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

Secondary Control of a Digital Hydraulic Motor for Winch Applications

Master's thesis Mechatronics MAS500 - University of Agder 2018The reliable traditional hydraulic systems for industrial purposes is being challenged by an emerging technology called digital hydraulics. This technology shows promising improvements in regards to e ciency, especially in comparison to systems dependent on hydraulic pumps or motors with variable displacement. Digital hydraulic motors eliminate the need for a servo valve by connecting each individual motor cylinder directly to the high-pressure and low-pressure line by means of fast-acting on/o -valves. In this thesis, the potential of digital hydraulics is investigated by developing a control system intended for a digital displacement motor used on an industrial winch application. The expected operation modes of the winch system are analysed, and di erent control strategies are discussed. The developed control system is tested for the expected operation modes before it is simulated with a model of an industrial winch. The digital displacement motor performs well during simulated testing of typical load cases for a winch system. Some challenges are discovered when the motor switches operation mode and when the reference velocity is zero. Solutions for counteracting the mentioned challenges are implemented, and further possible improvements are proposed. The presented results prove that the suggested control strategy has the potential for good reference tracking and that the overall solution is suitable for a winch system

SeisCORK engineering design study

The goal of SeisCORKs is to make simultaneous and co-located seismic, pressure, temperature, pore water chemistry and pore water biology measurements in the seafloor. We want to see the small events in the vicinity of the borehole for three reasons: 1) After an event fluid may flow in the formation in response to the changing stress regime. Down to what magnitude of event do the pressure transients in the well respond? 2) Fluid flow causes small earthquakes. One mechanism for example is by changing the temperature of the rocks which expand and contract, altering the stress regime. We want to look for this fluid flow. 3) Laboratory studies of rock deformation show that shear fracture is preceded by the coalescence of interacting tensile microcracks which are observed as “acoustic emissions”. By placing high frequency geophones next to faults it may be possible to observe these “acoustic” precursors to rock failure. Since in reservoirs on land small events appear in the frequency band 400-800Hz, no one has yet tried to observe them in oceanic crust. SeisCORKs also obviate the considerable logistical, administrative, and clearance difficulties associated with scheduling a shooting ship to run offset VSPs. We resolved to start with a “tubing conveyed” SeisCORK configuration consisting of four three-component sondes at 50m separation lowered on the outside of 4.5in casing (or drill pipe) inside 10-3/4in casing.Funding was provided by the National Science Foundation under Contract Nos. OCE-0221832 and OCE-0450318

Improving Energy Efficiency and Motion Control in Load-Carrying Applications using Self-Contained Cylinders

Because of an increasing focus on environmental impact, including CO2 emissions and fluid spill pollution, inefficient hydraulic systems are being replaced by more environmentally friendly alternatives in several industries. For instance, in some offshore applications that have multiple diesel generators continuously running to produce electricity, all hydraulic rotating actuators supplied from a central hydraulic power unit have been replaced with AC induction motors containing a variable frequency drive and gearbox. However, hydraulic linear actuators are still needed in most load-carrying applications mainly because of their high reliability associated with external impact shocks. Moreover, their force capacity is higher than that of their linear electromechanical counterparts. Valve-controlled linear actuators (cylinders) supplied from a centralized hydraulic power unit are standard in offshore load-carrying applications. In addition to the advantages mentioned above of hydraulic linear actuators, they have, nevertheless, a number of important drawbacks, which include: 1) a high level of energy consumption due to significant power losses caused by flow throttling in both the pipelines and valves, 2) reduced motion performance due to the influence of load-holding valves, 3) high CO2 emissions and fuel costs related to the diesel generator that supplies electricity to the hydraulic power unit, 4) significant potential for hydraulic fluid leakage because of many leakage points, 5) demanding efforts with respect to installation and maintenance, as well as 6) costly piping due to the centralized hydraulic power supply. The work presented in this dissertation and the appended papers are devoted to replacing inefficient hydraulic linear actuation systems traditionally used in offshore load-carrying applications with more environmentally friendly solutions. Two alternative technologies are identified, namely electro-mechanical and electro-hydraulic self-contained cylinders. The feasibility of replacing conventional valve-controlled cylinders with self-contained cylinder concepts is investigated in two relevant case studies.publishedVersio

Underwater Vehicles

For the latest twenty to thirty years, a significant number of AUVs has been created for the solving of wide spectrum of scientific and applied tasks of ocean development and research. For the short time period the AUVs have shown the efficiency at performance of complex search and inspection works and opened a number of new important applications. Initially the information about AUVs had mainly review-advertising character but now more attention is paid to practical achievements, problems and systems technologies. AUVs are losing their prototype status and have become a fully operational, reliable and effective tool and modern multi-purpose AUVs represent the new class of underwater robotic objects with inherent tasks and practical applications, particular features of technology, systems structure and functional properties

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

Modelling and Optimization of Wave Energy Converters

Wave energy offers a promising renewable energy source. This guide presents numerical modelling and optimisation methods for the development of wave energy converter technologies, from principles to applications. It covers oscillating water column technologies, theoretical wave power absorption, heaving point absorbers in single and multi-mode degrees of freedom, and the relatively hitherto unexplored topic of wave energy harvesting farms. It can be used as a specialist student textbook as well as a reference book for the design of wave energy harvesting systems, across a broad range of disciplines, including renewable energy, marine engineering, infrastructure engineering, hydrodynamics, ocean science, and mechatronics engineering. The Open Access version of this book, available at https://www.routledge.com/ has been made available under a Creative Commons Attribution-Non Commercial-No Derivatives 4.0 license