VERSION CONTROL

VERSION DATE CHANGES DONE BY CHECKED BY APPROVED BY

Raúl Benítez Name and surname Name and surnam
1.0 01/06/2020 New Procedure
Lelystad Platform CENTER CENTER

STACKER CRANES HEAD

MAINTENANCE
PROCEDURE A1
A1-ALM-PAQ-001
V1.0
 A1-ALM-PAQ-001
STACKER CRANES HEAD Date: 01/06/2020
Version: 1.0

Index
1. OPERATIVE / FUNCTIONALITY.................................................................................................................................................. 2
2. PROCEDURE REVISIONS.......................................................................................................................................................... 7

1
 A1-ALM-PAQ-001
STACKER CRANES HEAD Date: 01/06/2020
Version: 1.0

1. OPERATIVE / FUNCTIONALITY

The purpose of this procedure is to describe the operation of the different elements that make up the head of stacker cranes, which aim to
transport and manage the entry and exit of boxes from the Flat Pack Silo (FP Silo).

Basically, the automated system designed and implemented by TGW, is composed of roller and belt conveyors, control and verification
elements that allow the boxes to be transported between the entrance/exit tunnel to the FP Silo and the (EP / AP Stations) tables where
they are deposited so that each crane can finally carry out the pickup/delivery of boxes from/to the rack.

2
 A1-ALM-PAQ-001
STACKER CRANES HEAD Date: 01/06/2020
Version: 1.0

SILO ENTRANCE/EXIT TUNNEL

☐ STEP 01

Knapp system
Once the boxes finish the reception phase (unloading, verification and identification), they
begin the route to the FP Silo by getting in the Silo Entrance / Exit Tunnel. Here, where we
find the transition from the Knapp to the TGW transport system, can be considered the
beginning of the stacker crane head.

The boxes leave the FP Silo through two conveyors, the upper one comes from the north
TGW system
stacker cranes head and the middle one comes from the south head. The boxes enter the
silo only through the lower conveyor that serves the two heads.

☐ STEP 02

The system has two derivation lines to be able to make recirculations or accumulations of
boxes. They correspond to the returns (green route) of the output of the F23 North header
and the F22 South header.
1
This return possibility will be activated by a pair (master-slave) of barcode readers (Lenze
BCL348i) that will read the label located on the side of each box and send the information to
the management system, which will decide whether or not to divert the box according to the
system configuration and production management.

☐ STEP 03 A.
B. At the end of the corridor is the cabinet where all control and power elements are housed,
including PLC 21, which control silo's inputs and outputs until connection with Knapp system.
Main components of the main cabinets are:

 Main switch
 S7-300F PLC
 Input to busbars with circuit breaker.
 Monitoring for each phase
 Exit for busbar
 CPU S7-300F PLC
 24 VDC Power supply
 Ethernet connection for tablet connection.

☐ STEP 04

F
A. 0-ON: Key switch to activate/deactivate the conveyors.
B. Auto On: Lighted button to start the automatic mode of the conveyor functions.
C. Auto Off: Lighted button to stop the conveyor functions in automatic.
D. Ack alarm: Lighted button to acknowledge/accept alarms
F A B C D E E. Enable: To activate the preselection of the functions. Performs the
manual/automatic step.
F. E-Stop: Emergency button.

3
 A1-ALM-PAQ-001
STACKER CRANES HEAD Date: 01/06/2020
Version: 1.0

LOOP ENTRANCES/EXITS

☐ STEP 01

In the curve that starts the Silo Entrance, there is another pair of scanners (Lenze BCL380i)
that send the query data to the management system, the PLC will receive the answer of
which of the 24 crane aisles the box should be diverted to.

☐ STEP 02

PLC 22 manages the southern stacker cranes head (Cranes 13-24), while PLC 23 handles
the northern stacker cranes head (Cranes 1-12).

The silo input loop, together with its inputs and outputs, is divided by hardware/software
issues into South PLC F22 (Cranes 13-24), and North PLC F23 (Cranes 1-12). These two
PLCs receive boxes from F21 (Silo Entrance / Exit Tunnel).

The cabinets that house all the control and power elements of these PLCs are located on the
first floor of the FP Silo.

☐ STEP 03

Along the entry loop are PWT Pop-Up Transfers located at the fork to each crane. These are
formed by two rows of rollers and fed by a pneumatic system, they are responsible for
diverting the box to the corridor of the corresponding crane.

The entrances are governed by IT, it is the management system itself that decides which
corridor to enter at the corresponding decision point in the loop.

☐ STEP 04

Unlike the inputs, the outputs are controlled by the PLC, by virtue of their entry into the
ordinary flow via a position tracking control function.

There is a direct recirculation between inputs and outputs in the PLC F23, in the same way
the management system will decide which containers should or should not use this by-pass.

The Silo loop is kept running except that:

 All diversions are full, faulty, or disabled.
 The level of filling of the deviations does not vary in 1min the loop stops or
enters the energy saving of all the inputs and outputs.

4
 A1-ALM-PAQ-001
STACKER CRANES HEAD Date: 01/06/2020
Version: 1.0

INLET/OUTLET TABLES (EP/AP STATIONS)

☐ STEP 01

The decision to send boxes to the inlet tables (EP stations) is made by IT and is taken at the
decision point with scanner just before the EP. At this point IT answers only if that box can
enter the EP.

There is the possibility that a box is waiting at the point after the scanner with the empty EP
station if IT decides so.

The silo corridors do not have any counter to know the load exactly. It is obtained at fill level
with the photocells installed.

☐ STEP 02

Both EP and AP stations have a capacity of 3 boxes, the same capacity as the cradle or LHD
Twister of the crane.

The boxes are stored in the inlet table (EP Station) and will be transferred all at once when
the stacker crane asks for it after receiving the IT orders.

The default outlet table (AP station) is always ready to receive, unless it has a fault. The
crane will unload its entire load when indicated by IT.

☐ STEP 03

The infeed/outfeed tables are based on the TGW ZAS Timing Belt K model which is used to
transfer vertical or parallel loads to the conveyor lines. The loads are lifted by a lifting
mechanism and transferred by a timing belt conveyor which allows smooth transfers.

5
 A1-ALM-PAQ-001
STACKER CRANES HEAD Date: 01/06/2020
Version: 1.0

SILO CORRIDOR BEACONS

☐ STEP 01

The silo corridor markers have 4 elements, green-amber-white and blue.

The reset button inside the aisle has a special functionality, the long press of 5s allows to
reset the EP station after a handling error and to evacuate the boxes directly through the exit
table.

BUTTON BOXES

☐ STEP 01

The reset button inside the aisle has a special functionality, the long press of 5s allows to
reset the EP station after a handling error and to evacuate the boxes directly through the exit
table.

ERRORS

☐ STEP 01 An example of a typical error is shown below:

 Error Code: Remove all boxes from EP

 Description: It happens when any of the following conditions occurs:
 The Data Acquisition Module is not receiving the laser beam
or not with the proper intensity.
 If the status of the occupation of the PE is modified
 If a specific IT telegram is received
 If there is an excess of time in any of the load movements of
the RBGU
 If there is a jam control on the table
 If there is a gauge error in EP
 If there is a No reading in the previous scanner without the
box reaching its destination
 Solution: There are two possible operations to resolve the error:
 Empty the EP boxes and do a long reset.
 Correctly position the boxes and do a long reset.

NOTE: When a long reset is carried out, a specific message is generated between the head
PLC and IT, and subsequently IT generates the orders on the move to evacuate all the boxes
of the EP by the AP.

6
 A1-ALM-PAQ-001
STACKER CRANES HEAD Date: 01/06/2020
Version: 1.0

2. PROCEDURE REVISIONS
REVISIONS

Date Version Section Step Comments Validated by

01/06/2020 1.0 New Procedure Nombre Apellido1

APPROVAL

Date Version Section Step Comments Validated by

01/06/2020 1.0 New Procedure Nombre Apellido1