MotoCrane INS User manual
INS Operation Manual v1.1
NOVEMBER 2020
Safety Signal Words
This manual and the safety labels attached to this equipment utilize signal words that
signify safety hazards with different levels of severity. The words are preceded by a
triangle signifying that these are safety related. Below are the words used and the
definitions for these words:
● indicates a hazardous situation which, if not avoided, could result
in death or serious injury or damage
● indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury or damage
● is used to address practices not related to physical injury
The terms IMPORTANT and NOTE are also used to describe ideas for better and more
efficient use of the INS.
2
To minimize risk of serious injury, death or
damage, before using MotoCrane INS, all
drivers and operators must read this
Operation Manual and all on-product labels.
All practices and procedures stated herein are
required for the proper and safe operation of
the INS.
If there are any questions, please contact
MotoCrane Support at
Keep this Operation Manual near your INS for
future reference.
Contents
Safety Signal Words 2
Contents 3
Before the First Drive 5
IMPORTANT PRODUCT AND SAFETY INSTRUCTIONS 6
Safety 6
IMPORTANT: Restricted Use Statement 6
Disclaimer and Limitations of Liability 6
Limited Warranty 7
Intellectual Property 7
Parts of the INS 8
INS System Overview 8
Setting up INS Advanced Stabilization 9
INS Setup at a Glance 9
Installing the INS Sensor 10
Configuring & Tuning INS Advanced Stabilization 11
INS Configuration Layout 12
Status 12
Performance Monitoring Gauges 12
Tuning 12
Basic INS Tuning 13
Recommended Initial Tuning Values 13
Description of Settings 13
STRENGTH 13
STIFFNESS 13
FILTER 13
DEADBAND 13
OSCILLATION DAMPING 13
Understanding INS Advanced Stabilization 14
High-frequency vs. High-amplitude 14
Optimizing INS Tuning 15
Passive Isolator Tuning 15
STRENGTH/STIFFNESS Ratio 15
3
Filter, Deadband, Oscillation Damping Explained 15
Oscillation vs. Performance 15
Recommended- Flowcine Tranquilizer 16
Range of Motion Limits in INS Stabilization Mode 16
INS Restrictions 17
Useful Tips 18
Known Hazards 19
Transporting the INS 19
Troubleshooting INS Advanced Stabilization 19
Diagnosing with LEDs 19
Diagnosing with GUI Warning and Error Messages 19
Maintenance 22
Weather & Water 22
Specifications 22
Revision History 23
4
Before the First Drive
Do the following before using INS Advanced Stabilization for the first time.
1. Read this entire Operation Manual
2. Read the Warranty in the Terms of Sale
3. Watch the Video Tutorials at www.motocrane.com/support
4. Recommended: Attend MotoCrane Training for in-person demonstration
5
IMPORTANT PRODUCT AND SAFETY
INSTRUCTIONS
Safety
The INS Advanced Stabilization upgrade is not a toy and can cause serious injury,
death or damage if not used properly. You must exercise caution during use of the INS
to ensure a safe filming environment for everyone. This Operation Manual describes
safe operation and should be read in conjunction with the applicable online training
videos or additional in-person training.
IMPORTANT: Restricted Use Statement
The INS Advanced Stabilization upgrade must only be used by trained operators 18
years of age or older when properly mounted on an appropriate motor vehicle driven
on a closed course with paved or finished surfaces (for example, asphalt, concrete, or
tarmac) or moderate off-road (for example, gravel or dirt roads) conditions. In addition,
the speed and acceleration of the motor vehicle must not exceed system ratings for
INS as set forth in this Operation Manual.
Do not modify or adjust the INS assembly. The INS has been calibrated before it is
shipped to you. No modification or adjustment to the INS is allowed without the
express written approval of MotoCrane, LLC.
Disclaimer and Limitations of Liability
You agree that you are responsible for your own conduct and any content created
while using the INS, and for any consequences thereof. You agree to use this product
only for purposes that are proper and in accordance with local laws, regulations or
other legal requirements.
You also agree:
1. Any part of this disclaimer is subject to change without prior notice. Refer to
www.motocrane.com/support for the latest version.
2. MotoCrane, LLC reserves the right of final interpretation of this disclaimer.
3. MotoCrane, LLC has no control over the use, setup, assembly, modification or
misuse of the INS, and therefore no liability shall be assumed or accepted by
MotoCrane, LLC for any resulting damage, death, or injury incurred directly or
indirectly from the use of the INS. By the act of use, setup or assembly, the operator
accepts all resulting liability.
6
Limited Warranty
The INS has a limited manufacturer's warranty on parts and assembly. See the Terms
and Conditions of Sale for your INS for a complete description of this limited warranty.
This Limited Warranty is incorporated by reference into this Operation Manual.
Intellectual Property
MotoCrane™, INS, and are trademarks of MotoCrane, LLC. You may
not use the trademarks of MotoCrane, LLC without express written permission. All
rights reserved.
7
Parts of the INS
●1 pc INS Sensor + mount
●1 pc INS Cable
●1 pc INS Fulcrum Cover
●4 pc M4 x 30mm SHCS
INS System Overview
8
Setting up INS Advanced Stabilization
INS Setup at a Glance
Upon system power-up, INS Advanced Stabilization is turned OFF by default. This is
for safety reasons since INS is tuned for your particular payload and requires all Booms,
payload and counterweight to be added before turning ON.
INS Advanced Stabilization does not require Lift limits to be set up prior to turning ON,
but Lift limits are highly recommended.
1. Install the INS Sensor on to the Middle Boom
2. Setup ULTRA normally with all cables, booms, payload and counterweight
installed - make sure the payload and counterweight are properly balanced.
3. Connect the INS cable between the Fulcrum Cover and the INS Sensor.
4. Power up ULTRA (Turn MAIN PWR ON)
5. If limits are desired in INS mode, make sure Lift limits are configured properly
and turned ON.
6. On the MotoCrane Controller, go to SETTINGS > ADVANCED > INS CONFIG
7. Set TUNING parameters to the recommended default values for your payload.
8. Turn INS Stabilization ON
9. Check for oscillation, and adjust TUNING parameters as needed.
The INS has built-in intelligence and self-diagnostics, just like the rest of the ULTRA
system. The operator can access INS settings, diagnostics, and real-time information
from the MotoCrane Controller.
: Failure to follow these instructions and those below can result in serious
injury, death or damage.
These instructions will be demonstrated in our training videos and found online at
www.motocrane.com/support. All terminology is referred to in the above diagrams.
9
Installing the INS Sensor
Below is the proper setup sequence of the INS Sensor.
1. The INS Sensor will be placed on the Middle Boom section that is closest to the
Fulcrum. Loosely place the unit on the boom as shown, with about 45mm
between the INS Sensor and the boom mounting features (this dimension is not
critical, but should be +/- 5 mm).
2. Fasten the unit to the boom using the provided M4 fasteners - make sure the
top of the housing is horizontal (this is not
critical
, but the more accurate it is,
the better the performance will be - visual alignment should be sufficient)
10
Configuring & Tuning INS Advanced Stabilization
: INS setup/configuration should occur only after complete ULTRA setup,
with all booms, payload and counterweight attached. See ULTRA Operation Manual for
more information.
1. IMPORTANT: Start by confirming the Z-Axis Air Shock damping is adjusted to
100% “Slow” (fully damped), and that the blue lockout is in the “-” (disengaged)
position.
2. Connect the INS Cable from the Fulcrum Cover to the INS Sensor, making sure
the cable connectors are firmly seated. Secure the INS Cable to the top Boom
Tube using a velcro strap or elastic tie, so it does not get caught or snagged.
3. Turn PSU MAIN PWR “ON,”
4. If Lift limits are desired with INS Stabilization, configure Lift limits using the
MotoCrane Controller and turn Lift limits “ON”
5. Navigate to SETTINGS > ADVANCED SETTINGS and click the “CONFIGURE”
button within the INS window.
6. Before turning INS Stabilization ON, adjust your TUNING parameters to the
recommended default values listed in the chart in “Basic INS Tuning”(more
details for advanced tuning are presented later in this manual).
7. When INS Stabilization is turned ON, the arm will actively compensate the Lift
axis angle against incoming disturbances from terrain or vehicle chassis.
DO NOT TURN ON INS STABILIZATION BEFORE CONFIRMING TUNING PARAMETERS ARE
PROPERLY CONFIGURED FOR YOUR SETUP.
11
INS Configuration Layout
Within the INS CONFIG page, there is a STATUS section, Performance Monitoring Gauges
and adjustable TUNING parameters.
Status
This region shows the connection status of the INS Sensor and GYRO, and any active warnings or errors.
Performance Monitoring Gauges
The three bar graphs demonstrate the stabilization performance. In an ideal situation, Stabilization Error
should remain in the center (zero), while the Stabilization Force and Gyro Rate graphs should move
smoothly together. These illustrate the corrective action that is taking place to maintain a constant boom
angle during disturbances.
Tuning
The tuning section provides an interface to configure the performance characteristics of the stabilization.
Read the following sections to understand more about what these values do, and how to configure them
for optimal performance.
12
Basic INS Tuning
Recommended Initial Tuning Values
“HIGH” INS tuning values are those at or above the recommended values.
“MEDIUM” INS tuning values are those a few points below recommended values.
“LOW” INS tuning values are those at or half or less than recommended values.
*Default Setting
**Requires Heavylift Upgrade Kit.
Description of Settings
The most important tuning parameters are STRENGTH and STIFFNESS. Together, these 2 values directly
control how quickly and to what degree INS corrects the Lift axis angle.
STRENGTH
Controls the magnitude of the correction applied to the Lift axis based on position error - maintains
target angle of the Boom.
STIFFNESS
Controls the speed of the correction applied in order to minimize angular rate changes of the Boom -
improves the rate of response.
FILTER
Default set to “1”. A setting of 1 removes resonant frequencies and small amounts of noise from INS
Sensor data. Increasing the setting removes more noise, but slows system response.
DEADBAND
Applied in only low dynamic conditions. Controls minimum viable sensor data used for correction. The
deadband is not active when Oscillation Damping is turned ON.
OSCILLATION DAMPING
Overrides Deadband when enabled. Detects oscillations and dynamically adjusts correction (STRENGTH
+ STIFFNESS) to eliminate self-excitation. Applied only in low dynamic conditions, such as when the
vehicle is stationary or moving very slowly or on smooth roads.
13
PAYLOAD
STRENGTH
STIFFNESS
FILTER
DEADBAND
OSC-DAMP
40lbs/18kg
4
9
2
2
ON - 2
45lbs/20kg
5
10
1
2
ON - 2
*50lbs/23kg
5
10
1
2
ON - 2
55lbs/25kg
5
11
1
2
ON - 2
**60lbs/27kg
6
12
1
2
ON - 2
**65lbs/30kg
6
13
1
2
ON - 2
Understanding INS Advanced Stabilization
High-frequency vs. High-amplitude
The standard ULTRA Passive Isolator is built to buffer against high-frequency
disturbances. For example, continuously rough terrain like gravel, or sharp thuds/hits
on terrain like cracks, potholes, etc. There are inherent limitations to the disturbance
amplitude that the Passive Isolator can correct against.
Conversely, INS Advanced Stabilization actively corrects against high-amplitude
disturbances and vehicle movements. For example, driving up and down a ramp or
over rolling hills at moderate speeds. There are inherent limitations to the frequency at
which the Lift-axis can be moved in order to correct against disturbances.
Referring to the image on the
right, you can see how the
Passive Isolator damping and
INS Tuning can be optimized
for various terrain scenarios.
High
frequency
terrains are best
suited by an Isolator with
damping set to 80-100% FAST.
This, however, prevents INS
Tuning from reaching HIGH
Levels.
High
amplitude
terrains are best
suited by an Isolator with
damping set to SLOW.
This allows INS Tuning to reach
HIGH Levels with oscillations.
Mixed
terrains are best suited
by an intermediate combination
of Passive Isolator Damping
sand INS Tuning. This allows
both systems to reach
moderate levels of
performance.
14
Optimizing INS Tuning
Passive Isolator Tuning
In order for INS tuning to be optimized, the Passive Isolator Damping must be dialed
as “SLOW” as possible. This is to eliminate the tendency of the Lift-axis to self-excite
(oscillate) at higher tuning values. Keep in mind that based on the terrain you are
operating in, it may be more useful to speed up Passive Isolator Damping while
adjusting INS tuning values to MEDIUM or LOW levels.
STRENGTH/STIFFNESS Ratio
In attempting to maximize the performance of INS Stabilization, it is important to
maintain a relatively consistent ratio between STRENGTH and STIFFNESS. In general,
the STIFFNESS value should be roughly 2X that of the STRENGTH value. Do not
significantly increase or decrease one value while leaving the other unchanged, unless
E-STOP is applied, as this could cause unwanted and potentially dangerous
oscillations. Increasing or decreasing these values together is recommended.
Filter, Deadband, Oscillation Damping Explained
FILTER should not generally need to be adjusted except in rare situations - read more
about this above in the Basic INS Tuning section. Keep in mind that OSCILLATION
DAMPING and DEADBAND are mutually exclusive, and also only apply during low
dynamic conditions, such as when the vehicle is stationary or moving very slowly on
smooth terrain.
Oscillation vs. Performance
In general, if the system is oscillating too much, first make sure that the Passive Isolator
Damping is set to the slowest setting possible, given the terrain conditions you are
operating in (refer to the figure in the
High-frequency vs. High-amplitude section
).
Then, make sure that all rigging and connections between ULTRA modules are tight
and secure. Finally, if this does not solve the problem, begin by reducing both
STRENGTH and STIFFNESS (keeping in mind the 2X ratio mentioned above).
There is always a tradeoff between stability (no oscillations) and performance. Just like
with stabilized heads, lower tuning values will be less prone to
self-excitation/oscillation, but may be limited in the speed and bandwidth of response.
Conversely, high tuning values may achieve high stabilization performance, but are
likely to self-excite and oscillate. Experimentation with your particular setup is key to
fine-tuning and optimizing INS Stabilization, in addition to understanding the
performance and operation of the system.
15
Recommended- Flowcine Tranquilizer
In our testing, we have found that the Flowcine Tranquilizer assists in reaching the
highest levels of INS Tuning. The damping properties of the Tranquilizer help by
absorbing energy in the mid to high frequency bands, which reduces oscillation
tendencies and minimizes wear and heat generation in the Lift motor. With the addition
of the Tranquilizer, you should generally be able to increase tuning values for
STRENGTH by 1 or 2 points, and tuning values for STIFFNESS by 1 to 4 points, before
unwanted oscillations start to occur during normal operation and movement.
Range of Motion Limits in INS Stabilization Mode
When Lift limits are enabled, INS Stabilization uses limits that are absolute to the
outside world, where 0 degrees is horizontal and perpendicular to the direction of
gravity. This is in contrast to relative limits that are used during standard operation
without INS Stabilization. Relative limits operate on the relative angle measured from
the encoder between the ULTRA Fulcrum and Turret. For this reason, the operator
must be aware of the implications and how this influences the behavior of the Boom
during various terrain changes. The image here visually describes the operation of
absolute limits, and one potential type of terrain risk. This screen is displayed upon
turning ON the INS Stabilization feature to remind the operator. Knowledge of the
system and consistent practice with the INS Stabilization feature are critical to minimize
risk in operation.
16
INS Restrictions
The upgraded 1kW INS Lift Motor is very powerful and fast. However, if the vehicle
enters terrain at high speeds that causes high frequency and high amplitude
disturbances, INS stabilization may be ineffective, and in some cases worsen the
situation.
In these situations, it is better to turn off INS stabilization and rely on the default inertial
management stabilization, which prioritizes reducing stress on system components. If
the upper limit of stabilization performance is being reached, INS Advanced
Stabilization provides notifications to the operator via the MotoCrane Controller. The
upper limit of stabilization performance is directly dependent on the degree to which
the tuning values (Strength and Stiffness) have been optimized.
For most shooting conditions, INS Advanced Stabilization provides a substantial
difference in minimizing vertical translations seen by the camera (Passive Isolator tuning
is a key component of this equation).
In the figure above, the orange line represents the Lift axis (boom) angle, the blue line represents the
gyro rate, and the yellow line represents the warning that the vehicle is driving in conditions where
stabilization is not as effective. Notice at the :58 second mark, the INS warning is triggered, alerting the
operator that incoming disturbance has surpassed what the INS tuning is capable of.
From around 10 to 40 seconds the boom angle differs by less than 1 degree, even in the face of high
disturbances. In this particular run, the vehicle entered off road terrain at high speed at around 55
seconds. You can see that there are large spikes in gyro rate, and the stabilization controller can no
longer adequately compensate, causing the boom angle position to vary much more.
17
Useful Tips
●Balance - Proper balancing of the payload and counterweight should be done
before using INS. Ideally, the operator should be running a familiar setup that is
known to be well-balanced. For new setups, always refer to the balancing chart
in the ULTRA Operation Manual. If the balance is not set up properly,
stabilization effectiveness will suffer and the Lift axis motor will work harder than
necessary in order to maintain a proper Boom angle. This could cause excess
heat and accelerated wear on components.
●Limits - After installing INS for the first time, Lift limits should be set up again,
while the INS Sensor is connected and properly functioning. It is recommended
to set up limits BEFORE setting up and turning ON INS for the first time. Setting
up limits with the INS module installed allows for the system to capture BOTH
the absolute (INS) and relative (Encoder) angles of the Boom, so that limits can
be used in both stabilized and non-stabilized (standard) operating modes. It is
recommended to set up limits with the vehicle on a flat, horizontal surface.
●Mounting and Rigging - Loose or sloppy rigging, and the mounting of the
ULTRA Base, Booms, and Turret, directly contribute to the performance of INS
Stabilization, and directly limit the upper end of tuning possible. Make sure that
all mounting points are tight and checked regularly. Sloppy rigging and loose
connections between the Base, Booms, or Turret may cause oscillations and
poor performance.
●System Stability - The INS Stabilization system is built to accommodate a wide
range of vehicles, payloads, and terrain conditions. It may be possible to tune
the system to levels that are not stable and exhibit frequent oscillations during
vehicle maneuvers as well as operator movements of the Lift axis. If this type of
behavior is present, it is recommended to tune down both STRENGTH and
STIFFNESS to a more stable level, so that it feels smooth to make typical Lift
axis movements in INS Stabilization mode.
18
Known Hazards
The following list represents known hazards that exist when operating the
INS. This is not exhaustive, but represents some common hazards to watch out for.
●Lift Motor Temperature at rest. If the DISARM button is released while
stationary for long periods of time, the Lift Motor and Brake may
accumulate heat faster than it can be dissipated, and Lift Motor
Temperature warnings may be triggered. This is more likely to occur in
higher ambient temperatures. Avoided by pressing the DISARM button
whenever stationary, or whenever the arm is not in use.
●Motor stall at extreme Lift angles. If the Lift axis is positioned at
extremely high or low angles, the Fulcrum may “bottom out” and make
contact with the ULTRA Turret, causing the 1kW INS Lift Motor to stall
and momentarily draw extremely high amounts of power. It is likely in this
scenario that permanent damage may occur to the LDU, requiring
replacement.
●Motor stall on terrain, rigging, etc. Similar to the above, if the arm makes
contact with the terrain, vehicle rigging, or other objects, the 1kW INS Lift
Motor to stall and momentarily draw extremely high amounts of power. It
is likely in this scenario that permanent damage may occur to the LDU,
requiring replacement.
●Proper INS Tuning. Proper INS tuning is key to achieving good
stabilization performance, but also for preventing potentially damaging
shock loads to the system. The stabilization capabilities are directly
related to the strength and stiffness of the tuning, and therefore this can
limit the type of terrain the system can safely handle if not tuned well.
Extreme or sudden vehicle movements that greatly exceed the
stabilization capabilities of the system can potentially inflict mechanical
damage that can limit the usable life of the system.
●INS mounting. The INS Sensor should be mounted rigidly with the
appropriate threadlocker and torque specs, as per MotoCrane
instructions. This can be disregarded if the INS Sensor installation was
done by MotoCrane.
●Extreme/Off-Road Terrain. As mentioned earlier, the INS stabilization is
not effective for extreme terrain and high amplitude, high frequency
conditions. The system will inform the operator if these conditions are
being approached. Learn the differences where INS stabilization should
and should not be used.
19
●INS Cable. Ensure the INS Cable is properly installed and locked on to
the sockets on both ends.
●Operator awareness. The operator should be aware of the different INS
parameters, warnings and errors displayed on the MotoCrane Controller.
Transporting the INS
●Disconnect and store the INS cable if transporting the Turret module in the flight
case.
Troubleshooting INS Advanced Stabilization
Diagnosing with LEDs
The INS Sensor module contains a green LED to indicate it is receiving power. This
LED is the first indication of whether or not the connection is good. If INS functionality
is absent or causing warnings or errors, and the green LED is ON, please refer to the
next section for more detailed troubleshooting information.
Diagnosing with GUI Warning and Error Messages
ULTRA has multiple internal sensors and an error reporting system built into the GUI.
The INS shares this error and warning reporting infrastructure and allows the operator
to monitor these events via the MotoCrane Controller. If an active error or warning is
present, the respective red or yellow icon will be displayed. A yellow icon indicates a
warning, and the MotoCrane Controller will beep once to alert the operator. A red icon
indicates an error, and the MotoCrane Controller will beep repeatedly until the icon is
touched or the DISARM physical switch is pressed by the operator. Touching the error
or warning icon will bring you to the Status page, where you can see a list of active
errors and warnings. If you are experiencing an intermittent issue, and the warning or
error is not currently active, you can review events by navigating to the System Log,
which is accessible through the Diagnostics page. The System Log will also provide a
list of errors and warnings that have occurred, along with the time since the event
occurred (in 2 minute increments). Note that the System Log will only hold the most
recent 10 events. The new Controller firmware utilized in the INS update allows for
retrieval of the last 10 events that were saved to the System Log. From either the
Status or System Log page, you can access the Code Lookup Table, which will provide
you with a short description of the error or warning and a recommended first step for
troubleshooting and clearing the issue.
20
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