1. Mitsubishi crane solutions

2. Introduction
This presentation will help you to sell more easy to crane applications.
Please find attached:
Reference customers & applications
Inverter specific functions
Necessary Options
System solutions

3. Main crane types Tower crane Bridge crane Gantry / portal crane
Jib crane
Only the main crane type, not neglecting other crane like truck mounted cranes, floating cranes etc. But the generally these are the mechanical basics forms.
Tower cranes -> Counterweight whether on top or connected by steal ropes on the bottom of the crane. 360° Rotation angle of hole top structure and moving trolley with hoist on a boom.
Bridge cranes -> Rails on both side of the working area, on which a beam is moving. Trolley and hoist combination. Also including overhead cranes, which are mainly on a single rail / beam over the working area.
Gantry / portal cranes -> The portal moves on rails over the working area. Trolley and hoist combination.
Jib cranes -> Floor or wall mounted boom with moveable trolley and hoist.

4. Additional crane application information for MEU and partners
Following some information which should help to get a better understanding of the crane market requirements and where Mitsubishi has advantages and disadvantages.
Critical issues for certain crane types will be mentioned.
Feel free to use any of these information for your customers.

5. Typical for Cranes
High overload (Cranes are often overloaded from user side, and used outside the manufacturers specification)
Smooth movement
Control of mechanical Brake
Secure magnetization of sliding rotor motors (Works good with FR-A700)
Hoist speed 5-25m/min
Travel speed 15-80m/min
Brake resistor need high specification (40-50% power of hoist motor capacity, for 100% ED, because of long travel distance)
Brake control -> When RUN signal is switched of brake should close. Timing adjustable with starting frequency (Pr.13).

6. Typical for Cranes 90% of the hoists use an encoder feedback
70% of bigger cranes use piezo-ceramic load sensor for load management
For retrofit you have to take care of insulation class of the motor and shaft voltage ( insulated bearings).
Retrofit:
-> The motor should have insulation class F. If not use a Mitsubishi sine wave filter FFR-SI.
-> The earth connection can have a lower resistance to earth than the cable connection, due to massive metal connection. Or the crane was used as earth connection instead of a cable. This increases problems with shaft voltage and bearing current, if the bearing is not insulated.
If problems come up with the bearing, a special sine wave filter should be used. This sine wave filter should be filtering also to earth, e.g. Schaffner sinus filter plus.

7. Mitsubishi performance
High overload capacity
Easy and precise auto tuning
High temperature without derating (temp. under the roof can be 10-20°C higher than on the ground)
No booksize inverter, standard cabinets for cranes have mainly 300mm depth
Robust and dirt resistant design
Internal structure is built to resist high vibration levels (which are usual for cranes)
Steady and precise speed control

8. Things to take care of for tower cranes
Torsional forces due to wind or load movement
-> Independent torque limit for each working quadrant in FR-A700
Instantaneous power failure due to brush contacts
-> Instantaneous power failure function in FR-A700
Safe working angles
-> Define SW limit switches in inbuilt PLC function

9. Things to take care of for bridge and portal cranes
Travel motor can be way bigger than hoist motor (Travel structure can be really heavy. E.g. a bridge crane with 3.6 t nominal load and 28 m wingspan can reach a mass of 25 t)
Often two motor are connected to one inverter. Combined according to there motor capacity (Combination 1: hoist with boom hoist and trolley with gantry combination 2: hoist with gantry and trolley with boom)
A700 overload capacity is meeting the requirements (150% 60s is enough for travel, 150% 60s and 200% 3s is enough for hoist)
Electrical design of control is more complex due to safety issues
Mainly brushes are used, due to long moving distance and existing rail structure (Voltage dips/spikes should be avoided by using more than one set of pickups. AC choke and IPF-function helps too)
Hoist drive for cranes bigger 15 t often have a dual drum with a single rope (Problem is to have equal amount of rope on the two drums)
For container cranes a teachable positioning is used
Because of a quite similar structure between bridge and portal cranes similar things can be considered.
IPF-function -> Instantaneous power failure function
Dual Rope Drum -> Two possible solution.
1.) Simple: The stop limits are used to even out the rope between the drums. That is, once the stop limit is reached by one drum it will stop and the other will continue until it reaches its stop limit. This will then equal out the rope between both drums. In this case the motor and inverter can either be open or closed loop.
2.) Complex: The 2 drums are synchronised with both position and speed (Control techniques call this Digital Lock & SEW call it ISYNCH). Each drum has its own motor and inverter (closed loop), the position and speed of both drums is synchronised.
This is possible by using FR-A700 with A7AL in Master Slave control.
Teachable positioning -> When a cargo hatch has to be unloaded, the operator presses a button. He is going to the cargo position by manual operation. Then the external PLC is remembering the end position. The next time he needs to go the same hatch the movement to the end position can be done with maximum frequency automatically.
This reducing unload time. It is more flexible than stored position data, because a ship is always moving a little bit.

10. Things to take care of for Jib cranes
Easy crane structure, so only general requirements

11. Crane Types Categorisation
Due to the wide range of crane types it makes sense to divide the crane applications into different groups due to the complexity.

12. Crane Types Low complex
Controlled manually by joystick / push buttons in jog operation
No measurements of speed, position or load
Inverter technical features like s-curve acceleration, brake function etc. is enough
Inbuilt PLC is used for speed limit switches and pendant control
Control manually by joystick in jog operation -> Normally just 3 signal control up-down and high speed.
No measurements of speed, position and load -> Visually controlled, open loop vector control performance is enough.
Speed limit switch -> Slow down limits are usually required for all motions. If raising the hoist and a slow down limit is activated, travel in that direction must be limited to a slow speed however full speed must be available in the opposite direction from anywhere in that slow zone.
Pendant control -> When the 2 step button is pressed, the motor accelerates, if the button is released back to the first step the motor will hold the current speed. If the button is pressed to the second step again the motor will accelerate. If at any time the button is completely released the motor will stop. If while decelerating the button is pressed again the motor will pick up from the speed and accelerate again.

13. Crane Types Mid complex without external PLC
Controlled manually by joystick in jog operation, or easy vertical positioning
Encoder feedback
Inverter technical features like s-curve acceleration, brake function etc. is enough
Adjustment to application by internal PLC
Load management with external sensor and inbuilt PLC
Inbuilt PLC is used for speed limit switches and pendant control
Displaying data on HMI or PU07
Use of regenerative units 
Sometimes PLC is used for safety reasons even in this mid complex systems, but it is just checking the movement of the inverter. Therefore control signals are paralleled to the PLC e.g. a FX2N, but the movement is still controlled directly by the inverter.

14. Crane Types High complex with external PLC
Control automatically and manually
Encoder feedback
Network communication (Often Profibus and Ethernet)
Positioning vertical and horizontal
High complex functions like safety, load management, synchronising all moving axis are realised in the external PLC
Optimised duty cycle, by automatised movement
Displaying data on HMI
Use of regenerative units 
External PLC (e.g. FX or System Q) -> Controls all axis, piezo-ceramic load sensor is used for load management of bigger cranes >10t, positioning the crane by encoder feedback, for safety reason sometimes two PLC (FX) are used for checking inverter movements and each other. Or safety PLC is used.

15. End of additional internal information part.

16. Dedicated options and functions
There are a lot of possibilities to adjust the Mitsubishi inverters to the application. Whether standard functions , plug in options or dedicated firmware.

17. Torque performance of FR-A740
Closed-loop vector control (encoder) 200% (150%) 0.04Hz
Real sensorless vector control 200% (150%) 0.3Hz
Maximum torque for short time (0.4K to 3.7K)
Maximum torque for short time (5.5K to 55K)
Continuous torque (0.4K to 3.7K)
Output torque (%) (60Hz reference)
Speed (r/min)
Speed control
Control range 1:1500
Speed of response 300 rad/s
Torque control
Control range 1:50
Absolute torque precision ±10%
Position control
One pulse accuracy

18. Maintenance function and lifetime display
Alarm outputs can be activated to carry out maintenance tasks on the crane, depending on the number of hours of operation like:
-> Inrush current limit circuit life
-> Control circuit capacitor life
-> Main circuit capacitor life
-> Cooling fan life

19. Dedicated functions in FR-A740
Independent torque limit for each working quadrant (generation/ regeneration)
Built in PLC function
-> Realise secure working areas
-> Maximum load limiter
Deceleration ramp can be generated in the absence of power (not for hoist)
Instantaneous power failure
S-pattern acceleration / decelaration
Speed automatically adjusted depending on the load
Brake sequence function (torque proving)
Digital input functions
Realise secure working areas
-> Use the internal PLC, define SW limit switches in data registers, compare with remanent position pulses from pulse count FW
Maximum load limiter
-> Any movement can be prevented if the load exceeds the maximum permitted. Load estimation by current measurement or external load measurement device.
Digital input function : E.g. safety limiter for strong winds -> All the inverters could be shut down using a digital input which activates with wind speeds of over certain level.
Please see “Crane solution with Mitsubishi Electric.ppt” for detailed information.

20. FR-A740-C9 Special crane FW
FCFS first come first serve
2 encoder feedback cards can be mounted
-> Closed loop speed or torque control for 2nd. motor
Dedicated latched encoder feedback pulse register in inbuilt PLC
-> Semi multi turn positioning for 1st. motor -> Position tracking for 2nd. motor
Used for e.g. portal cranes, horizontal movement (gantry) in closed loop and vertical movement (hoist) in closed loop.
FCFS -> When the operator moves the joystick towards gantry moving direction gantry motor is served first, or respectively hoist motor.

21. FR-A740-C9 Special crane FW
Advantages:
-> Closed loop performance in horizontal and vertical movement
-> Vibration avoidance
-> Movement tracking and positioning
Vibration avoidance due to smooth movement in both axis.
Movement tracking and positioning by latched feedback pulse registers in the inbuilt PLC.

22. FR-A7AL option card Master slave operation -> Speed control
-> Position control
Synchronising 2 axis
Balancing load

23. FR-A7AL option card Master / Slave position control A700
In position control the slave uses the same encoder signals as the master for the positioning. Pulses are counted and are used as target position, the feedback of the slave encoder is used to check if the target position is reached.
In speed control the master has FR-A7AL card mounted and the slave has FR-A7AP encoder feedback card. The pulse output of FR-A7AL is connected to the JOG input of the slave. The slave is running in pulse train speed mode.

24. FR-A740 droop control
Sharing load of two motors on one shaft without a connection between the inverters M
FR-A740

25. FR-A740 droop control
In unbalanced situation inertia M1 > inertia M2
Factor M1 > 1 Factor M2 < 1
Factor M1 positive Factor M2 negative
Output frequency M1 decreases Output frequency M2 increases
Load balanced

26. Regenerative energy
Regenerative energy is always an issue in crane applications. The decision for a certain regenerative option is based on the following application characteristic.

27. Regenerative energy How much regenerative energy do I have to handle?
Calculation of the Brake power :

28. Duty cycle
How often do I have to handle it?
Duty cycle
[%]

29. Regenerative unit or brake resistor
-> Circular duty cycle with high ED and high PBrake
Brake resistor
-> Non circular duty cycle, even with high PBrake
Regenerative unit -> E.g. steal production with automatised movement and a short duty cycle time. With lowering every 30 sec.
Brake resistor -> E.g. bridge crane in production hall, use only on demand.
Please find detailed information about braking on confidential website:
Brake resistor calculation.ppt
how to calculate brake duty.ppt
minimum brake resistor value.ppt

30. Mitsubishi Regenerative Solution
Too much regenerative energy?
Short time regenerative
Continuous regenerative
FR-RC up to 55k
MT-RC up to 280k (no CE mark)
FR-CV up to 55k (no CE mark)
FR-HC up to 55k MT-HC-S up to 375k
(no CE mark)
FR-A701 up to 55k
Internal brake chopper with internal / external brake resistor up to 22k
BU-UFS up to 550k FR-BU2 up to 750k (no CE mark)
How much energy? For which time?
Convert to heat? Regeneration?
For more than one inverter?
Common DC Bus
more
equal
heat
regen
For detailed information please have a look at “Regeneration and low harmonic solution.ppt” on confidential web site.

31. FR-A701
FR-A701 is a FR-A700 with active front end, which allows 100% torque continuous regeneration and 150% torque overload regeneration for 60s.

32. FR-RC & MT-RC POWER REGENERATION CONVERTER
Energy generated at braking operation of the inverter can be regenerated to the power supply. Since a converter does not require a discharging resistor, it is effective in space and energy saving and it provides a large peak braking torque.
One inverter connected to one FR/MT-RC.

33. FR-CV POWER REGENERATION COMMON CONVERTER
Enables 100%-torque continuous regeneration to support continuous regenerative operation for line control.
Saves energy since regeneration energy is used for the other inverters and excess energy is returned to the power supply.
Up to six inverters connected to one FR-CV.

34. FR-HC & MT-HC HIGH POWER FACTOR CONVERTER
Substantially suppresses power harmonics. Power regeneration function featured as standard enables common converter system operation with multiple inverters connected.
Up to six inverters connected to one FR/MT-HC
THDI = 0

35. Mitsubishi system solution
Mitsubishi frequency inverters offer a great variety of inbuilt functions to adjust your system to the application needs. Additionally we have system solutions with high performance Mitsubishi components.

36. Complete Solution
HMI
FX3U
PLC
Modem
Lifting
Translation
Rotation

37. Mitsubishi system solution
Inverter + FX series PLC
Inverter + Q series PLC
Inverter + GOT HMI
Inverter + Mitsubishi PLC + GOT HMI

38. Mitsubishi system solution Inverter + FX series
Inverter + FX1N / FX2N / FX3U with RS-485 module
-> Dedicated function blocks for serial communication to up to 8 inverters
-> Control, read / write parameters and full monitor function
Inverter + FX1N (1 axis) / FX3U (3 axis) pulse train positioning
-> Dedicated function blocks for absolute positioning, homing, zero return and SW / HW limit switches
For detailed information see FX-Solution Pack SP1 FX-INV.

39. FX3U inverter instructions
Configure and control frequency inverters with single commands:
IVCK: Check inverter status
IVDR: Control inverter
IVRD: Read inverter parameters
IVWR: Write inverter parameters
IVBWR: Block write inverter parameters
User-friendly configuration and control of frequency inverters and 3-phase AC drives
These instructions can be used to communicate with inverters of the FR-F700, FR-A700, FR-V500, FR-F500, FR-A500, FR-E500 and FR-S500 series. FX3U-485-ADP needed.
The PLC is connected to the inverter via a serial interface.
Two instructions for communication with frequency inverters can be executed simultaneously on the same interface. 39

40. Safety features with FR-A700 in CL & FX3U
Maximum torque limiter can be variable depending on the position the trolley reaches
When this torque limit is exceeded you can:
Stop the trolley advance
Stop the raising of the hook
etc.
Load in kg
4.000
3.600
3.200
2.800
2.400
2.000
1.600
1.200
800
400
Reach in meters

41. Mitsubishi system solution Inverter + Q series
Inverter + system Q with C24 serial com. module
-> Dedicated function blocks for serial communication to up to 32 inverters
-> Control, read / write parameters and full monitor function

42. Mitsubishi system solution Inverter + Q series (MEU internal)
Inverter + system Q with Q62DA and QD62E two motor positioning
-> Dedicated function blocks for absolute positioning, homing, zero return and SW / HW limit switches
High performance solution.
The inverter is in speed mode and gets an analogue signal from the inverter. The encoder feedback is connected to the high speed counter. It is also possible to connect an encoder behind a gear box or on a produced material which has high slip.
Really difficult function block only suitable for drive and PLC experienced customers!!!

43. GOT1000 and inverter
GOT1000 series is fully compatible to 700 series inverters
-> Control and set parameters of up to 10 inverters with one HMI
-> Use multi language on GOT1000 for inverter control and alarm history
-> Displaying advanced process data and alarms
Serial communication to inverter, standard RS-485 terminals of GOT and inverter.
Use the GOT as an easy to use parameter unit.
Transparent mode access to all 10 inverters using FR-Configurator, whether over serial com. or USB in bigger GOT (GT11 or GT15).
GOT is able to use station number-related programming. (GD11 = Station number value)
GOT speaks any language (unicode support), easy adapting of any language by importing and exporting excel sheets into GT designer comment groups.

44. Mitsubishi Portal Crane Demo Main Screen
Displaying:
Load
Distance horizontal
Distance vertical
Time
Demo project available on confidential website.

45. Mitsubishi Portal Crane Demo Data Screen

46. Mitsubishi Portal Crane Demo Alarms Screen

47. Complete Solution Further Advantages
FX3U PLC
Managing/ control movements through communications as master
Connection for the 3rd party products
Event history (Black Box)
Preventive maintenance data base
Modem
Remote monitoring (alarms, event history, etc) Remote access
HMI (touch screen)
Monitoring by the end user
Web-page
Adjustment of crane parameters
Black Box display (hidden)

48. Our strength in crane applications - proven by many reference customers.

49. Company ZPMC Shanghai Zhenhua Port Machinery
World largest seaport crane manufacturer
FR-A740–C9 special FW for cranes
We got this customer due to special FW C9 for second motor closed loop control in FR-A740. By this the vibration in horizontal movement was avoided. Please see special FW description in this ppt.

50. Consys (Russia) Company Baltkran
-> All types of container and bridge cranes (10 to 60t)
-> FR-A to 160 kW
Company 55 MOZ
-> All types of container and bridge cranes (10 to 20t)
-> FR-A to 15 kW

51. CSC-Automation (Ukraine)
Company EMZ
-> Bridge crane for steel production
-> 5xFR-A to 160 kW, 1 MT-RC, Q series PLC, MAC-E600, CC-link network
-> Automatised movement
-> Power regeneration
-> Optimised duty cycle due to automation

52. MEU-Italy Company Gru Benedini -> Tower cranes
-> FR-A500 and FR-A700
Company Gru Comedil
-> FX1N, FX3U
-> F940GOT, GT1150/55
Inverter is in discussion

53. MEU-Spain Company Jaso -> Tower cranes -> FR-A700 5.5 to 11 kW
-> For translation

54. MEU-Germany Company SLR -> Overhead and bridge cranes
-> FR-A kW
Company Aggreko
-> Portal cranes
-> FR-F kW
Company Diefenbacher
-> Bridge crane
-> FR-V kW

55. Conclusion
Due to the wide range of inverter standard functions, dedicated FW and options, Mitsubishi is the first choice for your crane application.