With trolley travel distance sensors: The trolleys measure their distance from the end of the main girder in each case with a distance sensor laser beam. With this measurement, the braking function and shut-down can be implemented (instead of by the usual cross-type limit switch) and also the anti-collision device (instead of by the usual reflective light barriers) through the resulting calculated position of both trolleys. In the joint operation of both trolleys, the constant distance between the trolleys is also calculated and correspondingly controlled.
With crane travel distance sensor: The cranes measure their distance from another crane on the same run (or from both of the other cranes on the same run) via the distance sensor laser beam. This enables the braking function and the shut-down to the other crane/s on the same run to be implemented (instead of by the usual reflective light barriers). This also enables the constant distance to be controlled in tandem operation. The braking function and shut-down at the end of the crane track is implemented via the cross-type limit switch.
Reflective light barriers or one-way light barriers are generally used when there is a crane distancing system due to structural reasons or a load-dependent crane distancing system. Cross-type limit switches are generally used for building profile controls.
For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Abnahme" (commissioning) (user level ‚[2]) must be logged in.
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Danger due to malfunction The distance sensor can only fulfil its safety function when it is correctly fastened. Otherwise malfunctions could occur (e.g. if the distance sensor is not correctly attached and falls down). Carefully fasten and align the distance sensor and reflector. |
─ With crane travel distance sensor: The distance sensor of the crane and the reflector for the distance sensor of another crane on the same run are fastened on a shared mount on the end carriage. On the other crane on the same run, the placement of distance sensor and reflector are accordingly interchanged. The light beams of the distance sensors are not allowed to cross each other.
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─ With trolley travel distance sensor on the wire rope hoist GM modular: The distance sensor is pushed laterally onto a mount in the cover of the cable drum. The reflector is taped onto the end carriage of the crane as adhesive foil or fastened on a square tube.
─ With trolley travel distance sensor on the wire rope hoist GM compact: The distance sensor is installed on the trolley frame with a magnetic mount. The reflector is taped onto the end carriage of the crane as adhesive foil or fastened on a square tube.
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The distance sensor is either fastened with a mount on a square tube on the end carriage or attached to the wire rope hoist with a magnetic mount.
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Threaded bracket |
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Mount |
Pipe clamp | |
Attach the mount on the end carriage.
Bolt the mount onto the threaded
bracket.
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Threaded bracket |
Tightening torque |
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M8 |
25 Nm |
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M10 |
50 Nm |
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M12 |
75 Nm |
Slide on the two pipe clamps and secure
them.
Push the square tube in the pipe clamps and
screw tight.
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Adapter |
Mounting plate |
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Distance sensor |
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Push the entire mount onto the square
tube.
Screw in the mount using M8 rib nuts (4x)
and tighten by hand.
Push the distance sensor into the adapter on
the mounting plate and tighten the screws.
Select the appropriate size and type from
the following drawing.
Read the dimensions A and B from the
following table.
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Magnetic mount |
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Assembly position of the magnetic mount on wire rope hoist E
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Size |
Dimension A |
Dimension B |
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800 4/1 |
130 |
100 |
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1000 2/1 |
130 |
130 |
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1000 4/1 |
130 |
130 |
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2000 2/1 |
130 |
130 |
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2000 4/1 |
130 |
160 |
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3000 2/1 |
130 |
160 |
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3000 4/1 |
130 |
160 |
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5000 2/1 |
130 |
160 |
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5000 4/1 |
130 |
200 |
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6000 2/1 |
130 |
160 |
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Assembly position of the magnetic mount on wire rope hoist S. Observe dimension C and fasten the distance sensor as centred as possible on the rope drive.
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Size |
Dimension A |
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800 4/1 |
140 |
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1000 4/1 |
180 |
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2000 4/1 |
180 |
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3000 2/1 |
180 |
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3000 4/1 |
245 |
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Assembly position of the magnetic mount on wire rope hoist U. Observe the different positions for the left and right distance sensor.
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Size |
Dimension A |
Dimension B |
Dimension C |
Dimension D |
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5000 4/1 |
330 |
350 |
310 |
660 |
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6000 2/1 |
325 |
640 |
285 |
560 |
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6000 4/1 |
400 |
320 |
370 |
595 |
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7000 2/1 |
360 |
420 |
450 |
550 |
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Assembly position of the magnetic mount on wire rope hoist D.
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Size |
Dimension A |
Dimension B |
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800 4/1 |
210 |
60 |
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1000 4/1 |
200 |
50 |
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2000 2/1 |
200 |
50 |
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2000 4/1 |
200 |
50 |
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3000 2/1 |
225 |
50 |
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3000 4/1 |
225 |
50 |
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5000 2/1 |
200 |
50 |
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5000 4/1 |
130 |
50 |
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5000 4/2 |
200 |
50 |
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5000 6/1 |
130 |
50 |
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6000 2/1 |
200 |
45 |
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6000 4/1 |
170 |
50 |
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6000 6/1 |
200 |
50 |
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7000 2/1 |
190 |
50 |
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7000 4/1 |
190 |
50 |
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7000 4/2 |
190 |
50 |
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7000 6/1 |
190 |
60 |
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7000 8/2 |
190 |
50 |
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Assembly position of the magnetic mount on wire rope hoist DA.
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Size |
Dimension A |
Dimension C |
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800 4/1 |
540 |
30 |
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1000 4/1 |
250 |
35 |
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2000 2/1 |
520 |
55 |
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2000 4/1 |
520 |
55 |
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3000 2/1 |
470 |
50 |
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3000 4/1 |
550 |
60 |
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5000 2/1 |
550 |
45 |
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5000 4/1 |
610 |
55 |
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6000 2/1 |
565 |
50 |
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6000 4/1 |
700 |
55 |
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7000 2/1 |
590 |
70 |
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7000 4/1 |
390 |
170 |
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7000 6/1 |
350 |
200 |
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Assembly position of the magnetic mount on wire rope hoist DQA. Observe dimension C and fasten the distance sensor as centred as possible on the rope drive.
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Size |
Track |
Dimension C |
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2000 |
1400 |
100 |
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3000 |
1400 |
85 |
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2000 |
1600 |
100 |
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3000 |
1600 |
85 |
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5000 |
1600 |
75 |
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6000 |
1600 |
80 |
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2000 |
2000 |
95 |
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3000 |
2000 |
85 |
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5000 |
2000 |
75 |
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6000 |
2000 |
85 |
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2000 |
2500 |
100 |
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3000 |
2500 |
80 |
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5000 |
2500 |
75 |
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6000 |
2500 |
85 |
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7000 |
2500 |
100 |
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7000 |
3000 |
100 |
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7000 |
3500 |
100 |
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Assembly position of the magnetic mount on wire rope hoist Z.
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Size |
Dimension B |
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5000 4/2 |
535 |
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5000 8/2 |
580 |
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6000 4/2 |
565 |
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6000 8/2 |
570 |
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7000 4/2 |
725 |
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7000 6/2 |
850 |
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7000 8/2 |
660 |
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7000 10/2 |
300 |
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7000 12/2 |
470 |
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Assembly position of the magnetic mount on wire rope hoist ZA.
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Size |
Dimension A |
Dimension C |
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5000 8/2 |
315 |
355 |
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6000 8/2 |
315 |
200 |
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7000 6/2 |
440 |
500 |
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7000 8/2 |
420 |
482 |
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7000 10/2 |
500 |
570 |
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Magnetic mount |
|
Attach the magnetic mount to the wire rope
hoist.
The position specified refers to the point on the distance sensor at which the laser beam emerges from it.
Depending on the installation situation, the position for the magnetic mount may already be marked.
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Drum side |
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Pull off the cover from the drum side.
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Mount |
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| |
Push the mount with the slit laterally into
the cover.
Place the cover on the wire rope hoist.
Push the distance sensor into the adapter on
the mounting plate and tighten the screws.
During tandem control: Put the cranes at
maximum distance.
During the joint operation of two trolleys:
Put trolleys at maximum distance.
Move the adhesive foil so that the laser
point is as close to centred as possible.
The more precise adjustment is done later on the distance sensor. The position of the adhered adhesive foil can no longer be corrected.
Press on the adhesive foil.
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Threaded bracket |
|
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| |
|
Mount |
Pipe clamp |
Bolt the mount onto the threaded
bracket.
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Threaded bracket |
Tightening torque |
|
M8 |
25 Nm |
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M10 |
50 Nm |
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M12 |
75 Nm |
Slide on the two pipe clamps and secure
them.
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Square tube |
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Reflector |
Push the square tube in the pipe clamps.
Push the reflector onto the square tube.
Move the reflector so that the laser point
is as close to centred as possible.
The more precise adjustment is done later on the distance sensor.
Screw on the pipe clamps and reflector using
M8 rib nuts (4x) and tighten by hand.
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Fillister-head screw M6x20 |
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Adjust the distance sensor with M6x20
fillister-head screws (3x) so that the laser point is exactly on the centre of
the reflector.
● If the distance sensor receives the laser beam reflected from the reflector, the LEDs on the distance sensor light up.
● If the distance sensor does not receive the laser beam, one of the LEDs flashes.
Adjust the distance sensor with the rough and fine adjustment screws so that the laser point is exactly in the centre of the reflector.
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Fillister-head screw for the fine adjustment |
Fillister-head screw for the rough adjustment |
Release the fillister-head screw in the
elongated hole for the rough adjustment and tilt the distance sensor.
If necessary, release the fillister-head
screw for the fine adjustment and fine-adjust the distance sensor with the
short, crosswise-lying fillister-head screw.
● If the distance sensor receives the laser beam reflected from the reflector, the LEDs on the distance sensor light up.
● If the distance sensor does not receive the laser beam, one of the LEDs flashes.
Tighten the long fillister-head screws
(2x).
Travel along the entire traversing range
with the crane (or the trolley) and examine whether the laser beam meets the
reflector at every position and does not drift sideways or
upwards/downwards.
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Overview: Navigation in KranOS |
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User "Abnahme" (commissioning) à "Crane travel" à "Crane travel distance sensors" |
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User "Abnahme" (commissioning) à "Trolley travel" à "Trolley travel distance sensors" |
Log in as user "Abnahme" (commissioning)
(user level [2]) in KranOS. See Connecting laptop or
tablet computer with ABUControl, page .
Select the desired trolley drive or crane
travel drive (e.g. trolley travel 1 or crane travel) in the main menu.
● The window for the requested drive appears.
Click on the "Crane travel distance sensors"
(or "Trolley travel distance sensors") menu item in the "Settings" menu (gear
wheel on a yellow background).
Now the distance sensor will be taught in. For this purpose, the crane/trolley is travelled to the desired position and the distance sensor value determined for this position is saved in ABUControl.
Note regarding "Calibration mode"
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The upper area of the window "Crane travel distance sensors" or "Trolley travel distance sensors" is used to calibrate the distance sensor when the maximum distance to the reflector is greater than 35 metres. This is only necessary in rare cases. In addition, this area of KranOS is only intended for future versions of KranOS and is currently without any assigned functions.
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Description field with current position |
"Teach-in mode" button |
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"Write PLC" button |
Message with the next switching point to be travelled to |
Click on "Teach-in mode" button.
● The button's background turns green.
● "Teach-in mode" is switched on.
● The "Bridge limit switch" button turns red.
It is possible that switching points for braking function and shut-down already saved will now be ignored.
Thus, the trolley (the crane) can be moved to any new positions.
● A message appears for which switching point (braking function or shut-down) is to be travelled to.
Travel the trolley (the crane) to the
corresponding position.
The distance sensor must be at least 0.5 m away from the reflector.
In the column for the switching point which
is to be learnt: Click on the "Write PLC" button.
● The measured value for the current position is displayed in the description field.
The displayed value is a measured value without measurement unit, which is used to calculate the position later.
Repeat the process for all further switching
points.
After the switching points have been saved:
● The teach-in mode ends automatically.
● The limit switch bridging turns off automatically.
