Solution - Emerson

Crane Industry seminar
www.servo-payesh.com
info@servo-payesh.com
+98(21)44839534-44838867
June 05 Sales Conference - Amsterdam

Give you a personal impression about:
The crane industry

Competitors
Our experiences
Trends
Some dos and donts
and ..
Segments crane market
Port & Terminal equipment for handling:

containers
bulk
cargo
Industrial Cranes (mainly Overhead cranes)
Tower / Construction Cranes
Specials (heavy lift, offshore pedestal,

nuclear waste, etc.)
Port & Terminal equipment: container handling
Port & Terminal equipment for container terminal operations

Ship-to-Shore cranes
Rail mounted gantry cranes
Rubber Tired gantry cranes
Straddle carriers
Reach Stackers
Terminal Tractors
Port & Terminal equipment: container handling
Port & Terminal equipment for container terminal operations

Ship-to-Shore cranes
Rubber Tired gantry cranes
Straddle carriers
Reach Stackers
Terminal Tractors
Container handling: Ship to Shore (STS) cranes

Trolley traveling is
prohibited when the boom
is up
Main Hoist
Two @ 200 to 750kW
Typical Drives
Trolley
E-room
Boom
One @ 132 to 315 kW or

Gantry
Four @ 45 to 110 kW
Boom Hoist
One @ 75 to 315 kW
Spreader (trim&list)
Trolley
Gantry
8 to 16 @ 11 to 22kW
Full AC for new cranes
DC for retrofits
Container handling: Ship to Shore (STS) cranes

HV-supply by a cable reel
Control from a cabin connected to
the trolley
PLC-controlled
Crane management system
Trends:
Increasing demands (extended boom due to bigger ships; Panamax,
Post-Panamax and Superpost-Panamax)
Twinlift (2 containers in 1 move)
High speeds, high accelerations (full rope trolleys)
Second trolley
Semi-automation (anti-sway and position control)
More and more leasing of port equipment and because of this
remote condition monitoring is getting more important
Container handling concepts
Reachstackers
Rubber tired gantry cranes

Straddle carriers
Container handling: Gantry cranes
Typical Drives
Hoist
One @ 150 to 350 kW
Rail mounted Gantry cranes:

Supply by cable reel
Power regeneration
Trolley
Four @ 11 to 22 kW
Gantry
Four @ 11 to 30 kW
AC for new cranes
DC for retrofits
Rubber tired Gantry cranes:

Supply from diesel generator set
Automatic steering control
Braking resistors required
Container handling: Straddle Carriers

Straddle carriers are standard and built in series
Typical Drives
Hoist
One @ 90 to 150 kW
Gantry
Four @ 11 to 30 kW
AC for new carriers
DC for retrofits
Straddle carriers:
Supply from diesel generator set
Steering control
Braking resistors required
Each wheel is driven (highly advantaged control)
Highlights: Container Terminal Operations
Business is booming; a lot of container terminals are extended or will be

developed due to the increasing economical activities in the Far-East; so
a lot of new built container cranes at the moment

Besides local Port Authorities also the Fleet operators do develop their
own terminal operations (Maersk, NYK, P&O, PSA, Hutchison
Whampoa)

Whampoa)
Scale-factors are important (cost-saving) ; recent merge between Maersk

and P&O

Whampoa)

and P&O
OEMs have changed to one-stop-and-shop companies; although

business is good prices are under pressure due to competition from
Asia

Whampoa)

and P&O
OEMs have changed to one-stop-and-shop companies; all do business is

good prices are under pressure due to competition from Asia
Its a global market and the containers are highly standardized (20, 30,
40 and 45)

Whampoa)

and P&O
OEMs have changed to one-stop-and-shop companies; all do business is

good prices are under pressure due to competition from Asia
Its a global market and the containers are highly standardized (20, 30,
40 and 45)
Theres a difference in companies that are involved in intercontinental

and Short Sea Shipping (continental)
Port & Terminal Cranes: bulk handling
Port & Terminal equipment for bulk handling

Ship unloaders
Mobile grab cranes
Barge mounted (floating) grab
cranes
Slewing grab cranes
Stacker reclaimers
Scraper reclaimers
Bucket wheel reclaimers
Bulk handling: Ship unloaders

Hoist
1 or 2 @ 150 to 700 kW
50 85 tonnes grab cranes (180m/min) for unloading

ships only. The bucket empties above a hopper.
From the hopper further transport by conveyor belts
Typical Drives
Close
1 or 2 @ 150 to 700 kW
Trolley
1 or 2 @ 150 to 500 kW
Boomhoist
1 or 2 @ 75 to 160 kW
Gantry
8 to 16 @ 11 to 50 kW
Full AC for new cranes

DC for retrofits
Mainly handling iron ore and coal
Bulk handling: Slewing grab cranes

Hoist
One @ 150 to 350 kW
Typical Drives
Closing
In most cases
slewing grab
cranes do have
hook duty too.
One @ 150 to 350 kW

Slewing
2 to 4 @ 15 to 37 kW
Luffing
One @ 75 to 150 kW
Gantry
Jib crane
8 to 16 @ 11 to 30 kW
AC for new cranes
DC for retrofits
16 36 tonnes Lemniscate Floating grab

crane may have a diesel generator set as
power supply.
Highlights: Bulk handling

Business is tough; no serious expending market size
For this reason mainly one-off sales and more chances in
retrofitting
Built for purpose
Port & Terminal Cranes: cargo handling
Port & Terminal equipment for cargo handling
Jib cranes
Mobile cranes
Double boom cranes or double-link
level luffing cranes
Highlights: Cargo handling
Business is tough; no serious in size expending market, due to the

benefits of the highly standardized containers.

The smaller OEMs specialized on this market segment where the design
to the needs of the end-user specs is required.

The smaller OEMs specialized on this market segment where the design
to the needs of the end-user specs is required.
For the mobile cranes it is more a buy with or without the extras from the
catalogue.
Major OEMs Port & Terminal Cranes (1)

OEM
Head Office /
Production
Website
Incumbent Drive
Supplier
Comments
KCI (Konecranes,
Noell, Caillard)
Finland / Malaysia /
France / Germany
www.konecranes.com
Vacon, Siemens
Commercially tied with Vacon (brandlabel)
Liebherr
Germany / Austria /
Ireland
www.lcc.liebherr.com
Liebherr
ZPMC
China
www.zpmc.com
Siemens, ABB,
Yaskawa, CT
Kalmar (Partek)
Finland / Holland
www.kalmarind.com
Siemens
Kunz
Austria
www.kuenz.com
Siemens
Gottwald
Germany
www.gottwald.com
Siemens
Mobile cranes, gantry cranes and AGVs.

Part of Demag, 20% ownwership of
Siemens
Fantuzzi Reggiane
Italy
www.reggiane.com
Voest-Alpine
Austria
www.vamh.com
Siemens
Bulk handling
Femont
Belgium
www.femont.com
Siemens
Small local player
Paceco
US, Spain
www.pacecocorp.com
IMPSA
Argentina
www.impsaportsystems.com
Brandlabeling CTWW?!
Market leader, strong in price-competition
In 2002 Kone Corp took over Partek /
Kalmar
Major OEMs Port & Terminal Cranes (2)

OEM
Head Office /
Production
Website
MAN-Takraf
Germany
www.man-takraf.de
Hilgers
Germany
www.hilgers-ag.de
MHI Hiroshima
cranes
Mitsubishi
Japan
www.mhi.co.jp
Incumbent Drive
Supplier
Comments
Local player
Industrial Overhead Traveling Cranes
Typical Drives
Supply mainly via conductor

lines and shoegears
Hoist
1 or 2 @ 7,5 to 300 kW
Cross Travel
1 to 4 @ 1,5 to 45 kW
Long Travel
2 or 4 @ 22 to 45 kW
AC Drives Used
Highlights: Industrial overhead cranes
There is the huge market for standard industrial overhead cranes that
focuses on loads up to 10-tons. Mainly the single or double girder cranes
are equipped with Wire rope hoists.
The standard industrial crane market is highly competitive and money

driven. Implementing drives depends of the clients specs. OEMs do have
their own (brand-labeled) drive.
The standard industrial crane market is highly competitive and money

driven. Implementing drives depends of the clients specs. OEMs do have
their own (brand-labeled) drive.
Heavy duty cranes are more designed to the clients needs and therefore
in this area there are other smaller more specialized, local companies
active.
Major OEMs Standard Overhead Cranes

Website
Incumbent
Drive
Supplier
Comments
Finland
www.konecranes.com
Vacon
brandlabel
Demag
Germany
www.demagcranes.de
Demag
(Dedrive)
Abus
Germany
www.abus-kransysteme.de
P&H
US
www.morriscranes.com
OEM
Head Office /
Production
Kone
Typical Drives
Construction (Mobile) Tower Cranes

Hoist
One @ up to 45 kW
Slew
One @ up to 7,5 kW
Trolley
One @ up to 7,5 kW
AC on all electric driven cranes
From 1mt up to 30mt load and radius up to 50 meters
Highlights: (Mobile) Tower cranes
For the tower cranes it is more a sales from the catalogue.
These cranes are not automatically equipped with speed controlled

motors.

motors.
There are mobile tower cranes, these cranes are mounted on a truck and
can easily be erected on site.

motors.
Some OEMs choose for hydraulic driven solutions others for electric
driven.

motors.
Some OEMs choose for hydraulic driven solutions others for electric
driven.
Huge rental market
Major OEMs (Mobile) Tower Cranes

Incumbent
Drive
Supplier
Comments
www.liebherr.com
Liebherr
Self-made
France
www.potain.com
LS
Arcomet
Belgium
www.arcomet.com
MTC
Holland
www.mtc-cranes.com
Terex
Germany, Italy
www.comedil.com
OEM
Head Office /
Production
Website
MAN Wolffkran
Germany
www.wolffkran.de
Liebherr
Austria
Potain
CT / LS
Mobile cranes
Brands: Peiner,
Comedil
Specials
The market for specials is significant and divers for its

purpose:
Heavy lift cranes

Marine and offshore pedestal cranes
Cranes especially for handling nuclear waste
Cranes especially for the automotive industry
Etc.
Price break-down: STS-crane

STS-crane (53 100 tonnes) 4,8 6,8 mln

E-installation
0,7 1,1 mln
(15 20%)

E-installation
0,7 1,1 mln
AC-drives including AFE
0,09 0,13 mln
(15 20%)
(2 3%)

STS-crane (53 100 tonnes)
E-installation
AC-motors
4,8 6,8 mln

0,7 1,1 mln
0,09 0,13 mln
0,10 0,12 mln
(15 20%)
(2 3%)
(2 3%)

STS-crane (53 100 tonnes)
E-installation
AC-motors
4,8 6,8 mln

0,7 1,1 mln
0,09 0,13 mln
0,10 0,12 mln
(15 20%)
(2 3%)
(2 3%)
Conclusion:
Drives and motors are not dominant!

E-installation: STS-crane
Motors
Drives including DC-bus and AFE (or ERE-unit)
MV-supply including cable reel, MV-switch and transformer
LV Distribution
PLC control
Safety and control devices
Load measuring device
Auxiliary equipment
Condition monitoring
Walkway lighting and floodlights
Operator control equipment
Spreader cable reel
Communication equipment
Crane diagnose
Cabling, festoon system, mounting and installation parts
Spreader control
Anti sway system
Project management
Engineering (hard- & software)
Commissioning (FAT and SAT)
Warranty
Training
Typical drive system for a STS-crane

500 or 690 V
Kalmar Industries B.V.

M
52-tons container STS-crane

Dyn 11
690 / 400 V
Mains conditioning
Auxiliary supply
Bidirectional feed/regeneration unit
Common DC-bus
e M
Hoist
Trolley
M e
Boom hoist
e M
Cable reel
Crane travel
600 kW
4 x 25 kW
80 kW
5,5 kW
2 x 8 x 12 kW
1000/2000 rpm
1500 rpm
1500 rpm
1500 rpm
1500/1800 rpm
Channels to Market Port & Terminal Cranes

Drive Suppliers
Crane OEM (some OEMs incl. systembuilding)
Retrofit
New
CT Systems (via DCs)
New
Retrofit
New
System Integrators (e.g. Siemens, independents)
Terminal Operators
(e.g. PSA, Maersk, Sealand, P&O, Hutchison - Whampoa)
Siemens - Scope of Supply

Total solution supplier:
Project management, engineering, wide range of standard products, assembly, installation,
commissioning, after sales, financing
SIMOREG DC-MASTER
DC Motors
SIMOVERT AC MASTERDRIVE
AC Motors
Slipring motor drives
SIMATIC S7 PLC
Trim, list and skew-control
SICMA Crane Management System
HIPAC anti-sway system
TOUCHMATIC anti-sway system
Centre of Excellence
Safety PLC
Siemens Nederland N.V.
Electronic Steering
P.O. Box 16068
Active Safe Stability System
2500 BB The Hague
Automated positioning: (gantry & trolley)
The Netherlands
Spreader position detection with camera

ABB - Scope of Supply

commissioning, after sales
DC Drives
DC Motors
AC Drives
AC Motors
PLC
ASTAT Crane Controller
AutoControl three axis anti-sway
GrabControl minimum stress
PosControl
Centre of Excellence
ABB Automation Technologies
SwayControl
Crane Systems
SE-721 67 Vsters, Sweden
Yaskawa - Scope of Supply
AC Drive sales only
Tmeic GE - Scope of Supply

commissioning, after sales
DC Drives
DC Motors
AC Drives
AC Motors
GE Fanuc PLC
Crane Management System
GrabControl minimum stress
PosControl
Anti Sway Control
Competitor Market in the Harbor Crane Industry

Supplier
Centre of
Excellence
Siemens
The Hague,
Holland
ABB
Website
Scope of Supply
Comments
www.siemens.nl/cranes
Drives
Total solutions
Finance
Market Leader
Europe
www.abb.com/cranes
Yaskawa
Japan
Schneider
France
Alstom
France
Vacon
Rockwell
Drives
Total solutions
Drives only
www.schneider-electric.com
Drives
Total solutions
Finland
www.vacon.com
Drives only
US
www.automation.rockwell.com/drivesystems
www.controltechniques.com
CT
GE
US
www.geindustrial.com/cwc
Tmeic GE
US
www.tmge.com
Brand: Kone
Drives / Systems
Drives/
Total solutions
Joint venture: GE,

Toshiba, Mitsubishi
Technical dos and donts (1)

Dont use just one drive to control more than one slewing motor; the
polygon effect will cause unbalance between the motors

Do consider closed loop for the slewing movement

Do consider closed loop for the slewing movement
Modernizing the control of an existing MG-set (Ward-Leonard) is not an
easy job. In general the job is risky and needs special skills with a
minimum impact on sales, so dont be to easy on this. In our (CTBV)
perspective it is only useful to help existing clients or in cases where there
is more to win.

Having always the crane movements
working together, a common DC-bus
system is a must for harbor cranes!
Siemens has two regen concepts:
Active Front End (AFE) and thyristor
technology called the ERE. ERE is very
cost effective and in most cases
unbeaten. Do consider there is a
possibility with the Mentor as
regenerating unit, but has got serious
technical limitations.
Supply voltage:
Supply voltage:
500/690 Vac
500/690 Vac
choke
LCL-filter
IGBT
Rectifier
Thyristor
bridge
bridge
bridge
Common DC-bus
AFE
Common DC-bus
ERE

CT doesnt have anti-sway control! CTBV
has developed slew control to create a
better feel on the stick for the crane-driver.
For anti-sway there are two open loop and
closed loop. In closed loop theres a
sensor on the spreader, hook or bucket. By
means of a camera (Vision) the position is
constantly detected. In a processor the
dedicated software is responsible for the
correction on the trolley movement.
Companies that are selling anti-sway
control are CePlus (Magdeburg, Germany)
and Arck (Ramonville, France)

For anti-sway on ship unloaders open
loop can be an option. Positioning
above the hopper is not critical in most
cases.
CTBVs experiences so far

Learn from the past, to plan the future (1):
Port & Terminal cranes are the High-End of the market


Being successful in that field, can have a spin-off effect


Being successful in that field, can have a spin-off effect
Port & Terminal cranes and heavy duty cranes:

a conservative market with specialized system-integrators
in most cases competitors in industrial automation;
so the first thing they ask for is references.

System integrators do like to sell systems first;
in most cases they follow the paved roads created by the
successful excepted brands.

So, in most cases market penetration only selling drives,
DC or AC, has been highly in-successful.

So, in most cases market penetration only selling drives,
DC or AC, has been highly in-successful.
CTBV started at the bottom, to convince end-users of our

knowledge of systems and drives, and concentrate
on retrofits.

Our successes where in almost all cases DC-retrofits

(MG-sets and static converters).
Competition in this area is limited and added value (software)
integrated in the drives.
Software CTBV has developed:
grab control
slew control
load/speed control in fieldweakening

Our successes where in almost all cases DC-retrofits

(MG-sets and static converters).
Competition in this area is limited and added value (software)
integrated in the drives.
Software CTBV has developed:
grab control
slew control
load/speed control in fieldweakening
Modernizing a crane-installation, retrofitting, is most of the
times considered if the reliability is at stake.

Retrofitting a crane-installation is a matter of limiting

responsibilities.

Retrofitting a crane-installation is a matter of limiting

responsibilities.
By creating our own system-solutions in Holland one
our former competitors, a system-integrator, started
working with CT-products.

PLC control is fully excepted also in the crane business,

and the amount of I/O considered the best solution for
new built crane-systems.
De-centralized control in Mentor or Unidrive SP is in new built
cranes not an advantage, for instance on crane-systems
being partly modernized.


The drives-part is more dominant in a retrofit-project then
in a turnkey new built crane-installation.


The drives-part is more dominant in a retrofit-project then
in a turnkey new built crane-installation.
For turnkey new built crane-installations an project-oriented
organization with crane-partners is a must!
And (1)
To become a champion in cranes we need to focus on the target!

Thats why I am very pleased with this initiative to appoint a Crane
development manager to interchange ideas and crane technology.
And

A global strategy on cranes is of major importance!
And

A global strategy on cranes is of major importance!
Spreading the same news all over is highly important to develop the global
market.
And
Please consider for Port and Terminal cranes!!
The drives-budget in not of an overwhelming percentage of the

E-installation ( ~ 10-12%)
The success of competitors in industrial automation: they penetrated
the market at a crucial time.
For example: Siemens started in the 80s on a full integrated
automation project for Terminal operator ECT in Rotterdam, at that
time this was a prestigious project.
This has had a huge spin-off, a Centre of Excellence in The Hague
(Holland) for crane-technology.
And
For (mobile) tower cranes and simple industrial cranes an all-in drive-solution
in this market-segment important.
And
For (mobile) tower cranes and simple industrial cranes an all-in drive-solution
in this market-segment important.
System-integrators dont take the disadvantages, the components for the

drive-system need to be plug and play for all needs.
And
The Crane Industry

Its global market!
The Crane Industry
Its global market!
Lets support each other,

to create a
win-win situation
for all of us!
The Crane Industry
M.N.
Crane champion!!

Solution - Emerson

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Crane Industry seminar

June 05 Sales Conference - Amsterdam

June 05 Sales Conference - Amsterdam

Crane Industry seminar

The crane industry

June 05 Sales Conference - Amsterdam

Crane Industry seminar

June 05 Sales Conference - Amsterdam

Segments crane market

Port & Terminal equipment for handling:

Industrial Cranes (mainly Overhead cranes)

Tower / Construction Cranes

Specials (heavy lift, offshore pedestal,

June 05 Sales Conference - Amsterdam

Port & Terminal equipment: container handling

Port & Terminal equipment for container terminal operations

June 05 Sales Conference - Amsterdam

Port & Terminal equipment: container handling

Port & Terminal equipment for container terminal operations

June 05 Sales Conference - Amsterdam

Container handling: Ship to Shore (STS) cranes

One @ 132 to 315 kW or

June 05 Sales Conference - Amsterdam

Container handling: Ship to Shore (STS) cranes

Container handling concepts

Rail mounted gantry cranes

Rubber tired gantry cranes

Container handling: Gantry cranes

Rail mounted Gantry cranes:

Rubber tired Gantry cranes:

June 05 Sales Conference - Amsterdam

Container handling: Straddle Carriers

June 05 Sales Conference - Amsterdam

Highlights: Container Terminal Operations

Business is booming; a lot of container terminals are extended or will be

June 05 Sales Conference - Amsterdam

Highlights: Container Terminal Operations

Business is booming; a lot of container terminals are extended or will be

June 05 Sales Conference - Amsterdam

Highlights: Container Terminal Operations

Business is booming; a lot of container terminals are extended or will be

Scale-factors are important (cost-saving) ; recent merge between Maersk

June 05 Sales Conference - Amsterdam

Highlights: Container Terminal Operations

Business is booming; a lot of container terminals are extended or will be

Scale-factors are important (cost-saving) ; recent merge between Maersk

OEMs have changed to one-stop-and-shop companies; although

June 05 Sales Conference - Amsterdam

Highlights: Container Terminal Operations

Business is booming; a lot of container terminals are extended or will be

Scale-factors are important (cost-saving) ; recent merge between Maersk

OEMs have changed to one-stop-and-shop companies; all do business is

June 05 Sales Conference - Amsterdam

Highlights: Container Terminal Operations

Business is booming; a lot of container terminals are extended or will be

Scale-factors are important (cost-saving) ; recent merge between Maersk

OEMs have changed to one-stop-and-shop companies; all do business is

Theres a difference in companies that are involved in intercontinental

Port & Terminal Cranes: bulk handling

Port & Terminal equipment for bulk handling

June 05 Sales Conference - Amsterdam

Bulk handling: Ship unloaders

50 85 tonnes grab cranes (180m/min) for unloading