Status display

The status display offers a symbol?oriented, graphical display of the crane and crane components including the current operating values and statuses. It is a very useful tool for the crane driver. Important displays are always in view, and detailed views can be called up in just a few steps. Although the interface is based on icons, moving the mouse over the elements in the screen shows detailed information and text can be visualized with order to receive information about the used symbols.

The status display screen provides supplementary information which will help the crane driver in his work. He is then capable of recognizing the cause of simple faults, such as interlocking for certain movements.

A status bar at the top of the screen displays fault states symbolically, and this is supplemented by text messages at the bottom of the screen.

Graphical status display for the spreader

Replay function (playback)

The replay function is delivered in the standard basic package of SIMOCRANE CMS. This function enables personnel to visualize (playback) the data in the screens from the past recorded in the database (similar to a DVD player). Thanks to a replay controller the operator can set different parameters and navigate through the screens, for example: set time span for replayed data, use navigation buttons (play, stop, pause, back?forward, speed, etc.), and navigate through different replayed screens. The screens for the replay/payback function are freely configurable via Replay Configuration Editor.

Example of replay home screen for an STS crane

Example of replay screen for hoist screen of STS crane

Example of replay screen for an RTG crane

The screens for the replay/playback function are freely configurable via Replay Configuration Editor. The Replay Configuration Editor is integrated into SIMOCRANE CMS product Configuration Editor. This enables the configuration of replay screens for the replay function in runtime visualization. The replay function works completely independent from the CMS RT function, which continuously collects the data from the field. The replay function works in parallel with CMS RT data acquisition and can be switched on or off via the graphical user interface any time the operator requires replay.

Replay Configuration Editor for replay screen configuration

With the Replay Configuration Editor, you can make the following settings required for Replay:

• Maximum number of archive tags; see the SIMOCRANE CMS operating instructions.
• Select the pictures to be prepared for Replay
• Check one or more pictures prepared for Replay
• Repair pictures prepared for Replay
• Clean up tags that are no longer needed
• Deselect pictures
• You can expand and view the list of Picture Selector Tags (read only)

The Replay Configuration Editor checks whether the requirements for Replay have been met every time a picture is selected or repaired. The necessary tags and structures are checked for completeness.

The following are required for Replay:

• ReplayControl structure
• Tags of the group ReplayControl with ReplayControl structure tags
• Tags of the Screens group that are relevant for Replay
• Tags of the Settings group that are relevant for Replay
• Tags of the ReplayControl group that are relevant for Replay
• Picture selector tags
• ReplayArchive

Replay Configuration Editor – replay screen automatic generation of modules by screen changes in WinCC project

Error messages and advanced diagnostics

In the event of a fault, the error message system helps with troubleshooting and fault rectification. These complex functions support maintenance technicians with their work and help to reduce downtime. Detailed error lists present the course of the fault chronologically. Many filtering and sorting functions increase clarity.

Comprehensive message system

Example of screen for maintenance instruction function Chronological message bar – message instructions

When an error message is selected, further sources of information can be accessed, such as:

• Maintenance instructions and notes
• Circuit diagrams, manuals, operating manuals, data sheets
• Screens, drawings, fault diagnostics
• Jump to different Microsoft programs, as Excel, PPT, Word, etc.
• Jump to videos related to the message content
• Direct navigation and jump to the PLC program and block functions related to the fault message content

Jump functions to different CMS program content – in this example jump to manuals

Jump functions to different CMS program content – in this example jump to S7 program block functions

Apart from the chronological message list, there are also statistical views that provide information on the frequency and duration of faults (hit list).

These make it easy to identify weak points and to obtain information about downtimes.

Example of statistical analysis (hit list) for messages

Measured value acquisition

CMS continuously acquires and archives important parameters, such as

• Position values of different components of the crane – hoist, trolley, gantry, etc.
• Setpoint inputs and actual values
• Speed, velocity, etc.

These values can be displayed in the form of trend curves at any time, and easily configured in RT configuration editors, with no necessary know?how of engineering or complex programs.

Crane parameter value acquisition – extended configuration in RT environment

Cargo handling

The cargo handling data of a crane is acquired and archived in order of occurrence. The composition of the data fields (cargo handling data record) is freely configurable and can therefore be adapted to every crane type.

An overview can be called up in the list form at any time at the press of a button.

Cargo handling data

Container handling list

The archived data can be made available to higher?level systems for further evaluation.

MMBF – Mean Moves Between Failures

MMBF (cargo handling moves between failures) is one of the most important key performance indicators in crane technology. It provides information on the availability of the crane.

Runtime meter

Maintenance planning systems require counts from runtime meters and counters for the components with relevance to maintenance. These values are first acquired by the crane controller. The CMS acquires these values from the controller and makes them available to higher?level systems.

Screen with Move Data of containers operating hour counter

It is possible to acquire operating hours and counter values and process them.

These values can be initialized or backed up in the controller via the CMS user interface. This function is extremely helpful if the CPU in the PLC has to be replaced.

Reporting lists

A simple form of report output is integrated into the system. The following reports can be output on the standard Windows printer:

• Current or archived fault reports
• Report of cargo handling data
• MMBF report

The tools that are available with WinCC allow the reports included as standard to be adapted or expanded at any time, and you can create and design your own reports.

This report in PDF format can easily be output on a PDF printer.

Advanced reporting

On each CMS station advanced reporting generation can be processed. This report is based on integration of different information regarding messages, operational data (e.g. move data, MMBF, counters, timers), statistics, data mining. The access is possible direct from Microsoft SQL database. The report is web based and can be pre?configured for standard data records. Each report can be customized in order to fulfill the customer requirements.

• Advanced Reporting from CMS and RCMS stations possible on every mobile device.
• Being informed anytime – from everywhere: web?based reports and analyses using mobile devices
• Reporting and management using Microsoft SQL Server Reporting Services
• Transparent access to all historical CMS and RCMS data in Microsoft SQL database
• Cyclic activation based on demands or events
• Web?based administration
• Transparent data access thanks to integration in MS Word, MS Excel and MS PowerPoint
• Automatic report distribution by email
• Customized dashboards and Business Intelligence tools on board

Advanced reporting of crane data using information server