Crane Control and Automation: Global Solutions

Crane Control and Automation
Global Solutions
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Organization of Document
TMEIC designs, tests, and commissions complete crane automation systems. This document provides an overview
of the engineering processes and technology used in these systems. The figures below illustrate these processes and
technologies with each section identified with a numbered page icon ( ).
#
Comprehensive Engineering Process
A smooth crane system startup depends on a well-planned and executed engineering process. Starting with the system
proposal and specification, TMEIC’s application engineers manage the entire project through commissioning. This critical
engineering process is illustrated below and detailed in the Project Engineering section. Icons indicate where the various
teams of engineers in the factory and field service organizations are involved in the project.
Detailed
Technical System
Hardware & System
System Maintenance
Proposal Software Design Commissioning
Test and
Specification and Component
15 Procurement
Service
Customer Team 16 17 19 20
Field Team
Factory Team
Training Team
Project Engineering Process
A Flexible Control System Architecture

The Maxspeed® crane control system architecture uses a master controller to coordinate all the networked drives and
to communicate with the operator interfaces, input/output devices, and the yard management system. The Maxview®
system employs vision systems to automate the crane operation. TMEIC has adopted industry standards to simplify the
configuration and integration of these complex control systems for your application:
• Globally accepted communication protocols and open data interfaces for seamless integration of third-party systems,
and maximum flexibility for future growth and minimum risk of obsolescence
• Ethernet® communications between the controller, operator interfaces, and yard management, providing high-speed
communication and low-cost, standard spare parts availability
• Windows®-based configuration tools, familiar to all users, for all system components
Engineering Station Operator Screens Master Switch Controller

RX3i Link to Yard Management System 7
Toolbox 25 28 5 26 Vision
TMGE Systems
- AC
+
Manual & Automatic 7

Adjustable Speed Drives TM-10 TM -DC
Crane Systems 4 22 24
Technologies Employed
Page 2 of 32 © 2019 TMEIC Corporation. All Rights Reserved.

®
Why Our Equipment Helps Set Production Records

The advanced features of the TMEIC Maxspeed® and the Maxview® visions system allow operation of the yard at a higher
rate, often setting production records. In addition, the increased reliability helps reduce container and equipment damage.
The main system features providing this superior performance are outlined below.
System Features and Benefits
Maxview® Vision System allows Fast and Reliable Crane Operation

• Automatic landing system for accurate pick-up, drop-off, and stacking of containers
• Ship and Yard container profiling system provides safe and efficient operation of both manned
and unmanned cranes
• Chassis Guidance System guides the truck driver into the exact target position
• Direct position measurements are unaffected by rope stretch and wheel slippage
Maxspeed® Fast Operator Response Increases Throughput

• High-speed LANs (local area networks) link the I/O system, master controller, and drives so
the container precisely follows the operator input in manual mode, and follows the system input
in automatic mode
• Multi-tasking controller and the drives are all optimized for the fastest response
Remote Operator Console Streamlines Operation

• Automatic operation allows the operator to manage several cranes at the same time
• Remote operation facilitated with live video feed of container location and container corners
• Point and click container inventory interface allows the operator to locate containers and
associated data in real-time
• Point and click generation of crane work instructions
Ethernet Connectivity Increases Productivity

• Master controller, HMI system, and drives reside on industry standard Ethernet for rapid
exchange of data with computer systems, and for fast configuration
• Standard software, including MS Open Data Base Connectivity (ODBC), XML, OLE for Process
Control, plus drivers for MS SQL and Oracle, speed up communication between computer
systems
CraneDirector™ Container Tracking & Inventory System Provides Faster Operation

• All container movements are tracked and stored in a central data base accessible to yard
management and all crane automation systems
Graphical, Real-Time Maintenance & Diagnostic Reporting

• System level equipment diagnostics makes crane status available in many locations
• Maintenance management planning system creates alarms when equipment maintenance is
required
© 2019 TMEIC Corporation. All Rights Reserved. Page 3 of 32

Maxspeed Crane Systems
Manual Crane Control Systems
The Maxspeed crane control system uses adjustable speed drives to
control the speed and direction of the crane motors driving the gantry,
trolley, boom, cable reels, and hoist. The speeds and directions are
set by the operator using a master switch (joystick), which inputs
signals to the controller through the I/O racks. A high-speed local area
network (LAN) transmits the control signals to the individual drives,
which generate the variable frequency three-phase AC power to the
induction motors.
The link between the operator switch and the controller is optimized
for speed so the operator has fast and responsive control of the motor.
Earlier crane systems used DC drives and motors, but most regions of
the world are now standardized on AC technology. A typical manually-
controlled system is shown below.
Remote Crane Optional Local Crane

Management Management System
System RX3i Controller
Cab I /O
Operator
RF Transceiver
Ethernet Operator
Screen
Local Area Network
Master
TM-10e2 Adjustable Switch
Speed Drives:
Local Area Network
40,000 Hr MTBF
15 Minute MTTR
Remote I /O
Tachometer T T T
Benefits
Motor M M M Same architecture for Ship to Shore & Yard cranes
Brake B B Crane duty drives and Fast
motorsResponse
with global AC Drives
recognition for their quality and reliability
Hoist Trolley Gantry 1 Open architecture
Boom Gantry 2 System scalability allows a smooth integration of
Spreader Cable & advanced options
Main Cable Reel
Maxview vision systems can be added to fully automate is designed for computer control, but allows operator
the crane so that, in the case of rail mounted gantry control from a remote location if a problem occurs. A
cranes for example, no operator is required. The system typical computer-automated system is shown on page 7.

®
Fast Response to Operator Inputs

Since the introduction of electronic controls, operator The Local Area Network (LAN) protocol has been
joystick response has been an issue because of specifically designed for the frequent transmission of small
communication delays. The time for an operator input packets of data, in contrast to most popular protocols,
to reach the motor depends on three factors: which are optimized for occasional transmission of large
• The data rate that is possible with the plant cable packets of data. The crane control system is illustrated
and communication components below showing the three high-speed communication links:
• The efficiency of the protocol, driven by the size • A fast hard-wired link from the operator’s master switch
and quantity of messages required to transmit the to the cab input/output modules
packet of data • A high-speed LAN between the cab input/output
• The turnaround delay time in the sending and modules and the controller
receiving devices • A high-speed LAN between the controller and the drive
cabinet
Control Cab Crane Motor Room Trolley

Cab I/O
RX3i Controller
Hoist Drive
CPU
Hoist Motor
Hard Wired LAN LAN
M
Master Switch
Fast hard-wired High-speed LAN High-speed LAN

link from the between the cab between the PLC
operator's master I/O modules and and the drive
switch to the cab the PLC cabinet Load
I/O modules
Input logic in the Input logic in the

controller optimized controller optimized
for speed. for speed.
Immediate Operator Response using Fast Communications
Optimized Communications System Benefits

The RX3i controller has the latest • The load precisely follows the operator input, even with the higher
technology with microsecond loads currently being used.
processing times. To provide • The yard achieves a higher rate of productivity than previously
the fastest possible response to possible, often setting production records.
operator inputs, the input logic in
both the controller and the drives • The use of single cable LANs means there are no expensive wiring
has been optimized. So, from the requirements to link the various parts of the control system.
operator’s perspective using the • All the drives are on the LAN, so all motors have the same
master switch, this technology instantaneous response to operator inputs.
provides responsive control with
• The response using the remote operator station is just as fast as
hardwired-like functionality.
using inputs from the cab.

Energy-Saving RTG uses the MaxFuelSaver™ System
RTG energy RTG
saving tests operation
in Yantai
Save 30% diesel fuel using the MaxFuelSaver system

Engine PLC
Ethernet Gateway
RX3i
Engine speed feedback Reset Characteristics:
Engine temperature Twistlock locked
Engine torque ref. Engine
Existing
Standard TMdrive converter
Speed Hoist accelerating
Engine status Regulator Power limit crane PLC supplying DC bus
ECM Power demand
Standard TMdrive-10 inverter
supplying auxiliary loads
D DC Bus Option to include a regenerated
Sinewave
Constant Inverter filter energy storage and recovery
Voltage Aux. function to increase fuel savings
Diesel Loads
Generator
Option for a stand alone unit to
Set retrofit to third party inverters
IGBT converter Trolley
Line reactor Benefits:
G
Reduced crane fuel consumption
of 30% by optimizing engine
Variable Hoist/Gantry 1
AVR
speed and partially recovering
Voltage &
V/Hz Frequency regenerated energy
Reduced engine emissions
Gantry 2
Reduced audible noise
Reduced engine maintenance
cost
Energy Saving RTG Test Results
Engine speed
Fuel consumption
(accumulated)
Power demand
Several months of tests

on both Tier 2 and Tier
3 diesel generators
produced fuel savings
up to 42% depending
on the operating
conditions.
RTG before retrofit RTG after retrofit with MaxFuelSaver

®
Maxspeed Sensorless Electronic Sway Control

This patented system reduces the sway of the spreader Features of the TMEIC anti-sway control system:
caused by motion in the trolley direction or gantry direction • Faster moves and shorter cycle times
during load moves. • Hardware sensors are not required so the initial and
operating costs are lower, and the reliability higher
In Manual operation the operator is sending a speed • The system is not weather-dependent, so snow and
reference to catch the load as it swings, see the dotted rain do not effect its operation
blue line in the time plot below. Manually catching the • Installation is fast since there are no sensors to
load is difficult and not all operators can do it successfully. calibrate
The green line shows the swing motion of the load. • Sway control can operate in manual as well as in
automatic moves
In Automatic operation with Sway Control, the system
• The trolley and gantry sway performance is ±50 mm,
figures out how to catch the load by controlling the speed
which can be improved if required
of the spreader, see the lower time plot. The operation
• Skewing sway performance is less than one degree
is faster since the trolley and load come to rest at the
• The system is less expensive and more reliable than
same time, with no waiting for sway damping. The load
hydraulic anti-sway control systems
is controlled in one swing of the pendulum, and does not
The TMEIC sensor-less crane load measurements are
overshoot the stop position.
covered by U.S. Patent 6,527,130.
Manual Operation Manual Inputs

from Master
Switch
Speed/Position
Time
Trolley Speed
Feedback
Load Sway
Speed Feedback
Position
Ref. Ramp
Automatic Operation with Sway Control
Trolley and Manual Input
Load come to
Speed/Position
rest here
Sway Position
Time

Automated Crane System
The Maxview vision system, added to the basic Maxspeed control system and CraneDirector™
crane automation interface, provides several levels of scalable crane automation from semi-
automatic with manual assistance up to fully-automatic, unmanned operation:
• Laser scanners detect the edges and ends of the container
• The controls position the trolley, chassis, and spreader
• Cameras read the container IDs and communicate with the yard director computer
• The gantry is positioned using transponders or satellite signals
Terminal Operating System Remote Operator Stations

Yard Planning CraneDirector
& Container Crane Management &
Tracking System System Yard Director
ODBC
Server Computer
XML
Data Base
Ethernet
Maxview
Local Crane Management RX 3i Controller
Trolley
Position
Maxspeed
Sensor
Trolley
Adjustable Remote I /O Remote I/O

Video Speed
Cameras Drives
Laser
Scanners Spreader
T T T Tachometer
M M M Motor
Video B B Brake
Cameras
Hoist Trolley Gantry 1
Boom Gantry 2
Gantry Position Sensor Antenna Spreader Cable Reel
Main Cable Reel
Embedded Transponders

Yard Data Flow & Control Functions
TMEIC supplies all of the crane control and automation equipment, operator interfaces, and software shown in the diagram
below.
• The yard management system software in the central office is usually supplied by others
• The CraneDirector software linking the crane automation system with the yard management computer may be on the
crane or in the central office
• The remote crane operator station may be on the crane or in the central office
Yard Management
Yard Management Database
System
Generates Work Instructions
for container movement Work Instructions
Yard Layout
Yard Inventory
Central/Remote Office
Work Instructions Operator-Generated
Dock Yard
(Commands and Status) Work Instructions,
Inventory View
ODBC
ODBC
Remote Crane Operator Station
• Video displays
CraneDirector
TM
• HMI screens
• Desk devices
• Crane ground
• Work Instruction Processing level or central
• Container & Crane Tracking
• Data Collection & Logging
Manual Commands,
Status, Video
Tasks and
Status
Basic Crane Control
Control Logic  Drive Control
 Manual Control
 Relay Ladder
Crane Automation Logic
Positioning  Positioning
 Auto Landing
 Profile Scanning Crane Drives
 Anti-Sway
Local Operation
 Anti-Collision
(Cab - Optional)
Input/Output
Motors

Maxview® Systems
Maxview systems provide the measurements required for full
automatic crane operation, as well as for increased productivity and
reduced damage for manually operated machines.
Maxview Automatic Landing™ System

This Maxview Automatic Landing system provides simultaneous
measurement of the landing target and spreader during container
pickup and drop-off so the load can be positioned directly over the
landing target. This is essential for automatic pick-up and stacking of
containers in the yard.
Laser scanners on the trolley measure the position of the spreader

relative to the target container below (refer to the illustration on the
right). Using these measurements, the Maxspeed® crane control
automatically picks and lands containers in the yard, or places them
onto trucks or automatic guided vehicles.
The stack profile option provides a profile of the containers in the

yard for safe and efficient operation of both manned and unmanned
cranes. The stack profile is used by the crane automation system to
continuously calculate the safe height for automatic moves.
Maxview Smart Move™ System

The Maxview Smart Move system is tailored for RTG and RMG cranes.
It dynamically measures the spreader position and the objects below
the crane, providing trolley slowdown and stop inputs to the crane
control system to help prevent spreader collisions and stack topples.
Maxview Clear Path® System

The Maxview Clear Path system provides collision and area protection
for both dockside and yard cranes. The distance between the
crane and obstacles in its motion path is continuously calculated;
the Maxspeed crane control uses these measurements to assure
operation at the optimum, yet safe, speed. Measurement data
and sensor diagnostic information is readily available via Crane
Management System (CMS) screens.
Maxview Sensors detect container ends and sides
Maxview Gate Monitor™ System
The Maxview Gate Monitor system provides a continuous view of the
lanes at your truck gates, 24 hours per day, 7 days per week. This
Maxview system analyzes this view and provides your systems with
critical data about the traffic through your gates, including confirmation
of empty chassis at the gate, detection of all combinations of loaded
and empty chassis, and detection of any vehicle in a gate lane.
Maxview Chassis Guidance™ System

The Maxview Chassis Guidance system cuts cycle times and
increases productivity by guiding the truck driver into the exact target
position under the container-handling crane for a quick container
transfer.
Custom Maxview Systems

We can design systems to meet your special measurement needs, on
Maxview Smart Move system on an RTG Crane
the cranes or elsewhere in the terminal.

Maxview Smart Landing®
The Maxview Smart Landing system is a laser-
based ship profile and operator landing assist system
that increases ship-to-shore crane productivity and
reduces damage and operating noise. The system
is in service on ship-to-shore cranes today.
The design is based on TMEIC’s extensive

experience in crane automation applications in the
container handling and other heavy material handling
industries.
The system is particularly effective in assisting

the operator during container pick-up and drop-
off in deep vessel cells, resulting in increased
productivity. Once in the cell, the operator can lower
the spreader at “full stick”, while the system reduces
the speed as required for an optimal, soft landing at
a predetermined speed.
Benefits
• Reduced wear and tear on the spreader and head block - the hoist speed is limited to a pre-set value as the
spreader approaches the pick-up or drop-off point to assure smooth, soft landings.
• Reduced wear and tear on crane structure and wire ropes – smooth landings eliminate slack rope conditions and
reduce crane structural oscillations.
• Reduced container damage costs
• Hatch cover detection can be used for operational tracking and to enforce limitations during handling.
• Reduced operating noise level due to softer landings on containers, and hatch cover handling
• “Flipper Up” confirmation at vessel deck level further reduces spreader damage.
How it works
The Maxview system uses a laser scanner and TMEIC’s Maxview
software modules to measure and continuously update the
profile of containers and other obstructions under the crane. The
Maxview laser scanner has a range of over 80 meters, which
provides measurement to the bottom of the deepest vessels. The
profile is updated continuously, without need for additional trolley
motion (including during the first move over the vessel). The
Maxview system also tracks the spreader position (hoist position
and sway), and continuously compares the distance between the
spreader plus load and all objects in the stored profile. The system
can be easily retrofitted onto existing cranes.
The Maxview Smart Landing Crane Management System (CMS)

screen is provided for the crane operator to increase visual
awareness of the profile of containers and objects below the crane.
This CMS screen also indicates the system status. Spreader in cell (view from cabin)

Advanced Automation Systems
Sophisticated sensors are mounted on the crane to measure the position of the moving parts and the load so the crane
can operate automatically. The various sensing systems are shown in the diagram below.
Automatic Position Indication (API) - Trolley Position

Incremental Encoder, Automatically
Calibrated via Laser DME
API - Hoist Position

Incremental Encoders,
Automatically Calibrated via
Limit Switch
Crane Collision Avoidance

Network Position Broadcast
& Laser DME
Auto Landing System (ALS) -

Spreader and Container Position,
Container Profile and Anti-Collision
Crane Laser Scanner System
API - Gantry Position

Incremental Encoders, Automatically
Calibrated via Transponders
Automatic Position Indication System (API) – The API system makes direct measurements of the gantry, trolley, and
hoist position via laser rangefinders, unaffected by factors such as rope stretch and wheel slippage.
API - Gantry Position. An antenna picks up the signal from a transponder embedded in the surface. An interpreter card
generates a corresponding code signal, which is sent to the crane control so the gantry can be positioned accurately.
Alternatively, signals from the GPS satellite system can be used for positioning.
Recal
Code Signal
R
C
Inter
Ca el
a
pret
Interpreter Relay
rd
Card
ar
Card
er
Antenna y
d

®
Multiple Crane Automation – Yard Level System

Multiple cranes communicate with the yard management system over fiber optic cables. The cables come out of the crane
through a cable reel into a trench, and are connected to an Ethernet fiber optic hub. As an option, wireless communication
can be used instead of fiber optics. The network uses standard Internet Protocol (IP) for control and video signals, and the
network “heartbeat” is monitored for safety and emergency stop functions.
Crane Crane Controller

Automation
Computer
Remote Control Center

Yard Planning Cable Reel
and Container Fiber Optic
Tracking System
E Electro-Optical
O Converter Rotary Coupler
Yard Office
Fiber Patch
Note: Fiber Optics can be replaced with Panel of
wireless communication from the office Repeater Hub
to each individual crane.
Cable Reel and Fiber

Optic Cable in Trench
Ethernet
Fiber Optic
Hub
One Cable
for each
Crane
Example of Yard Automation

TMEIC’s experience includes the control and
automation of overhead bridge cranes in slab and
coil yards. TMEIC offers fully automated solutions
for slab, ingot and coil handling, from automation of
individual cranes to management of the entire yard.
Some of the advantages:
• Labor savings
• Reduced equipment maintenance and downtime
• Improved product tracking
• More precise product placement and storage
• Increased safety during heavy material handling
in the harsh environment of a metal rolling mill

Project Engineering
Project Engineering
TMEIC’s
TMEIC Crane
GE’s Engineering
Crane Team
Engineering in Virginia
Team in Virginia
Dedicated Crane Engineering Team
The material handling engineering team is dedicated to • Complete factory system test includes simulation of
Dedicated
the craneCrane
controlEngineering
and automationTeambusiness, and gained each AC and DC drive and motor, allowing us to ”move
Theexperience working engineering
material handling in the portsteamwithistechnicians
dedicated toand loads” from thefactory
Complete yard operator’s
system perspective.
test that includes
themechanical suppliers.
crane control This engineering
and automation business, and background,
gained simulation of each AC and DC drive and motor,
• The local commissioning engineers are part of the
itscoupled with working
experience state-of-the-art technology,
in the ports enables TMEIC
with technicians and allowing us to “move loads” from the yard
to consistently meet the demanding requirements of the project team,perspective.
operator’s allowing a seamless transition from the
mechanical suppliers. This engineering background,
industry.
coupled with state-of-the-art technology, enables TMEIC factory to your yard.
 The local commissioning engineers are part of the
GE to consistently meet the demanding requirements of project
• Factory team, allowing
automation a seamless
engineers organizetransition from
the factory test
theExperienced
industry. crane engineers jointly define the equipment
and control strategy with your engineers and the OEM. andthe factory
assist to the
with yourcommissioning.
yard.
This is followed
Experienced craneby engineers
detailed design
jointly ofdefine
the operator
the  Factory automation engineers organize the
The Local
factoryCommissioning Team
test and assist with ensures you have
the commissioning.
stations, configuration
equipment of the with
and control strategy drives,
yourand master and
engineers control
Knowledgeable Ongoing Service
theprogramming.
OEM. This is followed by detailed design of the TMEIC’s Installation
The Local & Field Service
Commissioning organization
Team ensuresis broad
you
operator stations, configuration of the drives, and master andhave
deep
Exhaustive
control Factory System Test Minimizes Risk
programming. Knowledgeable Ongoing Service the industry,
with extensive experience in
We understand that late delivery is very expensive, so we providing you with a strong local service presence for
TMEIC GE’s Installation & Field Service organization
take several steps toSystem
hold ourTest
aggressive startup schedule: startup and and
is broad ongoing
deepservice work, both
with extensive in the U.S.
experience and
in the
Exhaustive Factory Minimizes Risk
overseas.
industry, providing you with a strong local service
We understand that late delivery is very expensive, so
we take several steps to hold our aggressive startup presence for startup and ongoing service work, both
schedule: in the U.S. and overseas.
5
®
Technical Proposal Specification
System
architecture
illustration
During your project planning stage, Thorough

experienced material handling description of
application engineers prepare a control
technical proposal that includes: functions
• Customized system
architecture for your project
• Detailed system equipment
specifications
• Formal bid documentation
Detailed
description of
equipment
Our application engineers are highly qualified,

and many of them have over 15 years of
material handling industry experience.

Detailed Hardware/Software Design & Procurement
Electrical and
mechanical prints
Control logic design
Operator interface
screen design
Based on the proposal specification, the project engineering team proceeds with four main tasks:
• Control Software Design. • Hardware Design.
Control engineers configure the master controller All equipment is specified per the project requirements,
logic, sequencing, and drives. The illustration above and a complete set of elementary diagrams, layout, and
shows a typical logic function in Relay Ladder Diagram outline drawings is created.
format. • Component Procurement.
• Operator Screen Design. We work with our group companies to source the most
Operator interface screens for operation and cost effective system components for your application.
maintenance of the crane are configured using the
HMI engineering tools providing real-time crane data
and operator interaction.

®
System Test
TMEIC understands the importance

of a thorough system test. Our
engineering team conducts an
exhaustive factory test in the large,
fully-equipped system test lab
featuring:
• Complete staging of the
system with the controller, HMI
system, networks, and all drive
controllers.
• Unique to the industry, a motor
and load simulator in the drive
controller (see below) allowing
lifelike simulation of the
machine.
• Validation of all network
interfaces, including drives, HMI
stations, and other networked
devices.
• Crane mechanical model in the
PLC simulating the real world The picture above shows one of our test labs, featuring;
actuators and sensors. • 200-plus drive controllers with simulators
• 64 HMI and touch-screen operator stations
• 10 RX3i PLCs
• Complete Maxview sensor systems
Typical Factory Test Setup in the Test Lab
Crane
Management RX3i Controller
System
U
P
C
Drive Controller
Drive Controller M Load Control Logic
Drive Controller M Crane
Load Cab Operator
Process
M Load Model Interface
Devices
Selected
I/O Devices
Motor-Load Simulators

System Test
Enabling Technology for Process Simulation in a Factory System Test
Real-World Crane Environment System Simulation
Local Area Networks

(LAN) Power Bridge Local Area Networks Digital Motor
Motor Simulator
Drive Controller Drive Controller Digital Load
M Load
M Load
Simulator
Power Power
Power
Drive cabinet M Model Load Model

cotroller,
Power Bridge Intertia K 1 d N/d t
Friction K 2N
and Motor 2
Windage K 3N
On the crane, AC and DC drives control In the System Test, the drives control a
motor speed and mechanical load motor and mechanical simulator
Each AC drive has a controller with I/O and a gate driver, Each AC/DC drive in the system has its own digital motor
which controls the power IGBTs in the power bridge. The simulator based on a dynamic mathematical model. All
power bridge generates the adjustable frequency AC drive simulators are networked with the master controller
voltage supply to the three-phase motor controlling its and operator stations to test the entire system in real time.
speed and torque. Starts, stops, running modes, response to manual inputs,
LAN continuity, and drive configuration are all validated.
In the case of a DC drive, the power thyristor-based power
bridge converts the AC power to a variable DC voltage, This unique capability allows the entire team to obtain
which is applied to the motor armature. This controls the an intimate understanding of the system prior to the
DC motor’s speed and torque. commissioning, ensuring a smooth, on-time startup for
your project.

®
System Commissioning
In the commissioning phase of the project, the TMEIC

team includes the local field engineers you know and
trust, along with the engineer who designed and tested the
system. This overlap of teams between the factory and
the crane site ensures a smooth and on-schedule startup.
The TMEIC service engineer, who is responsible for startup
and commissioning, and for any future service required at
the port, is part of the project team and participates in the
design to become familiar with the system.
The available support for commissioning includes:
• Local service team
• Factory service engineers
• Factory control engineers
The commissioning phases are shown below.
Check out all wiring

1 and communication Commission
links, load all software, 2 crane manual
and commission drives Commission
control functions 3 crane automation
and motors
system
Commissioning
Phases
Yard
Teams Service
Involved Factory
Training
Commissioning Time Line
Working with the Field Service team, TMEIC offers a single source for installation and commissioning. All three phases
above are compressed by:
• The exhaustive factory acceptance test that includes all drive controllers, master controller, and communication links
• The timesaving commissioning and drive tune-up Wizards
• Training and familiarization of the entire team with the system at the factory

System Maintenance & Service
Global Customer Support Network

Comprehensive technical service is provided by our Customer Support Organization, staffed by TMEIC service engineers
with offices and spare parts depots across the globe.
In North and South America Remote Drive Diagnostics

Customers are supported by the TMEIC Corporation TMEIC Corporation supports drive customers through
service personnel, design engineers and Spare Parts the Remote Connectivity Module (RCM), a remote
Depot in Virginia, and the TMEIC Factory in Japan. diagnostic service link with the TMEIC design and service
engineers in Roanoke, Virginia. The RCM enables
In Europe
seamless integration between your drives and our
TMEIC service engineers service all drive systems in
engineers.
Europe, supported by the European TMEIC Spare Parts
Depot. Remote System Diagnostics
TMEIC’s remote system diagnostics tool, included in level
In Asia and the Pacific Rim
1 software, offers a quick path to problem resolution.
TMEIC services drive systems throughout China, India and
System faults are automatically identified, and provide
the Pacific Rim, supported by multiple Field Engineers,
an integrated view of product, process and system
Spare Parts Depots, and the TMEIC factory in Japan.
information. TMEIC design and service engineers in
Roanoke, Virginia, can analyze the data and provide
steps for resolution.
For Service or Parts, call

1-877-280-1835
INTERNATIONAL:
+1-540-283-2010
24 Hours / 7 days
Features Benefits
Quick support saves thousands of $ in lost production

• Reduced downtime and
TMEIC engineers can quickly connect* to the drive and diagnose many issues in a
Mean-Time-to-Repair
matter of minutes.
Customer-controlled access
• Secured connection All remote activity is conducted with permission of the customer. Drive start/stop
is not permitted remotely.
Proprietary Fault Upload Software

• Fault Upload Utility Historical drive faults are identifi ed; TMEIC design and service engineers can
analyze the issue resulting in the fault and provide a solution.

®
System Maintenance & Service
Training at the Factory or in Your Facility

Customer engineers, maintenance, and operations personnel
are trained on the drives and control system at the TMEIC
Training Center in Virginia. This world-class facility has large
classrooms and fully equipped training labs.
Classroom and hands-on training consists of 50% class time
and 50% hands-on lab time. Topics include:
• Overview of the drive system
• Function of the main assemblies
• Technical details of the components
• Operation of the control system from the local touch panels
and the central HMI
• Drive and control system programming using the Control
System Toolbox
• System diagnostics and service
Customized Training at the Port
As an alternative to the standard factory training in Virginia, TMEIC can offer a course tailored to your project and held at
your location. In this case, a project engineer and local service engineer train your operators, maintenance technicians, and
engineers in your facility.
Complete and Detailed Drive System Documentation

Along with the hardware and software, TMEIC
delivers complete system documentation:
• An electronic instruction book with
all the prints on CD with a hyperlink
index
• System configuration on CD and a
hard-copy form
• Detailed system manual
• Recommended wiring and grounding
procedures
• Renewal parts list
• Standard third-party vendor
documentation
At the end of the project, the drawings are
updated to reflect the final changes. Final
drawings are delivered to the customer on
CD ROM in AutoCAD format, together with a
hard-copy version.

TMdrive-10e2 TMdrive-DC TMdrive-30 TMdrive-MVG
Features of the Drive Family Benefits

Common Control Hardware
All TMdrive products share a common architecture: Spare parts inventory is always an issue in crane automation.
• Common I/O boards TMEIC reduces this investment with a common set of control
• Common LAN interface boards hardware for all of your low voltage AC and DC system drives.
• Common front panel display and keypad options
Common Toolbox
When commissioning the system, maintaining schedule is
A common Windows-based toolbox is used to configure and
everything. The commissioning and tune-up wizards ensure that
monitor all TMEIC system drives. The Toolbox features:
the system drives are not the critical path item in the start-up. In
• Integrated trending
ongoing maintenance work, the integrated trending tools provide
• Animated function block diagrams
an in-depth view into the regulation functions.
• Commissioning and tune-up wizards
Legacy System Interfaces
It is important for new drive system equipment to integrate with
The majority of crane automation projects today involve some form
legacy systems. All TMEIC system drives have several features
of modernization. The close tie that today’s TMEIC system drives
that address this point:
have with legacy GE systems reduces the cost of engineering,
• ISBus, Modbus, Profibus-DP, and DeviceNet LAN interface
commissioning, and training.
boards for PLC-based systems
• Common Control System Toolbox configuration

®
TMdrive-®10e2 Low Voltage System Drive
TMdrive®-10e2
The family of low voltage AC system drives has
an integral DC bus structure with a wide variety of
inverters (DC to AC) and converters (AC to DC) to
match virtually any application in the paper industry.
• 400, 460, 575, or 690 volt operation

• Motor power up to 1,949 kW
• Regenerative converter option
Draw-Out Style Inverters

For applications up to 193 kW (249 hp), draw-out style
inverters are available in a very compact package.
Draw-out inverters are mounted on heavy-duty slides

with staggered dc bus connectors on the back that
connect with the bus when slid into the cabinet.
Motor cables are terminated at a common terminal

block in the bottom of the cabinet. Heat Pipe Cooling Technology
The use of heat pipe technology provides a dramatic
advance in power bridge cooling, including a significant
reduction in the footprint of the power bridge, and fewer
fans lower the audible noise.
Condensor
The Thermal Cycle
Chill Condensate to Vapor
Plate 1
IGBT’s are mounted to the multi-channeled chill
plate which cools them. Heat generated by the
IGBTs vaporizes the refrigerant, moving it upwards
through the chill plate to the finned condensing unit.
Vapor To Condensate
2
Cooling air is pulled up through the IGBTs and the
condensing unit, and cools the refrigerant, which
IGBT Power condenses back to liquid.
Switches
Return of Condensate
3
The condensed refrigerant returns to the bottom of
the chill plate to start the thermal cycle over again.

TMdrive®-DC System Drive Overview
The TMdrive-DC family of system drives shares numerous components
with the TMdrive-10e2 AC products and are composed of several
frames offered in any combination of four form factors (digital front
end (DFE) control retrofits, frame assemblies, module assemblies,
complete cabinet assemblies).
This flexibility of form factors and commonality with the TMdrive-10e2

AC products suits the current modernization project trends in crane
automation:
• Digital Front End (DFE) control retrofits on larger DC drives,
saving the expense of replacing the existing power bridge and
motor.
• Selected DC drive frame upgrades to address incremental power
requirements.
• Frequent use of both DC and AC drive technology in projects.
Featuring Flexible Mechanical Design
TMdrive-DC’s flexibility in packaging allows it to meet virtually any new or retrofit application. Three of the more common
applications are illustrated below, from a DFE module to a complete DC drive and cabinet.
Legacy DC Drive Modernized TM-DC Drive
TMdrive-DC
DFE DFE Digital Front End
Hardwired I/O Interface Analog Regulator
Drive reference, feedback Current and speed Retrofit legacy drive control with
and status signals hardwired regulators built from TMdrive-DC digital front end and
with rest of the control analog components controls, preserving existing power
system bridge, auxiliary power components
in panel, cabinet, motor cabling, and
motor
TMdrive-DC
TMdrive-DC Module
Assembly
Retrofit legacy drive
control and panel with
TM-DC DFE controls,
new power bridge, and
panel components,
preserving exisiting
cabinet, motor cabling,
and motor
TMdrive-DC
& Cabinet
TMdrive-DC and Cabinet

Hardware Based Sequencer
Retrifit entire legacy drive with
Sequencing functions
TMdrive-DC drive including:
hardwired on TTL or relays
Power Bridge - Controls
Original DC source - Power bridge
in the DC Drive - Panel
- Cabinet
perserving existing motor
cabling and motor

®
TMdrive-Navigator Supports the Entire TMdrive® Family

The TMdrive-Navigator tool helps you
maintain TMEIC drives yourself. Engineers
and technicians are empowered to
understand how the drive works and what
the drive is doing. Any user can easily
access current drive expertise and know
how.
Desk-top like search technology links topical signal lists,

block diagrams, help files, product documentation,
change history, and user notes. Windows techniques
facilitate navigation within a drive and across the
system. The status of all drives is always in view.
High-speed data is automatically captured and saved in the

event of a drive fault. Users may also capture high speed
data based on their own trigger conditions or perform high
resolution real-time trending.
Fault data can be automatically “pushed” to key sers. The
client-server architecture allows access to high performance
data from remote locations with the same resolution as if
you were in the plant.
Wizards support tuning of drive functions.
Live block diagrams provide a real-time graphical view

of drive functions. Functions can be configured directly
from the graphical view. Product documentation is
integrated right into the tool. Users may even capture
their own notes to benefit future troubleshooting.
Compatible with:
• Windows XP, Vista 7
• Windows Server 2003, 2008

World Class Master Controller
PAC Systems™ RX3i

The PACSystems™ RX3i controller provides the crane control functions including logic, sequencing, and motor speed
signals. The controller rack contains the power supply, CPU, and spare slots for communication and I/O cards.
Controller Features Benefits

Configuring Software
Powerful and Easy to use
The Logic Developer PLC software provides
The choice of graphical and high-level languages
graphical programming languages including
makes the controller easy to use and powerful.
familiar ladder logic, block programming, and
Immediate access to all project information on the
SFCs. Real-time data and power flow are
screen saves configuring time and avoids errors.
highlighted in green.
Fast Controller More Control and Faster Response
The controller uses a 300 MHz processor and RX3i provides more control capability in a single
10 Mbytes of user memory with the very fast PCI controller than previous controllers, and faster
backplane. response to inputs.
Communication Options Seamlessly integrates with other Control
A selection of communication Local Area Networks Systems
and I/O device networks: Connectivity options provide seamless integration
• Ethernet, 10/100 MB/s with the rest of the dock yard systems and any existing
• Serial RS-232 and Serial RS-485 I/O such as Series 90-30, Genius, or Profibus.
• Genius Bus and VersaMax Ethernet Global Data (EGD) provides very fast
• Profibus and DeviceNet communication with other devices.
Dual Backplane I/O Flexibility and Speed
The controller supports both the high-speed PCI PCI dual backplane is 250 times faster than 90-
backplane (32 MB/s) and Series 90-30 backplane 30 backplane and allows both RX3i and 90-30 I/O
in one assembly for convenient upgrades. modules to be plugged in.
Latest I/O Modules Improved Performance
• High-density discrete I/O with 32 points Minimizes space requirements and cost and provides
• High-resolution analog I/O with 16-bit accuracy the highest possible control accuracy. Hot insertion
• Remove and insert modules with the power on simplifies repairs and reduces down time.

®
Graphical Programming Simplifies Controller Configuration

Advanced graphical programming is used to configure • RLL (Relay Ladder Logic) blocks
the controller. Several different programming languages • Math blocks and User Defined blocks
are available in the Windows-based Logic Developer • Control Regulator blocks including PID
PLC software, part of the Proficy Machine Edition • Instruction List Blocks
suite. Simple sequencing or permissive functions can • Structured Text Blocks and C programming
be configured in relay logic. More complex control • Sequential Function Charts
functions can be configured in a higher-level language: • Diagnostics using high-speed trends of drive variables
Navigator:
The project
and tools in a
tree structure
Navigator tabs:
Details of the
project
Inspector:
Details of the
selected
object, (Run
Enable switch)
Companion:
A dynamic
Help window
Editor window: Editor window tabs: Data Watch: Feedback Zone:

Create and edit Lets you switch between Displays the current Displays output
applications open editor windows values and status of information from
variables components
The screen above shows a typical layout of the tools Toolchest: This contains preconfigured objects that can
and editors available. The editor window shows a be dragged into Machine Edition projects.
ladder logic diagram with real-time data and power flow
InfoViewer: This is an embedded browser used to display
displayed in green. In addition to the windows shown
reports and comprehensive help.
above, two other windows can be added:

Monitoring & Diagnostic Interfaces
TOTAL
CONTROL
Two HMIs for Crane Monitoring and Diagnostics
Features Benefits
Small Panel-Mounted Touch Screen Convenient, Reliable Machine Control Panel
Mounted in the cab or the electric house, the Panel-mounted close to the operator, the touch screen
small touch screen station provides a selection of provides intuitive displays with data for operation and
displays providing both real-time crane operating maintenance. The rugged industrial computer stands
data and machine diagnostic data. up to the yard environment.
Crane Management HMI A Single Station for All Functions
The powerful HMI can be mounted in the electric Versatility of the crane management HMI is a major
house, the cab, ground station, or the maintenance advantage. The station can be used to operate
or operations office. Buttons at the base of the the crane, schedule maintenance, diagnose crane
screen bring up special displays for functions problems, reconfigure the crane control system and
including: the drives, and provide production data.
• Monitor: Crane details for maintenance and
operation The HMI can be used by yard personnel including:
• Alarms: Details of the recent crane alarms • Crane operators
• Production: Statistics on the number of
• Crane maintenance
moves, whether loading or unloading, the
type of loads, and the ships involved • Production personnel
• Maintenance: Records of the machine • Electricians
cycles, hours of operation, and maintenance
schedules • Crane engineers
• Drive: Toolbox software for drive
configuration, tuning, performance trending,
and monitoring
• PLC: Proficy Machine Edition software for
configuring the PLC and I/O
• Document: Instruction manuals on all
components
®
Crane Management System (CMS)

The CMS screen shown opposite
is an operator overview of the
entire crane with important real-
time data and status information
such as:
• Boom position in degrees
• Status of the twist locks
• Spreader status
• Crane load
• Wind speed
Buttons at the bottom of the screen
allow the call up of displays of all
crane components and control
functions including:
• Hoist
• Trolley
• Gantry
• Boom (see display below)
• Spreader
Data analysis is simplified using the Trend Recorder, which displays real-time and historical data, see above right. Multiple
signal traces are selected by dragging and dropping variables from the block diagram view. Movable cursors to read out
values of the trends are shown at the bottom of the screen. The recorder screen shows:
• Live data from the controller trended as fast as every 20 ms
• High-speed data from capture buffers in the drive trended every one ms or faster
Boom Status Display

Alarm List with Time
and Date
Dynamic graphic
showing Power
Flow
Animated Graphic
Dynamic Bar
Chart Displays
Permissive
Diagnostic Display
Icons for navigation

to other displays

Operation Report
The operation report, used by maintenance and technical
personnel, provides performance data on individual
cranes as follows:
• Operating duration in hours
• Number and type of containers lifted
• Crane utilization rate (time lifting/time with power on)
• The cycle time per container (seconds/lift)
• The average weight of container (tons/lift)
• Crane container handling rate (lifts/hour)
By adding data for all cranes, yard throughput and
productivity can be calculated.
Preventive Maintenance
This screen keeps track of the hours of operation of critical
components and compares with schedule settings showing
when maintenance should be performed. Alarms occur
when component maintenance is required, including:
• Brake pad inspection
• A/C and vent fan service
• Twist lock inspection
• Motor brush inspection
If alarms occur, maintenance can be performed and

expensive crane failures avoided. Downtime is minimized,
and service is only performed when actually required.
Power System Monitor

The screen provides real-time data on the crane
power supply power consumption, and harmonic
distortion. This data helps:
• Protect the electrical equipment
• Reduce power consumption
• Save money on maintenance and electric power
16000
CMS - Power Quality Monitor
14000
Line Voltage (VAC)
12000
Line Voltage
10000 Vab Overvoltage

(VAC)
8000
6000
4000 Vca Undervoltage
2000
55
1
13
17
21
25
29
33
37
41
45
49
53
57
99
Time, sec

Remote Operation
Remote operator stations in the yard office have screens with live video showing the crane pick up area and the top of
the containers. Operator master switches on the desktop allow manual intervention if a problem occurs. Stations can be
located on the crane or in the yard, if desired.
Remote Operator Console layout using:

Flat screens
Quad Video windows
Color touchpanels
Master switches
Vertical Screen Panel #1 & #4 - Wide View with: #2 & 3 - Diagonal

#1 - Operating Area Spreader Corners
#4 - Container ID No.
Alternative Operator
Console layout using:
Two screens
Quad View video
Desktop with pushbuttons
Master switches

Delivering customer success
every project, every time.
About TMEIC
A Global Network
TMEIC is built on the combined and proud heritage of Toshiba and Mitsubishi-Electric
in the industrial automation, control and drive systems business. TMEIC’s global
business employs more than 2,200 employees, with sales exceeding U.S. $2.4 billion,
and specializes in Metals, Oil & Gas, Material Handling, Utilities, Cement, Mining,
Paper and other industrial markets.
TMEIC Corporation, headquartered in Roanoke, Virginia, designs, develops and
engineers advanced automation and variable frequency drive systems, and is home to
our Global Center of Excellence for Crane Systems
TMEIC delivers high quality advanced systems and products to factories worldwide,
while serving as a global solutions partner to contribute to the growth of our customers.
TMEIC Corporation Americas | Roanoke, Virginia | Houston, Texas | WWW.TMEIC.COM

All specifications in this document are subject to change without notice. This brochure is provided free of charge and without obligation to the reader or to TMEIC. TMEIC does not accept, nor imply, the
acceptance of any liability with regard to the use of the information provided. TMEIC provides the information included herein as is and without warranty of any kind, express or implied, including, but not limited
to, any implied statutory warranty of merchantability or fitness for particular purposes. The information is provided solely as a general reference to the potential benefits that may be attributable to the technology
discussed. Individual results may vary. Independent analysis and testing of each application is required to determine the results and benefits to be achieved from the technology discussed.
TMdrive is a trademark of TMEIC Corporation Americas. I-3001

© 2021 TMEIC Corporation Americas. All Rights Reserved. Revised Aug 2021

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Crane Control and Automation

Project Engineering Process

A Flexible Control System Architecture

Engineering Station Operator Screens Master Switch Controller

Manual & Automatic 7

Page 2 of 32 © 2019 TMEIC Corporation. All Rights Reserved.

Why Our Equipment Helps Set Production Records

System Features and Benefits

Maxview® Vision System allows Fast and Reliable Crane Operation

Maxspeed® Fast Operator Response Increases Throughput

Remote Operator Console Streamlines Operation

Ethernet Connectivity Increases Productivity

CraneDirector™ Container Tracking & Inventory System Provides Faster Operation

Graphical, Real-Time Maintenance & Diagnostic Reporting

© 2019 TMEIC Corporation. All Rights Reserved. Page 3 of 32

Remote Crane Optional Local Crane

Page 4 of 32 © 2019 TMEIC Corporation. All Rights Reserved.

Fast Response to Operator Inputs

Control Cab Crane Motor Room Trolley

Fast hard-wired High-speed LAN High-speed LAN

Input logic in the Input logic in the

Immediate Operator Response using Fast Communications

Optimized Communications System Benefits

© 2019 TMEIC Corporation. All Rights Reserved. Page 5 of 32

Save 30% diesel fuel using the MaxFuelSaver system

Energy Saving RTG Test Results

Several months of tests

RTG before retrofit RTG after retrofit with MaxFuelSaver

Maxspeed Sensorless Electronic Sway Control

Manual Operation Manual Inputs

© 2019 TMEIC Corporation. All Rights Reserved. Page 7 of 32

Terminal Operating System Remote Operator Stations

Adjustable Remote I /O Remote I/O

Page 8 of 32 © 2019 TMEIC Corporation. All Rights Reserved.

Remote Crane Operator Station

© 2019 TMEIC Corporation. All Rights Reserved. Page 9 of 32

Maxview Automatic Landing™ System

Laser scanners on the trolley measure the position of the spreader

The stack profile option provides a profile of the containers in the

Maxview Smart Move™ System

Maxview Clear Path® System

Maxview Chassis Guidance™ System

Custom Maxview Systems

Page 10 of 32 © 2019 TMEIC Corporation. All Rights Reserved.

The design is based on TMEIC’s extensive

The system is particularly effective in assisting

The Maxview Smart Landing Crane Management System (CMS)

© 2019 TMEIC Corporation. All Rights Reserved. Page 11 of 32

Automatic Position Indication (API) - Trolley Position

API - Hoist Position

Crane Collision Avoidance

Auto Landing System (ALS) -

API - Gantry Position

Page 12 of 32 © 2019 TMEIC Corporation. All Rights Reserved.

Multiple Crane Automation – Yard Level System

Crane Crane Controller

Remote Control Center

Cable Reel and Fiber

Example of Yard Automation