Design of a Quay Crane Training Simulator

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Design of a Quay Crane Training Simulator

Degree project

Author: Boyang Chen, Mingyi Xu

Supervisor: Göran Ewing, Pieternella Cijvat

Examiner: Pieternella Cijvat Date: 15-06-2015

Course code: 2ED14E, 15hp Topic: Electrical Engineering Level: Bachelor of Science

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Summary

This thesis describes the whole process of crane training simulator designing. First the console control system scheme was made based on the functions of the crane training simulator. A PLC was chosen to achieve the goal of controlling the system. Secondly we decided to use a Siemens PLC S7-300 to evaluate the amount of inputs and outputs. Thirdly the functions were analyzed which the crane training simulator needs. Then the amount of inputs and outputs were counted and an I/O address distribution table was made. Next programming with the software STEP7 was done.

The result was shown in a watch table for every function with the software S7-PLCSIM. A simplified experiment was finally done with the S7-200 unit and an HMI unit. The limit of the project is that we didn’t make a full-scale physical demonstration due to equipment and economy reasons.

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Abstract

Nowadays, port enterprises pay more attention to train operators of heavy machinery, by mean of a simulator. An example is a quay crane training simulator. A perfect control simulator system can achieve the function of crane training better, make it more perfect, improve the efficiency of training operators and enhance the port management. This will promote the development of the port. This thesis mainly focuses on PLC implementation of a simulator system. The logical relationship between buttons on the console and input and output signals are presented and the information exchange between seat console and computer is achieved by programming with PLC.

Keywords: Quay crane, Training simulator, Control system, PLC, Seat console, Programming.

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Preface

This project is made within the framework of the innovation project we have in Shanghai Maritime university. We make it a more complete base on the framework, but the project still have a limit that we don’t make it a perfect physical stuff. But we have tried our best in the experiment of PLC S7-200, hope to do more physical connection with PLC. We deeply appreciate our

supervisor Göran Ewing’s support, all the experiment is under your help. Thanks to our supervisor Ellie Cijvat, giving us a lot of help with the report and design, your patient comment make this project more complete and logical.

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S u m m a r y . . . .

I I I

A b s t r a c t . . . I V P r e f a c e . . . V T a b l e o f C o n t e n t s . . . V I I 1. Introduction

1 . 1 P r o b l e m s t a t e m e n t . . . 1 1 . 2 P r o b l e m b a c k g r o u n d . . . 1 1 . 3 A i m o f t h e w o r k . . . 1

2. Crane simulator system

2 . 1 D e s c r i p t i o n o f a q u a y c r a n e . . . 3 2 . 2 D e s c r i p t i o n o f a q u a y c r a n e t r a i n i n g s i m u l a t o r. . . 5

3. M a t h e m a t i c a l m o d e l o f a q u a y c r a n e . . . .

1 7

4. PLC signal acquisition setup

4 . 1 C h o i c e o f P L C m o d e l . . . 2 1 4 . 2 I / O a d d r e s s d i s t r i b u t i o n . . . 2 1

5. Implementation and experiment

5 . 1 P r o g r a m m i n g . . . 2 5 5 . 2 S i m u l a t i o n o n s o f t w a r e . . . 2 6 5 . 3 E x p e r i m e n t w i t h P L C S 7 - 2 0 0 . . . 2 8

6 . D i s c u s s i o n a n d c o n c l u s i o n . . . .

3 3

7 . R e f e r e n c e s . . . .

3 5

A p p e n d i x . . . .

. 3 7

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1 . F u n c t i o n s o f t h e o p e r a t i o n p a n e l . . . 3 8 2 . I n p u t I / O a d d r e s s d i s t r i b u t i o n . . . 4 7 3 . O u t p u t I / O a d d r e s s d i s t r i b u t i o n . . . 5 4 4 . M a d d r e s s d i s t r i b u t i o n . . . 5 7 5 . T h e f u l l i n s t r u c t i o n . . . 6 2

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1 Introduction

1.1 Problem statement

To meet the needs for the continued rapid development of China’s port economy, the throughput of container ports are growing. Newer and higher requirements on the process of container port handling and container handling technology and equipment are enforced. Port container lifting equipment is developing towards the direction of high-speed, large-scale and automated direction. Training for operators has become increasingly important in that the cost of port container equipment is getting higher. The technical proficiency of operators plays a decisive role in safety, equipment service life and economic benefits of the port. Container cranes simulation training systems based on virtual reality have widely been used in many countries, as they have the advantages of safety, cost saving, better function and high training efficiency. Thus, it is of vital importance to research and develop the container crane training simulator that is in line with China’s national conditions and with independent intellectual property rights.

1.2 Background

Nowadays, a quay crane is the main equipment for loading the cargo of the containers. The ability and speed it works at have a direct relation to the port economy. With the development of overseas shipping trade and port trade, the amount of cargo becomes larger. So the crane needs to be larger and high-speed. A more safe and high efficiency training method is needed urgently. As a result, training simulator is becoming popular. It is a system which contains dynamics simulation technology, real-time 3D visual simulation technology, sensor and control technology, computer interface and communication technology, artificial intelligence and knowledge engineering. It is safe, high-efficiency and low cost,booming.

1.3 Aim of the work

The aim of the project is to describe a crane training simulator system and implement a program for signal acquisition and processing with PLC, building the control system for a quay crane training simulator. The program is implemented using a Siemens S7-PLC. More over a simplified program is implemented using an S7-200 unit and evaluated.

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2. Crane simulator system 2 .1 Description of a quay crane

A quay crane is a specialized kind of crane which is used to load and unload containers in front of the container terminal. There are thousands of quay crane in the world, these quay cranes have different appearance because of suppliers. The most common quay crane is made up with a door frame, tension member and bridges supported by the gantry. A trolley moves along the track on the beam, loading the containers by using a technical spreader. The gantry moves parallel to the shoreline so as to be easier to calibrate the lifting position and container position. For the convenience of the ship to moor and leave the dock, the part of the bridge which is out of shoreline can do the pitching movement up and down. There are several types of quay crane according to different classification methods, see the table below.

Table 1. Quay crane classification.

Quay crane

Main beam structure Single box-girder bridge structure Twin box-girder bridge structure Plate girder and truss structure Truss structure

Trolley shape Loading trolley Self propelled trolley Used trailed trolley Height restriction Pitching main beam

Stretching main beam Bending main beam Trolley work mode Single trolley

Twin trolleys

Double 40-inch single trolley

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Figure 2.1 A quay crane of gantry crane

The main steps of unloading containers

Typical steps performed when loading or unloading containers are: [2]

(1) Before the cargo ship mooring, move the quay crane along the track to the quay line.

(2) After the cargo ship mooring, move the quay crane to the accurate place.

(3) According to the cargo situation, move the trolley along the track to above the container which is going to be unloaded, put the spreader off.

Double 40-inch twin trolleys Type of cargo ship Panama quay crane

Post-panama quay crane

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(4) Make sure that the spreader and the container have been locked, lift the container on the ship.

(5) Move the trolley to the land along the track, hang the containers directly to the transport machine (such as a container truck)

(6) Detach the spreader and container.

(7) Lift up the spreader, move the trolley to the seaside. This is an unloading circle, again and again until all the containers have been unloaded.

Figure 2.2 Crane unloading sketch

2.2 Description of a crane training simulator

It is important that all steps can be performed in a training simulator, with an experience as close to real work as possible. A crane training simulator is based on virtual reality. It is a system which contains dynamics simulation technology, real-time 3D visual simulation technology, sensor and control technology, computer interface and communication technology, artificial intelligence and knowledge engineering. It is for training the operators to be familiar with the crane.

The PLC control system is the main focus of this work and will be discussed further in chapter 3. The cab system, providing the inputs to the PLC system, and the mathematical model will be briefly described below.

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Structure of a crane training simulator

A quay crane training simulator may be made up with the following modules Cab System

Instructor Station Control System 3D Imaging Visual System Dynamic Mathematical Model Motor Drive

PLC Control System Video System

Teaching Projection System Network Communication System

Trainee

Vision

Sound

Seat vibration

Instructor Station Control System including Mathematical Model

Instructor Cab operating

console

Signal acquisition PLC

Teaching Projection System

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The training system can be represented as shown in figure 2.3

*the PLC control system is responsible for the signal acquisition and mathematical model. ?

*3D Imaging Visual System is responsible for the vision.

*Network Communication System is for the connection between the models as well as communication between instructor and trainee..

*Dynamic Mathematical Model is the mathematical description of crane movement including containers movement and spreader movement and so on.

*Teaching projection system is the guide showed on the screen which can help the trainee to be familiar with the operation.

2.2.2 Cab System

The cab system includes Operation Console, Seat Simulation Vibration System, Windows system, Indoor Video System and interior Photographic Surveillance System.

The simulator works through the virtual environment, the result of controlling the visual system and sound system. The PLC need to collect signals from the switches, input signal buttons. It also sends output signals to go through the address Q to guiding lights and buzzers at the panel directly. Other output signals need to go through the address M to communicate with the PC, to control the visual environment system and sound system for the corresponding action.

The PC also needs some of the signals. These signals come through the PROFIBUS cable from the PLC to simulate the operating process of the various conditions and the current state of the crane, to achieve the effect of the simulation of real work.

As for this project, the PLC program is programmed on Step-7.

The cab simulation environment is shown in figure 2.4.

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Figure 2.4 Structure of the PLC system

Vision software communicates with PLC access OPC server.

Address：I For collecting all input

signals from panel

Address：M Use to communicate to

OPC server on PC

Address：Q For collecting all output

signals to panel

Input signals from panel such as buttons

Input signals to panel such as light,buzzer.

PROFIBUS cable

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Figure 2.5 Cab system of a training simulator

The crane seat has two operating panels, one on the left side of the seat and the other is on the right side.

The layouts of these panels are shown in the figures below.

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Figure 2.6 Right operation panel.

The button functions of the right panel from left to right are:

Row1: Unlock, lock (switch); stop (knob)

Row2: Guide plate rise or down (switch) ; relative position of two spreader (switch)

Row3: Overload ( light); overload alarm ( light); emergency stop (light)

Row4: Control connect (light+self reset button); anchor rise in high wind (light+self reset button); gantry anchor rise ( light+self reset button); wind speed 30m/s (light)

Row5: On or off (two way switch); spreader pump on (light+self hold button); wind speed 20m/s (light)

Row6: Head block cylinder manual rise or down (self reset button); head block cylinder choose left ,all or right (three way switch); automatic adjust (self reset button)

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Row7: Spreader reset position1 (self reset button); position2 (self reset button); spreader position set position1,stop or position2 (three way switch); spreader anchor choose seaside, stop or land side (three way switch);

Row8: Silencing (self reset button); electrical fault (light)

Row9: Beam move allowed (light+self reset button); beam stop moving (light+self reset button); beam goes up (light+self reset button); beam goes down (light+self reset button)

Figure 2.7 Left operation panel.

The button functions of the left panel from left to right are:

Row1: Seaside left guide plate (light+self hold button); seaside right guide plate (light+self hold button);

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Row2: Land side left guide plate (light+self hold button); land side right guide plate (light+self hold button);

Row3: Boom movement allowed (light+self reset button)

Row4: Trolley automatic stop (light+self reset button); trolley stop (light+self reset button);

Row5: 20 feet (light+self hold button); 40 feet (light+self hold button); 45feet (light+self hold button);

2×20feet (light+self hold button);

Row6: Van or trailer (two way switch); hook or spreader (two way switch); Lock shrink (self reset button); lock stretch (self reset button);

Row7:Lock memory stop or automatic or manual (three way switch);Seaside lock position set (light+self reset button); land side lock position set (light+self reset button);

Row8: Spreader choose sea, all or land (three way switch); head block pump on or off (self hold button);

head block cylinder stretch, stop or shrink (three way switch);

Row9: Spreader link (self reset button); spreader detach (self reset button); head block connect automatic or manual (two way switch).

2.2.3 Cab console units

The following units are present on the operation console:

Push buttons

Guiding light: Give information to the trainee about what is going on, red, yellow, green are available.

Self reset button: The button will reset after pressing.

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Two-way or three-way switch

Maximal contact load: 24VDC-2A.

Minimal contact load: 5VDC-1mA.

Figure 2.8 Joystick.

A four-way joystick is used to start, control the speed and rotating direction of crane motors, to control different crane motors simultaneously. The joysticks on the right operation panel and the left panel are the same kind of joystick shows in figure 2.8. The one on the right panel is a single axis joystick which controls the movement of trolley.

The one on the left panel is a dual axis joystick. Its X axis represents the movement of the gantry and its Y axis represents the up and down movement of the spreader.

Working conditions :

- Rated supply frequency AC 50Hz (60Hz) - Rated voltage 380V (440V) or lower

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Comfort seat, mechanical suspension with weight adjustment. 50-130kg with height adjustment 0-30-60-80-mm.

2.2.4 Cab operation panel functions

The table below shows the functions of the operation panel. The full table is in shown in appendix 1.

For example, when the overload is more than 100%, the red overload light will turn on and the trainee can see that light on the right operation panel. It is an output.

When the trainee chooses spreader reset position1 on the right operation panel, an input signal is sent to the PC.

Table 2. Some of the function of the operation panel.

Name Type of signal Function Descriptions

General

control

Power switch

DI

(Digital signal input)

Control power

Control

connect DI Controller is connected

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Light of connection

DO

(Digital signal output)

Light of connection turns on

Emergency

stop DI Stop every processes

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3 Mathematical model of a quay crane

As an illustration of crane movement, a simple model for two dimensions is presented here.[3] The model used in the simulator is more complicated, but is outside the scope of this thesis.

Figure 3.1 A 2-D model of the crane.

M is the mass of the trolley, m is the mass of the container. The length of the cable carrying the container is L. X is the position of the trolley.

According to the actual condition of the crane, it has the following assumptions:

(1) The displacement of the crane is ignored.

(2) The air resistance is ignored.

(3) The weight of the steel cable is ignored.

(4) The rotation of the container is ignored.

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From the force diagram we can get the two equations below.



 

















 sin cos

cos )

(

..

2 . . ..

..

g l x

x u F ml ml

x m M

Here F is the force in the direction of X and g is gravity. u is the friction of the trolley wheels.

Usually



is smaller than in 5^this model. So

cos   1

,

sin   

, and we can get









 











MlF Ml

g M x m

Ml u

M F M

x mg M x u

1 )

(

1

..



Transfer the equations to state-space representation



 











) ( ) ( ) ( ) ( ) (

.

t u t D t x t C t y

t u t B t x t A t x

] , , , [ ^

 

^

 x x x

And with u(t)=F ,Y=[x] we get

















 



 

) 0 0 (

1 0

0 0

1 0

Ml g m M Ml

u

M g m M

u A

 ¹ ⁰ ⁰ ⁰ 

1 0 1 0



 







 









C

Ml

B M

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So we give constant values to g, u, m, M and l from the data of a real crane.

g=9.81 m/s² u=0.05;

m=100000 kg;

M=40000 kg;

l=8 m;

Figure 3.2 Simulation result.

A math model used in a full-scale simulator would be more complicated for 3D. The model used here is an illustration. The math model can run on a PC, where combined with input from the instructor, suitable vision, hearing and seat vibration signals for the training system can be provided.

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4. PLC signal acquisition setup

4.1 Choice of PLC

There are 39 inputs and 15 outputs on the control panel at the right side, and 49 inputs and 16 outputs on the left control panel. So the PLCS7 - 200 can not meet the requirements of the access number, and therefore PLCS7-300 is selected as core [6]. According to the S7-300 Instruction Manual, 6ES7321-1BL00-0AA0 (DI32×24VAC) is selected as input module. The output module is 6ES7322-1HH01-0AA0 (DO16×DC24VDC/0.5A). Both sides of the control panels have two input modules and one output module.

4.2 I/O address distribution

Table 3. I/O address distribution, as an example of the list of inputs. Input Module 6ES7321-1EL00-0AA0. The full table is shown in appendix 2. This is module No.1 of 4 input modules.

I/O address Function Condition Received signal

from PC

Send signal to PC

I0.0 mute button I0.1

Spreader pump on button

Not spreader reaches the limit signal, not spreader fault signal

M0.5 spreader reach es the limit signal, M0.6 spreader fault

signal

M5.0 Spreader pump on signal

I0.2

Spreader unlock

Spreader pump on signal, container in the

right place signal

M0.7 container in the right place signal

M5.1 Spreader unlock signal

I0.3

Spreader lock

Spreader pump on signal, spreader in the

right place signal

M1.0 spreader in the right place signal

M5.2 Spreader lock signal

I0.4

Guide plate go up

Seaside right guide plate choose signal, seaside left guide plate

M1.1 container shipment signal

M5.3 Guide plate go up signal

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choose signal,land side left guide plate choose signal,land side right

guide plate choose signal I0.5 Guide plate go

down

M5.4 Guide plate go down signal I0.6

I0.7

I1.0 Spreader left leans

Spreader pump on signal

M5.5 Spreader left leans signal I1.1 Spreader right

leans

M5.6 Spreader right leans signal I1.2 Spreader

forward

M5.7 Spreader forward signal

I1.3 Spreader

backward

M6.0 Spreader backward signal I1.4

Spreader position 1

M6.1 record spreader position 1

signal I1.5

Spreader position 2

M6.2 record spreader position 2

signal I1.6

I1.7

Table 4. Output Module 6ES7322-1BH01-0AA0. The full table is shown in appendix 3. This is module No1 of 2 output modules.

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I/O address ^Function ^Condition Received signal from PC

Send signal to PC

Q0.0

Red overload lights

overload 100% signal, lights on with blinking,interval1s.

M0.0 overload 100% signal

Q0.1 Yellow overload lights

overload 75% signal M0.1 overload 75% signal Q0.2

wind velocity30 Warning lights

wind velocity30 warning signal, lights on with blinking,interval1s.

M0.2 wind velocity30 alarm

signal

Q0.3

wind velocity20 Warning lights

wind velocity20 warning signal

M0.3 wind velocity20 alarm signal Q0.4

Q0.5

Q0.6

Q0.7

Address M distribution

Table 5. Address M distribution. The full table is shown in appendix 4. This is the first byte of the M-memory.

I/O address Function

M0.0

overload 100%

M0.1

overload 75%

M0.2

wind velocity 30 alarm

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M0.3

wind velocity 20 alarm

M0.4

Electrical fault warning

M0.5

spreader reaches the limit

M0.6

spreader fault

M0.7

container in the right place

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5. Implementation and experiment

5.1 Programming

The program is divided into nine parts, as the following image shows. Each function handles one part of the crane. The full instruction is shown in appendix 5.

OB1 is a Cyclic Program and it is executed continuously until OB1 is interrupted by others. It is available to call other function blocks in OB1 (FB, FC).

FC1 is designed to control the alarm system.

FC2 is designed to control the spreader system.

FC3 is designed to control the guide board.

FC4 is designed to control the boom movement.

FC5 is designed to permit the pitching control.

FC6 is designed to control the trolley.

FC7 is designed to control the crane movements.

FC8 is designed to control the head block movements.

FC9 is designed for other control signals.

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5.2 Simulation on software

After the PLC program is written, software S7-PLCSIM is used to debug. S7-PLCSIM is a software which is developed by Siemens Company. The software is used to simulate and test S7-300. S7-PLCSIM and STEP7 is integrated together, and for simulation, it is not needed to be connected to any PLC hardware. It provides ports for monitoring and modifying programs.

S7-PLCSIM can be opened from the SIMATIC Manager. Because there are so many inputs and outputs, as well as M memory address communicating with the PC, this chapter will not show every function of PLC, just show some result of watch table and explain them.

Example1: Input overload signal（M0.0), the overload alarm （Q0.0）is energized and flashing，and a buzzer

（Q1.6）is energized.

Example2: When you turn on the spreader motor (I0.1), the “Spreader motoe on” light turns on（Q0.5).

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Example 3: Input strong wind signal（M0.2，the wind alarm（Q0.2）is energized and flashing，a buzzer

（Q1.6）is energized.

The pitching operation is canceled (Q2.4).

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5.3 Experiment with PLC S7-200 [4] [5]

Serial communication is when data is transmitted one bit at a time. A data word has to be separated into its constituent bits for transmission and then reassembled into the word when received. Serial communication is used for transmitting data over long distances. This might be used for the connection between a computer and a PLC. The possibilities for serial communication between PLC and PC are shown below.

PPI communication:

The PPI interface is used for the S7-200 PLC. It is a point to point interface.

- OPC server

- The additional module CP243 can be used in order to enable the S7 protocol communication via the PmS7 driver

- The S7-200 CPU226 devices support also the communication interfaces MPI and PROFIBUS.

- The designer can implement simple ASCII protocol into the PLC S7-200 and then to use the PmChar- Driver for communication by user defined ASCII/BIN protocol in the PROMOTIC

system.

MPI communication:

The MPI interface is a "Derivation" of the PROFIBUS-DP. It is I is Multi Point Interface. The communication line is RS485, the speed rate is preset to 187.5kb/sec. The speed rate can be decreased to 19.2kb/sec and according to the device (CPU300, OP, CP6511) it can be even increased to

12Mb/sec.

- PmS7 - Driver for communication by S7-TCP/IP protocol. The driver can be used only together with the Netlink converter.

- OPC server

- Communication using the PRODAVE or Soft NET-S7 libraries is considered obsolete and is not recommended.

PROFIBUS communication:

PROFIBUS is a physical interface that cannot be directly connected to the PC. The connection is managed by additional PROFIBUS PC card.

- PmS7 - Driver for communication by S7-TCP/IP protocol. The driver can be used together with the Netlink converter.

- OPC server.

In our experiment PROFIBUS was used.

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The OPC server:

Virtually all mentioned communication types can be executed through the OPC server. It is supplied by default with PLC programming environment or it can be purchased in its software package

SOFTNET. The OPC server supports virtually all protocols required for the communication with the PLC of the Simatic type (serial link, MPI, PROFIBUS, PROFINET, PPI, etc.).

Figure 5.1 Setup of the experiment. Figure 5.2 The PLC-200

HMI is the abbreviation of Human Machine Interface. It is the medium of exchange between human and a technological system. HMI can connect PLC or similar of industrial control equipment, and show information and operate by screen. It is made up of two parts, software and hardware. Using HMI, it is more convenient to operate systems and more easy to get information from a machine.

In this thesis, the KTP 600 DP is selected as HMI device to connect human and the PLC system. After finishing the programming, we made a HMI project by using TIA Portal V12. Both KTP 600 and TIA portal are developed by Siemens. This HMI project is based on some functions we selected from the complete crane training simulator. It can explain the function of the simulator clearer and easier to understand.

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When someone opens the HMI project, the root screen is shown on the screen. Then the root screen button can be touched and the screen is shown as below.

Click Start to turn on the simulator

Press alarm to enter to the alarm part.

Switch on wind 20 signal resulting in the yellow light alarm and switch wind 30 signal resulting in the red light alarm.

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For the trolley part, we can give the analog signal value to control the movement of the trolley on the X axis by the knob. The position of the trolley will also be shown on the right side of the screen.

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6 Discussion and conclusion

A crane training simulator occupies an important position when the port enterprise is training their staff because of its safety and economical efficiency. Every simulator has its special control system, different control systems give simulators different functions. This thesis aimed to design a console control system fit for a crane simulator.

This thesis described the whole process of crane training simulator designing. Firstly the console control system scheme was made based on the functions of a crane training simulator. PLC was chosen to achieve the goal of controlling the system. Secondly, we decided to use PLC S7-300 to evaluate the amount of inputs and outputs. Thirdly, the functions was analyzed which the crane training simulator needs and then the amount of input and output was counted and a I/O address distribution table was made. At last, programming with the software STEP7 was done and a simplified experiment was done with the S7-200 unit. The limit of the project is that we didn’t make a full-scale physical demonstration due to equipment and economy reasons.

To improve the result, a 3D mathematical model can be made by matlab to simulate the movement of the crane. But a 3D mathematical model is complicated to make so we simplified it into a two dimensional model.

The technique of simulation is now emerging in the port management and training. We can use the model and the method of making the model for the other kinds of cranes. The success of simulator applications to the port provides new risks and bigger development space. With the perfection of training simulators, the training of operators will be more efficient and formal. More and more skilled operators will be sent to the port to meet the need of development of port trade and container shipping industry.

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7.References

[1] Wilson, B.H., Mourant, R.R., Li, M., et all. “A Virtual Environment for Training Overhead Crane Operators: Real-Time” in IIE Transaction 1998, Page 589-595

[2] DONG Haoming; XU Guifang, CHEN Dingfang. “Research on Overhead Crane Training System and its Construction Based on Virtual Reality”, In ICAIE 2010, Page 197-208

[3] G.F Franklin, J. D. Powell, and A. Emami-Naeini. Feedback Control of dynamic systems. Pearson, seventh edition, 2014.

[4] SIMATIC HMI HMI device KTP400 Basic, KTP600 Basic, KTP1000 Basic, TP1500 Basic Operating Instructions, Siemens, 2007

[5] SIMATIC S7-200 Programmable controller System Manual, Siemens, 2008 [6] PLC S7-300, CPU Specifications CPU 312 IFM to CPU 318-2 DP, Siemens, 2001

(44)

(45)

Appendix

Appendix 1: Functions of the right and left control panel Appendix 2: Input I/O address distribution

Appendix 3: Output I/O address distribution Appendix 4: M address distribution

Appendix 5: The full instruction

(46)

Appendix 1 Functions of the operation panel

Right control panel

Name Type of

signal Function Descriptions

General control

Power switch

DI(Digital signal input)

Control power

Control

connect DI Controller is connected

Light of connection

DO (Digital

signal output)

Light of connection turns on

Emergency

stop DI Stop every processes

Emergency

stop light DO Light turns on when emergency stop runs

Alarm

Red overload

light DO Light turns on when overload is more than 100%

Yellow

overload light DO Light turns on when overload more than 75%

The wind speed 30 red alarm

light

DO Red light turns on when wind speed is more than 30

The wind speed 20 yellow alarm light

DO Yellow light turns on when wind speed is more than 30

(47)

Mute button DI Mute the buzzer Error alarm

light DO Alarm light turns on when a fault occurs on the crane

Buzzer alarm DO Buzzer alarm rings when any fault occurs

Spreader movement

Spreader pump DI Spreader pump open/close

Spreader pump

light DO Light turns on when spreader pump open Spreader

unlock DI Spreader Container open

Spreader lock DI Spreader Container to close Guide plate rise DI

Control Direction of guide plate Guide plate

drop DI

Spreader operation

Spreader lean

left DI Control spreader lean left

Spreader lean

right DI Control spreader lean right

Spreader Lean

Forward DI Control spreader lean forward Control

spreader lean backward

DI Control spreader lean backward

Spreader reset signal

Spreader

position 1 DI Setting spreader position 1 Spreader

position 2 DI Setting spreader position 2

(48)

Spreader stop --- Reset position

1 DI

Press the button,spreader moves to the specific location

Reset position

2 DI

Spreader anchor

Sea side

Anchor DI Sea side spreader anchor

Land side

anchor DI Land side spreader anchor

Stop ---

Spreader anchor in special Situation

Anchor rise in

high wind DI Rise the spreader to specific location when there has high wind alarm.

Light of Anchor rise in

high wind

DO Light turns on when Anchor rise in high wind

Gantry anchor

rise DI Press the bottom, move the gantry to specific location

Head block

Head block cylinder

left select

DI Select head block cylinder

Light of Truck

anchor rise DO Lights turns on when gantry anchor rise Head block

Cylinder right select

DI

Select all --- Manual rising DI

Head block Cylinder up/down movement Manual

downing DI

Automatic adju DI Automatic lifting position of Head block

(49)

stment Cylinder

Boom movement

Movement

permit DI Permit boom movement

Light of movement

permit

DO Light turns on when permitting boom movement works

Movement stop DI Stop boom movement

Light of

movement s DO Light turns on when movements stop

Boom up DI Control boom up

Light of boom

up DO Light turns on when boom up

Boom down DI Control boom down

Light of boom

down DO Light turns on when boom down

Trolley Forward

Trolley moves

left DI

Trolley handle Trolley moves

right DI

Trolley’s speed

(8) DI

(50)

Left control panel

Name Type of

signal Function Descriptions

Guild board

Choose left guild board at

seaside

DI Choose left guild board at seaside

seaside light

DO Light turn on when someone choose left guild board at seaside

seaside

seaside light

seaside

seaside light

seaside

seaside light

Pitching permit

light DO Light turns on when pitching is permit

Trolley Trolley stop DI Trolley stop at specific position

(51)

control automatically button Light of trolley

stop automatically

DO Light turns on when trolley stop automatically

Trolley stop

button DI Trolley stop movement

Light of trolley

stop button DO Light turns on when trolley stop Container

selection TTDS DI Twin-twenty detection system

Select 20 feet

container DI Mode for 20 feet container

Select 20 feet

container light DO Light turns on when someone select 20 feet container

Select 40 feet

Select 45 feet

Select double 20 feet containers

DI Mode for double 20 feet containers

Select double 20 feet containers light

DO Light turns on when someone select double 20 feet containers

Select Trolley DI Trolley/ Truck mood select

(52)

Select truck DI

Select hook DI Hook/ Spreader mood select Select hook DI

Spreader and headline

Lock shrink DI Lock shrink

Lock stretch DI Lock stretch

Lock memory-manua

lly

DI Adjust lock position manually/automatic

Lock memory-autom

atic

DI

Lock

memory-stop -- Set lock

position at sea side

DI Set lock position at sea side

Light of set lock position at

sea side

DO Light turns on when someone set lock position at sea side

Set lock position at land

side

DI Set lock position at land side

Set lock position at land

side light

DO Light turns on when someone set lock position at land side

Select spreader-seasid

e

DI Select spreader seaside/land side/both

Select spreader-land

side

DI

(53)

Select spreader-

all --

Head block

pump on/off DI Head block pump on/off

Guiding light of head block pump on/off

DO Light turns on when head block pump works.

Head block

cylinder stretch DI Head block movement stretch/shrink/stop Head block

cylinder shrink DI Head block

cylinder stop -- Spreader link

button DI Two spreader connect together

Guiding light of spreader

connect

DO Light turns on when two spreader connect together

Spreader disconnect

button

DI Two spreaders separate

Guiding light of spreader disconnect

DO Light turns on when two spreader disconnect

Head block connect-manual

ly

DI Head block connect manually/automatic

Head block connect-automa

tic

--

(54)

Crane goes

forward DI 4 way joystick

Crane goes

backward DI

Crane speed (8) DI

Spreader up DI 4 way joystick

Spreader down DI Spreader speed

(8) DI

(55)

Appendix 2 Input I/O address distribution

Input Module 6ES7321-1EL00-0AA0

I/O address Function Condition Received signal

from PC

Send signal to PC

I0.0 Mute button

I0.1

Spreader pump on button

Not spreader reach the limit

signal, not spreader fault

signal

M0.5 spreader reach the limit signal,M0.6 spreader fault signal

M5.0 Spreader pump on signal

I0.2

Spreader unlock

Spreader pump on signal,container in

the right place signal

M0.7 Container in the right place signal

M5.1 Spreader unlock signal

I0.3

Spreader lock

Spreader pump on signal,spreader in

the right place signal

M1.0 Spreader in the right place signal

M5.2 Spreader lock signal

I0.4

Guide plate go up

Seaside right guide plate choose signal, seaside left guide

plate choose signal,land side

left guide plate choose signal, land side right guide plate choose signal

M1.1 Container shipment signal

M5.3 Guide plate go up signal

I0.5 Guide plate go

down

M5.4 Guide plate go down signal

(56)

I0.6 - I0.7

I1.0 Spreader left

leans

M5.5 Spreader left leans signal I1.1 Spreader right

leans

M5.6 Spreader right leans signal

I1.2 Spreader

forward

M5.7 Spreader forward signal

I1.3 Spreader

backward

M6.0 Spreader backward signal I1.4

Spreader position 1

M6.1 Record spreader position 1

signal I1.5

Spreader position 2

signal I1.6 Position 2 reset Spreader pump on

signal

M6.3 Spreader return to position 1 signal

I1.7 Position 2 reset M6.4 Spreader

return to position 2 signal

I2.0 Spreader sea side anchors

M6.5 Spreader sea side anchors signal

I2.1 Spreader land

side anchors I2.2

Strong wind anchor rise

Wind velocity30 alarm signal or

strong wind anchor button

M6.7 Strong wind anchor signal

(57)

pressed Spreader pump on signal I2.3

Crane anchor rise M7.0 Crane anchor

rise signal I2.4

Left head block

2*20 Inch container choose

signal

M7.1 Signal of Left head block

I2.5 Right head block M7.2 Signal of right

head block I2.6

Head block up M7.4 Signal of Head

block up I2.7

Head block down M7.5 Signal of Head

block down

I3.0

Automatic adjust M7.6 Signal of

Automatic adjust I3.1

Front beam move

Interlock with front beam stop

signal

M1.4 Trolley in the initial position signal

M7.7 Front beam move allowed signal

I3.2

Front beam stop

Inter lock with front beam move

signal

M8.0 Front beam stop signal

I3.3

Beam goes up Front beam move signal

M8.1 Front beam goes up signal I3.4

Beam goes down Front beam move allowed signal

M8.2 Front beam goes down signal I3.5 -I3.7

I4.0-I4.7 Trolley speed

I5.0 Trolley goes left M1.5 Trolley track M12.1 Trolley goes

(58)

no obstacle signal left signal I5.1 Trolley goes

right

M1.5 Trolley track no obstacle signal

M12.2 Trolley goes right signal I5.2 - I5.7

I8.0 Seaside right

guide plate choose

Seaside right guide plate choose, seaside right guide plate choose, land side left guide plate choose, land side right guide plate choose, four signal interlock

M8.3 Choose

seaside left guide plate signal

I8.1 Seaside right

guide plate choose

M8.4 Seaside right guide plate choose signal

I8.2 Land side left

guide plate choose

M8.5 Land side left guide plate choose signal

I8.3 Land side right

guide plate choose

M8.6 Land side right guide plate choose signal

I8.4

Trolley automatic stop button

M1.2 Trolley move to the right place

signal

I8.5 Trolley stop

button

M9.0 Trolley stop signal

I8.6 TTDS

I8.7

I9.0 20 Inch container Spreader pump on M1.6 Spreader M9.1 20 Inch

(59)

choose unlock signal, four choose mode interlock

without load signal signal

I9.1 40 Inch container choose

M1.6 Spreader without load signal

M9.2 40 Inch container choose signal

I9.2 45 Inch container choose

M9.3 45 Inch container choose signal

I9.3 2*20 Inch

container choose

M9.4 2*20 Inch container choose

signal I9.4 - I9.7

I10.0

Lock shrink

2*20 Inch

container choose signal

M10.1 Signal of lock shrink

I10.1

Lock stretch M10.2 Signal of

lock stretch

I10.2 Lock

memory-manuall y

M10.3 Signal of Lock memory-manually

I10.3 Lock

memory-automati c

M10.4 Signal of Lock

memory-automatic I10.4 set lock position

at sea side

M10.5 Signal of set lock position at sea side

I10.5 Set lock position at land side

M10.6 Signal of Set lock position at land side

I10.6 - I10.7

(60)

I11.0

Spreader choose-seaside

M10.7 Spreader choose-seaside

signal I11.1

Spreader choose- land side

M11.0 Spreader choose- land side

signal I11.2

Head block pump on/off

M1.3 Fault signal of head block

M11.2 Signal of head block pump

turning on I11.3

Head block cylinder stretch

M11.3 Signal of Head block cylinder

stretch

I11.4 Head block

cylinder shrink

M11.4 Head block cylinder shrink I11.5

Spreader link button

Spreader pump on signal, 2 status

interlock

M11.5 Spreader link signal

I11.6 Spreader detach

button

M11.6 Spreader detach signal

I11.7

I12.0-I12.7 Crane speed I13.0

Crane go ahead M12.3 Crane go

ahead signal I13.1

Crane retreat M12.4 Crane retreat

signal I13.2

Spreader go up Spreader pump on signal

M12.5 Spreader go up signal I13.3

Spreader go down Spreader pump on signal

M12.6 Spreader go down signal I13.4 - I13.7

I14.0 - I14.7 Spreader speed

(61)

(62)

Appendix3 Output I/O address distribution

Output Module 6ES7322-1BH01-0AA0

I/O address ^Function ^Condition Received signal from PC

Q0.0

Red overload lights

Overload 100% signal, lights on with blinking,interval1s.

M0.0 Overload 100% signal

Q0.1 Yellow overload lights

Overload 75% signal M0.1 Overload 75% signal

Q0.2

Wind velocity30 Warning lights

Wind velocity30 warning signal, lights on with blinking,interval1s.

M0.2 Wind velocity30 alarm signal

Q0.3 Wind velocity20 Warning lights

Wind velocity20 warning signal

M0.3 Wind velocity20 alarm signal Q0.4

Electrical fault warning lights

Electrical fault warning signal,

lights on with blinking,interval1s

M0.4 Electrical fault warning signal

Q0.5 Spreader pump on lights Q0.6 - Q0.7

Q1.0 Strong wind

anchor rise lights

Q1.1 Crane anchor

rise light

Q1.2 Front beam move light

Q1.3 Front beam stop light

(63)

Q1.4 Beam goes up light

Q1.5 Beam goes down

light Q1.6

Warning buzzer

Overload 100% signal or overload 75% signal or

wind velocity30 warning signal or wind

velocity20

warning signal or Electrical fault warning signal.

M0.0 Overload 100% signal, M0.1 overload 75% signal, M0.2 wind velocity30 alarm

signal, M0.3 wind velocity20 alarm signal

Q1.7

Q2.0 Seaside left guide plate choose light

Seaside right guide plate choose, seaside right guide plate choose, land side left guide plate choose, land side right guide plate choose, four signal interlock

Q2.1 Seaside right

guide plate choose light Q2.2 Land side left

guide plate choose light Q2.3 Land side right

guide plate choose light

Q2.4 Pitching

operation allowed light

Not wind velocity30 alarm , trolley stop signal, gantry stop signal, spreader

(64)

stop signal Q2.5 Trolley automatic

stop lights Q2.6 Trolley stop light

Q2.7 Light of head

block pump on

Q3.0

Light of set lock position at sea

side

2*20 Inch container choose signal

Q3.1 Light of set lock position at land

side Q3.2

Spreader link lights

Spreader pump on signal, 2 status interlock

Q3.3 Spreader detach lights Q3.4 - Q3.7

(65)

Appendix 4: M address distribution

Address M distribution

I/O address Function Description

M0.0. Overload 100%

M0.1. Overload 75%

M0.2. Wind velocity30 alarm

M0.3. Wind velocity20

alarm

M0.4. Electrical fault warning

M0.5 Spreader reach the limit

M0.6. Spreader fault

M0.7 Container in the right place

M1.0 Spreader in the right place

M1.1 Container shipment signal

M1.3. Head block fault

M1.4 Trolley in the initial position

M1.5 Trolley track no obstacle

M1.6 Spreader without load

M1.7

(66)

M5.0 Spreader pump on

M5.1 Spreader unlock

M5.2 Spreader lock

M5.3 Guide plate go up

M5.4 Guide plate go down

M5.5 Spreader left leans

M5.6 Spreader right leans

M5.7 Spreader forward

M6.0 Spreader backward

M6.3 Spreader return to position 1

M6.4 Spreader return to position 2

M6.5 Spreader sea side anchors

M6.6 Spreader land side anchors

M6.7 Spreader land side anchors

M7.0 Crane anchor rise

M7.1 Left head block

M7.2 Right head block

M7.3 Choose all head block

M7.4 Head block up

M7.5 Head block down

M7.6 Automatic adjust

(67)

M7.7 Front beam move allowed

M8.0 Front beam stop

M8.1 Front beam goes up

M8.2 Front beam goes down

M8.3 Choose seaside left guide plate

M8.4 Choose right guide plate

M8.5 Choose land side left guide plate

M8.6 Choose land side right guide plate

M9.0 Trolley stop

M9.1 20 Inch container

M9.4 2*20 Inch container

M9.5 Van carrier choose

M9.6 Choose trailer

M9.7 Choose hook

(68)

M10.0 Spreader choose

M10.1 Lock shrink

M10.2 Lock stretch

M10.3 Lock memory-manually

M10.4 Lock memory-automatic

M10.5 Set lock position at sea side

M10.6 Set lock position at land side

M10.7 Spreader choose-seaside

M11.0 Spreader choose- land side

M11.1 Choose both side of spreader

M11.2 Head block pump turning on

M11.3 Head block cylinder stretch

M11.4 Head block cylinder shrink

M11.5 Spreader link

M11.6 Spreader detach

M11.7 Head block connect-manually

M12.0 Head block connect-automatic

M12.1 Trolley goes left

M12.2 Trolley goes right

M12.3 Crane go ahead

M12.4 Crane retreat

(69)

M12.5 Spreader go up

M12.6 Spreader go down

M12.7

(70)

Appendix 5:The full instructions

The function is divided into nine parts:

FC1: Faults

Network1: Red overload light

(71)

Network2 : Red overload light

Network3: Yellow overload light

Network4: Wind speed 30 alarm

(72)

Network7: Error alarm

(73)

Network8: Error alarm

Network9: Buzzer

(74)

Network10: Mute

(75)

Network11: Mute

FC2: Spreader

Network1: Pump of spreader

Network2: Spreader lock

(76)

Network3: Spreader lock

Network4: Spreader leans left

(77)

Network5: Spreader leans right

Network6: Spreader leans forward

Network7: Spreader leans backward

(78)

Network8: Spreader position 1

Network9: Spreader position 2

Network10: Spreader position 1 reset

Network11: Spreader position 2 reset

(79)

Network12: Spreader anchor at seaside

Network13: Spreader anchor at land side

Network14: Anchor in wind

(80)

Network15: Select spreader for 20 foot container

Network16: The spreader for 40 foot contain

(81)

(82)

Network19: Lock shrink

Network20: Lock stretch

Network21: Select spreader at seaside

(83)

Network22: Select spreader at land side

Network23: Select all spreader

Network24: Connect spreader

(84)

Network25: Disconnect spreader

FC3: Guild Board

Network1: Guild board up

Network2: Guild board down

(85)

Network3: Left guide board at seaside

Network4: Right guide board at seaside

(86)

Network5: Left guide board at land side

Network6: Right guild at land side

(87)

FC4: Boom

Network1: Permit boom movement

Network2: Stop boom movement

(88)

Network3: Boom up

Network4: Boom down

(89)

FC5: Pitching

Network1: Permit pitching

FC6:Trolley

Network1: Trolley stop automatically

(90)

Network2: Trolley stop manually

FC7: XYZ

Network1: Trolley toward to left

(91)

Network2: Trolley toward to right

Network3: Crane move forward

Network4: Crane moves back

(92)

Network5: Spreader up

Network6: Spreader down

Network7: Trolley speed

(93)

Network8: Crane speed

Network9: Crane speed

(94)

FC 8: Head block

Network1: Head block cylinder toward left

Network2: Head block cylinder toward right

Network3: Select all head block

(95)

Network4: Head block cylinder up

Network5: Head block cylinder down

Network 6: Head block cylinder automatic adjust

(96)

Network7: Turn on head block pump

Network8: Head block stretch

(97)

Network9: Head block shrink

FC 9: Others

Network 1: Select carrier

Network 2: Select trailer

(98)

Network 3: Select spreader

Network 4: Select hook

Network 5: Lock shrink

Network 6: Lock stretch

(99)

Network 7: Manual lock memory

Network 8: Automatic lock memory

Network 9: Set lock at seaside

(100)

Network 10: Set lock at land side

(101)

Design of a Quay Crane Training Simulator