SIMOCRANE CMS and RCMS package components

The SIMOCRANE (R)CMS package is a combination of different components. The scope of delivery of the SIMOCRANE CMS package comprises the CMS product components and a CMS Standard Application. In order to understand the components of the CMS & RCMS package, please refer to the picture below.

SIMOCRANE CMS/RCMS package components: SIMATIC WinCC (grey), SIMOCRANE CMS Product (green) and CMS Application (blue)

With the SIMOCRANE CMS Package standard tools are provided in order to make the configuration for standard features based on customer requirements – for example messages, message instructions, data transfer intervals from CMS to RCMS, replay screens, etc. In the CMS Application part, the screens can be easily changed or new objects can be added by need depending of the customer requirements (configuration of faceplates and objects, new crane configuration with different options for hoisting, etc.).

Example of customized screen for an industrial crane in steel pipe industry

SIMATIC WinCC (SCADA)

SIMATIC WinCC is the SCADA system from Siemens. SIMATIC WinCC is used as platform for SIMOCRANE CMS product development. At the same time, WinCC is used also as Runtime (RT) license for CMS Application (WinCC project example). It contains the basic functions for condition monitoring, the error message system and process value archiving in Microsoft SQL database.

SIMATIC WinCC options

WinCC optional packages like WebNavigator, Information Server, DataMonitor and Performance Monitor are required for evaluating data, reporting, KPI calculation and for accessing a CMS station remotely.

SIPLUS CMS (X‑Tools)

Using this software package, Fast Trace functions can be implemented for visualizing of high‑speed signals.

SIMOCRANE CMS product (system software)

Based on the open interfaces of WinCC, the SIMOCRANE CMS system software package expands the basic system with the sector‑specific crane technology functions. This covers, for example the acquisition and processing of cargo handling data, expanded diagnostic functions, replay function (playback), jump functions (Step7 function blocks, documentation, screens, drawings, etc.), bulk engineering, connection protocol to a central CMS (RCMS), connection to graphical user interface based on CMS Standard Application.

SIMOCRANE CMS Standard Application

The product components named here are part of the tool kit for implementing the functionality of a Crane Management System. The scope of delivery also includes a standard application that demonstrates practical implementation. The standard CMS Application is provided as an example and it can be modified at any time and customized based on customer requirements. In the CMS Standard Application the Replay Controller is also integrated for example. Such controls can be customized or the customer can add new functions when needed.

With the package SIMOCRANE CMS an example of application is provided on the installation software DVD in order to provide a standard user interface and application example for SIMOCRANE CMS.
This example is divided into two categories: one for CMS Lean package, including an example for a WinCC project with standard features for a RTG/RMG crane. The CMS Basic is a project example of a CMS Application consisting of a WinCC project for a STS crane. The standard application can be extended for a large number of variants for crane applications. An example for an STS crane (CMS Basic) or RTG/RMG (CMS Lean) is provided and therefore makes starting a CMS project much easier. In the simplest case, it is sufficient to set parameters at the controller interface to obtain a fully functional Crane Management System ready to use with minimum engineering and configuration effort.

Overview of SIMOCRANE CMS/RCMS main components

Experience has shown that a number of functions offen always remain almost the same in crane projects for Crane Management Systems. This means that the modules can be reused in other projects as well. In some cases, project‑dependent configurations are necessary in order to fulfill the customer requirements. Most of these requirements are related to CMS screens, which are part of the CMS Standard Application. The CMS system from Siemens is sufficiently open to allow the customer to fulfill these requirements with own project engineering work.

The standard CMS Application can cover the most commonly used harbor cranes (for example STS, RMG, RTG) and industrial cranes (for example ladle crane).

The CMS Application is used by way of example and can be any time changed and adapted to the customer needs.

SIMOCRANE CMS package components: WinCC, CMS Application and CMS Product (green components are crane‑specific items based on own development)

Interface between PLC & Drive components and CMS

Normally the Crane Management System is connected directly to a PLC or drive components. In case of the SIMOCRANE CMS, the channel used is an S7 channel available in WinCC for Siemens controllers of S7 type, S7‑300 and S7‑400. When S7‑1500 TIA Portal is to be used, the interface should be tested and adapted to the customer requirements – please ask our Customer Support department or Cranes Application Supportabout this kind of application (for contact data please refer to the separate section).

Standard interface between S7 and Drives and SIMOCRANE CMS

The interface is based on a defined standard based on a S7‑300/400 controller. It is standardized on other SIMOCRANE‑based products, such as Basic Technology (BT), Drive‑Based Technology (DBT), Sway Control (SC), Truck Positioning System (TPS) and ECO Technology. The interface is provided in a separate document, where the detailed tags in WinCC and DB structure in S7 are described. This document can be downloaded free from customer support page from Siemens. When using the standard S7 channel from WinCC, advanced diagnostics functions can be generated and used directly in the CMS Application project with a very limited effort. This makes it possible for diagnostics functions from the S7 layer to be integrated directly into the CMS level.

Communication CMS stations to RCMS (Remote CMS)

The communication between CMS Lean/CMS Basic stations and RCMS station(s) is based on a proprietary protocol included and delivered with the product SIMOCRANE CMS. For the communication between CMS and RCMS it is not necessary to buy a separate channel, the communication between CMS and RCMS is automatically included in each CMS station. When the customer buys a CMS Lean or CMS Basic station and later needs to connect to a RCMS (Remote CMS station), the channel is included in the packages already bought. Only the configuration needs to be done on CMS and RCMS stations in order to define the crane topology structure for CMS and RCMS (e.g. crane names, IP address of CMS, name of RCMS, IP address of RCMS, etc.)

Configuration of connection for SIMOCRANE CMS to RCMS (Remote CMS)

Overview of the configuration of SIMOCRANE CMS stations and one RCMS station

Installation sites and environment

Electrical room

The drive and control technology and the CMS station are located in the electrical room. An industry‑standard Rack PC or a Panel PC can be used as hardware platform. It is recommended that the embedded hardware of the new generation of Rack PC or Panel PC is used, i.e. with no moving parts such as fan or hard drive, using a SSD card instead. In this way high availability of the hardware components can be achieved.

The user group mainly consists of service and maintenance technicians. It is possible to call up detailed diagnostics information here, access documentation, circuit diagrams, S7 programmable data blocks, etc. Also the service and maintenance personnel can perform Replay/Playback actions at CMS in the electrical room.

Crane driver cabin

The CMS operator panel in the crane driver cabin is preferably a Touch PC and primarily supports the crane driver in his work.

The crane driver receives information on the fault messages, the operating states and operating data, as well as readily understandable diagnostics information. It is only possible to set the operating mode for the crane from the crane driver cabin; and this also applies to activation and deactivation of the technological functions, such as sway control or truck positioning.

Maintenance building/remote crane access

The maintenance and system technicians are based here on standby. They require remote access to the CMS systems of the cranes. This requires a standard PC which, as web client, can call up diagnostics and other information from every crane in the terminal. From maintenance building the Replay function can be activated and used on the CMS system. Remote control of cranes can also be performed from the maintenance building as well.

Control center/control room

In the case of a network of several cranes and a central data server for long‑term archiving and consolidated evaluation, the RCMS server is located here and any further RCMS operator stations with remote access to the cranes.

Administrators, the plant operator, as well as maintenance and service technicians or crane drivers with remote control desks work here. The Replay function can be used via remote station, in web environment, in order to visualize the information from the past.

From an RCMS operator station, the terminal operator has a complete overview of the crane terminal and can quickly access an individual crane without the need to be physically on the crane.

User groups and functions

Crane driver

The straightforward arrangement provides this user group with the most important information about the operating state of the crane. It is important in a fault situation that the crane driver can detect the cause as fast as possible. He must be able to decide quickly whether they are capable of correcting the fault themselves or whether they require support from a technician.

Apart from presenting information, they can also make operational adjustments, i.e. by activating and deactivating options such as SIMOCRANE Sway Control, SIMOCRANE Truck Positioning, etc.

Maintenance technician

This user group has specific knowledge of the system and can therefore call up more extensive diagnostics information for fast rectification of faults. Maintenance technicians must be able to quickly access the main sources of information that they require for fault rectification purposes. With regard to error messages, maintenance technicians can access specific circuit diagrams and manuals. The Replay function can also be activated and used by this user.

Terminal operator/manager

The terminal operator/manager is interested in statistical information and operating data. This user group is provided with this information content in the form of reports and statistics. The Replay function can also be used in the context of remote operation of the crane from a central control desk.

Administrator

The administrator has access to all authorizations and can set up and manage users. This usually comprises the personnel of the IT department of the plant operator.