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
Department of Physics and Electrical
Engineering
Faculty of Technology
II
III
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.
IV
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.
V
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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VII
Table of Contents
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 mu 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
VIII
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
1
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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3
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
Figure 2.3 Crane training simulator schematic diagram.
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
9
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)
11
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.
Self hold button: The Button will hold on after pressing.
13
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
14
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
15
Light of
connection
DO
(Digital signal
output)
Light of connection turns on
Emergency
stop DI Stop every processes
16
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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.
sincos
cos)(
....
.2.....
glx
xuFmlmlxmM
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 1cos , sin , and we can get
FMlMl
gMmx
Ml
u
FMM
mgx
M
ux
1)(
1
..
..
Transfer the equations to state-space representation
)()()()()(
)()()()()(.
tutDtxtCty
tutBtxtAtx
],,,[ xxx
And with u(t)=F ,Y=[x] we get
0)(
0
1000
00
0010
Ml
gmM
Ml
u
gM
m
M
u
A
0001
10
10
C
Ml
MB
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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.
29
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.
30
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.
31
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.
32
33
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.
34
35
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
36
37
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
38
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
39
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
40
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 adjuDI
Automatic lifting position of Head block
41
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
42
Left control panel
Name Type of
signal Function Descriptions
Guild board
Choose left
guild board at
seaside
DI Choose left guild board at seaside
Choose left
guild board at
seaside light
DO Light turn on when someone choose left
guild board at seaside
Choose left
guild board at
seaside
DI Choose left guild board at seaside
Choose left
guild board at
seaside light
DO Light turn on when someone choose left
guild board at seaside
Choose left
guild board at
seaside
DI Choose left guild board at seaside
Choose left
guild board at
seaside light
DO Light turn on when someone choose left
guild board at seaside
Choose left
guild board at
seaside
DI Choose left guild board at seaside
Choose left
guild board at
seaside light
DO Light turn on when someone choose left
guild board at seaside
Pitching permit
light DO Light turns on when pitching is permit
Trolley Trolley stop DI Trolley stop at specific position
43
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
container DI Mode for 40 feet container
Select 40 feet
container light DO
Light turns on when someone select 40 feet
container
Select 45 feet
container DI Mode for 45 feet container
Select 45 feet
container light DO
Light turns on when someone select 45 feet
container
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
44
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
45
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
--
46
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
47
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
48
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 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
Spreader pump on
signal
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
49
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
50
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
M8.7 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
signal,spreader
M1.6 Spreader M9.1 20 Inch
container choose
51
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
M1.6 Spreader
without load signal
M9.3 45 Inch
container choose
signal
I9.3 2*20 Inch
container choose
M1.6 Spreader
without load signal
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
52
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
53
54
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
55
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
56
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
57
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
M1.2 Trolley move to the right place
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
58
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
M6.1 Record spreader position 1
M6.2 Record spreader position 2
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
59
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
M8.7 Trolley move to the right place
M9.0 Trolley stop
M9.1 20 Inch container
M9.2 40 Inch container
M9.3 45 Inch container
M9.4 2*20 Inch container
M9.5 Van carrier choose
M9.6 Choose trailer
M9.7 Choose hook
60
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
61
M12.5 Spreader go up
M12.6 Spreader go down
M12.7
62
Appendix 5:The full instructions
The function is divided into nine parts:
FC1: Faults
Network1: Red overload light
63
Network2 : Red overload light
Network3: Yellow overload light
Network4: Wind speed 30 alarm
64
Network5: Wind speed 30 alarm
Network6: Wind speed 20 alarm
Network7: Error alarm
65
Network8: Error alarm
Network9: Buzzer
66
Network10: Mute
67
Network11: Mute
FC2: Spreader
Network1: Pump of spreader
Network2: Spreader lock
68
Network3: Spreader lock
Network4: Spreader leans left
69
Network5: Spreader leans right
Network6: Spreader leans forward
Network7: Spreader leans backward
70
Network8: Spreader position 1
Network9: Spreader position 2
Network10: Spreader position 1 reset
Network11: Spreader position 2 reset
71
Network12: Spreader anchor at seaside
Network13: Spreader anchor at land side
Network14: Anchor in wind
72
Network15: Select spreader for 20 foot container
Network16: The spreader for 40 foot contain
73
Network17: The spreader for 45 foot contain
Network18: The spreader for 20 foot contain
74
Network19: Lock shrink
Network20: Lock stretch
Network21: Select spreader at seaside
75
Network22: Select spreader at land side
Network23: Select all spreader
Network24: Connect spreader
76
Network25: Disconnect spreader
FC3: Guild Board
Network1: Guild board up
Network2: Guild board down
77
Network3: Left guide board at seaside
Network4: Right guide board at seaside
78
Network5: Left guide board at land side
Network6: Right guild at land side
79
FC4: Boom
Network1: Permit boom movement
Network2: Stop boom movement
80
Network3: Boom up
Network4: Boom down
81
FC5: Pitching
Network1: Permit pitching
FC6:Trolley
Network1: Trolley stop automatically
82
Network2: Trolley stop manually
FC7: XYZ
Network1: Trolley toward to left
83
Network2: Trolley toward to right
Network3: Crane move forward
Network4: Crane moves back
84
Network5: Spreader up
Network6: Spreader down
Network7: Trolley speed
85
Network8: Crane speed
Network9: Crane speed
86
FC 8: Head block
Network1: Head block cylinder toward left
Network2: Head block cylinder toward right
Network3: Select all head block
87
Network4: Head block cylinder up
Network5: Head block cylinder down
Network 6: Head block cylinder automatic adjust
88
Network7: Turn on head block pump
Network8: Head block stretch
89
Network9: Head block shrink
FC 9: Others
Network 1: Select carrier
Network 2: Select trailer
90
Network 3: Select spreader
Network 4: Select hook
Network 5: Lock shrink
Network 6: Lock stretch
91
Network 7: Manual lock memory
Network 8: Automatic lock memory
Network 9: Set lock at seaside
92
Network 10: Set lock at land side
93
