Crane down time monitoring (crane availability and Gantt views)

On each CMS the availability of the crane can be visualized using the WinCC option package Performance Monitor. The calculation of KPI’s or data representation for CMS is automatically integrated into the project. Pre‑defined reports and data representation can be recalled at any time in order to generate advanced reports quickly and easily. Data representation is simple and the option package Performance Monitor has several very useful functions standard on board.

Example of screen in CMS for Crane Performance Monitor – crane availability and Gantt view graph

Example of screen in CMS for Crane Performance Monitor – reporting of data (number of loads)

In order to access MS SQL data and retrieve data with one mouse click, a tool in Microsoft Excel has been developed. The Excel tool can be installed on any office PC in the terminal. The only prerequisite to access the MS SQL data from the archive on CMS & RCMS stations is to have connection to the CMS & RCMS PC. This can be checked via the integrated Topology Configuration Menu, where the CMS & RCMS stations, with PC name and IP address are defined.

Using the Excel data access tool, all alarms and archive tags from archives in CMS and RCMS stations can be retrieved and visualized in the Excel sheet integrated into the delivered tool. Statistics of alarms and information from operational data, such as moves, MMFB, counters, timers, etc. can be easily visualized and saved in the Excel data sheet. The Excel tool is an applicative solution, delivered as standard with CMS Application and free of charge with the SIMOCRANE CMS and RCMS product.

Easy access of data from CMS and RCMS stations via Microsoft Excel

Example of screen in Excel for alarms analysis from SIMOCRANE CMS station

Example of screen in Excel for tag logging data analysis from SIMOCRANE CMS station; browsing of all archive data in Microsoft SQL database on CMS /WinCC station

Multi‑user system for CMS Lean and CMS Basic – WebClients

Using the optional package WinCC WebNavigator, the CMS station can be expanded with additional operator stations. A typical application is an operator panel in the crane driver cabin or at another location in the crane.

Access is, however, also possible from the outside provided that the CMS station on the crane is accessible over the network or the Internet.

The access rights can be individually configured for each operator station and each user.

WinCC WebNavigator is provided as option for the CMS Basic and CMS Lean packages.

Example of screen of a WebClient with WebNavigator

The CMS Basic offers 3 WebClients. For CMS Lean two options are offered: (1) with one WebClient or (2) with three WebClients. If more WebClients are needed for the local CMS, additional clients by WinCC can be ordered separately.

Further information: See "Technical specifications", "Selection and ordering data" and SIMATIC HMI Catalog ST 80.

CMS Lean – Crane Central DataMonitor

On the CMS Lean package, the Crane DataMonitor concept uses a DataMonitor license only for one DataMonitor Client. This client is connected to all other local CMS stations, which are installed on the crane. The connection from each crane is made via an encrypted connection from the DataMonitor webserver and the clients. The advantage of this configuration is that it is a simple and cost effective solution that can provide different configurations for industry crane applications as well as for harbor areas. When needed, the number of DataMonitor clients can be extended with additional licenses on the DataMonitor webserver.

With CMS DataMonitor a project already configured using DataMonitor is included with the standard CMS Application.

The optional package DataMonitor offers user‑friendly functions for the graphical evaluation of cargo handling data, number of faults and other operating data of the crane. You can use a webbased user interface to create your own evaluations or adapt existing ones at any time.

These evaluations are possible directly on the CMS station or from a normal office PC, which, however, must be connected to each CMS on the crane over the network.

Overview of CMS Central Crane DataMonitor

Data Aggregation using CMS Central Crane DataMonitor

Graphical data representation in DataMonitor

In addition to data evaluation, the DataMonitor can also be used for remote access to the local cranes and CMS user interface. In this case, however, it is purely a monitoring mode. For most applications, this is adequate as a remote access function. The option package CMS WebNavigator for remote access purposes is not necessary in this case.

CMS Lean and CMS Basic Crane Performance Monitor

For CMS Lean and CMS Basic packages the optional package from WinCC Performance Monitor can be used in order to calculate KPI’s or perform crane availability for each crane. The WinCC Performance Monitor is delivered as an optional package for CMS Lean and CMS Basic as a separate article number – please refer to section for CMS Lean and CMS Basic ordering data.

When the Crane Performance Monitor option is activated via the license, the screens predefined in the CMS Application can be activated via the settings menu in the CMS Application (WinCC project). The screens are predefined for standard reports on the CMS, showing information about crane status, number of loads, weight of loads, consumed energy, etc.

The calculation of KPI’s for each crane can be modified depending of the project requirements. Custom reports generated in runtime on the CMS station can be realized. The information of the Crane Performance Monitor can be visualized remotely as well via WebNavigator using WebClients. In order to choose the correct article number, please refer to the ordering number structure of CMS Lean and CMS Basic packages.

Example of screen for CMS Crane Performance Monitor option

CMS Basic – Fast Trace function with SIPLUS CMS

An important source of information in the event of a fault is the signal profile of: Speed, Torque, Current, and Voltage, this in combination with a selection of important digital signals such as: Limit switches, Commands, etc.

Example of screen in X-Tools for Fast Trace function

Most of these are dynamic variables. If an error occurs, the system plots the signal profile for a predefined number of signals and saves them for a period before and after the error.

SIPLUS CMS with X‑Tool software used for this application is a high‑performance software package that is well‑proven in other sectors. As well as recording trace data, the "X‑Tools" program included in the scope of delivery offers high‑performance tools for data analysis and continuous monitoring of operating parameters (Condition Monitoring). This component is integrated into the SIMOCRANE CMS user interface in such a manner that values stored in the context of an error message can be retrieved as easily as possible. The maintenance technician requires no special training for this tool.

Trace display in WinCC picture

Configuration of using Fast Trace

IONs – Input-Output Nodes

SIPLUS CMS offers "IONs" for acquiring measured values. These are hardware or software modules that acquire the measured values. The software nodes, IONs are included in the standard software X‑Tools when this option is ordered. The hardware for IONs should be ordered separately, it is not part of the optional package in CMS Basic. Such hardware depends of the project configuration.

With the numerous hardware IONs in the SIPLUS product range, measured values can be acquired directly where they occur. This avoids incorrect interpretations which may result due to the time taken to transmit them via a controller. Sampling rates of up to 40 kHz (analog) or 50 kHz (binary) are possible using hardware IONs.

Software IONs

SIPLUS CMS records the data directly from the SIMATIC S7 and SIMOTION controllers using appropriate software IONs (Input‑Output Nodes). The sampling rate using software IONs depends on the controller platform used. A "cycle‑synchronized" trace can thus be achieved.

PROFIBUS ION

The PROFIBUS ION, also known as "Spy", is particularly versatile. This module can be used to record any values which pass via the PROFIBUS. The spy is a totally passive node and affects neither the bus nor the cycle time of controllers. The sampling rate that can be achieved is the PROFIBUS cycle. The PROFIBUS ION should be ordered separately.