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Crane safety implementation

Here are some selected examples showing how to implement the most common safety functions for overhead crane movements. ACS880 drives include safe torque off (STO) function built-in as standard. The easiest way of adding more safety functions to the drive is to attach an optional safety functions module to it (FSO-12/-21). If a drive does not support the safety functions module, the same safety functions can be constructed with AC500-S safety PLC.

How you benefit from ABB crane safety solutions

  • Motor contactors are not needed in our crane safety solutions
  • The safety functions ensure application safe state and fast restarting
  • Speed safety functions can be realized either with or without a motor shaft encoder
  • Less wiring is needed
  • Reduced safety design effort by using certified safety building blocks and ABB's functional safety design tool software
  • The same software is used for drive, PLC and safety system configuration

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Long travel safety
Trolley safety
Hoist safety

Description

Safely limited speed (SLS) and safe stop 1 (SS1) safety functions make the crane slow down in a controlled way and stop in predefined locations and thus help prevent crane or load collision.

How it works

The nominal speed of the long travel movement changes to predefined slowdown speed (SLS) when the crane hits the safety limit switch 1.

Safe stop 1 (SS1) safety function is activated and the crane slows down to full stop when safety limit switch 2 is reached. As a result of the activation of SS1 function, the drive will go to safe torque off (STO).

What's needed for drive based solution

  • Long travel AC motors with disc brakes 
  • Safety certified limit switches
  • ACS880 drive
  • FSO-12/-21 safety functions module add-on for the drive

What's needed for PLC based solution

  • Long travel AC motors with disc brakes
  • Motor encoders
  • Safety certified limit switches
  • ACS880 or ACS380 drive
  • SM560-S safety CPU
  • DX581-S safety I/O module

Description

Safely limited speed (SLS) and safe stop 1 (SS1) safety functions make the crane slow down in a controlled way and stop in predefined locations and thus help prevent crane or load collision.

How it works

The nominal speed of the trolley movement changes to predefined slowdown speed (SLS) when the crane hits the safety limit switch 1.

Safe stop 1 (SS1) safety function is activated and the crane slows down to full stop when safety limit switch 2 is reached. As a result of the activation of SS1 function, the drive will go to safe torque off (STO).

What's needed for drive based solution

  • Trolley AC motors with disc brakes 
  • Safety certified limit switches
  • ACS880 drive
  • FSO-12/-21 safety functions module add-on for the drive

What's needed for PLC based solution

  • Trolley AC motors with disc brakes
  • Motor encoders
  • Safety certified limit switches
  • ACS880 or ACS380 drive
  • SM560-S safety CPU
  • DX581-S safety I/O module

Description

Safe brake control function (SBC) prevents accidental hoist slipping and thus helps protecting people and the load. Safe direction function (SDI) ensures that the hoist can only move in selected safe direction. It helps prevent lifting too heavy loads and can also be used to let the operator bring material to a defined danger area.

How it works

Hoist movement information from a motor encoder is constantly required for detecting the load speed even when modulation is stopped. The pulse encoder interface module FSE-31 can be used for this purpose. When combined with safety functions module FSO-21 it enables building certified safety functions for hoisting movements.

The slowdown areas and end limits of long travel and trolley movements typically apply also for hoisting. Safely limited speed (SLS) function is used in slowdown areas, and safe stop 1 (SS1) function together with SBC for the end limits. SBC ensures that the brake is on after activation of SS1 function. The SCB function also always activates together with safe torque off (STO). This ensures safe control of hoist holding brake in the torque-free state.

The SDI function makes sure that the hoist can move only in one selected direction. It can be used in hoisting to prevent crane breakage by stopping lifting too heavy loads. This is realized by combining overweight detection and SDI functionality of FSO-21. Another typical use of the SDI function is to let the operator enter a defined danger area by ensuring that the hoist can only move in a safe direction.

What's needed for drive based solution

  • AC motors for the hoist movement 
  • Motor shaft encoder
  • ACS880 drive
  • FSE-31 pulse encoder interface module
  • FSO-21 safety functions module add-on for the drive

Additional information and downloads

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