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Crane drive and control systems: Part 1

Mahadevan Balasubramaniam, Siemens Netherlands, The Hague, Netherlands; Gerhard Fischer and Robert Fakkeldij, Siemens AG,
Erlangen, Germany

The container transportation industry has witnessed a energy is stored during hoisting and released during lowering,
remarkable growth over the last decade. More cranes are being the AC drive systems were designed to deliver power with
purchased annually then ever before and crane sizes have the capability to regenerate. Over the last 10 years AC drive
increased dramatically. The myriad of crane types required in technology has been further improved by gradually introducing
terms of form and function have always been evident. Thus, self-commutated line-side converters that offer the end-user
more efficient AC converter solutions were developed to cater an almost perfect power factor, low harmonic injection and a
the demand for ‘power hungry’ cranes yet with the availability high tolerance with respect to line voltage fluctuations. Also,
of different power configurations, ease of maintenance and the line commutated converters have become more robust and
reliability in mind to meet the demands of the ever challenging efficient compared to their predecessors. Line side converters
container transportation industry. Siemens as the leading with common DC bus configurations deliver the torque
supplier for container crane drive systems now introduces an required for all motions on the crane apart from being efficient
innovative drive and control system solution that offers crane and reliable to the end-user. Nevertheless, safety should not be
builders, system integrators and end-users for the first time compromised for performance hence the relevant standards and
standardized yet flexible hardware and software solutions. norms have to be fulfilled.

Crane drive systems The principle of infeeds

The different types of cranes available in the market have The AC converter system converts the AC line supply of 50 Hz or
one thing in common: a need for power. Since on cranes, 60 Hz to variable voltage/frequency required for all motions on a

FIgure 1. Typical overview of a tandem lift STS drive system.

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Figure 2. Overview of general infeed types. Figure 3. SINAMICS S120 Cabinet Module.

crane. The diode bridge rectifier or IGBT types are the two most • Draw-out type phase modules
commonly found infeed configurations in the market today. The
Based on Siemens vast experience in the building of crane
former is used for 2 Quadrant non-regenerative operations, for
control panels, a modularized range of standard crane drive cabinets
example on a RTG and straddle carrier. This type of unregulated
comprising the necessary line connection, switch-over, motor
infeed is usually robust and compact yet in principle, fairly priced.
modules (MoMo) and-multi motor modules have been developed.
However, braking modules and resistors have to be implemented
to dissipate the regenerative energy which is mostly generated by
the hoisting system, leading to high energy cost. Modern RTG’s
nowadays are equipped with hybrid solutions, such as Siemens
ECO RTG’s, which are more fuel efficient then conventional
RTG’s. These hybrid solutions utilize 4 Quadrant infeed systems.
Self commutated IGBT infeed is the preferred solution for
regenerative operation in STS and RMG’s. The IGBT’s are
actively pulsed using a pulse width modulation method and are
not susceptible to short time line voltage fluctuations (within
limits), thus maintaining a constant DC bus voltage at all times.
Also, the power factor of near unity (during loaded operation)
is attainable, making it the preferred solution for end-users with
ever increasing electricity bills from power utilities. Furthermore,
the latest development in state-of-the-art IGBT’s, have a higher
power density, hence they are more compact in size with lower
conduction losses. Due to lower thermal losses, the heat sinks are
also smaller. An optimised modulation scheme allows lower PWM
carrier switching frequency which results in reduced losses within
the drive system.

Line modules
The Siemens drive system SINAMICS S120 has recently been
introduced to the crane market. There are three basic types of line
side converters available for different types of cranes as shown in
Figure 2:
a) Basic line module (BLM) is a thyristor or diode bridge rectifier,
which is extremely compact.
b) Smart line module (SLM) is a line commutated infeed that is
enhanced by the use of IGBT’s that avoid commutation faults/
failures as known for thyristor based rectifiers.
c) Active line module (ALM) is a self-commutated infeed with a
high dynamic performance and a ‘line friendly’ solution.
SINAMICS adds to features well known from the SIMOVERT
MASTERDRIVES series such as wide power range, modularity
and global support with additional benefits:
• Increased power density
• Improved efficiency
• Minimal cooling fan noise Figure 4. Direct parallel connection.

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Drive configurations injection into the system. The advantage of SLM’s as an IGBT
inverter in comparison to their thyristor based predecessors is
With the availability of a grid network as power source for
that it can now be switched off at any time hence commutating
the crane, the self commutated converter is the best option for
short circuits do not occur during regenerative operation in the
regenerative operation in 4 Quadrant applications. Redundancy
event of supply voltage failures.
of the infeeds can be achieved with a single control unit as
SINAMICS converters and the corresponding line side system
shown in Figure 4 above and can be described as ‘direct parallel
components such as line reactors are designed to be connected
connection’ redundancy. In cases where one infeed fails, the
to supplies with a permanent level of voltage harmonics in
operator or service personnel can switch into emergency mode
accordance with EN 61000-2-4, Class 3. For the active line
and the remaining infeeds can be operated again but with lower
crane capacity i.e reduced motion speeds. This is a cost effective module, Total Harmonic Distortion factor of the line voltage,
solution as a two winding transformer, a single crane switch as THD(V) is typically three per cent.
per IEC60204-32, a single control unit for the infeeds, reduced The overall drive system should be an insulated earth (IT)
low voltage devices such as auxiliary contacts and terminals are supply. TN systems suffer from substantially higher voltage stress
sufficient. The line contactors are used as crane On/Off switches levels on motor windings due to common mode oscillation. For
while the ACB’s upstream are utilised as an E-Stop. IT supply, an insulation monitoring device is installed to comply
For a more stringent requirement on availability of infeeds, with IEC60204-32 (refer to application note “Crane Drive
the crane drive and control configuration differs. The ‘galvanic System Configurations – SINAMICS S120 Active Line Module
separation’ operation, as shown in Figure 1, is where a failure Sizing and Configuration”).
of one or more infeeds will not disrupt the operation other From past experience, failure of infeeds are more critical then
than the availability of reduced power on the crane in line with the motor side in terms of two aspects; time required to service/
the remaining healthy infeeds. Such an availability however, has replace components quickly to avoid long downtimes and the cost
a price to be paid compared with the previous solution, with of such failures. Unpredictable behaviour of the grid which affects
the need of individual galvanic isolated secondary windings, the supply of the crane in terms of voltage, frequency and current
individual crane switch and individual control units, and could put a higher demand on the sizing and configuration of the
additional low voltage devices for each line side converter. Also, system.
with additional equipment comes the need for more space
required to place the control cubicles. Conclusion
The line side commutated converters or SLM’s used in 4 The rapid growth in the production of container cranes poses
Quadrant operations with the capability to regenerate are new requirements to crane builders, system integrators and
foreseen in a ‘galvanic separation’ configuration as mentioned also end-users. Drive and control configuration determine
above with the exception that a 12 pulse parallel connection the performance, reliability and safety of the crane. Siemens’
is implemented via a symmetrical three winding transformer new crane drive and control solutions based on SINAMICS
which are recommended to be vector group Dy5d0 or Dy11d0. with SIMOTION D can offer flexibility yet dynamic
Also, a line reactor with a relative short circuit voltage of 4 performance and enhanced reliability. The latest development in
per cent should be installed. ‘Direct parallel connection’ is not crane control system will be discussed further in the next edition
advisable with SLM type infeeds due to the high harmonic of Port Technology International.

ABOUT THE COMPANY ENQUIRIES

Siemens is one of the world’s largest electrical engineering companies. Siemens Siemens AG
is committed to delivering state of the art solutions which minimize the impact on I DT MC CR
the environment. With over a century of experience in supplying electrical traction 5th Floor, Building 38 Frauenauracher Str. 80
equipment a revolutionary new drive system has evolved in the crane market. 91056 Erlangen
Germany

Tel: +49 9131 98 4849

Web: www.siemens.com/cranes

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