Details

Written by Wolfgang Wichner

Created: 01 December 2012

Here you can watch some videos, illustrating the functions and operating modes of our Sway Control System "OptiSway®".

Further sample videos you can find in section References among the technical information of the related projects.

Details

Written by Wolfgang Wichner

Created: 25 November 2012

In order to guarantee a safe crane operation, the OptiSway® system is equipped with software limit switches, reliably preventing the crane from approaching buffer stops and entering restricted areas.

Additionally, OptiSway® provides extensive surveillance functions. The system monitors, for instance, whether:

• the communication with all OptiSway® Profibus slaves works
• the processor of the crane PLC works
• the OptiSway® processor works. This is monitored by a PLC program module within the crane PLC, which is included in the delivery
• the drives follow the set speed, given by OptiSway®
• the analogue setpoint outputs of OptiSway® transmit the correct value, i.e. the analogue outputs are monitored for possible hardware failures
• the OptiSway® internal position detection matches the values, detected by the crane PLC. Through this redundancy, too fast approach of end limits as well as wrong positioning in automatic mode are reliably avoided.
• the pendulum movement has not reached extreme values. This might happen in case of an extraordinary event, e.g. collision of the load with an obstacle or emergency stop at full speed.
• the pendulum angle measuring system (as far as installed) does not deliver any data, e.g. in the case of contamination of the optics. Temporary failures do not affect proper operation. In this case, the pendulum angle measurement values are replaced by mathematical model calculation. Same applies to system variants without pendulum angle sensor.
• the target point received from the crane PLC in automatic mode lies within the permitted operating range of the crane

Details

Written by Wolfgang Wichner

Created: 25 November 2012

Interface OptiSway® <-> Crane PLC:

Via DP/DP coupler, the crane PLC sends run commands, setpoints, target coordinates and limit switch signals to OptiSway®.

OptiSway® sends actual values, feedback signals, fault messages etc. to the crane PLC.

Interface OptiSway® <-> Peripherics:

OptiSway® reads its actual values over the system's own PROFIBUS.

The position of trolley and crane be measured either over PROFIBUS compatible absolute measuring system or over the ET200S with incremental encoders.

The drives receive their speed setpoints from OptiSway® usually via analogue interface.

For Siemens Sinamics frequency converters, the connection can also be implemented via ProfiNET coupling, for Masterdrive systems - via PROFIBUS.

Details

Written by Wolfgang Wichner

Created: 25 November 2012

Basic components

The core - or better the "brain" - of the sway control system OptiSway® is a Siemens "Microbox" industrial PC.

Thanks to its high computing power, it facilitates short cycle times and therewith highest precision and dynamics of drive operation even for highly complex control tasks.

Another component present in all OptiSway® installations is the Siemens DP/DP coupler, functioning as interface to the crane PLC. In case of Profinet systems, the Siemens PN/PN coupler is used instead.

An own power supply is also part of the system's basic equipment.

Options

As standard, OptiSway® is equipped with its own sensorics, connected via dedicated PROFIBUS network.

The sensor system is designed according to the application-specific requirements. CATS will gladly advises you on the best choice.
Advantages of a sensor system directly connected with OptiSway®:

• Avoidance of dead times in the control circuits, caused by PLC cycle times and bus runtimes =>significantly higher control quality
• Redundancy to the sensorics of the crane PLC =>Maximum safety
  (up to control category 3 / Performance Level d acc. to DIN EN 954-1 and EN ISO 13849)

The same applies to the pre-setting of the drive speed setvalues. In the following example these values are sent by an ET200S via OptiSway® Profibus as analogue signals to the FCs of trolley and crane drive.