TELKOM
NIKA Indonesia
n
Journal of
Electrical En
gineering
Vol.12, No.4, April 201
4, pp. 3053 ~ 3
0
5
8
DOI: http://dx.doi.org/10.11591/telkomni
ka.v12i4.4835
3053
Re
cei
v
ed Se
ptem
ber 13, 2013; Revi
se
d No
vem
ber
7, 2013; Acce
pted De
cem
b
er 14, 201
3
Resear
ch and Design of Nuclear Fuel Manipulate Crane
Control System
Mu Zhaohui*
1
, Liu Rao
2
, L
i
Weidong
3
Coll
eg
e of Elec
trical Eng
i
ne
eri
ng, Dal
i
an U
n
iv
ersit
y
of T
e
chn
o
lo
g
y
(
D
LUT
)
116
02
4, Dali
an
, Liaon
in
g Prov
ince, Ch
ina, Ph
./F
ax: +
86-755-
844
70
324/8
4
4
375
24
*Corres
p
o
ndi
n
g
author, e-ma
i
l
: mzh502
@qq.
com*
1
, raoliu@dlut.edu.cn
2
, w
d
li@
dlut.e
du.c
n
3
A
b
st
r
a
ct
In order to sol
v
e the disa
dva
n
tages of the
Nucl
e
a
r F
uel
Mani
pul
ate Cr
ane
(a
b. MC),
the contro
l
system of MC
is res
earched
and de
signed,
which is
based
on the operation
expe
riences about
Nuclear
F
uel T
r
anstio
n
and Stora
ge
System (a
b.PMC) in
Day
a
Bay and
Lin
g
’
ao Nuc
l
ear P
o
w
e
r Plant.T
he new
control syste
m
ado
pts sing
le f
a
ilur
e
pri
n
ci
ple
and
makes us
e of the D
e
vice
-net techn
o
lo
g
y
that is diffuse
l
y
app
lie
d an
d ex
traordi
nary trie
d in practic
e
. T
here ar
e tw
o Device-
nets an
d
one Ethern
e
t, the tw
o kinds of
nets are co
mb
ine
d
.Apply
i
n
g
the n
e
w
techno
logi
es
a
nd n
e
w
equip
m
ents, the new
contr
o
l syste
m
solv
es
the
defects w
h
ich Ethernet a
n
d
a sing
le set o
f
PLC don
’
t
sati
sfy single fai
l
ur
e
princ
i
pl
e, imp
r
oves the safet
y
and w
hol
e
p
e
rformanc
e
of MC loa
d
in
g
a
nd
unl
oad
in
g of
n
u
cle
a
r fuel
ass
e
mbly,
an
d
ma
kes contro
l sys
te
m
simply to wire. According to the
design of the new contro
l system
, the product of MC has been successf
ully
app
lie
d to Ed
u
c
ate Ce
nter i
n
Daya B
a
y
Nucl
ear Pow
e
r Sit
e
and F
a
n
g
ch
en
gga
ng N
u
cl
ear
Pow
e
r Plant,
a
n
d
the result is ob
vious.
Ke
y
w
ords
:
P
M
C, man
i
p
u
lat
e
crane, eth
e
rn
et, device-n
e
t, control syste
m
Copy
right
©
2014 In
stitu
t
e o
f
Ad
van
ced
En
g
i
n
eerin
g and
Scien
ce. All
rig
h
t
s reser
ve
d
.
1. Introduc
tion
The Nu
clea
r Fuel
M
anipul
ator Crane (a
b.
MC)
i
s
on
e of the
esse
ntial equi
pme
n
ts in
a
nucl
ear po
we
r
station. 5.1
9
Event
that i
s
the
mo
st
seriou
s
accid
e
n
t in
Chin
a i
s
aro
u
sed
by t
h
e
control
syste
m
of M
C
. Th
e majo
r
sup
p
liers of
PM
C are
Westh
o
u
se
in Ame
r
i
c
a
and
REE
L
in
Fran
ce.
We
st
hou
se’
s
control sy
stem i
s
advan
ced
but
with p
o
o
r
se
curity, be
ca
u
s
e th
eir
pro
d
u
cts
heavily depe
nded o
n
Ethe
rnet, and
so
me de
sign
s o
f
c
ontrol
syst
em are
n
’t co
n
s
iste
nt with si
ngle
failure p
r
in
ci
ple, the equi
pment was f
r
om
We
sth
o
u
se in
5.19
Event. REEL’s produ
cts h
a
ve
better
se
cu
rity, but are
co
nse
r
vative, th
e ne
w techn
o
logie
s
and
equipm
ents a
r
en’t
applie
d
into
control sy
ste
m
s. With th
e
rapid
develo
p
m
ent of c
ontrol tech
nolo
g
i
e
s, it is n
e
ce
ssary to h
a
ve
a
n
in-de
p
th stu
d
y
of MC to apply the ne
w technolo
g
i
e
s a
nd eq
uip
m
ents a
nd
make th
e co
ntrol
system to mo
re advan
ce a
nd safe
r [1-7]
.
Makin
g
a p
a
rticular a
nalysis o
n
th
e fun
c
tion
re
quire
ments of
CP
R10
00
and
CNP100
0,
combi
ned
op
eration
expe
riences in
Da
ya Bay
and
Ling’a
o
Nucl
ear P
o
wer Pl
ants, thi
s
p
a
per
desi
g
n
s
a
wh
ole st
ru
cture
of cont
rol
system, whi
c
h i
s
desi
gne
d a
r
ound
one
Ethern
e
t an
d two
Device-n
et bus net
works, and ba
se
d on
single failu
re
princi
ple.
2.
Ov
erall Control Model
MC, above the RX Pool, mainly con
s
ist
s
of br
idge, tro
lley, hoist, auxiliary cran
e, and so
on. It can
mo
ve on the X
-
Y-Z coordinat
es, revolve 0
~
36
0° in
re
actor core,
co
ntrol the
grip
pe
r to
gra
s
p an
d loo
s
en n
u
cl
ear f
uel assem
b
ly.
The ne
w design of MC co
ntrol system
is
still adopte
d
master/
s
lav
e
mode whi
c
h with
mature
techn
o
logy a
n
d
wi
dely u
s
ed.
T
he
co
re
equi
pments
con
s
i
s
t of Upper
Comp
uter (to
u
ch
scree
n
co
m
puter), Programm
abl
e Lo
gic Controll
e
r
(PLC),
Dri
v
e and Servo Motor. The
differen
c
e i
s
to add a Safet
y
PLC to prot
ect se
cu
rity [8-16]. The
overall
control model i
s
sh
o
w
n
in Figure 1.
In Figure 1, Fuel Op
erato
r
input
s the
control
sign
als into PLC by
Upp
e
r
Comp
uter an
d
Operating Eq
uipment, an
d
pro
c
e
s
s the
feedba
ck dat
a from PL
C.
Upp
e
r
Com
p
uter di
splay
s
the
necessa
ry informatio
n. Wo
rk PL
C controls t
he
DRIV
E
after re
ceiv
ing the comm
and inp
u
tting
by
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02-4
046
TELKOM
NI
KA
Vol. 12, No. 4, April 2014: 3053 – 3
058
3054
Fuel Op
erato
r
, then proce
s
ses the fe
ed
back data
fro
m
DRIVE an
d sen
d
s
relat
ed inform
atio
n to
Upp
e
r
Comp
uter. Wh
en g
e
tting PLC co
mmand
s, the
DRIVE execu
t
es rel
e
vant a
c
tion
s to co
ntrol
Servo Moto
r runnin
g
and
can dete
c
t servo motor in
real time, it pa
sses th
e rele
vant messag
e to
PLC. Servo motor is run
n
ing un
der t
he co
ntrol of
DRIVE and
feedba
ck the
runnin
g
stat
e to
DRVIE thoug
h internal
sen
s
or. Th
e ne
w added Safet
y
PLC is red
unda
nt desi
g
n for the se
curity
of Work PL
C,
aims to give
se
curity prot
ection
to the
runni
ng of M
C
an
d re
solv
e the defe
c
ts of
Wo
rk PL
C wit
h
singl
e failure prin
ciple.
Figure 1. Overall Mod
e
l Ch
art of MC Co
ntrol System
Figure 2. Con
nectio
n
Ch
art
of Ethernet
In de
sign, in
orde
r to
avoid
colli
sion
an
d
falling of n
u
cl
ear fu
el a
s
se
mbly and
a
c
cord
with
singl
e failu
re
prin
ciple, th
e
redu
nda
nt de
sign
is ne
ce
ssary fo
r
man
y
equipm
ents and
protecti
on
function
s to meet the req
u
irem
ents of
se
curity and
accuracy.
3.
Design o
f
Etherne
t
The control system of M
C
dem
and
s i
t
s
data tra
n
smissi
on
rapid
and
safe. When th
e
Ethernet i
s
e
rro
r, the sy
stem nee
ds to
ensur
e th
e
safe
stop of
MC, not colli
sion
and falli
ng
nucl
earfu
el a
s
sembly, the
mech
ani
cal f
r
ame
run
n
i
ng i
n
the
allowed
ope
rating
area. Based
up
on
above re
qui
rements, the
Ethernet
of n
e
w control
sy
stem ad
opts
t
he 100M
hig
h
-spee
d indu
strial
swit
che
s
with
supe
rio
r
performan
ce a
n
d
high tra
n
smissi
on rate. The equi
pm
ents a
r
e lin
ked
together via the star
netwo
rk. See Fig
u
re 2.
Evaluation Warning : The document was created with Spire.PDF for Python.
TELKOM
NIKA
ISSN:
2302-4
046
Re
sea
r
ch an
d De
sign of Nucle
a
r Fu
el Manipul
ate Cra
ne Co
ntrolS
ystem
(Mu Zh
aohui
)
3055
In Figu
re
2, Hig
h
-Sp
eed
Switch
is the
core of
Ethernet’
s
in
formation
ex
cha
nge.
Operating
Up
per
Com
pute
r
, usin
g by the
ope
rator
to control MC an
d
re
ad
im
port
ant
informatio
n,
is touch-scre
en co
mpute
r
with huma
n
–
machine
i
n
terface (HMI) softwa
r
e an
d inputs
co
n
t
rol
comm
and through tou
c
h.
In addition, it has PLC p
r
og
ram to m
onitor an
d m
odify the PLC
prog
ram
s
at test a
nd failu
re. Cam
e
ra
S
y
stem
Uppe
r
Comp
uter i
s
displ
a
y equi
p
m
ent of mo
ni
tor
came
ra
s d
u
ri
ng M
C
runni
n
g
, the differe
nce f
r
om
We
sthou
se
and
REEL is: th
e
new
de
sign
is not
only di
splay,
but al
so i
s
a
touch-scre
e
n
comp
ut
er with
d
ual-net
work
card; o
ne ca
rd co
nn
ects
with Ethern
e
t of came
ra sy
stem it self, the other
ca
rd
conn
ect
s
wit
h
high-sp
eed
swit
ch, maki
n
g
it
as a re
dun
d
ancy Uppe
r Comp
uter. When Uppe
r
Compute
r
fault happen
s, it can exit video
monitor inte
rface to
start
the sam
e
prog
ram
as
Upp
e
r
Comp
uter, and i
n
stead
of Up
per
Comp
uter.
Work P
L
C a
c
ts as the lo
gic
control c
ente
r
of MC’
s
wo
rk to
cont
rol
MC’s
ope
rati
on.
Safety PLC i
s
redu
nda
ncy
de
sign
for th
e safe fun
c
ti
on of
wo
rk P
L
C, it m
onito
rs sig
nal
s
wh
ich
include positi
on (front, back, left, right, and up),
absolutely overload, ab
solutel
y
underl
oad,
over
spe
ed, hoo
ks sliding, axis
brea
kin
g
, and
so on.
4.
Design o
f
De
v
i
ce-net Bus
Net
w
o
r
k
In orde
r to
solve the defe
c
ts of
We
sth
ous
e an
d RE
EL’s p
r
od
ucti
ons, the
ne
w control
system ad
opt
s the Devi
ce-net bus
n
e
twork.
Device
-n
et, which h
a
s develope
d near 20 yea
r
s, is
widely u
s
e
d
in Site Bus tech
niqu
e wit
h
advanta
g
e
s
of
simpl
e
wirin
g
, havin
g self-dia
gno
sis
function, lo
w-co
st and sta
b
l
e comm
uni
cation [17-2
5
].
The New
co
n
t
rol syste
m
m
a
ke
s the b
e
st
of
Work PL
C and Safety PLC, an
d usi
n
g them
as the ma
ster station to de
sign 2
Device
-net bu
s networks, a
s
sh
own in Figure 3 and Figu
re 4.
Figure 3. Con
nectio
n
Ch
art
of Device-ne
t
1
In
F
i
g
u
r
e
3
,
D
e
vice
-
n
e
t
bu
s
ne
tw
ork
1 c
o
nn
ec
ts
Wo
r
k
PL
C
,
fou
r
D
r
ives
,
s
i
x En
c
o
de
rs
and three P
o
sition M
onit
o
rs,
whi
c
h si
mplifies h
a
rd
ware wi
ring
and en
su
re
s the prom
pt and
accurate of communi
catio
n
. But for safe operation o
f
MC, bus net
work 1 h
a
ven
’
t conne
cted t
he
sign
als of limi
t
position
s
an
d importa
nt secu
rity
into network thou
g
h
I/O module
of bus netwo
rk,
and
con
n
e
c
te
d these si
gna
ls di
rectly to
Wo
rk PL
C
o
r
cont
rol lo
op
to gua
rantee
the diversity of
redu
nda
nt de
sign. Bu
s net
work 1 u
s
e
d
Wo
rk PL
C as
master
station, other
s a
s
terminal stati
on
to achi
eve th
e monito
ring
and
cont
rollin
g of Wo
rk P
L
C to
other
device
s
. Work PL
C
contro
ls
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02-4
046
TELKOM
NI
KA
Vol. 12, No. 4, April 2014: 3053 – 3
058
3056
Drive
s
throug
h bu
s n
e
two
r
k, an
d ultima
tely cont
rols
motors. Inste
ad of traditio
nal me
ch
ani
cal
swit
che
s
, six
absolute En
coders u
s
in
g for po
sition
d
e
tect
directly con
n
e
c
ts
to bus network.
In
orde
r to
prevent en
co
ders’
failure,
all e
n
co
ders
have
red
und
ant d
e
sig
n
to
com
pare
ea
ch
ot
her.
After calculat
ing the posit
ion sign
als
of abs
olute
cod
e
rs, Wo
rk PLC outp
u
ts the posit
ion
messag
es of
main
cod
e
rs throu
gh b
u
s netwo
rk an
d
displ
a
ys the
m
on Po
sitio
n
Monito
rs. T
he
displ
a
y pro
c
e
ss i
s
with le
ss lin
ks,
sho
r
t
e
r del
ay
and
clea
re
r di
spla
y, and provides m
o
re
pre
c
ise
real time lo
ca
tion of MC, espe
cially its d
y
namic lo
cati
on.
In
F
i
g
u
r
e
4
,
D
e
vice
-
n
e
t
bu
s
ne
tw
or
k
2 c
o
nn
ec
ts
Safe
ty PL
C
a
n
d
th
r
e
e
Enc
ode
r
s
, an
d
Safety PLC as ma
ster
station, three a
b
sol
u
te
Enco
ders u
s
ed for detecting p
o
sition
s of hoi
st,
bridg
e
and trolley as termi
nal station. T
he majo
r
fun
c
tion of bu
s netwo
rk 2 i
s
to colle
ct po
si
tion
informatio
n of Encode
rs.
Figure 4. Con
nectio
n
Ch
art
of Device-ne
t
2
The main fu
nction of Bu
s Net
w
o
r
k 1
is co
ntrol a
nd po
sition
MC, whil
e that of Bus
Network 2
i
s
position
M
C
. These
t
w
o
bus networks relate
di
rectly to the stab
ility,
high speed and
pre
c
iou
s
po
si
tion of M
C
.
Con
s
id
erin
g t
he im
porta
nce of
po
sition
sig
nal i
n
th
e whole
cont
rol
pro
c
e
ss, th
e
new
co
ntrol
system not o
n
l
y
desig
ns
th
e
redu
nda
nt Enco
der i
n
bu
s netwo
rk 1, b
u
t
also
add
s the
bus
network
2 to co
mpa
r
e
with Bu
s Network
1 to re
d
u
ce th
e e
rro
r
data cau
s
ed
by
B
u
s Net
w
o
r
k
1.
5.
Ov
erall Net
w
ork Struc
t
ur
e
The d
e
si
gn
of the ne
w
control
syste
m
co
nverg
e
s the Etherne
t and
Device
-net b
u
s
netwo
rk, an
d
c
on
ne
cts thro
ugh PLC. Th
e two kin
d
s o
f
nets can
co
mmuni
cate a
nd ma
ke full use
of their advan
tages. Th
e overall conn
ecti
on of
the two kind
s of nets
as Figu
re 5
showed.
In Figure 5,
PLCs are the
co
re e
quip
m
ents,
info
rma
t
ion exch
ang
e interm
edia
r
y of the
two kind
s of nets,
a
nd
th
e
ma
ster
stati
on of th
e two
Devi
ce-net
b
u
s net
w
o
r
ks.
Wo
rk
P
L
C
is
to
control the ru
nning of M
C
with mo
st co
mplicate
d
co
nfiguratio
n a
nd proc
ess
most data; S
a
fe
ty
PLC is to
give se
cu
rity pro
t
ection for th
e
runni
ng of M
C
; it is the re
dund
ant de
si
gn of Work P
L
C
for security fu
nction. T
h
e
s
e
two PL
Cs
ca
n commu
nica
te throu
gh
hi
gh
spee
d
swi
t
ch of Ethe
rn
et,
and then re
alize the co
mmuni
cation
of two Devi
ce-net bu
s netwo
rks,
ultimately the data
validation am
ong two b
u
s
netwo
rks an
d
one Ethern
e
t.
In addition to
the above n
e
twork
con
n
e
c
tion, Figu
re 5
desi
g
n
s
thre
e
came
ra
s to
monitor
the handli
ng
nucl
ear fu
el a
s
sembly process of MC, it
can h
e
lp the
operator in th
e trolley to ha
ve
a cle
a
rer
ob
servation
of the han
dling
si
tuation.
T
h
e
th
r
e
e inc
r
emen
ta
l e
n
c
o
de
rs
ar
e
to
d
e
t
ec
t
runni
ng spee
ds of bri
dge,
trolley and ho
ist, using
Saf
e
ty PLC to provide over-sp
eed protectio
n
;
they are the redun
dant de
sign of Wo
rk P
L
C for ove
r
-speed p
r
ote
c
tion.
Evaluation Warning : The document was created with Spire.PDF for Python.
TELKOM
NIKA
ISSN:
2302-4
046
Re
sea
r
ch an
d De
sign of Nucle
a
r Fu
el Manipul
ate Cra
ne Co
ntrolS
ystem
(Mu Zh
aohui
)
3057
Figure 5. Structure
Cha
r
t of
MC for Control Sys
t
em
6. Conclu
sion
This pap
er a
dopts
the wid
e
ly
used
a
nd adv
an
ced
De
vice-n
et tech
nology, abi
de
s
single
failure p
r
in
cip
l
e, and de
sig
n
s a whole
structu
r
e of
co
ntrol sy
stem. The de
sign of
the new cont
rol
system
is ba
sed
on
on
e
Ethernet
and
two
Device
-net bu
s networks, th
e two
kin
d
s of
net
s a
r
e
comm
uni
cate
d and m
ade f
u
ll use
of the
advantag
es
t
hemselves. T
he ne
w control system
sol
v
es
the defe
c
ts o
f
Westh
o
u
s
e
and
REEL in
desi
gn,
an
d
make
s the
control to m
o
re advan
ce
d
and
saf
e
r.
In this de
sig
n
,
Safety PLC is ne
w de
sig
n
,
and give
se
curity p
r
ote
c
tion for the
ru
n
n
ing of
MC. It’s th
e
redun
dant
pro
t
ection
of
Wo
rk PLC for secu
rity fun
c
tion,but Safety
PLC isn’t u
s
ed
enou
gh, an
d
need
s to fu
rther e
n
ri
ch.
Device-n
et
b
u
s n
e
two
r
k h
a
s the
advan
tages
of sim
p
le
wirin
g
an
d st
able
comm
u
n
icatio
n,wh
ereas fo
r
the safe
run
n
ing, these equip
m
ents con
n
e
c
ted
in
to
De
vic
e
-
n
e
t
b
u
s
ne
tw
ork
ar
e
few
,
bus
ne
tw
or
k 2
pa
r
t
ic
u
l
a
r
ly, is
c
o
ns
er
va
tive
, D
e
vic
e
-n
e
t
bu
s
netwo
rk’
s
ad
vantage of easy to co
n
nect is n
o
t given full play. After practice applyi
ng,
equipm
ents i
n
Device-n
et bus n
e
two
r
k
can b
e
add
ed
further.
Evaluation Warning : The document was created with Spire.PDF for Python.
ISSN: 23
02-4
046
TELKOM
NI
KA
Vol. 12, No. 4, April 2014: 3053 – 3
058
3058
Akno
w
l
e
dge
ments
This
work wa
s su
ppo
rted
by the Nation
al High Te
ch
nology Rese
arch and
Dev
e
lopme
n
t
Program of China (8
63Pro
gram
) (No. SQ201
0AA040
1265
006
)
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