G1476M010700en / REV. A / 11.02.

2014
DYNAPILOT COMPUTER AIDED CRANE CONTROL

DYNAPILOT COMPUTER AIDED CRANE CONTROL

Table of contents

1 GENERAL DESCRIPTION ........................................................................................................................ 2

1.1 SAFETY ................................................................................................................................................ 2
2 OPERATOR CONTROL INTERFACE ....................................................................................................... 3
3 USE OF DYNAPILOT ................................................................................................................................ 4
3.1 Main Principles ..................................................................................................................................... 4
3.2 DynAPilot Swing Control ...................................................................................................................... 4
3.3 “DynAPilot OFF” Foot Pedal Switch ..................................................................................................... 4
3.4 AutOPilot Positioning tool ..................................................................................................................... 4
3.5 DynAPilot operation at trolley slowdown and end limits ....................................................................... 5
3.6 Storing of the target positions ............................................................................................................... 5
4 DYNAPILOT OPERATOR TRAINING ....................................................................................................... 6
4.1 Shape of acceleration and deceleration ramps .................................................................................... 6
4.2 Stopping the trolley at the target while driving manually ...................................................................... 6
4.3 DynAPilot operation while fine positioning the load .............................................................................. 6
4.4 Training to use DynAPilot ..................................................................................................................... 7
4.5 Exercise 1 – How to modify acceleration and deceleration ramps and the stopping distance ............ 7
4.6 Exercise 2 – Moving short distances .................................................................................................... 7
4.7 Exercise 3 – Fast and accurate positioning of the load ........................................................................ 7
4.8 Exercise 4 – Landside positioning with the AutOPilot tool ................................................................... 7
4.9 Exercise 5 – Driving past the target with the AutOPilot tool ................................................................. 8

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2014)
Konecranes Plc. All rights reserved.
G1476M010700en / REV. A / 11.02.2014
DYNAPILOT COMPUTER AIDED CRANE CONTROL

1 GENERAL DESCRIPTION
This crane is equipped with a control system, which assists the crane operator in the following tasks:
 Stopping the trolley at a selected target position.
 Load swing control in manual control and during automated operation.
 Stopping the trolley at the access gate position
The crane operator initiates any movement of the crane; the trolley is not making any movements
automatically. The control system is modifying the given acceleration and deceleration ramps to optimise
motor power usage and minimising the load swing and positioning the load.

1.1 SAFETY

The DynAPilot control system has to be switched off when the crane is not
WARNING
used for the normal work for which the system is built and tuned for.

DynAPilot control system optimizes the trolley movements. As a result of this optimization the resulting
speed control is modified and the trolley movements differ from usual. In some conditions the trolley can stop
for a moment and then continue driving to compensate the load sway. This re-start can be unexpected to the
drivers and the maintenance personnel.
The access gate to the crane cabin should be used only after the trolley has stopped and the main contact
has been opened.
If the crane is used for other work than container handling it is possible that the control system does not
perform as well as expected. In these cases it is recommended to switch the DynAPilot to OFF state. Typical
examples are (the list is not complete):
 When hoisting the load with another method than using a container spreader.
 When moving a load, which differs significantly from a normal container.
 When moving the trolley during inspection, service and maintenance work.
 When the crane’s electrical drive system is faulted or not in normal working condition.
 During load height position measurement failure.
 If the lifted load is not swinging free.
 In other occasions when the crane is used for something else than its normal operations.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2014)
Konecranes Plc. All rights reserved.
G1476M010700en / REV. A / 11.02.2014
DYNAPILOT COMPUTER AIDED CRANE CONTROL

2 OPERATOR CONTROL INTERFACE

Equipment Description of Operation
OPERATING MODE The switch is used to select the DynAPilot operation mode
selector switch

OFF : Normal operation without DynAPilot DynAPilot OFF mode.

ON : DynAPilot and positioning DynAPilot operation with AutOPilot positioning and active
residual sway dampening.
CONTAINER LANE ON DOCK These buttons are used to select the lane, to which the
Selection buttons, illuminated trolley is automatically stopped when the crane operator is
driving the trolley from waterside to landside. The
Operator panel, Returnline positions
illumination of a button indicates the selected lane.
STORE CONTAINER LANE This button is used to enable storing of container lane
Pushbutton positions on the quay.
Operator panel, Returnline positions
DYNAPILOT OFF While this pedal pressed the DynAPilot system is temporally
Foot pedal switch switched off. When the switch is released DynAPilot system
returns active.
DYNAPILOT OFF While this pushbutton pressed the DynAPilot system is
Pushbutton temporally switched off. When the pushbutton is released
DynAPilot system returns active.
Right master joystick

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2014)
Konecranes Plc. All rights reserved.
G1476M010700en / REV. A / 11.02.2014
DYNAPILOT COMPUTER AIDED CRANE CONTROL

3 USE OF DYNAPILOT

3.1 Main Principles

DynAPilot control system does not move the crane automatically. The system is used only as a tool for the
operator. The crane operator controls the crane’s motions and the speed and the travelling path of the load.
DynAPilot system is utilised to:
 Modify the operator’s speed commands to optimise the motor power usage and to avoid load swing.
 Stop the trolley at selected lane positions when driving towards landside.

3.2 DynAPilot Swing Control

DynAPilot control system optimises the trolley's drive torque during acceleration and deceleration. At the
same time the system prevents creation of load swing. The load swinging has a major effect to the need of
motor torque. So, keeping the swing angle small allows higher momentary trolley accelerations. DynAPilot
helps the operator to maintain high productivity.
DynAPilot computer modifies the trolley acceleration and deceleration speed patterns. The operator needs to
learn the DynAPilot operating principles.
DynAPilot system can be switched off temporally by depressing a foot operated pedal switch. It causes the
trolley speed to follow operator speed reference directly with linear acceleration and deceleration ramps.
DynAPilot returns to operation when the pedal switch is released.

3.3 “DynAPilot OFF” Foot Pedal Switch

While picking and landing the containers the crane operator sometimes needs to make small trolley
movements without DynAPilot control. Therefore the DYNAPILOT OFF foot pedal switch is included. When
necessary the operator can temporally switch DynAPilot system to OFF state by depressing the foot pedal.
This can be done at any time, also during the crane movements. Switching DynAPilot off during crane
movements will cause load swing.
If load swing is created because of off-centre lifting, collision or other disturbance the operator can switch
DynAPilot off using the pedal switch, catch the swing manually, and return to the DynAPilot operation by
releasing the switch.

3.4 AutOPilot Positioning tool

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2014)
Konecranes Plc. All rights reserved.
G1476M010700en / REV. A / 11.02.2014
DYNAPILOT COMPUTER AIDED CRANE CONTROL

The crane operator can use the Auto-Pilot positioning tool to stop the trolley at programmed lane positions.
When Auto-Pilot target is selected the trolley will stop at that co-ordinate position when the operator is driving
the trolley against it towards landside.

The positioning is operating as follows:

 DynAPilot control system calculates the distance from which the slowdown and stop must be at the latest
started. This distance is the shortest possible distance to stop the trolley motion without load swing.
 When the crane distance to the target position is same as the calculated stopping distance the slowdown
and stop sequence is started. While stopping the trolley DynAPilot control optimises trolley drive motor
torque and prevents creation of load swing.
 When the operator returns the trolley speed master control switch to zero position near to the Lane
Position he is allowed to continue driving the trolley over the target position with 10 % speed. Ship
direction speed is not limited when Lane Position is active.
AutOPilot function is active as long as the target is activated.

3.5 DynAPilot operation at trolley slowdown and end limits

When DynAPilot control is selected the trolley speed pattern is optimised also when driven to stop limits and
parking position.
If the control system detects an immediate risk of collision with the crane’s sill beam the system will stop the
trolley immediately.

3.6 Storing of the target positions

DynAPilot control system operates with AutOPilot positioning system. AutOPilot system helps the crane
operator to stop the trolley at the landside lanes.
There are ten push buttons on the operator panel for lane selection. The operator can store lane positions.
Storing the lane positions is made as follows:
 Select the Returnline positions sreen on the operator panel
 Trolley is manually positioned exactly above the target lane
 Select the corresponding lane number from the screen
 Save to position by selecting SET TO SELECTED LINE button on screen
 The stored container lane positions can be monitored on the operator panel.
Lane Position storing error messages
TARGET OUT OF RANGE The stored lane position must be on the quay area (not
above the water). Move the trolley to landside direction
and repeat the store. Make sure, that the trolley position
measurement is operating correctly.
TROLLEY POSITION MEASUREMENT FAULT If trolley position measurement is not accurate, storing of
lane positions is not allowed.
STORED COORDINATE NOT LOGICAL Lane Positions should be stored in logical order. The
most shipside position is stored to button nearest to the
ship, and all other lanes in logical order.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2014)
Konecranes Plc. All rights reserved.
G1476M010700en / REV. A / 11.02.2014
DYNAPILOT COMPUTER AIDED CRANE CONTROL

4 DYNAPILOT OPERATOR TRAINING

4.1 Shape of acceleration and deceleration ramps

While DynAPilot control is active the trolley speed acceleration and deceleration control is modified to:
 Smoothen the start and the end of every trolley movement
 Optimize trolley traversing drive torque
 Avoid loading peaks to the crane structure
When DynAPilot control is active the operator gives a target speed to the computer system. DynAPilot then
modifies the trolley speed to reach that target speed in the optimal way.
The operator should avoid making his own swing dampening controls while driving the crane.

4.2 Stopping the trolley at the target while driving manually

WARNING The emergency stop switch is the fastest and the most reliable method to
stop the crane in case of emergency.

In DynAPilot control the trolley stopping distance depends on the trolley’s actual speed, swing angle and
angular velocity of the load, and the lifting height. DynAPilot control is very much similar with the way a very
good crane operator drives the crane.
The operator should learn how the trolley stops to be able to reach the full crane capacity.
The most efficient way to drive the DynAPilot crane is the following
 Accelerate directly to the target speed
 Drive trolley and hoist motions simultaneously
 Slow down (to about 10 – 20% speed), when you are close to the target position
 Stop the trolley right to the target position without “positioning jogging”

4.3 DynAPilot operation while fine positioning the load

In a ship-to-shore crane the load pendulum length is long, therefore the load is swinging very slowly. When
the operator makes a small movement with the trolley it takes several seconds before the load follows. A
good operator can predict how the load will respond, and he can time his controls correctly to stop the load
swing right at the position.
When making small adjustments to the load position the DynAPilot control system operates as follows:
 Trolley is moved a short distance towards the target position. It initiates load swing to the target direction.
 Trolley speed is stopped or lowered down before the target position is reached, to wait until the load
swings to the other side of the trolley (i.e. load pivot point)
 When the load is near to the target position and at the end of the swing to that direction the trolley is
accelerated towards the target and then stopped right at the target. This movement also kills the load
sway.
The above-described procedure takes several seconds. During this time an inexperienced operator makes a
series of small controls, often to different directions. The result is that the operation gets slower and the
crane makes several unnecessary movements.
With DynAPilot the crane is operated faster, with less control actions by the operator.
Since DynAPilot control has no other way to operate than waiting the natural delay of load swing it is
sometimes necessary to switch it OFF momentarily. Therefore DynAPilot control system comes with a pedal
switch for easy switching off. When the pedal is depressed DynAPilot is in OFF state, and when it is released
DynAPilot returns to operation. A typical situation where DynAPilot is switched OFF is while operating inside
ship’s cell or against other containers.
If there is load sway caused by off-centre lifting or a collision DynAPilot has to be switched off to catch the
swing. When the load is stable again DynAPilot is switched ON again.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2014)
Konecranes Plc. All rights reserved.
G1476M010700en / REV. A / 11.02.2014
DYNAPILOT COMPUTER AIDED CRANE CONTROL

4.4 Training to use DynAPilot

With DynAPilot it is very easy to drive long trolley movements. The most demanding part of the job is to
position the container fast and accurately to a predefined position. In a ship-to-shore crane the target
position is difficult to determine because of continuous changes in the ship’s position, high trolley speed and
a long distance between the operator and the target.
In the training we will concentrate to understand the DynAPilot operating principles and then to utilize it in
normal working conditions.

4.5 Exercise 1 – How to modify acceleration and deceleration ramps

and the stopping distance
 Accelerate the trolley to a target speed by moving the master switch to that speed with one, fast
movement.
 Then stop the trolley and accelerate again to the same speed by moving the master switch slowly. First
give just a small control signal and start to increase the speed control when the trolley starts to move.
 Notice the difference in crane speed response. Do the same while decelerating the trolley speed.
 Test how you can alter the stopping distance by changing the speed with which you move the master
switch to the zero position.

4.6 Exercise 2 – Moving short distances

 Give a speed control, which makes the trolley start and then return the master switch to the zero position.
Notice how long the trolley moves, how the load swings and how the load swing is finally killed.
 Test how long distance the trolley moves in response to different types of controls.
 Give several small controls, some of them to opposite direction to test the trolley behavior.
 Set a target position near to the current location and try to get there with just one correctly sized speed
control pulse. Try different strategies: one high, short and sharp pulse, then a longer but smaller pulse,
etc. Try to get a feeling what the DynAPilot control system does.
 Give a large speed control, wait until the load has reached a large swing angle and return the control
switch to the zero position. Note how the trolley moves and how long it takes to stop the trolley. Then do
the same, but turn the master control switch to the opposite direction for a few seconds and then to zero.
Notice the strategy and difference in stopping of the trolley.

4.7 Exercise 3 – Fast and accurate positioning of the load

The container crane operation efficiency is limited by the operator’s skill in stopping the load from full speed
directly at the target position in the shortest possible time. DynAPilot control system helps the operator to use
optimal acceleration and deceleration ramps, even with simultaneous hoisting or lowering of the load. This is,
however, useless if the operator cannot predict the right distance and the moment on which he should start
stopping the trolley movement.
The only way to master load positioning is to repeat driving to a target position until the operator has learnt
the DynAPilot operation principles, and can predict how it operates. The following test should be repeated 20
– 30 times.
 Mark the target position clearly (for example a test container on the quay).
 Drive to a fixed starting point and load height (for example on waterside, spreader 1/3 high).
 Start the movement towards the target always in the similar way.
 Slow down the trolley speed and stop at the target.
 If the positioning was not successful do not start making small adjustments; instead start the test again
from the beginning until it is repeatedly successful.
The same training must be repeated from different directions, load heights and speeds. It is strongly
recommended that the crane operator repeats these exercises until he is successful before operating in the
ship.

4.8 Exercise 4 – Landside positioning with the AutOPilot tool

While using the computer aided positioning system AutOPilot the operator drives against the selected target
position. AutOPilot stops the trolley at the target and DynAPilot system optimizes the deceleration and avoids
creation of load swing.
For safe operation the operator should learn to use the selectors, buttons etc. confidently. The operator
should also learn how the system stops the trolley so that he can monitor the operation of the system.
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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2014)
Konecranes Plc. All rights reserved.
G1476M010700en / REV. A / 11.02.2014
DYNAPILOT COMPUTER AIDED CRANE CONTROL

 Activate one of the CONTAINER LANE ON DOCK buttons.

 Drive against the limit with varying speeds and load heights.
 Keep the speed control active towards land side.
 Note on which distance the trolley starts to decelerate.
 Note how the system operates if the load is lowered while stopping.

4.9 Exercise 5 – Driving past the target with the AutOPilot tool
If the operator keeps the speed control active all the time, the trolley is stopped at the selected position.
Operator can drive over that point with 10 % speed if he returns the master switch to the zero position (when
the trolley speed is low or stopped against the lane position limit), and then gives again landside speed
control.
 Select a Lane Position.
 Drive against the limit.
 When the crane is nearly stopped set the controller to zero for a short moment and then continue driving
to landside.
 Notice the difference compared with Exercise 4.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2014)
Konecranes Plc. All rights reserved.