FORD EL2-1993 RADIO CONTROLS FOR CRANES《起重机的无线电控制系统》.pdf

1、 Manufacturing StandardsFord Motor Company199306 RADIO CONTROLS FOR CRANES EL2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 1 of 261. SCOPE: This standard outlines the general requirements for radio control equipmentfor cranes.2. APPLICATION: This standard i

2、s applicable to Company locations where radio controlof cranes will provide safer operation and improve production and maintenanceefficiency.3. PROCUREMENT PROCEDURE:3.1 Manufacturing Procedure IIId8, available from Plant Engineering Office,Manufacturing Staff, shall be followed in the procurement o

3、f radio cranecontrols.3.2 In accordance with Manufacturing Procedure IIId8, the Plant or Facilityshall submit requests for frequency allocations to TelecommunicationServices, Finance Staff, who will coordinate the assignment of frequenciesand maintain records of equipment operating at radio frequenc

4、ies.4. STANDARDS AND APPROVAL OF SPECIFICATIONS:4.1 The electrical portion of the equipment and installation shall comply inall respects to the latest applicable standards of the National ElectricCode and Ford Manufacturing Standards, Section E, which includes StandardEX-1 (Electrical Standards for

5、Mass Production Equipment).4.2 The electronic components shall comply with applicable ElectronicIndustries Association (EIA) Standards. The electronic portion of theequipment and installation shall comply with Ford Manufacturing Standard,ELX (Electronic Standards for Mass Production Equipment and Ge

6、neralPurpose Machine Tools).4.3 Rechargeable battery packs shall conform to applicable requirements andtests specified in ANSI Standard C18.1, Dry Cells and Batteries.4.4 Additional specifications, if any, and the information required in theApplication Data Form, (Exhibit A), shall be submitted to t

7、he PlantEngineering Office, Manufacturing Staff, for approval before release forquotations.4.5 The local plant engineer, in cooperation with the local plantcommunications representative, shall furnish pertinent information onplant or production equipment operating at 10 KHZ or above and capable ofem

8、itting electromagnetic radiation. This information shall be submittedto the Telecommunication services via the Division Staff for use in thereview and allocation of radio crane control frequencies.Manufacturing StandardsFord Motor Company199306 RADIO CONTROLS FOR CRANES EL2Engineering Standards & Pr

9、inted copies are uncontrolled.Systems Engineering (ESSE) Page 2 of 264.6 Prior to any installation of radio controls, an electromagneticinterference susceptibility study shall be conducted for any facilitywhere Industrial Scientific and Medical (ISM) equipment will coexist withradio remote control c

10、ranes sharing the same frequency bands.5. SYSTEM EQUIPMENT:5.1 TRANSMITTER:5.1.1 The transmitter shall be a battery operated portable unit carried by anoperator.5.1.2 The controls on the transmitter shall duplicate the functions of anymanual controls on the crane. All controls shall be visible to th

11、eoperator of the transmitter.5.1.3 A key operated switch shall apply battery power to the transmittercircuits.5.1.4 A pull-on/push-off or similar detented switch shall be located on thetransmitter and used to turn on power at the crane. The switch shall belocated so that it can be readily operated t

12、o the “off“ position butcannot be accidentally moved to the “on“ position.5.1.5 Function lever switches shall provide direction and speed control of cranedrive motors and when specified, control the bridge service brake. (See6.4.1.3 and 6.4.1.4)5.1.6 Pushbutton and/or toggle switches shall control a

13、uxiliary devices, such ashorns, brakes, magnets, special hook controls and remote weighingequipment when specified.5.1.7 A “dead-man“ switch is not required, unless specified by therequisitioning activity.5.2 BATTERY CHARGER:5.2.1 A battery charger shall be furnished if rechargeable batteries are us

14、ed tooperate the transmitter.5.3 CRANE MOUNTED EQUIPMENT:5.3.1 The receiver, receiver antenna, intermediate relay panel, disconnectswitches, main line contactor, indicating lights and transfer switch ifused, shall be mounted on the crane and are shown on Exhibit C.Manufacturing StandardsFord Motor C

15、ompany199306 RADIO CONTROLS FOR CRANES EL2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 3 of 265.3.2 RECEIVER:5.3.2.1 The receiver shall be activated by coded radio signals from thetransmitter and shall be used to decode the information from these signalsto

16、activate the proper sensitive output relays.5.3.3 INTERMEDIATE RELAY PANEL:5.3.3.1 The intermediate relays shall be actuated by the sensitive output receiverrelays and shall be used to control the various contactors and devices onthe crane.5.3.4 DISCONNECT AND TRANSFER SWITCHES:5.3.4.1 A manual main

17、 line disconnect switch shall be used to supply all power tothe crane from the energized crane rails.5.3.4.2 A main line contactor shall be used to supply all power and control to thecrane, except for radio control equipment, and acts as the principlesafety feature for the radio controlled crane sys

18、tem. This contactorshall be held closed by repetitively transmitted coded signals from theradio transmitter. (See 6.5.2)5.3.4.3 A two pole power disconnect switch shall be furnished to supply power tothe receiver and intermediate relay panel. (See 6.6.6.2and 6.6.6.3)5.3.4.4 When specified, a two pos

19、ition manually operated transfer switch shall beused to transfer control from manual to radio and vice versa. (See 6.6.7)5.3.5 OPERATION INDICATING LIGHTS:5.3.5.1 The following indicating control lights shall be furnished using roughservice incandescent lamps with a minimum size of 25 watts and thes

20、pecified colored globe:(1) AMBER - main line contactor closed.(2) Green - bridge and/or trolley brake released.5.3.5.2 A revolving RED light shall be furnished to indicate when a bridge ortrolley motor is operating against its applied service brake. Thisrequirement does not apply if a spring return

21、to off switch is used forthe control of the brake.Manufacturing StandardsFord Motor Company199306 RADIO CONTROLS FOR CRANES EL2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 4 of 265.3.5.3 When specified, the following lights shall be furnished with a globeco

22、lored as indicated:(1) BLUE (one lamp) Transmitter “A“ in control of crane(2) BLUE (two lamps) Transmitter “B“ in control of crane(3) CLEAR (one lamp) Lift magnet latch relay “latched“(4) CLEAR (two lamps) Lift magnet latch relay “unlatched“5.3.6 A single NEMA 12 control enclosure is preferred for e

23、nclosing thefollowing:(1) The radio receiver and output relays or solid state outputs.(2) The intermediate relays.(3) Power supplies as required.(4) Two pole power disconnect switch and fuses.(5) Transfer switch, if specified.(6) Print pocket.6. SYSTEM REQUIREMENTS:6.1 THE FEDERAL COMMUNICATION COMM

24、ISSION (FCC) RULES AND REGULATIONS:6.1.1 CARRIER FREQUENCY:6.1.1.1 The Federal Communications Commission (FCC) designated ManufacturersRadio Service Band, 72-76 MHZ is preferred. In countries other than theUnited States, frequency assignments shall comply with the regulations ofthat country.6.1.2 Th

25、e FCC requires that technicians performing services on the transmitterRF section must be licensed. The RF section shall be separately enclosedand shall be labelled to indicate limited access by licensed technicians.6.2 SYSTEM COMPATIBILITY:6.2.1 The design of the radio control system shall permit si

26、multaneous operationof at least 30 separate radio controlled cranes in the same buildingwithout interference to each other.6.2.2 The radio control system shall be capable of simultaneous control of anycombination of crane functions.6.2.3 It shall not be necessary to dwell in an intermediate position

27、 of thefunction lever switches when changing speed or direction.6.2.4 When specified, the radio system shall have the capability of beingcontrolled by two transmitters (pitch and catch). No more than twotransmitters shall control a system. Only one transmitter shall becapable of controlling a system

28、 at any time. (See 6.5.12)Manufacturing StandardsFord Motor Company199306 RADIO CONTROLS FOR CRANES EL2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 5 of 266.3 RANGE OF OPERATION:6.3.1 Means shall be provided to limit the operating distance from 100 to 1,000

29、feet between the transmitter and the receiver.6.4 FUNCTIONS TO BE CONTROLLED:6.4.1 THE TRANSMITTER SHALL CONTROL THE FOLLOWING FUNCTIONS:6.4.1.1 The crane main line contactor by operating the “POWER“, pull-on/push-offor similar type switch.6.4.1.2 The horn or siren by momentary pushbutton switch.6.4

30、.1.3 The bridge, trolley, auxiliary hoist and main hoist motors by means offunction lever switches arranged as shown in typical Transmitter ControlLayout Exhibits B-1 to B-4.6.4.1.4 The bridge and/or trolley service brake by one of the following methods:(1) Actuation of a maintained switch on the tr

31、ansmitter(2) Automatic actuation with brake torque steps varying according to speed of crane(3) Actuation of a function lever switch on the transmitter to apply discrete brake torque increments(4) Other methods as specified by the requisitioning activity6.4.1.5 Where used, a low level service brake

32、torque shall be applied by a toggleswitch marked OFF-DRAG on the transmitter.6.4.2 When specified, the transmitter shall be capable of controlling additionalfunctions such as:6.4.2.1 The lifting magnet by a momentary contact switch. The magnet releaseshall require the operation of two momentary cont

33、act switchessimultaneously.6.4.2.2 A coil grab and rotator, using two motors, controlled by momentary contactreversing toggle switches.6.4.2.3 A power sheet lifter, using three motors, controlled by momentary contactreversing toggle switches.6.4.2.4 ELECTRONIC WEIGHING WITH:(1) Zero balance controll

34、ed by a momentary contact pushbutton or toggle switch.(2) Scale read out controlled by a momentary contact pushbutton or toggle switch.Manufacturing StandardsFord Motor Company199306 RADIO CONTROLS FOR CRANES EL2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page

35、6 of 266.4.2.5 Stepless auxiliary and main hoist control operated by function levers.6.4.2.6 Stepless bridge service brake control operated by a function lever.6.5 SAFETY:6.5.1 The transmitter OFF-ON switch shall be a key-lock type.6.5.2 A minimum of two differently coded signals shall be present to

36、 energizethe crane main line contactor. Failure of any of these signals shallcause the cranes main line contactor to open and automatically apply thebrakes.6.5.3 The operation of any function under control of the radio system shall bedependent upon the presence of at least four inter-related signals

37、 orconditions. Frequency modulated digital systems are preferred. Theconditions and signals may consist of:(1) A continuous or repetitively transmitted frequency modulated (FM)radio frequency carrier(2) A second FM signal to modulate the first FM carrier(3) Pulse width modulation(4) Pulse code modul

38、ation(5) Pulse position modulation(6) Tone modulation with time coding(7) Verification of coded signals(8) Other techniques subject to the approval of the PlantEngineering Office and Telecommunication Services.6.5.4 Failure of any component in the radio control system shall not cause cranemotion or

39、operation of devices controlled on the crane.6.5.4.1 Circuitry shall be incorporated in the system to monitor the intermediaterelay contacts. If any of these relays should remain in the energizedposition without being commanded, this circuitry shall automaticallyrespond by deactivating the power to

40、that function or the entire system,to effect a safe condition.6.5.5 It shall be possible to counteract any failure in the radio control systemby de-energizing the transmitter. This shall open the crane main linecontactor, interrupting all power to the crane motive equipment andapplying the bridge pa

41、rking brake.6.5.6 The brake system and the radio control shall be designed so that theparking brakes will be applied in case of crane power failure or the craneis beyond the working range of the transmitter.6.5.7 Function lever switches on the transmitter shall be SPRING RETURN TO OFFtype, except as

42、 noted in 6.4.2.5 and 6.4.2.6.Manufacturing StandardsFord Motor Company199306 RADIO CONTROLS FOR CRANES EL2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 7 of 266.5.8 Function lever switches shall be guarded to prevent unintentionalactuation.6.5.9 A minimum o

43、f three means shall be available at the transmitter to stop anycrane motion. These are:(1) Release of function lever switches(2) Shut off “POWER“ switch(3) Turn off “TRANSMITTER“ key switch6.5.10 The system shall be capable of operating safely in the presence of anyelectrical or radio interference.6

44、.5.11 The simultaneous operation of any number of commanded functions shall notcause an uncommanded function to operate.6.5.12 A receiver that can be controlled by more than one transmitter shall beinterlocked to prevent actuation by a second transmitter until control hasbeen released by the first t

45、ransmitter.6.5.13 Low transmitter battery voltage shall not create uncommanded crane motion.6.5.14 Radio control equipment shall be installed on the crane, so that shock andvibration cannot cause operation of, or damage to the equipment.6.6 EQUIPMENT REQUIREMENTS:6.6.1 RADIO TRANSMITTER:6.6.1.1 The

46、enclosure shall be constructed to exclude dust, liquids and othercontaminants and be capable of withstanding an impact of up to 20 Gswithout causing false commands.6.6.1.2 The size of the transmitter should be as small as possible, consistentwith good design.6.6.1.3 The weight shall not exceed 8poun

47、ds, including harness and battery. Thisrestriction may be waived by the requisitioning activity. The harness andbelt shall be constructed to evenly distribute the weight of thetransmitter on the operators shoulders. Snaps shall be used fordetaching the harness from the transmitter.6.6.1.4 Function l

48、ever switches, toggle switches and pushbuttons shall be soarranged and guarded to prevent unintentional operation. If the enclosurehandle is used as a lever switch guard, it shall clear the top of thefunction lever switches by at least three quarters of an inch.Manufacturing StandardsFord Motor Comp

49、any199306 RADIO CONTROLS FOR CRANES EL2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 8 of 266.6.1.5 Detents shall be furnished on function lever switches and bridge servicebrake control. Detents shall not be furnished for stepless control, butspring return to neutral shall be furnished.6.6.1.6 Function lever switches shall be capable of operating in any of fivepositions, in each direction, with spring return to the “OFF“ position.All five steps shall be under the direct control of the operator. Timesequenced speed steps are not accepta