Development of Motion Control Systems for Hydraulically Actuated Cranes with Hanging Loads

Automation has been used in industrial processes for several decades to increase efficiency and safety. Tasks that are either dull, dangerous, or dirty can often be performed by machines in a reliable manner. This may provide a reduced risk to human life, and will typically give a lower economic cost. Industrial robots are a prime example of this, and have seen extensive use in the automotive industry and manufacturing plants. While these machines have been employed in a wide variety of industries, heavy duty lifting and handling equipment such as hydraulic cranes have typically been manually operated. This provides an opportunity to investigate and develop control systems to push lifting equipment towards the same level of automation found in the aforementioned industries. The use of winches and hanging loads on cranes give a set of challenges not typically found on robots, which requires careful consideration of both the safety aspect and precision of the pendulum-like motion. Another difference from industrial robots is the type of actuation systems used. While robots use electric motors, the cranes discussed in this thesis use hydraulic cylinders. As such, the dynamics of the machines and the control system designmay differ significantly. In addition, hydraulic cranes may experience significant deflection when lifting heavy loads, arising from both structural flexibility and the compressibility of the hydraulic fluid. The work presented in this thesis focuses on motion control of hydraulically actuated cranes. Motion control is an important topic when developing automation systems, as moving from one position to another is a common requirement for automated lifting operations. A novel path controller operating in actuator space is developed, which takes advantage of the load-independent flow control valves typically found on hydraulically actuated cranes. By operating in actuator space the motion of each cylinder is inherently minimized. To counteract the pendulum-like motion of the hanging payload, a novel anti-swing controller is developed and experimentally verified. The anti-swing controller is able to suppress the motion from the hanging load to increase safety and precision. To tackle the challenges associated with the flexibility of the crane, a deflection compensator is developed and experimentally verified. The deflection compensator is able to counteract both the static deflection due to gravity and dynamic de ection due to motion. Further, the topic of adaptive feedforward control of pressure compensated cylinders has been investigated. A novel adaptive differential controller has been developed and experimentally verified, which adapts to system uncertainties in both directions of motion. Finally, the use of electro-hydrostatic actuators for motion control of cranes has been investigated using numerical time domain simulations. A novel concept is proposed and investigated using simulations.publishedVersio

Using Digital Hydraulics in Secondary Control of Motor Drive

Due to the increased focus on pollution and global warming, there is a demand for energy efficient systems. This also applies to the offshore oil and gas industry. Normally used hydraulic systems tend to suffer from low energy efficiency, especially when operating with part loads. In the last decades, a new pump and motor technology has experienced increased interest due to the potential of high energy efficiency in a wide range of operation conditions. This new technology is called digital displacement machine technology. Nowadays, there is a desire from the offshore oil and gas industry to use this digital displacement machine technology to design highly efficient hydraulic winch drive systems. The main objectives of the work presented in this thesis are to design a controller for a digital displacement winch drive system and evaluate its control performance. The design of a controller is one part of the work needed to realizing a winch drive system with digital displacement machines. A winch with a lifting capacity of 20000 kg and a drum capacity of 3600 m of wire rope is used as a case study. Digital displacement machines have strict requirements for the on/off valves used to control each cylinder chamber. It is important to activate the valves at optimal times to ensure operation with high energy efficiency and low pressure and flow peaks. Only a small mistiming of the valves will affect the performance of the digital displacement machine significantly. One of the first contributions presented in this thesis is a method for defining how early or late the valves can be timed without reducing the energy efficiency significantly. The control of digital displacement machines is complicated and non-conventional. Each cylinder can be controlled individually and multiple displacement strategies can be used to achieve the same displacement. Each displacement strategy has its dynamic response characteristics and energy efficiency characteristics. The dynamic response characteristics of the drive system are highly relevant when designing control systems. Therefore, in addition to the conventional classical controller, also a suitable displacement strategy must be designed. Designing controllers for digital displacement machines are therefore more complex than designing controllers for conventional hydraulic machines. One of the main focuses of this project has been to analyze the transient and steady state response characteristics of different displacement strategies. In all, three displacement strategies are examined: full stroke displacement strategy, partial stroke displacement strategy and sequential partial stroke displacement strategy. Also, during this work, a new version of the partial stroke displacement strategy has been developed and included in the dynamic response analysis. The dynamic response analysis is a simulation study, where the simulation model is experimentally validated. The experimental work is conducted on a prototype of a single cylinder digital displacement machine. The prototype consists of a five cylinder radial piston motor where one cylinder is modified to operate with the digital displacement technology. The rest of the cylinders are not changed and not used. In addition to validating the simulation model, the prototype is used to test all of the analyzed displacement strategies in low speed operation. The results from the dynamic response analysis are used to select the displacement strategy that is most suited for use in a winch drive system. Then, controllers for the digital displacement winch drive system are developed. The main focus in the control design phase is not to design a new type of controller but to examine already developed controllers and fit them to a winch system driven by digital displacement machines. In the end, the simulation results of the designed controllers are shown and the results are discussed. The simulation results show that digital displacement machines can be used in winch drive systems and achieve both high motion control performance and wire tension control performance.publishedVersio

Volume 3 – Conference

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group 8: Pneumatics Group 9 | 11: Mobile applications Group 10: Special domains Group 12: Novel system architectures Group 13 | 15: Actuators & sensors Group 14: Safety & reliabilit

Improving Automated Operations of Heavy-Duty Manipulators with Modular Model-Based Control Design

The rapid development of robotization and automation in mobile working machines aims to increase productivity and safety in many industrial sectors. In heavy-duty applications, hydraulically actuated manipulators are the common solution due to their large power-to-weight ratio. As hydraulic systems can exhibit nonlinear dynamic behavior, automated operations with closed-loop control become challenging. In industrial applications, the dexterity of operations for manipulators is ensured by providing interfaces to equip product variants with different tool attachments. By considering these domain-specific tool attachments for heavy-duty hydraulic manipulators (HHMs), the autonomous robotic operating development for all product variants might be a time-consuming process. This thesis aims to develop a modular nonlinear model-based (NMB) control method for HHMs to enable systematic NMB model reuse and control system modularity across different HHM product variants with actuators and tool attachments. Equally importantly, the properties of NMB control are used to improve the high-performance control for multi degrees-of-freedom robotic HHMs, as rigorously stability-guaranteed control systems have been shown to provide superior performance. To achieve these objectives, four research problems (RPs) on HHM controls are addressed. The RPs are focused on damping control methods in underactuated tool attachments, compensating for static actuator nonlinearities, and, equally significantly, improving overall control performance. The fourth RP is introduced for hydraulic series elastic actuators (HSEAs) in HHM applications, which can be regarded as supplementing NMB control with the aim of improving force controllability. Six publications are presented to investigate the RPs in this thesis. The control development focus was on modular NMB control design for HHMs equipped with different actuators and tool attachments consisting of passive and actuated joints. The designed control methods were demonstrated on a full-size HHM and a novel HSEA concept in a heavy-duty experimental setup. The results verified that modular control design for HHM systems can be used to decrease the modifications required to use the manipulator with different tool attachments and floating-base environments

Modelling and control of subsea installation

Ph.DDOCTOR OF PHILOSOPH

Design and Analysis of Electric Powertrains for Offshore Drilling Applications

Doktorgradsavhandling ved Institutt for ingeniørvitenskap, Universitetet i Agder, 2016The global energy market is challenged with an ever increasing need for resources to meet the growing demands for electric power, transportation fuels, etc. Although we witness the expansion of the renewable energy industry, it is still the fossil fuels, with oil and gas dominating the scene of global energy supply sector, that provide majority of worldwide power generation.However, many of the easily accessible hydrocarbon reserves are depleted which requires from the producers of drilling equipment to focus on cost-effective operations and technology to compete in a challenging market. Particularly high level of activity is observed in both industry and academia in the field of electrical actuation systems of drilling machines, as control methods of alternating current (AC) motor drives have become an industrially mature technology over the past few decades. In addition, state-of-the-art AC motors manufacturing processes allow to conform to the strict requirements for safe operation of electrical equipment in explosive atmospheres. These two main reasons made electric actuation systems a tough competitor to hydraulic powertrains used traditionally by the industry. However, optimal design of induction motor drives and systematic analysis of factors associated with operation in harsh offshore conditions are still considered as a major challenge. In this thesis, effective methods for design and analysis of induction motor drives are proposed, including aspects of optimization and simulation-based engineering. The first part of the thesis is devoted to studying methods for modeling, control, and identification of induction machines operating in offshore drilling equipment with the focus to improve their reliability, extend lifetime, and avoid faults and damage, whereas the second part introduces more general approaches to the optimal selection of components of electric drivetrains and to the improvement of the existing dimensioning guidelines. A multidisciplinary approach to design of actuation systems is explored in this thesis by studying the areas of motion control, condition monitoring, and thermal modeling of electric powertrains with an aspiration to reach the level of design sophistication which goes beyond what is currently considered an industrial standard. We present a technique to reproduce operation of a full-scale offshore drilling machine on a scaled-down experimental setup to estimate the mechanical load that the designed powertrain must overcome to meet the specification requirements. The same laboratory setup is used to verify the accuracy of the estimation and control method of an induction motor drive based on the extended Kalman filter (EKF) to confirm that the sensorless control techniques can reduce the number of data acquisition devices in offshore machines, and thus decrease their failure rate without negatively affecting their functionality. To address the challenge of condition monitoring of induction motor drives, we propose a technique to assess the expected lifetime of electric drivetrain components when subjected to the desired duty cycles by comparing the effects of a few popular motion control signals on the cumulative damage and vibrations. As a result, the information about the influence of a given control strategy on drivetrain lifecycle is made available early in the design stage which can significantly affect the choice of the optimal powertrain components. The results show that some of the techniques that have a well-proven track record in other industries can be successfully applied to solve challenges associated with operation of offshore drilling machines. One of the most essential contributions of this thesis, optimal selection of drivetrain components, is based on formulating the drivetrain dimensioning problem as a mixed integer optimization program. The components of powertrain that satisfy the design constraints and are as cost-effective as possible are found to be the global optimum, contrary to the functionality offered by some commercially available drivetrain sizing software products. Another important drawback of the dimensioning procedures recommended by the motor drives manufacturers is the inability to assess if the permissible temperature limits given in the standards do not become violated when the actuation system experiences overloads different than these tabulated in the catalogs. Hence, the second most significant contribution is to propose a method to monitor thermal performance of induction motor drives that is based exclusively on publicly available catalog data and allows for evaluating whether the standard thermal performance limits are violated or not under arbitrary load conditions and at any ambient temperature. Both these solutions can effectively enrich the industrially accepted dimensioning procedures to satisfy the level of conservatism that is demanded by the offshore drilling business but, at the same time, provide improved efficiency and flexibility of the product design process and guarantee optimality (quantitatively, not qualitatively, measurable) of the final solution. An attractive direction for additional development is to further integrate knowledge from different fields relevant to electric powertrains to enable design of tailored solutions without compromising on their cost and performance

Annual General Assembly of the International Association of Maritime Universities

978-84-947311-7-

Volume 1 – Symposium

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group A: Materials Group B: System design & integration Group C: Novel system solutions Group D: Additive manufacturing Group E: Components Group F: Intelligent control Group G: Fluids Group H | K: Pumps Group I | L: Mobile applications Group J: Fundamental

Volume 2 – Conference

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group 1 | 2: Digital systems Group 3: Novel displacement machines Group 4: Industrial applications Group 5: Components Group 6: Predictive maintenance Group 7: Electro-hydraulic actuatorsDer Download des Gesamtbandes wird erst nach der Konferenz ab 15. Oktober 2020 möglich sein.:Group 1 | 2: Digital systems Group 3: Novel displacement machines Group 4: Industrial applications Group 5: Components Group 6: Predictive maintenance Group 7: Electro-hydraulic actuator