Ref.

Ares(2019)1487274 - 05/03/2019
D4.3 Remote Control

D4.3 Prototype of Full-Scale Remote Control Unit – Ver. 1.3

YawSTOP

Kolberg Caspary Lautom AS

SME Instruments phase 2
GRANT NUMBER – 783518
Acronym - YawSTOP
EU Project Officer - Valentina Vignoli

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1 Contents
2 Introduction ..................................................................................................................................... 3
3 Definitions acronyms and abbreviations ......................................................................................... 4
4 The design process .......................................................................................................................... 5
4.1 Specifications and requirements ............................................................................................. 5
4.2 Selecting subsupplier............................................................................................................... 6
4.2.1 Key elements review ....................................................................................................... 7
4.2.2 Linus 4 controller ............................................................................................................. 7
5 Modifications................................................................................................................................... 9
6 Evaluation ...................................................................................................................................... 10
7 Conclusion ..................................................................................................................................... 10
8 ACCEPTANCE ..................................................................................................................................... 11
9 References ..................................................................................................................................... 12
Annex 1- Dimensions Linus 4 controller ............................................................................................ 13
Annex 2 Technical Datasheet Linus 4 ................................................................................................ 14
Annex 3 Technical Datasheet FSE 727 ............................................................................................... 15
Annex 4 Dimensions Receiver Housing HR165 and Snap-In Wall Brackets ...................................... 16

R EVISION D ESCRIPTION OF C HANGE E FFECTIVE D ATE

v1.0 D4.3 Prototype of Full-Scale Remote Control Unit 2018.07.31

v1.1 The evaluated companies were put in to tables in 2019.01.30
section 4
v1.2 Section 4.2.1, Key elements review added 2019.02.04
v1.3 Technical datasheets moved and attached as 2019.02.08
annex. Table of contents updated

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2 Introduction
The YawSTOP system’s main function is to control and stop unwanted rotation of cargo suspended in
one point without the use of personnel with tag lines.

The YawSTOP unit is a retrofit solution that is connected between the crane wire and the cargo. The
user controls the rotation of the suspended cargo with a remote control. This report describes the
functionality and design of the remote control.

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3 Definitions Acronyms and Abbreviations

Table 4.3- 1 Definitions acronyms and abbreviations

Definitions

Term Definition
YawSTOP Registered name for the product
YawSTOP system All components, i.e. docking station, radio transmitter and YawSTOP module
End user Crane operator or ground crew controlling the YawSTOP unit
DECT Digital Enhanced Cordless Telecommunication
GUI Graphical User Interface
RC Remote Control
LED Light-emitting diode
ATEX EU directives describing what equipment is allowed in an explosive atmosphere

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4 The Design Process

4.1 Specifications and Requirements
KCL does not have any in-house expertise on design of radio controllers. It was decided in December
2017 that we would reach a better solution if we found a sub supplier that could provide us with a
remote control and receiver.

When selecting the correct sub supplier, the requirements from “D1.1 System Specifications for
Upscaling v1.1”, was used as a checklist to verify the capabilities of the remote control system.

Besides from the requirements in table 4.3-2, the criteria for selecting a controller was:

- Possibility to adapt an off-the shelf module to fit our specification

The price for the system will be significantly lowered if we choose a system that is already in
production.
- Certified for operating in EX zones
When we select a system that is already certified, we will reduce the time for the system to
be verified for use in EX zones.
- Reliability
We will only buy from established companies that have been working with similar systems
for more than 5 years. It was also important that the producer controlled the whole
production line from product design (hardware and software) to production and quality
control. This is because it will reduce the risk of a system failure because the technology
already is proven.
- Solid appearance
The end users will expect the remote control to be of a sturdy design that can withstand the
daily use in a harsh environment.

Table 4.3- 2 Requirements for the remote control system

Technical requirements test Task 4.3

Max Min unit
Remote control system
Radio transmitter
Bandwidth 2,4 Ghz
Operating voltage 24 12 VDC
Range 150 m
operational
temperature 50 -30
Weigh 1 kg
Ip rating 67 65
Radio receiver
Ip rating 67 65
Weight 1
Voltage 24 12 VDC

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4.2 Selecting Sub Supplier

Based on the requirements and specifications we collected, it was collected 16 different companies
that fit some or all of the requirements that we have specified. Based on a preliminary review of the
companies and their products, the companies were divided in to 3 groups (see table 1 below).
Table 1

Group 1: Small and agile Group 2 : Companies that are Group 3 : Companies that only
companies which offers too big or mainly focus on delivers parts of the system
customized solution: other areas: that we need:
Abitron1 Curtiss-Wright8 Bauser 13
Autec 2 Dold 9 Frei 14
Hetronic 3 Emas a.s10 GH Cranes components15
Ravioli S.p.A 4 Lilaas 11 Input Tech 16
TER Tecno Elettrica Ravasi 5 Magnetek12
Tele Radio6
HBC-radiomatic7

Based on the review, the companies from group 1 would presumably deliver the products that best
fit our requirements. The companies were contacted and we described what the YawSTOP project
was and what we needed from them as a sub supplier. From this process, we were able to narrow
the selection down to three companies shown in table 2.

In order to be able to select the best solution, we rated the 3 companies on some key elements that
are not described in the requirements section. These elements are:

1. Service grade
This is a measurement on how cooperative the companies were when we contacted them.
Based on a scale from 1-5, where 1 is worst and 5 is best, the service grade of the company is
shown in table 2.
2. Proximity
It is important for us to be able to communicate efficiently with the sub supplier. In any
development, there can be changes that have to be acted on quickly. Therefore, proximity
was regarded as a key element. The proximity is on a scale from 1-5 where 1 is the company
farthest away and 5 is the closest.
3. Appearance
As described in section 4.1, it is important that the end users see that the remote control is
of a sturdy design and of a good quality. On a scale from 1-5 the companies solutions were
reviewed and rated.
4. Lead time
The delivery time is important for us to be able to keep our schedule. The lead-time is rated
from 1-5 where 1 is the longest time and 5 is shortest.

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4.2.1 Key elements review

The results from our contact with the three companies are reviewed and rated in table 2. The
company with the highest sum from the rating will be chosen as our sub supplier.

Figure 2 J-series n-Joy from

Figure 3 Linus 4 from HBC Radiomatic
Ravioli S.p.A
Figure 1 Nova XL from Abitron
Table 2

Company Service grade Proximity Appearance Lead time Sum

name
Abitron1 3 3 5 3 14

Ravioli S.p.A4 4 2 3 4 13

HBC- 5 5 4 2 16
radiomatic7

From the review HBC Radiomatic receives the highest sum. Initially, HBC Radiomatic had a very long
lead time(6 months). This affected their rating for this section. But they were able to fix a solution for
us that reduced the lead time for the first controller down to 6 weeks, which affected their service
grade.

Abitron was rated as the best visual solution. It is possible that this company will be a potential
supplier for us at a later point, but for now at the development stage we are dependent on
communicating efficiently with the manufacturer.

We decided to go for HBC Radiomatic as our supplier. In addition to comply with the requirements
above they offer a wide range of transmitters, receivers and batteries including an ATEX approved
segment.

4.2.2 Linus 4 controller

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The RC transmitter and receiver used in this prototype is not ATEX approved, as the development of
an ex-safe RC system is both costly and time-consuming. Because of the lead-time we decided that
ATEX was not important at this point. HBC Radiomatic will be able to provide us with an ATEX
certified system later.

During WP5 “Piloting and validation in operation environment” we will gather valuable information
and feedback regarding the RC-system, and GUI which will be implemented and tested before
launching an ATEX approved system. Technical information about the controller is attached in annex
1 and 2.

FSE 727 Radiobus receiver weighs 2,6 kg but compromises by having a modular card system which
makes it easy to program and customize according to our needs.
The Linus 4 transmitter weighs approximately 1 kg and is delivered with a small and light NiMH
battery, with a capacity of 2100 mAh, enough to power the unit for 16 hours continuous use.
Its small and ergonomic design has enough levers and buttons to expand our system if needed.
It also offers a range of special features, which may be implemented to increase safety (see table 4.3-
2). The technical datasheet for the receiver is attached in annex 3 and 4.

Table 4.3- 2 Special features

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5 Modifications
The Remote Control (RC) is based on HBC Radiomatic`s hand control unit “Linus 4” and receiver “FSE
727”. (See Figure 4.3-1)

Figure 4.3- 1 Linus 4 and FSE 727

Linus 4 may accommodate up to 4 stepless linear levers, and a combination of pushbuttons, toggle
and rotary switches. In this prototype, the number of buttons and functions have been reduced to a
minimum in order to make the RC equipment as easy to operate as possible. The operator only needs
to use the following three buttons (see figure 4.3-2 to locate the buttons on the transmitter):

S5) Start/Stop is activated by a Quick push + Push and hold for a few seconds.
The transmitter now connects to the receiver in the YawSTOP, when connected the system is
prepared for operation (ramp-up time) and when ready a LED light on the transmitter starts to shine.

S1) Rotation Control is activated by pushing or pulling the lever.

Max rotation speed is 6 RPM, and the speed increases proportional with the lever, this makes it easy
to use the YawSTOP even when performing lifting operations that require a high level of precision.

Emergency Stop is activated by pushing the red button, and securely shuts down all processes in the
YawSTOP.

The remaining three leavers (Z1, Z2 and Z3) has been removed and replaced by blind lids, while
button S6, S7 and S8 has been deactivated, but are kept in place in case the need for additional
functions such as “transferring control” or “activate sound alarm” should arise.

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6 Evaluation
When evaluating the RC-system according to the technical requirements defined in D1.1 (see table
4.3-3) the operating voltage is not sufficient, but since the power needed to run the transmitter is so
low this is not a problem. The transmitter can be used in -25 degrees Celsius, but the battery time is
reduced when the temperature goes below 0. This needs to be improved before the product is
launched. In addition the receiver unit is slightly too heavy, but this is easy to improve and has little
impact on the YawSTOP unit.
Table 4.3- 3 Evaluation of Technical requirements

7 Conclusion
The Remote Control has been tested on the YawSTOP system, and functions as desired.
When tested the YawSTOP was not enclosed in its shock absorbing panels, new tests needs to be
performed in order to see how these panels affect the range of the RC system. We will also consider
implementing LED lights in the shock absorbing panels to replicate the light signals given by the
LED light in on the transmitter.

Since only a few function buttons are being used, a smaller and lighter transmitter unit might be an
option. But for now we will keep working with Linus 4 as more buttons may be requested in future
tests.

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9 References
1: https://www.abitronremote.com/en/

2: https://www.autecsafety.com/en/product

3: http://www.hetronic.com/

4: http://www.raviolispa.com/

5: http://www.terworld.com/sfoglia.php?catID=25&name=Radio+remote+controls

6: https://www.tele-radio.com/no/

7: https://www.hbc-radiomatic.com/en/

8: http://www.cw-industrialgroup.com)

9: http://www.dold.com

10: http://www.emasas.com.tr/en/urunler.asp?id=4

11: https://www.lilaas.no/

12: https://www.magnetek.com/

13: https://www.bauser-control.de

14: www.Frei.de

15: https://www.ghcranes.com/GH-western-europe/products/accessories-and-options/

16: http://www.inputtec.com/

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Annex 1- Dimensions Linus 4 controller

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Annex 2 Technical Datasheet Linus 4

Max. number of control commands 10 digital + 4 analogue + E-STOP

Unique system addresses Over 1.000.000 combinations
Supply voltage 3.6 V
Safety function
E-STOP:
The mains supply is cut off by a STOP switch. Therefore, the
criteria for an elimination of errors according to EN ISO 13849-2
chapter D.5.3., table D.8 (non-opening of contacts) are met. The
performance level of the respective receiver applies.
Frequency ranges
2,4 GHz: 2402-2480 MHz DECT: 1790 - 1930 MHz
Channel spacing
2.4 GHz: 1 MHz DECT: 1.728 MHz
Antenna Internal
Battery type BA2230_0 (NiMH)
Battery capacity 2100 mAh
Continuous operating time
TC240: approx. 40 h TC180: approx. 20 h
Operating temperature range -25 °C ... +70 °C (-13 °F ... +158 °F)
Housing material Impact-resistant plastic
Dimensions 166 x 126 x 148 mm (6.54 x 4.96 x 5.83 inches)
Weight (incl. battery) Approx. 900 g (1.98 lbs.)
Protection class IP 65

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Annex 3 Technical Datasheet FSE 727

Max. number of control commands 20 + E-STOP

(12 relays 12 V/2 A + 8 x semiconductor switches 12 V/1 A)
Unique system addresses Over 1 000 000 combinations
Supply voltage 10-30 V DC
Power consumption Max. 16 W
Inputs -
Outputs -
Interfaces
2 x PWM, 2 x 0 - 10 V or 0 - 20 mA 2 x Opto-ln for feedback
E-STOP resp. Si1, Si2 control unit 1 x E-STOP output, 2 relays 4 A
Safety function
E-STOP:
Performance Level d, category 3 according to EN ISO 13849-1:2015
Frequency ranges 405 - 475 MHz1, 865 - 870 MHz, 902 - 928 MHz, 1210 - 1258 MHz1 2,4 GHz:
2402-2480 MHz DECT: 1790 - 1930 MHz

Channel spacing

1 2 . 5 / 2 0 / 2 5 / 5 0 / 2 5 0 kHz 2.4 GHz: 1 MHz DECT: 1.728 MHz

Connection Cable gland (metric M20/25)
Harting Han 16 or Han 25
Antenna
External, FL 30 or FL 70
Option: internal, car antenna with 5 m cable and BNC connector
Operating temperature range -25 °C ... +70 °C (-13 °F ... +158 °F)
Housing material Plastic
Dimensions 165 x 165 x 70 mm (6.5 x 6.5 x 2.8 inches)
Weight Approx. 1.0 kg (2.2 lbs.)
Protection class IP 65
1 Not all frequency ranges available.

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Annex 4 Dimensions Receiver Housing HR165 and Snap-In Wall Brackets

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