1.1 3D sensor

The 3D sensor power supply cables need to be assembled. We recommend a 7 x 4 mmshielded power supply cable. Harting Han 6 HsB sockets are provided on the scanner. Werecommend the use of screw-type terminal strips at the control cubicle end.

Pin assignments for the 3D sensor power supply

L+ servo motor (48 V) M electronics (24 V) M servo motor (48 V) L+ laser heater (24 V) L+ electronics (24 V) M laser heater (24 V)

Connector type for connecting the power supply to the 3D sensor:

Insert: Harting Han 6 HsB

Housing: Harting Han 16B gs M32

This set is supplied as standard with the 3D sensor. Replacements or alternative housingsare available from:HARTING Deutschland GmbH & Co. KG, P.O. Box 2451, D - 32381 Minden, Germanywww.harting-connectivity-networks.de/


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5.1 Power supply



5.1.2 SIMOCRANE sensor controller

5.1.2.1

Connection elements

COM3 Serial interface (RS422) 9-pin SUB-D connection; for connecting 3Dsensor ID0

COM4 Serial interface (RS422) 9-pin SUB-D connection; for connecting 3Dsensor ID1

CAN fieldbus 0 9-pin CAN fieldbus SUB-D connection; for connecting servo motors CAN fieldbus 1 9-pin CAN fieldbus SUB-D connection; for connecting servo motors

PROFIBUS DP/MPI PROFIBUS DP/MPI interface (RS485, electrically isolated), 9-pin SUB-Dsocket.

Industrial Ethernet RJ45 Ethernet connection 2 (shared PCI interrupt) for 10/100/1000Mbps.(Interface for service and commissioning, default address IP192.168.2.141; if possible, do not change the default address of Ethernetconnection 2.)

COM1 Serial interface (RS232) 9-pin SUB-D connector Industrial Ethernet RJ45 Ethernet connection 1 (exclusive PCI interrupt) for 10/100/1000

Mbps.(communication interface; default address IP 192.168.1.140)

Note:The IP address of Ethernet connection 1 and 2 must be in differentsubnets (service interface; see ); must be adapted to the presentnetwork configuration, if necessary.)

USB 4 x USB 2.0 connection (high speed, low current) DVI/VGA DVI/VGA connection for CRT or LCD screen with DVI interface PE terminal The PE terminal (M4 thread) must be connected to the protective ground

of the system in which the device is to be operated. The wire cross-section must be at least 2.5 mm2.

24 V DC Connection for 24 V DC power supply


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5.1 Power supply



5.1.2.2 On/Off switch

CAUTION

The On/Off switch does not disconnect the device from the supply voltage.

Position of on/off switch Pos Description

The on/off switch turns off the outputvoltages of the power supply but notdisconnect from the supply system.

The delivery condition is:

On/Off switch turned off.

5.1.2.3

Connecting the 24 V DC power supply

To be noted before you connect the device

The following regulations must be observed to ensure safe operation of the sensor controller:

WARNING

The device should only be connected to a 24V DC power supply which satisfies therequirements of safe extra low voltage (SELV). A low power source (LPS) or a line-sidefuse or line-side circuit-breaker is required. The power needs to be limited to a value below4.16 A. The fuse value required: Max. 4 A.

Use the special plug supplied to connect the supply voltage. Connect the PE conductors asdescribed in the next section.

Note

The permitted wire cross-section for the 24 V DC connection is 0.75 mm2 to 2.5 mm2.

Note

If a CompactFlash card is used in the device, make sure that the card is seated correctlybefore you connect it.


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5.1 Power supply



Note

To protect the hard disk from damage, we recommend supplying the sensor controller with

power by means of a 24 V UPS (uninterruptible power supply). This will allow the sensorcontroller to be shut down properly in the event of a power failure.

Connecting

1. Switch off the 24 V DC power source.

2. Connect the power supply using the plug (included in the scope of delivery).

3. Connect the PE conductor.

5.1.2.4 Connection for equipotential bonding

NOTICE

Equipotential bonding required

Equipotential bonding between two spatially separated plant parts can lead to highequalizing currents via external power supply cable, signal cable or cable to peripheralsand destroy their interfaces.

To protect the device, an equipotential bonding line is required to discharge equalizing

currents between device and cabinet or system in which the device is installed. Theminimum cross-section of the equipotential bonding line is 2.5 mm2.

Required tool: TORX T20 screwdriver.

PE terminal

1.

Connect the PE terminal (M4thread) on the device with large-area contact to the equipotentialbonding line. The minimum cross-section of the equipotential bonding

line is 2.5 mm2.2.

Connect the equipotential bondingline with large-area contact to theprotective ground conductor of thecabinet or the plant in which thedevice is to be installed.


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5.2 Data interfaces



5.2

Data interfaces

Note

When installing and connecting up data transmission cables, please observe the appropriaterequirements and recommendations defined in the transmission standard with respect tocable type and properties, installation method and permissible cable length.

5.2.1

3D sensor

The data cables must be pre-assembled for connection to the 3D sensors. Sockets of type

Harting Han 16E-F-s are provided on the device; we recommend the use of screw-typeterminal strips at the control cubicle end. We strongly recommend the use of three separatecables for CAN IN, CAN OUT, and RS 422 at the scanner end.

Recommended cable types

As a bus medium, we recommend twisted pair cables in accordance with ISO 11898-2(High-Speed Medium Access Unit), with an impedance of 108 to 132 ohms, e.g.

CAN bus UNITRONIC BUS CAN UL/CSA 2 x 2 x 0.5.

RS4222 UNITRONIC Li2YCY (TP) 3 x 2 x 0.5.

Both types are available from:

U.I. LAPP GmbH, Schulze-Delitzsch-Strasse 25, 70565 Stuttgart, Germanywww.lappkabel.de


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5.2 Data interfaces



Pin assignments for the 3D sensor data cables

CAN L IN(from the sensor controller or from pin 9 ofanother 3D sensor)

CAN L OUT(connection to an additional 3D sensor)

CAN H IN(from the sensor controller or from pin 10 ofanother 3D sensor)

CAN H OUT(connection to an additional 3D sensor)

RS 422 RxD + RS 422 RxD - RS 422 TxD + RS 422 TxD - RS 422 shield Reserved Reserved Reserved Reserved Reserved CAN shield / CAN GND Reserved

Connector type for connecting the data cables to the 3D sensor:

Insert: Harting Han 16E-Fs

Housing: Harting Han 16B gs M32

This set is supplied as standard with the 3D sensor. Replacements or alternative housingsare available from:

HARTING Deutschland GmbH & Co. KG, P.O. Box 2451, D - 32381 Minden, Germanywww.harting-connectivity-networks.de/

5.2.2

CAN interface

The CAN bus is operated at a transmission speed of 250 kbit / s. According to the relevantstandard, this means a maximum permissible cable length of 250 m under idealenvironmental conditions (no sources of interference). It is absolutely essentia

Documents

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