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Crane Control System by Visual Language Programming

1. Preface
A crane control system has been formed with a programmable logic controller (PLC) as the main control system, and the control logic has been described by ladder programming language. To decode this ladder programming language, crane users had to master the programming language for each PLC, and it was difficult to understand the complicated numerical operation by ladder diagrams. To solve these problems, we have adopted a visual language system for mechanical control allowing control logic to be described easily by visual programming language, and, using a control microcomputer, developed an advanced crane control system incorporating an increased decoding capability of the control logic and the conventional crane control know-how. In this technical review, this crane control system is introduced specifically. processing logic specific to the device can be described by C language, to a graphic as the element function of FBD. In order to construct an advanced control logic, a function capable of preparing a function by C language is useful. Fig. 1 shows a comparison, in ladder language, of the same logic between FBD specimens. The FBD connects signals using logic elements and numerical calculation elements such as AND and OR to show intended logic and numeral calculations graphically. As a result, it is easy to visually understand the content of the logic, and, therefore, suitable for expression of a mechanical control logic. On the other hand, the ladder language is described by an expression such as an electric circuit where contact signals are connected in series and in parallel with each other which, therefore, makes it easier to visually understand the content of logic when compared to the visual programming language. Particularly, the FBD is far more suitable for the expression of block diagrams and numeral calculations, such as for the feedback control system, than ladder diagrams. Fig. 2 shows the specimens of SFC. The SFC expresses sequential order control as a state transition diagram. According to the transition conditions, the control state is moved from an upper

2. Purpose of the crane control system by visual language programming


The purpose of this crane control system is to present a control program with an increased decoding capability using visual language programming so as to increase the maintainability of crane control at the end user, and contribute to a reduction in maintenance time. An additional purpose is to increase efficiency of the development of software by visual language programming capable of easily performing logic verification so as to advance crane control function using a unique advanced control logic. This technical review introduces the following: (1) Increase in visibility of crane interlock logic (2) Visualization of Anti sway control logic (3) Advancement of the lifting load weight calculation function (4) Development of variable acceleration control (increase in speed)

Reversal element LD Operation stop button LD Operation permitted LD Operation start button FBD Operation start button Operation Operation permitted stop button Operation instruction AN D R S Set / O
R eset

Flip-flop O R

LD

3. Outline of visual language programming system


The visual language programming system used for the development of the crane control system was developed by us as a programming development support tool specifically for mechanical control so as to increase the productivity and reliability of the software. This visual language programming system can draw graphics on drawings to express a control logic that generates the control program automatically from the drawn information. It also has a function to monitor, in real time, the status of execution of the control logic on the prepared drawing and, on this logic monitoring screen, perform a change in parameter setting and forced ON/OFF of signals for efficient logic verification. There are two graphic drawing configurations: FBD (Functional Block Diagram) and SFC (Sequential Function Chart). In this system, some functions required for mechanical control are incorporated as various types of element functions. Also in this visual language programming system, a

Operation instruction

Ladder programming language

Fig. 1 Sample of Functional Block Diagram


This shows the samples of FBD used in the visual language programming system.

Table 1 Specifications of Container Crane Main Drives


Drive Hoisting Trolley traveling Boom hoisting Gantry traveling Rated power kWj i 400 x 2 units 210 x 1 unit 220 x 1 unit 22 x 8 units Rated speed m/minj i 80/160 210 64 45

step to a lower step. This visual language programming system features transition condition logic that can be described, by FBD, directly in the same sheet describing the SFC. In the SFC step, a lower macro can be described, and special processing can be described in that state. Also, because this visual language programming system allows a multi-task control configuration, the control system can be configured with a plurality of control tasks with different control frequencies and priorities. In addition, it has a function indispensable to promoting advancement of the control function.

through a master PLC and a communication link. The master PLC functions also as the I/O device connected to each control device. The self-developed control microcomputer and master PLC, as main control devices, are connected to each other through Ethernet communication, and all crane controls are processed on the control microcomputer side. With this system configuration, the crane control logic forming the core of the system configuration can be standardized without depending upon the main drive system. Figure 4 shows the appearance of the control microcomputer and of the visual language programming system development computer.

4. Configuration of crane control system


4.1 Specifications of applicable crane The control system was configured for a large-sized container crane with the drive specifications shown in Table 1. 4.2 Configuration of control system The system configuration of the crane control system operated by visual language programming is shown in Fig. 3. The input/output data necessary for control is communicated
St ar t State step Transits to a lower macro when the state transition condition 1 is ON.

5. Features of control software by visual language programming


5.1 Increase in visibility of crane interlock logic For the development of logic, an increase in the visibility of crane interlock logic was positioned to be an important theme linked directly to an increase in maintainability of crane control. Crane interlock logic is normally requested to perform complicated processing such as when all drives are stopped urgently according to an interlock level, only an individual drive is stopped urgently, or all drives are stopped normally or decelerated forcibly. Therefore, as shown in Fig. 5, interlock processing logic was configured in a tree structure so that the crane interlock structure could be visual-tracked easily. In Fig. 5, each tree portion of the tree structure shows each interlock detection section, and the trunk portion shows the operationpermissible signals obtained by collecting these interlock signals or those related to an emergency stop. In the actual verification of logic for crane interlocks, the interlock detect position at the end was followed visually by tracing back the tree. As a result, the logic verification, which was difficult for those other than software developers, could be performed easily by merely learning monitor operation. 5.2 Visualization of Anti sway control program on drawing A container crane adopts an electric anti sway control for controlling the swing of a lifting container by changing the trolley traveling speed automatically during the trolley

ST1 LD Transition condition 1

Macro

M 10 LD Transition condition 1

M 11 ST Transition condition

ST

ST

ST2 Transition condition ST M 11 SFC

EN D

Fig. 2 Sample of Sequential Function Chart


This shows the sample of SFC used in the visual language programming system.

Ethernet communication Master PLC Visual language programming PC Control microcomputer Communication link Remote PLC

Hoist No. 1/ Gantry travel (Land side) drive

Hoist No. 2/ Trolley ravel/ Gantry travel Boom hoist (Sea side) drive drive

Fig. 3 Control System Configuration


This shows the control system configuration of a crane on which the visual language programming system is mounted.

Fig. 4 Picture of Micro Computer and Visual Language Programming PC


This shows the appearance of a crane control micro computer and a PC for preparing a visual language program.

Hoist speed LD Interlock bypass LD Master I/L flag 1 LD Master I/L flag 2 O R AN D LD Common master permission flag Top speed Calculation end Calculation start Base speed

LD Master I/L flag n LD Hoist master I/L flag n LD

O R Common master permission flag generating section O R Hoist torque Hoist master permission flag generating section Hoist operation permission flag generating section Hoist acceleration V

Time

Top speed V Load calculation function M Lifting load weight M Top speed setting function

Common master permission flag

Fig. 5 Logic Configuration of Crane Interlocks


This specifically shows the logic of crane interlocks graphically.

Fig. 6 Block Diagram of the Load Weight Calculation


This shows the block configuration of the load calculation function.

movement operation. The anti sway control is formed of an optimum feedback control system which generates a trolley movement speed command by multiplying each of a number of stated amounts, such as trolley movement position, trolley movement speed, lifting rope length, load swing amount, and load swing speed by a control gain decided according to the intention of the control for these stated amounts. In addition to the anti sway control, the container crane incorporates multiple functions, such as a lane selective operation function to allow the crane to automatically reach a target lane, an instantaneous anti sway function to allow a swing to instantaneously stop automatically, and a fine positioning function to allow a fine-trolley movement to be performed while a swing stop is performed automatically. The anti sway control logics have been prepared using C language because they are formed of advanced calculations or complicated processing systems. The logic monitoring for anti sway control was very difficult for end users. To solve this problem, the anti sway control logic was visualized to re-construct a system capable of visually observing the control state of the anti sway control, which had been a black box. The system enabled the execution state of automatic control to be monitored in real time by the notation of transfer of the state by SFC and the notation of an optimum feedback control system. Then, the function of the system as the anti sway control maintenance tool could be improved remarkably. 5.3 Advancement of the lifting load calculation function The lifting load calculation is a calculation function to estimate, for calculation, the weight of a lifting load from the output torque of a hoist motor. Figure 6 shows the load calculation processing block diagram. Based on the estimated weight of a lifting load obtained by the load calculation, the maximum hoist speed a hoist motor is capable of outputting in a constant power control area is set in the diagram. Though

this technology has been used for container cranes, because a complicated calculation processing logic can be constructed easily with visual language programming, a more reliable load calculation logic reflecting long-time know-how on container crane control was constructed. In the lifting load calculation, if the calculated load is estimated lighter than the lifting load, the lifting load may fall, leading to a serious accident. In order to increase the reliability and accuracy of estimation for load calculation, the calculation logic was designed to satisfy the following requirements: (1) The lifting load calculation processing can meet even the requirement for variation in hoist acceleration. A hoist speed and torque state signal were sampled at high speeds and at regular intervals so as to realize a highly stable lifting load calculation. In the actual verification, a detection stability of approx. 2 ton could be obtained. (2) The lifting load calculation can be run again during a constant-speed operation. In the system, a logic was built which, during hoist operation at a constant speed, checks, for validity, the result of the lifting load calculation obtained during hoist acceleration operation and, when it judges that the speed is exceeded, lowers the target speed. In this way, even if it fails to calculate, load handling can be performed safely. 5.4 Development of variable acceleration control The variable acceleration control is a speed control system newly developed in the construction of this crane control system by visual language programming. The hoist speed command sets, as the target speed, the maximum hoist speed capable of being output in the hoist motor constant power control area according to a lifting load weight obtained from the above-mentioned result of the lifting load calculation. So far, even in the constant power control area, the system has been accelerated to the target speed at the same acceleration or deceleration as that between the

0. 5s 3 Top speed 2. 5 Speed@ m sj i / 2 1. 5 Base speed 1

acceleration control. The speed pattern shown with dotted lines is the conventional speed command, and the speed pattern for the newly developed variable acceleration control is shown with solid lines. Figure 7 shows that an acceleration time of 2.75 sec, required for an acceleration to be doubled, can be reduced to 2.25 sec by the variable acceleration control.

6. Results
0. 5 0 0. 5

1. 5

2. 5 Time@ sj i

3. 5

Fig. 7 Speed Pattern Diagram by Real-Time Calculation of Acceleration Following Motor Power Limit
This shows the speed pattern generated by variable acceleration control.

of zero and base speed. Because the area between 0 and base speed is a constant torque control area, a specified acceleration must be given in order to maintain load calculation accuracy. However, because the weight of a lifting load is a known physical amount when the load calculation is complete, it was noted that the speed and acceleration output performance of the hoist motor could be induced by a simple power balance expression. Then, when a speed command is generated, for speed control in the constant power control area, using the limit of hoist motor output performance, the acceleration and deceleration time can be reduced remarkably even by a motor of the same capacity. The variable acceleration control can calculate, in real-time, maximum possible acceleration using a power balance expression (1) for the hoist motor and lifting load immediately after the speed command comes to the constant power control area when the load calculation is complete, and can further generate the next instantaneous speed command using an expression (2). @ @ 1 Pm-MgVn-1/ @ @ a= @ @ Vn-1 ( )2GD2@ @ Vn = Vn-1 + aTs@ @ (1) (2)

With the introduction of the visual language programming system, an environment where control logic programming can be performed easily even by those persons other than software engineers was created. In this environment, longtime accumulated know-how on crane control technologies was reflected in the visual language programming, and a control system having specific features, such as advanced load calculation function and variable acceleration control, could be constructed. For preparation of control logic, visual programming describing method was studied sufficiently before programming, and, therefore, a program capable of being visually understood easily could be configured. The visual recognizing capability of the newly developed visual language programming system could be increased remarkably over that of the control program by ladder programming language. As a result, the trial operation and adjustment period could be shortened in the actual verification.

7. Summary
With the adoption of the visual language programming system, visual recognizing capability could be increased remarkably over that of the conventional control program by ladder programming language. Thus, the function of the control program as a maintenance tool could be increased remarkably by an increase in efficiency of verification of control logic. Also, long-time accumulated knowhow on crane control technologies was reflected, the function for load calculation was advanced, and a new speed control method was assembled for construction of the visual language programming control logic. As a result, the function of the crane control could be advanced. These results could be realized by fully utilizing the advantages of visual language programming. The container crane control system by the newly developed visual language programming will be improved further with every effort. In addition, the application of the system to cranes other than container cranes is presently being promoted. In the future, we would like to cultivate this system as a standard system for crane control. References: (1) Nishizaki, et al: Increase in productivity and reliability of software by visual language programming of control logic, Mitsubishi Heavy Industries, Ltd. Technical Review Vol. 36, No. 2 (1999) P. 58

Where, Pm: Motor max. power M: Lifting load weight (result of load calculation) GD2: Comprehensive inertia of device Comprehensive mechanical efficiency of device (in hoist up) : (inverse number in hoist down) : Number of rotations (rps)/speed (m/s) g: Gravity a: Limit of acceleration capable of being output by motor V: Current speed command value Vn: Speed command value in the next control frequency Ts: Control frequency Figure 7 shows the chart for hoist operation by variable

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