Simplifying Cranes PDF

Simplifying Cranes
Simplifying Cranes
Topics
• Universal encoder system U-ONE®

• Fibre optic signal transmission
• Existing solutions
• Problems of responsibilities
• Specifying systems
• Modernisations
• Support and service worldwide
www.huebner-giessen.com Slide 2 © 2013 Johannes Huebner GmbH, Giessen - Germany

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Year of foundation: 1934

Employees: 95
Sales: 14 M EUR
Direct Export: 65%
Subsidiary: USA
International Representatives: 60 world-wide
Quality Management System: DIN EN ISO 9001:2008

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Worldwide

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Made in Germany
• Development
• Construction
• Production
• Sales
• Administration
100% MADE IN GERMANY

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GMP Le Havre - Retrofit reggiane cranes

Existing solution
3 couplings not
torsion resistant
(INACCURACY)
Mechanical Cam
Limit Switch Absolute encoder
Gear to meet the

required 2 driven shafts
for absolute encoder
and mech. Overspeed
switch
(INACCURACY)
Speed increasing gear with internal Mechanical base frame only Sockets for different
coupling (INACCURACY) neccessarry for the mounting! mounting levels
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Pusan Newport phase 1_1 - Retrofit ZPMC cranes

Existing solution Gear from ZPMC to
provide two shafts
(INACCURACY)
Speed increasing gear

EGS 4 K from ZPMC to meet the
required minimum
Provided by ABB
speed for Electrical
Cam Limit Switch
(INACCURACY)
4 Couplings to connect all thes single parts Mechanical base frame only Electrical Cam Limit
(INACCURACY) neccessarry for the mounting! Switch required by GBB
Simplifying Cranes
GMP Le Havre - Retrofit ZPMC cranes

Existing solution
Gear to meet the 4 couplings not

required 3 driven torsion resistant
shafts for absolute
(INACCURACY)
encoder, overspeed
switch and cam limit
switch
(INACCURACY)
Mechanical Cam
Limit Switch
Soccets only for

different mounting
Absolute encoder Base frame only neccessarry for mounting! levels

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Example: hoist
Existing Solution New Solution with U-ONE®

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U-ONE® SYSTEM - New solution

Decoder Absolute CANBus Switchboard
UO-EM-D2 UO-EM-AMC
2 FOC
Incremental Absolute output

output PROFIBus UO-
UO-EM-FG EM-AMP
Overspeed switch 0,63 – Electronic position

4800 1/min UO-EM-EGS4 switch UO-EM-ERC
U-ONE UOM 4 L-1212

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U-ONE® SYSTEM - Further developments

Switchboard
2 FOC
• EtherCAT
• PROFISAFE
• Synchronization module for slip
compenzation
• Diagnostic module (Intranet suitable)
U-ONE UOM 4 L-1212

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U-ONE® SYSTEM - Comparison of installed discs
Pulse dic of an incremental encoder Main disc of an absolute encoder

(pulse encoder) pulse rate: e.g. 250 resoluttion: 4096 steps/rev. (12bit)
ppr
For ABS-series (Absolute encoder)
For FG-series (Incremental Encoder) AMC = Canbus
and EGS-series (Overspeed Switch) AMS = SSI
AMP= Profibus
AME = Ethernet
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U-ONE® SYSTEM - Function principle
+ = U-ONE® basic unit
FG-Module EGS-Module BUS-Module

Speed control overspeed Position
switch control

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U-ONE® SYSTEM - Basic unit mounted at the drum or the

motor

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U-ONE® SYSTEM - Electronic modules in the switch board

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Problems old solution
Inaccuracy 1
caused by drum coupling
Inaccuracy 2
caused by gear
Inaccuracy 3
caused by coupling
Inaccuracy 4
caused by mounting and
alignment
Total inaccuracy 1+2+3+4

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What is behind the old solution?

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Drum, Gear or Motor Shaft

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Drum coupling (1)

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Base frame 1

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Distribution gear

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Coupling 2

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Coupling 3

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Coupling 4

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Base frame 2

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Base frame 3

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Base frame 4

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Mechanical cam limit switch

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Electronic overspeed switch

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Absolute encoder

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4 cable connections

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U-ONE® SYSTEM - Our solution

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U-ONE® SYSTEM - Programming
U-One®Pro
Select the module you like to program
EGS4Pro
Parameter setting for
UO-EGS4-Module
ERCPro
Parameter setting for
UO-ERC + UO-AMC + UO-AME

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U-ONE® SYSTEM – U-ONE®Pro
Select the module you

like to program

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U-ONE® SYSTEM - EGSPro
Setting of overspeed
switches
• Overspeed switch 1
• Overspeed switch 2
• System switch S
(error switch)

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U-ONE® SYSTEM - ERCPro
Parameter setting of position switches

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Complete solutions

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Hoist
Pulse encoder
FG(H) 40L with
1. U-ONE Multiturn
UOM 41L 1212
fiber optic
2. GTES transmission
Motor
Mecanical cam-limit switch
Gear
Rope drum
box
Power supply
12-30 VDC 2 1
Fiber optic
cable
3. UO-EM-D41
3 4 5 Decoder
4. UO-EM-EGS 41
Overspeed switch
5. UO-EM-AMP
Absolute output interface

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Boom lifting gear

Pulse encoder
FG(H) 40L with
1. U-ONE Multiturn
UOM 41L 1212
fiber optic
transmission
Motor
Gear
Rope drum
box
Power supply
12-30 VDC 1
Fiber optic
cable
2. UO-EM-D41
2 3 4 5 Decoder
3. UO-EM-EGS 41
Overspeed switch
4. UO-EM-AMP
5. UO-EM-ERC
Electronic position switch
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Rope-driven trolley
Motor
Pulse encoder
FG(H) 40 L with
Gear
Rope drum
box fiber optic
transmission
Power 1
supply
12-30 VDC
1. U-ONE Multiturn
UOM 41L 1212
Trolley
Fiber optic
cable
2. UO-EM-D41
2 3 4 Decoder
3. UO-EM-ERC
Electronic position switch
4. UO-EM-AMP

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Trolley
Motor
Digital Encoder
FGH 40L-1024G-90G
(hollow shaft version)
Fiber optic
NON DRIVEN WHEEL OR DRUM signal transmission
U-ONE System for positioning

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Traversing gear
Digital Encoder FG 40 L-1024G-90G
mounted on non-drive end of motor
Fiber optic
signal transmission
NON DRIVEN WHEEL
U-ONE System for positioning
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Fibre optics signal transmission
Possible problems in installations

• Electrical or magnetic interferences on control cables caused by:
• Power cable too narrow (e. g. on cranes or any festoon cabling)
• High starting current of powerful motors
• Influence of high-power magnetic brakes
• Long distances to the control room e. g.:
• in steel works
• in harbours, mining and other large plants
• Any problem with signals of Incremental encoders in existing
installations
Solution: Fibre optics signal transmission

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Princip of fibre optic signal transmission

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Pulse encoder with integrated fiber optic converter
Fiber optic decoder

with 2 output blocks
Pulse encoder with
integrated transmitter HTL and/or TTL
(converter)
Copper cable
Fiber optic cable
Available for all encoder series

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Pulse encoder with separate fibre optics converter

for new installations and upgradings
Fiber optic decoder

Copper cable with 2 output blocks
Fibre optics transmitter HTL and/or TTL
for installation in
switchboard
Copper cable
Fiber optic cable
Digital encoder with

electrical signal output
Fiber optic transmitter protection class IP66

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Pulse encoder with separate fibre optics converter

for new installations and upgradings
Fiber optic decoder

with 2 output blocks
Fiber optic transmitter HTL and/or TTL
Copper cable
for installation in
switchboard
Fiber optic cable Copper cable
Digital encoder with

electrical signal output
Fiber optic transmitter protection class IP66

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References
DP WORLD Jebel Ali with fiber optic signal transmission

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Main advantages of
• EMI proof
• Long distances
• Snap-on mounting modules
• One fiber optics cable for all channels
• Decoder with 2 output blocks (TTL/HTL)
• Alternative solutions

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New standard incremental encoder FG 2 ECOCODER®

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Main features FG 2 AK-1024G-90G-NG
• axial terminal box

• 1024 pulses (option: 2048)
• two HTL/TTL signals displaced
by 90° (track A and B)
• additional marker pulse
• additional inverted signals
• shaft diameter 11 mm
• temperature range -25° ... +85°
• max. speed 7.000 rpm
• protection class IP 66 / IP 67
• standard protection against salty
ambient conditions

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Product classification: main differences to the approved FG

40 / FG 4
• smaller size
• no second shaft end
• no other pulse rates than 1024 or
2048
• no other temperature ranges
than -25° ... +85°
• no other protection classes than
IP 66 / IP 67

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Unique selling points / advantages against POG 10
• Standard pulse encoder with newest scanning

technology for high signal precision
• Higher mechanical reliability because of stronger
bearings (overdimensioned) and special heavy duty
housing
• Easier electrical connection because of bigger terminal
box
• Higher connection reliability because of spring forced
connector block
• Higher protection class IP 66 and IP 67 (for usage under
permanent wet conditions)
• Compact design with axial terminal box
• Attractive price level with quantity scale
• Very good price-performance ratio („value for money“)

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Magnetic encoder MAG
Major features and advantages

• only one scanning head for speed and position signals possible
Scanning head MAG 200

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Major features and advantages

• optional split construction for easy retrofitting and maintenance

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Example tandem motor

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Example measurement roll CSM
After installation After 8 month operating time

under hard conditions without
any problems

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Complete solutions

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PSA EXOLGAN TERMINAL BUENOS AIRES - Retrofit RTG

cranes
Mechanical cam limit switch against U-ONE®

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PSA EXOLGAN TERMINAL BUENOS AIRES - Retrofit RTG

cranes
- Additional overspeed protection through electronic module UO-EM-EGS4

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U-ONE® system needs to be specified in the crane

specification / tender!
To measure the speed, position and overspeed for following motions one single device
called U-ONE® by Johannes Huebner Giessen / Germany shall be provided and installed
in the back side of drum.
Main Hoist: Up-Slowdown, Up-Stop, Up-Hoist Stop, Dock-Slowdown, Down-Slowdown,
Down-Stop, Sill beam protection and overspeed of the load.
Trolley Travel: Waterside slow downs, waterside stops, waterside over travel stops, land
side slowdown, landside stop, landside over travel stop.
Boom Hoist: Lower Stop, Upper Stop, Lower slowdown, Upper slowdown, End positions.
The device shall consist of an universal basic unit and electronic function modules to be
installed in the control panel (cabinet). The basic unit and modules shall be connected by
optical fibre cables which are immune to EMI. The modules are linked by an internal bus
structure and can be freely connected and extended in series by integrated plugs.
To maximize the function of the device the input signal from motor side incremental
encoders supplied by Johannes Huebner shall be compared by the PLC with the
incremental output signal from drum side U-ONE®.
For speed control the encoders of Johannes Huebner have to use fibre optic signal
transmission.
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Project handling - Project Pusan Newport
Old solution - responsibilities not clear...
Mechanical OEM
Electrical OEM
...if the system is not specified!

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U-ONE® SYSTEM
Main advantages U-ONE®

• Compact design
• EMI immune fiber optics signal
transmission
• Switchboard mounted electronics
• Central programming
• Extreme reduction of cable costs
• Extreme reduction of
commissioning time
• Easy to extend
• High flexibility
• Saving spares

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1. Development target
Universal encoder system (second generation) U-ONE® SAFETY with different standardized
function modules and interfaces, among others certified switches (position, overspeed,
speed difference) and certified absolute encoders for functional safety applications
according to EN 61508: SIL CL2 and EN ISO 13849: PL d. Resolution Singleturn/Multiturn
will be up to 13/15 bit for all absolute encoders (except SSI: 13/12 bit).
Two different design types:
U-ONE® SAFETY Compact U-ONE® SAFETY LWL

Universal basic unit with direct Universal basic unit connected to electronic
mounted electronic function modules function modules in the control cabinet
in a compact heavy duty housing. via fiber optic cable.

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2. System overview – Planned modules

Central unit Absolute encoders Switches
UOS U-ONE® SAFETY basic unit SPB Safe Profibus (Profisafe) SRC-R Safe position switch (relais
contacts)
SCU Safety control unit with fiber SPN Safe Profinet (Profisafe) SGS-R Safe overspeed switch (relais
optic decoder and interfaces, e.g.: contacts)
 fatal error exit for internal (device) SOE Safety over Ethercat SDS-R Safe speed difference switch
failures; restart via USB on site (relais contacts)
 warning error exit for external (envi- ESI Standard SSI SDC Safe incremental entry (for
ronment) failures; restart via reset speed difference calculation)
 Incremental output (1024 or 4096 EPB Standard Profibus SRC-HL Safe position switch (solid-
pulses) state relais)
 Analog output 4-20 mA (position or EPN Standard Profinet SGS-HL Safe overspeed switch
speed signal) (solid-state relais)
 USB programming interface EOE Standard Ethercat SDS-HL Safe speed difference
switch (solid-state relais)
 Reset and Preset input EIP Standard Ethernet/IP
Grey colour: Standard interfaces without safety certification
Yellow colour: Certified for functional safety according to EN 61508: SIL CL2 and EN ISO 13849: PL d

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Electronic overspeed switch EGS® 41

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Absolute Encoder
For extreme operation conditions in steel mills,

Mining and Cranes
Optional with SIL/Ple-certification

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Simplifying Cranes

• Universal encoder system U-ONE®

www.huebner-giessen.com Slide 2 © 2013 Johannes Huebner GmbH, Giessen - Germany

Year of foundation: 1934

www.huebner-giessen.com Slide 3 © 2013 Johannes Huebner GmbH, Giessen - Germany

www.huebner-giessen.com Slide 4 © 2013 Johannes Huebner GmbH, Giessen - Germany

100% MADE IN GERMANY

www.huebner-giessen.com Slide 5 © 2013 Johannes Huebner GmbH, Giessen - Germany

GMP Le Havre - Retrofit reggiane cranes

Gear to meet the

Pusan Newport phase 1_1 - Retrofit ZPMC cranes

Speed increasing gear

GMP Le Havre - Retrofit ZPMC cranes

Gear to meet the 4 couplings not

Soccets only for

www.huebner-giessen.com Slide 8 © 2013 Johannes Huebner GmbH, Giessen - Germany

Existing Solution New Solution with U-ONE®

www.huebner-giessen.com Slide 9 © 2013 Johannes Huebner GmbH, Giessen - Germany

U-ONE® SYSTEM - New solution

Incremental Absolute output

Overspeed switch 0,63 – Electronic position

www.huebner-giessen.com Slide 10 © 2013 Johannes Huebner GmbH, Giessen - Germany

U-ONE® SYSTEM - Further developments

U-ONE UOM 4 L-1212

www.huebner-giessen.com Slide 11 © 2013 Johannes Huebner GmbH, Giessen - Germany

U-ONE® SYSTEM - Comparison of installed discs

Pulse dic of an incremental encoder Main disc of an absolute encoder

U-ONE® SYSTEM - Function principle

+ = U-ONE® basic unit

FG-Module EGS-Module BUS-Module

www.huebner-giessen.com Slide 13 © 2013 Johannes Huebner GmbH, Giessen - Germany

U-ONE® SYSTEM - Basic unit mounted at the drum or the

www.huebner-giessen.com Slide 14 © 2013 Johannes Huebner GmbH, Giessen - Germany

U-ONE® SYSTEM - Electronic modules in the switch board

www.huebner-giessen.com Slide 15 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

Total inaccuracy 1+2+3+4

www.huebner-giessen.com Slide 16 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

What is behind the old solution?

www.huebner-giessen.com Slide 17 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

Drum, Gear or Motor Shaft

www.huebner-giessen.com Slide 18 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

Drum coupling (1)

www.huebner-giessen.com Slide 19 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

www.huebner-giessen.com Slide 20 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

www.huebner-giessen.com Slide 21 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

www.huebner-giessen.com Slide 22 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

www.huebner-giessen.com Slide 23 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

www.huebner-giessen.com Slide 24 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

www.huebner-giessen.com Slide 25 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

www.huebner-giessen.com Slide 26 © 2013 Johannes Huebner GmbH, Giessen - Germany

Problems old solution

www.huebner-giessen.com Slide 27 © 2013 Johannes Huebner GmbH, Giessen - Germany