Identification and Experimental Validation of an Induction Motor Thermal Model for Improved Drivetrain Design

The ability of an electric powertrain to perform according to mechanical specifications is equally important as assessing its thermal protection limits, which are affected by its electrical and thermal properties. Although rated parameters (such as power, torque, etc.) are easily accessible in catalogs of equipment producers, more specific properties like mass/length of copper winding, heat dissipation factor, etc., are not available to customers. Therefore, an effective selection of drivetrain components is limited due to the lack of sufficient data and the need to consult critical design decisions with suppliers. To overcome this limitation, we propose a method to estimate the temperature…

Novel Concept for Electro-Hydrostatic Actuators for Motion Control of Hydraulic Manipulators

Self-contained hydraulic cylinders have gained popularity in the recent years but have not been implemented for high power articulated hydraulic manipulators. This paper presents a novel concept for an electro-hydrostatic actuator applicable to large hydraulic manipulators. The actuator is designed and analyzed to comply with requirements such as load holding, overload handling, and differential flow compensation. The system is analyzed during four quadrant operation to investigate energy efficiency and regenerative capabilities. Numerical simulation is carried out using path control and 2DOF anti-swing of a hydraulic crane as a load case to illustrate a real world scenario. A comparison wi…

Erratum to ‘A Robust Forward-Displacement Analysis of Spherical Parallel Robots’ [Mech. Mach. Theory, 2009, 44(12), pp. 2204–2216]

A Review on Approaches for Condition Based Maintenance in Applications with Induction Machines located Offshore

Published version of an article in the journal: Modeling, Identification and Control. Also available from the publisher at: http://dx.doi.org/10.4173/mic.2012.2.4 Open access This paper presents a review of different approaches for Condition Based Maintenance (CBM) of induction machines and drive trains in offshore applications. The paper contains an overview of common failure modes, monitoring techniques, approaches for diagnostics, and an overview of typical maintenance actions. Although many papers have been written in this area before, this paper puts an emphasis on recent developments and limits the scope to induction machines and drive trains applied in applications located offshore.

A Novel Solution for the Elimination of Mode Switching in Pump-Controlled Single-Rod Cylinders

This paper concerns the stability issue of pump-controlled single-rod cylinders, known as mode switching. First, a review of the topic is provided. Thereafter, the most recently proposed solution for the elimination of mode switching is investigated and shown to result in unstable behavior under certain operating conditions. A theoretical analysis is provided demonstrating the underlying mechanisms of this behavior. Based on the analysis, a novel control strategy is proposed and investigated numerically. Proper operation and stability are demonstrated for a wide range of operating conditions, including situations under which the most recently proposed solution results in unstable behavior a…

Development of Point-to-Point Path Control in Actuator Space for Hydraulic Knuckle Boom Crane

This paper presents a novel method for point-to-point path control for a hydraulic knuckle boom crane. The developed path control algorithm differs from previous solutions by operating in the actuator space instead of the joint space or Cartesian space of the crane. By operating in actuator space, almost all the parameters and constraints of the system become either linear or constant, which greatly reduces the complexity of both the control algorithm and path generator. For a given starting point and endpoint, the motion for each actuator is minimized compared to other methods. This ensures that any change in direction of motion is avoided, thereby greatly minimizing fatigue, jerky motion,…

Hydraulic vs. Electric: A Review of Actuation Systems in Offshore Drilling Equipment

This article presents a survey on actuation systems encountered in offshore drilling applications. Specifically, it focuses on giving a comparison of hydraulic and electric drivetrains along with detailed explanations of their advantages and drawbacks. A significant number of industrial case studies is examined in addition to the collection of academic publications, in order to accurately describe the current market situation. Some key directions of research and development required to satisfy increasing demands on powertrains operating offshore are identified. The impact of the literature and application surveys is further strengthened by benchmarking two designs of a full-scale pipe handl…

Design optimization on the drive train of a light-weight robotic arm

A drive train optimization method for design of light-weight robots is proposed. Optimal selections of motors and gearboxes from a limited catalog of commercially available components are done simultaneously for all joints of a robotic arm. Characteristics of the motor and gearbox, including gear ratio, gear inertia, motor inertia, and gear efficiency, are considered in the drive train modeling. A co-simulation method is developed for dynamic simulation of the arm. A design example is included to demonstrate the proposed design optimization method.

Offshore Wind Payload Transfer Using Flexible Mobile Crane

This article presents an offshore-simulated loading and unloading of a payload from a floating platform to a fixed structure. The experiments are performed in a dry-lab, where a Stewart platform is used to simulate the motion of the vessel. A hydraulically actuated vehicle loader crane is used to perform the tasks of payload transfer. The crane includes a hydraulic winch where the wire force is measured by a load cell. A mathematical model of the winch is derived and is experimentally verified. The control strategies include a heave compensation and a constant tension mode. A motion reference unit is used to generate the reference motion of the moving platform. Experimental results show the…

Robust Tool Point Control for Offshore Knuckle Boom Crane

Author's version of a chapter in the book: Proceedings of the 18th IFAC World Congress 2011. Also available from the publisher at: http://dx.doi.org/10.3182/20110828-6-IT-1002.03004

Load Torque Estimation Method to Design Electric Drivetrains for Offshore Pipe Handling Equipment

One of the main design objectives for electric drivetrains operating in offshore drilling equipment is to keep them as small, yet as effective, as possible, to minimize space they occupy on drill floor and maximize their performance. However, practical experience shows that typically choices made by design engineers are too conservative due to the lack of enough data characterizing load conditions. This results in too costly and too heavy selected components. Therefore, in the current paper we present a method to estimate required full-scale motor torque using a scaled down experimental setup and its computational model. A gripper arm of an offshore vertical pipe handling machine is selecte…

A ride comfort tyre model for off-highway vehicles

Tyre modelling is a major challenge when using time domain multibody simulation models to evaluate ride comfort on off-highway commercial vehicles. Further, parameters for these big tyres are difficult to obtain and thus, commercial car tyre models are difficult to apply. In this research work, a simple vertical tyre model for off-highway ride comfort evaluation is suggested. A displaced volume approach has been developed and combined with the slip theory to yield a tyre model that can be characterised by only three parameters. Full scale measurements on a dump truck have been carried out. Force responses from measurements are compared to the simulation results. Acceleration responses and t…

On the Energy Efficiency of Dual Prime Mover Pump-Controlled Hydraulic Cylinders

Abstract This paper concerns the energy efficiency of a special class of pump-controlled hydraulic cylinders utilizing two prime movers. The performance of such circuits has been studied previously motivated by their capability of providing an actuator stiffness similar to that of servo valve-controlled systems. This characteristic may improve performance and robustness in applications requiring feedback control. In this paper, the presence of losses similar to that of fluid throttling, in the sense that they occur even in the absence of component inefficiencies, are demonstrated for such circuits and shown to degrade the overall energy efficiency of the system. The conditions under which s…

Model Based Design Optimization of Operational Reliability in Offshore Boom Cranes

AbstractThis paper presents a model based approach for design of reliable electro-hydraulic motion control systems for offshore material handling cranes. The approach targets the system engineer and is based on steady-state computations, dynamic time domain simulation and numerical optimization.In general, the modelling takes into account the limited access to component data normally encountered by engineers working with system design. A system model is presented which includes the most important characteristics of both mechanical system and hydraulic components such as the directional control valve and the counterbalance valve.The model is used to optimize the performance of an initial des…

Synthetic Esters and Dynamics of Pressure Compensated Proportional Directional Control Valves

The purpose of this paper is to help reduce the uncertainty in behavior introduced when changing hydraulic oil from mineral oil (HLP) to biodegradable oil (synthetic esters - HEES) by comparing the behavior of proportional valves with HLP and with HEES at various temperatures. The focus of this article is on classic proportional valves used in the industry. The study is based on tests and modelling with characterization of dynamic behavior in mind. The characterization is based on tests of two pressure compensated proportional valves, one with closed loop control of the spool position, and one without. The two ester types tested are one based on a saturated, fully synthetic ester and a regu…

Improving Separation of Oil and Water With a Novel Coalescing Centrifugal Pump

Summary A novel centrifugal pump that increases oil-droplet sizes in produced water has been developed. This paper investigates a concept of pumping-pressure optimization, with respect to downstream separation efficiency, for the new pump. The investigation shows that the coalescing centrifugal pump always increased the separation efficiency of a downstream hydrocyclone. Furthermore, it is shown that the pumping pressure can be adjusted to maximize the improvement. Experimental results demonstrate how pumping conditions that minimize the volume fraction of droplets with a diameter smaller than the cut size of the hydrocyclone maximize the separation efficiency. Finally, it is demonstrated h…

Modeling of Wind Turbine Gearbox Mounting

In this paper three bushing models are evaluated to find a best practice in modeling the mounting of wind turbine gearboxes. Parameter identification on measurements has been used to determine the bushing parameters for dynamic simulation of a gearbox including main shaft. The stiffness of the main components of the gearbox has been calculated. The torsional stiffness of the main shaft, gearbox and the mounting of the gearbox are of same order of magnitude, and eigenfrequency analysis clearly reveals that the stiffness of the gearbox mounting is of importance when modeling full wind turbine drivetrains.

Discrete Learning Control with Application to Hydraulic Actuators

In this paper the robustness of a class of learning control algorithms to state disturbances, output noise, and errors in initial conditions is studied. We present a simple learning algorithm and exhibit, via a concise proof, bounds on the asymptotic trajectory errors for the learned input and the corresponding state and output trajectories. Furthermore, these bounds are continuous functions of the bounds on the initial condition errors, state disturbance, and output noise, and the bounds are zero in the absence of these disturbances.

Analysis of Offshore Knuckle Boom Crane - Part Two: Motion Control

In this paper design of electro-hydraulic motion control systems for offshore knuckle boom cranes is discussed. The influence of the control valve bandwidth along with the ramp time for the control signal are investigated both analytically with simplified system models and numerically with an experimentally verified crane model. The results of both types of investigations are related to general design rules for selection of control valves and ramp times and the relevance of these design rules is discussed. Generally, they are useful but may be too conservative for offshore knuckle boom cranes. However, as demonstrated in the paper, the only proper way to determine this is to evaluate the mo…

Novel concept for stabilising a hydraulic circuit containing counterbalance valve and pressure compensated flow supply

In this paper, a novel concept for stabilising a hydraulic system containing a counterbalance valve and a pressure compensated flow supply is presented. The concept utilizes a secondary circuit where a low-pass filtered value of the load pressure is generated and fed back to the compensator of the flow supply valve. The novel concept has been investigated theoretically and experimentally. A linear model has been developed to verify the improved stability conditions. The novel concept has been implemented on a single boom actuated by a cylinder. The results show that the pressure oscillations in an otherwise unstable system can be suppressed with the novel concept. This happens without any c…

Force Variations on Heave Compensating System for Ultra-Deepwater Drilling Risers

This paper discusses modeling aspects related to dynamic analysis of deep water drilling risers. These risers must have a heave compensator that maintains a near constant tension in the riser independent on platform motions. Traditional riser analysis will apply constant top tension or a simple parametric model that may give approximate tension variation. The present paper describes an alternative analysis procedure that consists of the following step: • Global riser analysis including calculation of dynamic stroke of the heave compensator from platform motions and riser dynamics. A “pipe-in-pipe” approach is used to represent the hydraulic cylinders. • Calculation of dynamic tension variat…

Adaptive Feedforward Control of a Pressure Compensated Differential Cylinder

This paper presents the design, simulation and experimental verification of adaptive feedforward motion control for a hydraulic differential cylinder. The proposed solution is implemented on a hydraulic loader crane. Based on common adaptation methods, a typical electro-hydraulic motion control system has been extended with a novel adaptive feedforward controller that has two separate feedforward states, i.e, one for each direction of motion. Simulations show convergence of the feedforward states, as well as 23% reduction in root mean square (RMS) cylinder position error compared to a fixed gain feedforward controller. The experiments show an even more pronounced advantage of the proposed c…

Numerical and Experimental Study of a Novel Concept for Hydraulically Controlled Negative Loads

This paper presents a numerical and experimental investigation of a novel concept that eliminates oscillations in hydraulic systems containing a counterbalance valve in series with a pressure compensated flow supply. The concept utilizes a secondary circuit where a low-pass filtered value of the load pressure is generated and fed back to the compensator of the flow supply valve. The novel concept has been implemented on a single boom actuated by a cylinder. A nonlinear model of the system has been developed and an experimental verification shows good correspondence between the model and the real system. The model is used for a parameter study on the novel concept. From the study it is found…

Mitigation of Fatigue Damage and Vibration Severity of Electric Drivetrains by Systematic Selection of Motion Profiles

The offshore drilling industry is among the most demanding markets for electrical equipment. Heave motion, irregular cyclic loads, harsh weather conditions, and vibrations are causing accelerated deterioration of drilling equipment. One of the most common solutions to these problems is to design actuation systems of such machinery overly conservative to gain additional safety, which results in too high initial investment and maintenance costs. To mitigate the fatigue damage and vibration severity of rotating elements of electric drivetrains operating offshore, this paper presents a comparative analysis of four popular input functions used in motion control of industrial systems. We evaluate…

Iterative Learning Applied to Hydraulic Pressure Control

This paper addresses a performance limiting phenomenon that may occur in the pressure control of hydraulic actuators subjected to external velocity disturbances. It is demonstrated that under certain conditions a severe peaking of the control error may be observed that significantly degrades the performance of the system due to the presence of nonlinearities. The phenomenon is investigated numerically and experimentally using a system that requires pressure control of two hydraulic cylinders. It is demonstrated that the common solution of feed forwarding the velocity disturbance is not effective in reducing the peaking that occurs as a result of this phenomenon. To improve the system perfor…

Controlling a Negative Loaded Hydraulic Cylinder using Pressure Feedback

Non-linear optimization of track layouts in loop-sorting-systems

Optimization used for enhancing geometric structures iswell known. Applying obstacles to the shape optimization problemis on the other hand not very common. It requires a fast contact search algorithmand an exact continuous formulation to solve the problem robustly. This paper focuses on combining shape optimization problemswith collision avoidance constraints by which a collision detection algorithmis presented. The presentedmethod is tested against the commercial loop-sorting-system used for sorting of medium sized items. The objective is to minimize price and footprint of the system whilemaintaining its functionality. Contact constraints are in this context important to include as variou…

Axial Load Capacity of Cold Formed Pipe Flange Connection

In this paper, a cold forming process is used where the connection between a pipe and a flange is created by means of radially expanding tool segments inside the pipe. The method is investigated with two purposes, to set up a robust procedure for the process that allows for connections to be made on site, and to set up finite element (FE) simulations that can capture the forces and deformations when pulling the pipe axially out of the flange. Experimental data and FE simulations are used to describe and understand the forces and deformations during the connection process. The rapid increase in radial stiffness experienced when the pipe comes in full circumferential contact with the flange i…

Automatic Operation and Control of a Novel Coalescing Centrifugal Pump for Improved Oil/Water Separation

Summary In this paper we present the development and implementation of automatic operation and control for a pump/hydrocyclone produced-water-treatment system to maximize oil/water-separation efficiency. A so-called perturb-and-observe (P&O) algorithm is adapted for a novel centrifugal pump to continuously optimize the point of operation. The novel pump coalesces and increases the size of oil droplets in the produced water, resulting in a unique relationship between the coalescing effect and the point of operation, and allowing for the successful implementation of the P&O algorithm. The algorithm was implemented in two different setups, one measuring the droplet-size distribution be…

Online Deflection Compensation of a Flexible Hydraulic Loader Crane Using Neural Networks and Pressure Feedback

The deflection compensation of a hydraulically actuated loader crane is presented. Measurement data from the laboratory are used to design a neural network deflection estimator. Kinematic expressions are derived and used with the deflection estimator in a feedforward topology to compensate for the static deflection. A dynamic deflection compensator is implemented, using pressure feedback and an adaptive bandpass filter. Simulations are conducted to verify the performance of the control system. Experimental results showcase the effectiveness of both the static and dynamic deflection compensator while running closed-loop motion control, with a 90% decrease in static deflection.

CFD Assisted Steady-State Modelling of Restrictive Counterbalance Valves

The counterbalance valve is an important component in many hydraulic applications and its behaviour hugely impacts system stability and performance. Despite that, CBVs are rarely modelled accurately due to the effort required to obtain basic model parameters and the complexity involved in identifying expressions for flow forces and friction. This paper presents a CFD assisted approach to steady-state modelling of CBVs. It is applied to a 3-port restrictive commercially available counterbalance valve. The model obtained is based on detailed measurements of the valve geometry, a single data set and CFD modelling and includes flow forces and friction. The CFD assisted model is compared to expe…

Modeling and Parameter Identification of Deflections in Planetary Stage of Wind Turbine Gearbox

The main focus of this paper is the experimental and numerical investigation of a 750[kW] wind turbine gearbox. A detailed model of the gearbox with main shaft has been created using MSC.Adams. Special focus has been put on modeling the planet carrier (PLC) in the gearbox. For this purpose experimental data from a drive train test set up has been analyzed using parameter identification to quantify misalignments. Based on the measurements a combination of main shaft misalignment and planet carrier deflection has been identified. A purely numerical model has been developed and it shows good accordance with the experimental data.

Integrated dimensional and drive-train design optimization of a light-weight anthropomorphic arm

An approach to minimize the mass of robotic manipulators is developed by integrated dimensional and drive-train optimization. The method addresses the influences of dimensions and characteristics of drive-trains in the design optimization. Constraints are formulated on the basis of kinematic performance and dynamic requirements, whereas the main objective is to minimize the total mass. Case studies are included to demonstrate the application of the optimization method in the design of assistive robots.

Reducing whole-body vibration exposure in backhoe loaders by education of operators

Author's version of an article published in the journal: International Journal of Industrial Ergonomics. Also available from the publisher at: http://dx.doi.org/10.1016/j.ergon.2012.03.001 Whole-body vibration is a health hazard for operators of construction machinery. The level of whole-body vibration exposure on the operator is governed by three different factors; performance of the suspension system of the machine, planning of the work and the skills of the operator.In this research work it is investigated whether there is a potential in bringing down the level of whole-body vibration exposure by educating operators of backhoe loaders. This is carried out by an experimental setup. Six ex…

Robust adaptive backstepping control design for a Nonlinear Hydraulic-Mechanical System

The complex dynamics that characterize hydraulic systems make it difficult for the control design to achieve prescribed goals in an efficient manner. In this paper, we present the design and analysis of a robust nonlinear controller for a Nonlinear Hydraulic-Mechanical (NHM) System. The system consists of an electrohydraulic servo valve and two hydraulic cylinders. Specifically, by considering a part of the dynamics of the NHM system as a norm-bounded uncertainty, two adaptive controllers are developed based on the backstepping technique that ensure the tracking error signals asymptotically converge to zero despite the uncertainties in the system according to the Barbalat lemma. The resulti…

Identification of induction motor thermal model for improved drivetrain design

Selection of components of electric drivetrains is not only based on evaluating their ability to perform according to mechanical specifications, but — what is equally important — on assessing their thermal protection limits. These are typically affected by electrical and thermal properties of motors and drives. Although rated parameters (such as power, torque, speed, etc.) are easily accessible in catalogs of equipment producers, more specific properties like mass / length of copper winding, heat dissipation factor, rotor / stator dimensions etc. are not available to customers. Therefore, effective selection of drivetrain components is limited due to the lack of sufficient data and the need…

Variable Step Size P&O Algorithms for Coalescing Pump/Deoiling Hydrocyclone Produced Water Treatment System

This paper presents three variable step size P&O algorithms for optimizing the separation efficiency of a coalescing pump/deoiling hydrocyclone produced water treatment system. By continuously adjusting the pumping pressure, and subsequently the coalescing effect, the algorithms are used to minimize the oil concentration downstream the hydrocyclone. Due to the variable step size, the algorithms react rapidly to changes in the upstream produced water characteristics, at the same time as they reduce (or eliminate) steady-state oscillations. Based on both simulation and experimental testing, the study discusses advantages and disadvantages of the algorithms.

A Control Algorithm for Active/Passive Hydraulic Winches Used in Active Heave Compensation

Abstract The most common active heave compensated offshore cranes have hydraulic winch systems. This paper investigates an active/passive hydraulic winch system with variable-displacement motors and variable-displacement pumps. The paper addresses the challenges when the active motors are set with a low displacement. The active motor displacement is shown to have significant impact on the dynamics of the closed loop hydraulic system. The classical control strategy for this type of system do not address these challenges and will in certain situations have significantly reduced performance. Therefor, a new control method is presented that utilize the variable displacement of the pumps and mot…

A Cost-Effective Approach to Hardware-in-the-Loop Simulation

This paper presents an approach for developing cost effective hardware-in-the-loop (HIL) simulation platforms for the use in controller software test and development. The approach is aimed at the many smaller manufacturers of e.g. mobile hydraulic machinery, which often do not have very advanced testing facilities at their disposal. A case study is presented where a HIL simulation platform is developed for the controller of a truck mounted loader crane. The total expenses in hardware and software is less than 10.000$.

A New Quasi-Static Cylindrical Roller Bearing Model to Accurately Consider Non-Hertzian Contact Pressure in Time Domain Simulations

The accuracy of the fatigue life calculations in rolling bearing simulations is highly dependent on the precision of the roller-raceway contact simulations. Several different methods exist to simulate these pressure distributions and in time domain bearing simulations, where many contacts need evaluation, the simple and time efficient methods are more popular, yielding erroneous life estimates. This paper presents a new six degree of freedom frictionless quasi-static time domain cylindrical roller bearing model that uses high precision elastic half-space theory to simulate the contact pressures. The potentially higher computational demand using the advanced contact calculations is addressed…

Using input shaping and pressure feedback to suppress oscillations in slewing motion of lightweight flexible hydraulic crane

This paper presents a method to actively reduce vibrations in the flexible mechanical structure of a hydraulically actuated vehicle loader crane. Based on information on the natural frequency and damping of a simplified model of the crane an input shaping scheme is set up to control the proportional valve leading to substantially reductions in oscillations. The method is compared and combined with a pressure feedback control of the proportional valve that actively suppresses transient variations in pressure. A full scale vehicle loader crane is used in the experimental verification of the method, and the motion of the tool point of the crane is measured by a high precision laser tracker. Th…

Steady State Counterbalance Valve Modeling with the Influence of Synthetic Ester Oils Using CFD

This study looks in details at the effects of synthetic esters being applied to a counterbalance valve from the perspective of a system engineer. There is limited literature on the subject of applied synthetic esters and as such limited unbiased sources for information. This creates reluctance against the use of these fluids in sectors and regions with no prior experience and knowledge of what to expect. This study expands the applied literature by investigating a commercially available valve using commercial oils, a basic synthetic ester, a fully saturated synthetic ester and a typical mineral oil type for benchmarking. The investigation is based on both computational fluid dynamics and ex…

Temperature Rise Estimation of Induction Motor Drives Based on Loadability Curves to Facilitate Design of Electric Powertrains

Thermal protection limits are equally important as mechanical specifications when designing electric drivetrains. However, properties of motor drives like mass/length of copper winding or heat dissipation factor are not available in producers’ catalogs. The lack of this essential data prevents the effective selection of drivetrain components and makes it necessary to consult critical design decisions with equipment's suppliers. Therefore, in this paper, the popular loadability curves that are available in catalogs become a basis to formulate a method that allows to estimate temperature rise of motor drives. The current technique allows for evaluating a temperature rise of a motor drive for …

A Digital Twin for Lift Planning With Offshore Heave Compensated Cranes

Abstract This paper presents a state-of-the-art digital twin of a hydraulic actuated winch that is used for heave compensation in offshore applications. The digital twin is used as part of a larger simulation model that involves all necessary components to perform lift planning and, subsequently, determine the corresponding weather window. The winch simulation model is described and verified by means of full-scale measurements. In addition, a set of acceptance criteria are presented that should be used whenever verifying digital twins of heave compensating winches that are to be used for lift planning.

An iterative based approach for hysteresis parameters estimation in Magnetorheological dampers

The following work entails the problem of regenerating the hysteresis loop in the Magnetorheological (MR) dampers. The collected data from tests are not sufficient neither efficient for designing optimal controls compensating for the hysteresis in the dampers. This work presents an iterative based approach for estimating the hysteresis parameters, the method however can be generalized for different kind of dampers or actuators hence the hysteresis loop can be generalized using available test data. Some assumptions can be introduced in order to facilitate the underlines of the parameters estimation, one of the assumptions in this work is to use predetermined hysteresis parameters and regener…

Numerical and Experimentical Study of Motion Control Using Pressure Feedback

This paper is concerned with the inherent oscillatory nature of pressure compensated motion control of a hydraulic cylinder subjected to a negative load and suspended by means of an overcenter valve. A pressure feedback scheme that indirectly eliminates the oscillations is investigated. The indirect control scheme utilizes pressure feedback to electronically compensate the metering-out allowing for the removal of the compensator and, subsequently, elimination of the oscillations. The suggested electronic compensation scheme is implemented and examined in a single degree-of-freedom test rig actuated by means of a double acting hydraulic cylinder. The control scheme is compared with other con…

Boom Motion Control Using Pressure Control Valve

This paper focuses on the reduction in oscillations created by counterbalance valves by using a proportional pressure control valve. The motion control of a cylinder boom is presented using this valve, which is a 4/3-way directional control valve with the main spool in series with an upstream compensator. The input to the valve control is a main spool position reference and, indirectly, the compensator downstream pressure. This gives a different flow gain and, therefore, a different feedforward scheme as compared to applications with the more common pressure compensated flow control valve. The theory behind the pressure control valve is presented and applied to both a theoretical and experi…

Analysis of Offshore Knuckle Boom Crane - Part One: Modeling and Parameter Identification

This paper presents an extensive model of a knuckle boom crane used for pipe handling on offshore drilling rigs. The mechanical system is modeled as a multi-body system and includes the structural flexibility and damping. The motion control system model includes the main components of the crane's electro-hydraulic actuation system. For this a novel black-box model for counterbalance valves is presented, which uses two different pressure ratios to compute the flow through the valve. Experimental data and parameter identification, based on both numerical optimization and manual tuning, are used to verify the crane model. The demonstrated modeling and parameter identification techniques target…

mplicit Identification of Contact Parameters in a Continuous Chain Model

Accurate contact modeling is of great importance in the field of dynamic chain simulations. In this paper emphasis is on contact dynamics for a time-domain simulation model of large chains guided in a closed loop track. The chain model is based on theory for unconstrained rigid multibody dynamics where contact within the chain and with the track is defined through continuous point contacts using the contact indentation and rate as means. This paper presents an implicit method to determine contact parameters of the chain model through the use of none gradient optimization methods. The set of model parameters are estimated by minimizing the residual between simulated and measured results. The…

Suspension system performance optimization with discrete design variables

Published version of an article in the journal: Structural and Multidisciplinary Optimization. Also available from the publisher at: http://dx.doi.org/10.1007/s00158-013-0888-7 Suspension systems on commercial vehicles have become an important feature meeting the requirements from costumers and legislation. The performance of the suspension system is often limited by available catalogue components. Additionally the suspension performance is restricted by the travel speed which highly influences the ride comfort. In this article a suspension system for an articulated dump truck is optimized in sense of reducing elapsed time for two specified duty cycles without violating a certain comfort th…

Enhanced chain dynamics in loop-sorting-systems by means of layout optimization and a kinematic model of the polygon action

Published version of an article in the journal: Structural and Multidisciplinary Optimization. Also available from the publisher at: http://dx.doi.org/10.1007/s00158-011-0743-7 Poor dynamics owing to polygon action is a known concern in mechanical applications of closed articulated chains. In this paper a kinematic model of the polygon action in large chains of loop-sorting-systems is proposed. Through optimization techniques the chain dynamics is improved by minimizing the polygon action using a parametric model of the track layout as design variables. Three formulations of the kinematic polygon action are tested on an average sized planer tracks layout to find a superior model. Verificati…

Development of 3D Anti-Swing Control for Hydraulic Knuckle Boom Crane

In this paper, 3D anti-swing control for a hydraulic loader crane is presented. The difference between hydraulic and electric cranes are discussed to show the challenges associated with hydraulic actuation. The hanging load dynamics and relevant kinematics of the crane are derived to model the system and create the 3D anti-swing controller. The anti-swing controller generates a set of tool point velocities which are added to the electro-hydraulic motion controller via feedforward. A dynamic simulation model of the crane is made, and the control system is evaluated in simulations with a path controller in actuator space. Simulation results show significant reduction in the load swing angles …

Re-analysis of fatigue data for welded joints using the notch stress approach

Abstract Experimental fatigue data for welded joints have been collected and subjected to re-analysis using the notch stress approach according to IIW recommendations. This leads to an overview regarding the reliability of the approach, based on a large number of results (767 specimens). Evidently, there are some limitations in the approach regarding mild notch joints, such as butt joints, which can be assessed non-conservatively. In order to alleviate this problem, an increased minimum notch factor of Kw ⩾ 2.0 is suggested instead of the current recommendation of Kw ⩾ 1.6. The data for most fillet-welded joints agree quite well with the FAT 225 curve; however a reduction to FAT 200 is sugg…

Anti-swing control of a hydraulic loader crane with a hanging load

Abstract In this paper, anti-swing control for a hydraulic loader crane is presented. The difference between hydraulic and electric cranes are discussed to show the challenges associated with hydraulic actuation. The hanging load dynamics and relevant kinematics of the crane are derived to create the 2-DOF anti-swing controller. The anti-swing controller is added to the electro-hydraulic motion controller via feedforward. A dynamic simulation model of the crane is made, and the control system is evaluated in simulations with a path controller in actuator space. Simulation results show significant reduction in the load swing angle during motion. Experiments are carried out to verify the perf…

A robust forward-displacement analysis of spherical parallel robots

The forward-displacement analysis of spherical parallel robots (SPRs) is revisited. A robust approach, based on the input–output (I/O) equation of spherical four-bar linkages, is proposed. In this approach, the closed-loop kinematic chain of a SPR is partitioned into two four-bar spherical chains, whose I/O equations are at the core of the analysis reported here. These equations lead to a trigonometric equation in the joint angles, which is solved semigraphically to obtain the joint variables for the determination of the moving plate orientation. Examples are included to demonstrate the application of the method.

The Effect of Friction in Passive and Active Heave Compensators of Crown Block Mounted Compensators

Abstract This paper studies the effects of friction model during passive and active heave compensation of offshore drilling equipment. The main purpose of heave compensation while drilling from vessels or semi-submersible platforms is to maintain the drilling operation unaffected by the wave induced motion. The investigated system is of an existing crown mounted compensator. A model of the system is developed which includes mechanics, hydraulics and pneumatics. The passive heave compensation scheme is described including force equalising hydraulic cylinders. In this paper the detrimental effect of friction on the heave compensation performance in both passive and active heave compensation i…

Improving Separation of Oil and Water Using a Novel Coalescing Centrifugal Pump

Abstract A novel centrifugal pump, which increases oil droplet sizes in produced water, has been developed. This paper investigates a concept of pumping pressure optimization with respect to downstream separation efficiency, for the new pump. The investigation shows that the coalescing centrifugal pump always increases the separation efficiency of a downstream hydrocyclone. Furthermore, it is seen that the pumping pressure can be adjusted to maximize the improvement. Experimental results demonstrate how pumping conditions, which minimize the volume fraction of droplets with a diameter smaller than the cut size of the hydrocyclone, maximize the separation efficiency. Finally, it is exemplifi…

Modeling of Friction Losses in Offshore Knuckle Boom Crane Winch System

This paper presents a method for friction modeling in a hydraulically actuated multi motor winch system of an offshore knuckle boom crane. The method is based on a combination of a model of the variable displacement axial piston motor based on measurements from the sub supplier, and combined with a model of the remaining friction loss obtained from measurements on the full system.

odeling of Human Arm Energy Expenditure for Predicting Energy Optimal Trajectories

Human arm motion can inspire the trajectory planning of anthropomorphic robotic arms to achieve energy-efficient movements. An approach for predicting metabolic cost in the planar human arm motion by means of the biomechanical simulation is proposed in this work. Two biomechanical models, including an analytical model and a musculoskeletal model, are developed to implement the proposed approach. The analytical model is developed by modifying a human muscle expenditure model, in which the muscles are grouped as torque providers for computation efficiency. In the musculoskeletal model, the predication of metabolic cost is conducted on the basis of individual muscles. With the proposed approac…

Performance Improvement of a Hydraulic Active/Passive Heave Compensation Winch Using Semi Secondary Motor Control: Experimental and Numerical Verification

In this paper, a newly developed controller for active heave compensated offshore cranes is compared with state-of-the-art control methods. The comparison is divided into a numerical part on stability margins as well as operational windows and an experimental validation of the expected performance improvement based on a full-scale testing on site with a crane rated to 250 metric tons. Such a crane represents the typical target for the new control method using a combination of active and passive hydraulic actuation on the main winch. The active hydraulic actuation is a hydrostatic transmission with variable-displacement pumps and variable-displacement motors. The new controller employs feedf…

A model for torque losses in variable displacement axial piston motors

This paper includes a comparison of earlier presented models for torque losses in hydraulic motors and several proposed models that all rely on data typically available for a system engineer. The new models and the old ones are compared. The new models are all based on a model developed by Jeong 2007 with an expansion that include variable displacement. All of the new models yield very good accuracy down to approximately 50% of maximum displacement and down to approximately 15% of maximum speed. In these operational ranges the deviation in torque is less than 1%. The main purpose of the new models is to facilitate simulations of hydraulically actuated winches with a balance between accuracy…

Numerical and Experimental Study of Friction Loss in Hydrostatic Motor

Published version of an article in the journal: Modeling, Identification and Control. Also available from the publisher at: http://dx.doi.org/10.4173/mic.2012.3.2 Open access This paper presents a numerical and experimental study of the losses in a hydrostatic motor principle. The motor is designed so that the structural deflections and lubricating regimes between moving surfaces and, subsequently, the leakage and friction losses, can be controlled during operation. This is done by means of additional pressure volumes that influence the stator deflection. These pressures are referred to as compensation pressures and the main emphasis is on friction or torque loss modeling of the motor as a …

EKF-based estimation and control of electric drivetrain in offshore pipe racking machine

A typical challenge for electric drivetrains is to reduce the number of sensors required for control action or system monitoring. This is particularly important for electric motors operating in offshore conditions, since they work in hostile environment which often damages data acquisition systems. Therefore, this paper deals with verification and validation of the extended Kalman filter (EKF) for sensorless indirect field-oriented control (IFOC) of an induction motor operating in offshore conditions. The EKF is employed to identify the speed of the induction motor based on the measured stator currents and voltages. The estimated speed is used in the motor speed control mode instead of a ph…

A Tire Model for Off-Highway Vehicle Simulation on Short Wave Irregular Terrain

Manufacturers of construction machinery are challenged in several ways concerning dynamic loads. Considering off-highway dump trucks that travel through high amplitude short wave irregular terrain with considerable speed two aspects concerning dynamics are important.The first is the legal requirements that prescribe the maximum limit on the vibration exposure on the operator which is a measure for ride comfort.The second is the importance of knowing the dynamic loading of the structural parts. In order to use the wide variety of computer-aided design tools to size and optimize mechanical joints, spring-damper elements and the welded structures it is crucial to have information on the time h…

Torque peak reduction and overload monitoring of induction motors in offshore drilling operations

Current drivetrain design procedures for electric actuation systems operating in offshore conditions typically consider two major requirements: to provide sufficient steady-state and maximum motor torques. As a result of this, no information regarding the transient state (e.g. during motor acceleration) is utilized when selecting drivetrain components. This leads to potentially dangerous situations when motors undergo saturation in these regions due to too high dynamic loads. A common reason for this (apart from lack of information about transient state when designing a drivetrain) is applying trapezoidal reference motion profiles that cause discontinuities in system acceleration and infini…

Presenting a Multi-level Superstructure Optimization Approach for Mechatronic System Design

Synergism and integration in the design process is what sets apart a Mechatronic System from a traditional, multidisciplinary system. However the typical design approach has been to divide the design problem into sub problems for each technology area (mechanics, electronics and control) and describe the interface between the technologies, whereas the lack of well-established, systematic engineering methods to form the basic set-off in analysis and design of complete mechatronic systems has been obvious. The focus of the current paper is therefore to present an integrated design approach for mechatronic system design, utilizing a multi-level superstructure optimization based approach. Finall…

Practice for determining friction in hydraulic winch systems

This paper presents a method for estimating friction in hydraulic active heave compensated (AHC) offshore winches. The method is a two-step approach where the first step is to model the friction loss in the hydraulic motors based on data from the sub-supplier. The second step requires real-life testing, where the remaining friction losses in the winch system is identified and modeled. In this context, a practice is characterized by obtaining a friction loss estimation with the highest possible accuracy over the widest possible range of operating conditions with a limited amount of experimental work. The method benefits from the use of parametric models, sub-supplier data, and real-life meas…

Numerical and experimental verification of new method for connecting pipe to flange by cold forming

Abstract In this paper a new method of connecting pipe to flange without welding is presented. This method is a cold forming process that is based on plastic expansion/deformation of the pipe into a modified standard flange by use of a cold forming tool. The method is patented by Quickflange Technology AS and represents a highly feasible alternative to welding. The successful use of the method requires the ability to predict dimensional and stress/strain characteristics of the pipe and flange after the connection process in order to evaluate the connectivity to the adjacent flange as well as the leak tightness. In addition the ability to predict the process force during the connection proce…

Developing a Tool Point Control Scheme for a Hydraulic Crane Using Interactive Real-time Dynamic Simulation

This paper describes the implementation of an interactive real-time dynamic simulation model of a hydraulic crane. The user input to the model is given continuously via joystick and output is presented continuously in a 3D animation. Using this simulation model, a tool point control scheme is developed for the specific crane, considering the saturation phenomena of the system and practical implementation. This paper describes the implementation of an interactive real-time dynamic simulation model of a hydraulic crane. The user input to the model is given continuously via joystick and output is presented continuously in a 3D animation. Using this simulation model, a tool point control scheme…

Numerical and experimental study of hydrostatic displacement machine

This paper presents a simulation tool to determine the structural deflections and corresponding leakage flow in a hydrostatic displacement motor. The simulation tool is applied to a new motor principle that is categorized as an extreme low-speed high-torque motor with dimensions that calls for attention to the volumetric efficiency. To counteract structural deflections the motor is equipped with compensation pressure volumes that may be used to limit the leakage flow across the end faces of the circular rotor. This leakage flow is investigated by solving Reynolds equation for the pressure distribution across both end faces. The fluid pressure is combined with structural calculations in a fl…

Tool-Point Control for a Redundant Heave Compensated Hydraulic Manipulator

Abstract In this paper, theoretical and experimental implementation of heave compensation on a redundant hydraulically actuated manipulator with 3-dof has been carried out. The redundancy is solved using the pseudo-inverse Jacobian method. Techniques for minimizing velocities and avoiding mechanical joint saturations is implemented in the null space joint motion. Model based feed-forward, combined with a PI-controller handles the velocity control of each joint. A time domain simulation model has been developed, experimentally verified, and used for controller parameter tuning. Model verification and experimental results are obtained while the manipulator is exposed to wave disturbances crea…

Comparison of Post-Weld Treatment of High-Strength Steel Welded Joints in Medium Cycle Fatigue

This paper presents a comparison of three post-weld treatments for fatigue life improvement of welded joints. The objective is to determine the most suitable post-weld treatment for implementation in mass production of certain crane components manufactured from very high-strength steel. The processes investigated are: burr grinding, TIG dressing and ultrasonic impact treatment. The focus of this investigation is on the so-called medium cycle area, i.e. 10 000-500 000 cycles and very high stress ranges. In this area of fatigue design, the use of very high strength steel becomes necessary, since the stress range can exceed the yield-strength of ordinary structural steel, especially when consi…

Integrated Design Optimization of a 5-DOF Assistive Light-weight Anthropomorphic Arm

An integrated dimensional and drive train optimization method was developed for light-weight robotic arm design. The method deals with the determination of optimal link lengths and the optimal selection of motors and gearboxes from commercially available components. Constraints are formulated on the basis of kinematic performance and dynamic requirements, whereas the main objective is to minimize the weight. The design of a human-like arm, which is 10 kg in weight with a load capacity of 5 kg, is described. An integrated dimensional and drive train optimizationmethod was developed for light-weight robotic armdesign. The method deals with the determination of optimallink lengths and the opti…