SCS 3 SPREADER CONTROL SYSTEM A Tradition Of Innovation
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The Power of Easy. The Power of 3. Only from Bromma. Bromma s next generation spreader control system Bromma SCS 3 is a major advance in spreader control technology. SCS 3 builds on the foundation of Bromma SCS 2 (first introduced in 2001), in that it is a comprehensive spreader control system that makes possible fast and specific fault diagnosis. However, in significant ways, SCS 3 represents a major step forward beyond SCS 2, as SCS 3 features a much higher level of userfriendliness, a significant simplification in design, and the opening up of a new area of functionality spreader prognostics. In short, the new SCS 3 system will allow terminals to push operational performance higher. Among the many operational advantages of the SCS 3 system things that Bromma technology can do, that competing technology cannot are the following: With the new SCS 3 system, terminal operators can perform various on-line functions, such as adjusting sensors or scanning for bus faults. (The single biggest fault problem on a spreader is a sensor that s out of adjustment. The ability to make sensor adjustments online is a great time saver.) With the new SCS 3 system, terminal users can do predictive maintenance Twistlock losing signal; twistlock mechanics need adjustment Flipper decreasing in speed; check chain at next service interval or Twin-latches are close to the margin; sensors need adjustment before they start missing due to rules-based artificial intelligence. With the new SCS 3 system, terminal users can automatically transmit spreader events, logs, alarms, and MMBF statistics to the terminal organization headquarters for comprehensive spreader fleet performance analysis. With the new SCS 3 system, terminal users can dramatically simplify the number of relays and terminal points on the spreader (Greater design simplicity often results in greater reliability.) With the new SCS 3 system, terminal users can look at the error log even after the spreader is pulled from the crane. (With spreaders that use the competing technology ASi, all data is very often lost when the spreader is pulled from the crane. The ability to review error log data is what allows the terminal to do retroactive fault analysis.) With the new SCS 3 system, a terminal engineer can evaluate and control the spreader from the central terminal control room. He is not dependent on anyone else on site to evaluate and provide feedback on the situation. The engineer can in real time view the same information in the central operating area as the technician sees when he s looking at the spreader. (This means faster operational decisionmaking in terms of whether the spreader can be repaired or adjusted within the typical 15 minute window before the terminal pulls the spreader from the crane.) With the new SCS 3 system, terminal users can capture very specific diagnostic fault information immediately after a fault occurs. (Shorter fault duration leads to more uptime and fewer spreader change-outs.) With the new SCS 3 system, terminal users have access to all spreader diagrams, drawings and manuals right on the spreader via the PDF display. Also, the on-board touch-screen display has been designed for high readability and durable performance under the many challenging environmental conditions found at the port such as sun glare and high heat, among others. The SCS 3 system is not just new technology it is new technology that makes possible a series of practical, functional advantages. These are features and benefits that only Bromma Group can offer terminal operators today benefits that are the latest in Bromma s long-term tradition of innovation. 3
The Power to See the Present... and the Future Bromma SCS 3 lets spreader users see more and see more easily. A large touch-screen monitor, using simpleto-understand language, makes possible superior easeof-use. Information is not only there but it is easy to access, understand, and act upon. With Bromma SCS 3 terminals finally have a technician operator interface with high functionality that is also simple to use. What do operators see? When the red light goes on, Bromma SCS 3 delivers very specific diagnostic information, and then captures that information with a powerful database-driven software engine. The engine includes: An EVENT LOG for an easy-to-follow sequence of events An ALARM LOG with alarms stored separately and acknowledged ATREND LOG, through which to follow performance over time and observe changes in spreader behaviour ASTATISTICAL LOG for internal storage of everything from container count to sub-system MMBF numbers ABLACKBOX RECORDER storing a snapshot of signal sequences when an alarm is triggered Plus, as noted earlier, with the new SCS 3 system, terminal users can continue to examine the error log even after the spreader is pulled from the crane. (With other crane spreader brands, all data is very often lost when the spreader is pulled from the crane. The ability to review error log data is what allows the terminal to do retroactive fault analysis.) 4
It is well known that high spreader reliability is essential for high terminal performance. Spreader return on investment derives directly from spreader productivity, and spreader productivity is highly leveraged to fault frequency and duration. This is why the diagnostic capabilities of Bromma SCS 3 can have a significant impact, over the spreader fleet lifetime, on terminal financial performance. System diagnostic software identifies the spreader fault area, and then, identifies either a single fault cause or, in certain cases, a narrow range of causes. This extremely precise diagnostic data is the key to shortening downtime duration and eliminating the need for operationally disruptive spreader change-outs. See The Future One of the important functional advances in SCS 3 is the addition of spreader prognostics. SCS 3 software uses rule-based artificial intelligence to identify future fault behaviour before the fault actually occurs. Rules-based predictive maintenance Twistlock losing signal; twistlock mechanics need adjustment Flipper decreasing in speed; check chain at next service interval makes possible a shift in focus from corrective (problem-solving) to preventive (problem-preventing) activities. Bromma spreader prognostics provide the information flow for a whole range of predictive and preventive spreader service activities. Steadily narrowing the time the service technician team spends on corrective activities, and steadily increasing the time the service technician team spends on preventive activities, will produce significant benefits in spreader uptime and optimized performance. 5
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The Power of Advanced No spreader control and communications system delivers more information, more easily, than Bromma SCS 3. The visualization monitor illustrates spreader sensors and valves, the communications status of buses, the control panel for operating the spreader, and runtime and spreader data. It allows operators to tune spreader parameters online or revert them to factory settings. It also allows advanced users the opportunity to make more detailed configurations. Also, security controls extend to up to seven user levels. Beyond this, the SCS 3 system has a full range of external communications capabilities, creating unsurpassed accessibility to external resources. On the system, all user interfaces have a web equivalent which can be accessed with a web browser. Depending on how the spreader is hooked up, information can be accessed either by cable, WLAN or internet. The onboard PDF reader provides access to manuals, diagrams, drawings, and spare parts data. engineers can evaluate and control the spreader from the central terminal control room. (The single biggest fault problem on a spreader is a sensor that s out of adjustment. The ability to make sensor adjustments online is a great time saver.) Global terminal management organizations also gain an important information collection tool terminal users can automatically transmit spreader events, logs, alarms, and MMBF statistics to the terminal organization headquarters for comprehensive retroactive spreader fleet performance analysis. Easy. Simple. Intelligently advanced. The new SCS 3 spreader control system represents the new frontier in spreader control, diagnostics, prognostics and communications. Terminals can perform various on-line functions, such as adjusting sensors, as terminal 7
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The Power of Simple The transition from Bromma SCS 2 to Bromma SCS 3 will allow for a considerable improvement in overall system simplicity in a typical installation. The box below summarizes how a typical spreader installation will allow for the following simplification in system requirements: SYSTEM SIMPLIFICATION WITH BROMMA SCS 3 Bromma SCS 2 Bromma SCS 3 3 SCS nodes 1 SCS node 4 cabinets + 2 junction boxes 2 cabinets Over 300 wired terminal points Approx. 100 wired terminal points This dramatic reduction in component clutter will in itself likely boost spreader reliability, as wired terminal points are a common source of electrical faults. In fact, electrical faults are the #1 source of spreader downtime. Greater than 9 ASB boxes Approximately 130 1/O relays Less than 8 ASB boxes Less than 25 I/O relays 9
System Configuration Bromma SCS 3 is built around a powerful 500 MHz Pentium PLC with IEC 61131 conformance for run-time machine control. Enhanced functionality includes function blocks for all spreader functions and the capability to monitor performance within each box. Internal I/O modules include RS485, SSI, and RFID. CANopen and a flexible Anybus gateway provide a robust and elegant system architecture. Modern IT technology (USB, TCP/IP, and UMTS) is fully integrated. SCS 3 features a CAN booster which is designed to amplify communication above noise levels. There is 24v differential amplitude on the bus line and 3w output power on communication. The CAN booster acts as a fuse/protection on the control system and is compatible with BCAN and CAN standard. Noise immunity the level of noise the system can take is 100 times above permissible levels. System hardware can handle advanced HMI and distributed scalable systems, and can support multiple interfaces. Software provides multiple pre-defined spreader views. A universal crane-spreader interface is achieved with DS444, which is a global standard for crane-spreader interface managed by the CIA organization CAN in Automation. This device-specific profile for crane-to-spreader communication is integrated in SCS 3. An ASi converter converts any configuration of ASi to CANopen, eliminating any concerns over compatability between differing interfaces or protocols. 10
Technical Specifications Dimensional drawing Technical information Processor XScale Operating system CE.NET Communication interfaces CAN 2 ports ISO 11898 2.0B USB 2 host ports RS232 Up to 115 200 baud Ethernet 10/100 Base-T Front panel Touch screen Resistive Buttons On/off Power supply Voltage 18 30 V Current Less than 1 A at 24 V Battery Replaceable rechargeable Li-Ion pack for standby power. Standby time 7 days Display Type Color TFT, 10.4 Resolution 800 x 600, 4:3 aspect ratio Environment Storage temperature -40 to +70 C Operating temperature -40 to +65 C 1 Enclosure class IP65 Mechanical Dimensions 264(W) x 202(H) x 36(D) mm Weight Approximately 2 kg 1 Backlight intensity is reduced at high temperatures to limit the battery temperature to below 70 C. Environmental tolerance Environmental Test Standard Comments Vibration & Shock IEC 60068-2-64 IEC 60068-2-27 Enclosure EN 60529 IP67 EMC Immunity, Transient EN 61000-4-4 EN 61000-4-5 EMC Immunity, ESD EN 61000-4-2 EMC Immunity, RF EN 61000-4-3 EMC Emission EN 61000-4-6 EN 55022 Class A All technical specifications may be changed and are subject to notice. 11
A Tradition Of Innovation Bromma is part of Cargotec Corporation BROMMA CONQUIP AB Malaxgatan 7 164 74 Kista, Sweden PHONE: +46 8 620 0900 FAX: +46 8 739 3786 E-MAIL: sales@bromma.com BROMMA INC. 4400 Ben Franklin Blvd. Suite 200 Durham, NC 27704 USA PHONE: +1 919 471 4000 FAX: +1 919 471 4343 E-MAIL: brommaus.sales@bromma.com BROMMA FAR EAST Blk. 102E Pasir Panjang Road #08-07, Citilink Warehouse Complex Singapore 118529 PHONE: +65 6272 0400 FAX: +65 6272 0411 E-MAIL: bfe@bromma.com BROMMA SHANGHAI Shanghai, China Representation Office B, 20 Fir, Liang Feng Mansion No. 8 Dong Fang Road, Pudong Shanghai 200120, China PHONE: +86 21 588 871 64 PHONE: +86 21 588 874 09 FAX: +86 21 588 874 08 E-MAIL: jeff_jiefu@bromma.com.cn BROMMA Sdn. Bhd. Lot 19, Jalan Kelebang 1/6 Kinta Free Industrial Zone Poskod 31200 Chemor Perak, Malaysia PHONE: +60 529 388 90 FAX: +60 529 140 99 E-MAIL: malaysia@bromma.com BROMMA UK The Loughton Seedbed Centre D11 Langston Road Loughton Essex, IG10 3TQ UK PHONE: +44 (0)20 8787 7031 FAX: +44 (0)20 8787 7086 E-MAIL: carl.kesselmark@bromma.com BROMMA GmbH Im Klint 12 D-30938 Burgwedel Germany PHONE: +49 513 980 6630 FAX: +49 513 980 6644 E-MAIL: spreader.sales@bromma-gmbh.de BROMMA MIDDLE EAST BROMMA M.E. FZCO P.O. Box 17909 Dubai, United Arab Emirates PHONE OFFICE: +971 488 725 20 PHONE MOBILE: +971 505 518 255 FAX: +971 488 725 25 E-MAIL: graham.boxall@bromma.com www.bromma.com PRINTED MAY 2007