“Effect of Electrification on the Quantitative Reliability of an Offshore Crane Winch in Terms of Drive-Induced Torque Ripples”

Authors: Mohamed Yousri, Georg Jacobs and Stephan Neumann,
Affiliation: RWTH Aachen
Reference: 2023, Vol 44, No 1, pp. 1-16.

Keywords: Reliability, Offshore, Winch, Electrification, Electric, Hydraulic, Drive

Abstract: Offshore crane winches are equipment installed on sea vessels and designed for accurate lifting and lowering of payloads at subsea levels in all conditions and are equipped with Active Heave Compensation (AHC) capabilities which keep the handled payload stable relative to the seabed. Due to logistical challenges and short maintenance windows imposed by sea conditions, maintenance of offshore crane winches in open sea is costly and time consuming, and its reliability is therefore of the highest importance. In recent times, electric drives for the actuation of the winch drum have seen a surge in popularity in favour of hydraulic drives owing to advances in control technologies of AC motors, as well as higher efficiency, lower noise and lack of an oil reservoir. In light of these changes and the importance of reliability, a study on the effect of the electrification (ie. switching from hydraulic to electric actuation) of offshore crane winches from a reliability viewpoint is necessary. In previous studies, it has been established that the different inherent properties of electric and hydraulic drives lead to torque ripples of different magnitudes and frequencies which may induce additional mechanical stresses in the drivetrain. The effects of these ripples on a system level have so far only been studied from a Noise-Vibration-Harshness (NVH) viewpoint in applications where driver comfort takes precedence in design (ex. electric vehicles, tractors). In this paper, these drive-induced ripples are simulated for common electric and hydraulic drive configurations used in offshore crane winches, and their effect on the reliability of the driven gearbox, as the most critical component in the drivetrain, is analysed. It was found that electric drives produce in general ripples of smaller magnitude (between 0.44% and 1.07% of static torque for electric compared to between 3.12% and 3.30% for hydraulic), which enhances the reliability of the driven gearbox (1.25% to 3.44% reduction in lifetime due to electric ripples, and 9.29% to 9.67% due to hydraulic ripples in comparison to an ideal torque source with no ripples). However, depending on the design and number of pumps in use, the size of the hydraulic torque ripple can have a wider range of between 1.31% and 7.69% and the subsequent reduction in lifetime compared to the ideal case ranging between 4.07% and 21.37%.

PDF PDF (2927 Kb)        DOI: 10.4173/mic.2023.1.1

References:
[1] ABB. (2013). All-compatible ACS880 single drives, 2013. https://new.abb.com/drives/low-voltage-ac/industrial-drives/acs880-single-drives. Accessed: 2022-08-15.
[2] Albers, P. (2010). Motion Control in Offshore and Dredging, Springer Netherlands. doi:10.1007/978-90-481-8803-1
[3] Aly, A. (2012). Model reference pid control of an electro- hydraulic drive, International Journal of Intelligent Systems and Applications, 2012. 4:24--32.
[4] Begh, M. and Herzog, H.-G. (2018). Comparison of field oriented control and direct torque control, Technical report.
[5] Bjonnes, T. and Moe, N. (2012). Backslash in slew bearings: the advantages of an all-electric drive system, Master's thesis, University of Agder. http://hdl.handle.net/11250/2446986.
[6] Busca, C. (2010). Open loop low speed control for PMSM in High Dynamic Applications, Master's thesis, Aalborg University. https://projekter.aau.dk/projekter/files/32306486/Report_final.pdf.
[7] Danfoss. (2010). Drives for marine winches and cranes, 2010. https://www.danfoss.com/en/markets/marine-and-offshore/dds/drives-for-marine-winches-and-cranes/#tab-overview. Accessed: 2022-08-15.
[8] DeKlerk, M.L. and Saha, A.K. (2022). Performance analysis of DTC-SVM in a complete traction motor control mechanism for a battery electric vehicle, Heliyon. 8(4). doi:10.1016/j.heliyon.2022.e09265
[9] Depenbrock, M. (1988). Direct self-control (DSC) of inverter-fed induction machine, IEEE Trans. Power Electron.. 3(4):420--429. doi:10.1109/63.17963
[10] Deppen, T.O., Alleyne, A.G., Stelson, K.A., and Meyer, J.J. (2011). Model predictive control of an electro-hydraulic powertrain with energy storage, In ASME 2011 Dynamic Systems and Control Conference and Bath/ASME Symposium on Fluid Power and Motion Control, Volume 2. ASMEDC, 2011.
[11] DIN 3390. (0). Calculation of load capacity of cylindrical gears; introduction and general influence factors, Standard, Beuth, 1987.
[12] DIN ISO 281. (0). Rolling bearings - dynamic load ratings and rating life, Standard, Beuth, 2010.
[13] ElOuanjli, N., Derouich, A., ElGhzizal, A., Motahhir, S., Chebabhi, A., ElMourabit, Y., and Taoussi, M. (2019). Modern improvement techniques of direct torque control for induction motor drives - a review, Prot. control mod. power syst., 2019. 4(1). doi:10.1186/s41601-019-0125-5
[14] ElOuanjli, N., Motahhir, S., Derouich, A., ElGhzizal, A., Chebabhi, A., and Taoussi, M. (2019). Improved DTC strategy of doubly fed induction motor using fuzzy logic controller, Energy rep., 2019. 5:271--279. doi:10.1016j.egyr.2019.02.001
[15] Entao, Z., Wenlin, Y., and Junzhe, L. (2009). Predictive control of hydraulic winch motion control, In 2009 2nd IEEE International Conference on Computer Science and Information Technology. IEEE.
[16] Farsakoglu, T., Pedersen, H.C., and Andersen, T.O. (2022). Review of offshore winch drive topologies and control methods, 2022.
[17] Gu, P., Walid, A.A., Iskandarani, Y., and Karimi, H.R. (2012). Modeling, simulation and design optimization of a hoisting rig active heave compensation system, International Journal of Machine Learning and Cybernetics, 2012. 4(2):85--98. doi:10.1007/s13042-012-0076-x
[18] Guan, C., Jiao, Z., and He, S. (2014). Theoretical study of flow ripple for an aviation axial-piston pump with damping holes in the valve plate, Chinese Journal of Aeronautics. 27(1):169--181. doi:10.1016/j.cja.2013.07.044
[19] Hiba, H., Ali, H., and Othmen, H. (2013). DTC-SVM control for three phase induction motors, In 2013 International Conference on Electrical Engineering and Software Applications. IEEE. doi:10.1109/ICEESA.2013.6578421
[20] Ivantysyn, J. and Ivantysynova, M. (2003). Hydrostatic pumps and motors: principles, design and performance, modeling, analysis, control and testing, Tech Books International.
[21] Kennel, R., El-refaei, A., Elkady, F., Mahmoud, S., and Elkholy, E. (2004). Torque ripple minimization for induction motor drives with direct torque control (DTC), In The Fifth International Conference on Power Electronics and Drive Systems, 2003. PEDS 2003. IEEE. doi:10.1109/PEDS.2003.1282756
[22] MacGregor. (2019). Offshore cranes, 2019. https://www.macgregor.com/Products/products/offshore-and-subsea-load-handling/offshore-cranes/. Accessed: 2022-08-08.
[23] Mandal, N.P., Saha, R., and Sanyal, D. (2008). Theoretical simulation of ripples for different leading-side groove volumes on manifolds in fixed-displacement axial-piston pump, Proc Inst Mech Eng Part I J Syst Control Eng. 222(6):557--570. doi:10.1243/09596518JSCE580
[24] Mao, Y., Zuo, S., Wu, X., and Duan, X. (2017). High frequency vibration characteristics of electric wheel system under in-wheel motor torque ripple, J. Sound Vib.. 400:442--456. doi:10.1016/j.jsv.2017.04.011
[25] Mathworks. (2012). Simulate an AC motor drive, 2012. https://de.mathworks.com/help/physmod/sps/powersys/ug/simulating-an-ac-motor-drive.html. Accessed: 2022-08-07.
[26] Neumann, S., Woell, L., Feldermann, A., Strassburger, F., and Jacobs, G. (2016). Modular system modeling for quantitative reliability evaluation of technical systems, Modeling, Identification and Control: A Norwegian Research Bulletin. 37(1):19--29. doi:10.4173/mic.2016.1.2
[27] Pasch, G., Jacobs, G., and Berroth, J. (2020). Nvh-systemsimulation eines traktors mit hydrostatisch-mechanischem leistungsverzweigungsgetriebe, 2020. doi:10.15150/lt.2020.3254
[28] Paul Forrer AG. (2011). Korrekte berechnung für hydraulikleitungen, 2011. https://www.deutzforum.de/index.php?attachment/97119-berechnung-hydraulikleitung-d-pdf/. Accessed: 2022-09-09.
[29] Slemon, G.R. (1989). Modelling of induction machines for electric drives, IEEE Trans. Ind. Appl.. 25(6):1126--1131. doi:10.1109/28.44251
[30] Sullivan, R.A., Davenport, M.R., and Clements, R.E. (1984). Multipurpose active/passive motion compensation system, In Offshore Technology Conference. Offshore Technology Conference. doi:10.4043/4737-MS
[31] Takahashi, I. and Noguchi, T. (1986). A new quick-response and high-efficiency control strategy of an induction motor, IEEE Transactions on Industry Applications. IA-22(5):820--827. doi:10.1109/TIA.1986.4504799
[32] del Toro, X., Jayne, M.G., Witting, P.A., Pou, J., Arias, A., and Romeral, J.L. (2005). New direct torque control scheme for induction motors, In 2005 European Conference on Power Electronics and Applications. IEEE. doi:10.1109/EPE.2005.219544
[33] Uddin, M.N. and Hafeez, M. (2010). FLC based DTC scheme to improve the dynamic performance of an IM drive, In 2010 IEEE Industry Applications Society Annual Meeting. IEEE. doi:10.1109/IAS.2010.5614089
[34] Woell, L., Feldermann, A., and Jacobs, G. (2017). Sensitivity analysis on the reliability of an offshore winch regarding selected gearbox parameters, Modeling, Identification and Control: A Norwegian Research Bulletin. 38(2):51--58. doi:10.4173/mic.2017.2.1
[35] Woell, L., Jacobs, G., and Kramer, A. (2018). Lifetime calculation of irregularly oscillating bearings in offshore winches, Modeling, Identification and Control: A Norwegian Research Bulletin. 39(2):61--72. doi:10.4173/mic.2018.2.2
[36] Woodacre, J., Bauer, R., and Irani, R. (2015). A review of vertical motion heave compensation systems, Ocean Engineering. 104:140--154. doi:10.1016/j.oceaneng.2015.05.004
[37] Xia, Y.Y., Fletcher, J.E., Finney, S.J., Ahmed, K.H., and Williams, B.W. (2011). Torque ripple analysis and reduction for wind energy conversion systems using uncontrolled rectifier and boost converter, IET Renew. Power Gener.. 5(5):377. doi:10.1049/iet-rpg.2010.0108
[38] Yousri, M., Jacobs, G., and Neumann, S. (2020). Impact of fiber versus steel ropes on the lifetime of crane winches, Modeling, Identification and Control: A Norwegian Research Bulletin. 41(3):129--139. doi:10.4173/mic.2020.3.1
[39] Zhang, B., Ma, J., Hong, H., Yang, H., and Fang, Y. (2017). Analysis of the flow dynamics characteristics of an axial piston pump based on the computational fluid dynamics method, Eng. Appl. Comput. Fluid Mech.. 11(1):86--95. doi:10.1080/19942060.2015.1091686


BibTeX:
@article{MIC-2023-1-1,
  title={{Effect of Electrification on the Quantitative Reliability of an Offshore Crane Winch in Terms of Drive-Induced Torque Ripples}},
  author={Yousri, Mohamed and Jacobs, Georg and Neumann, Stephan},
  journal={Modeling, Identification and Control},
  volume={44},
  number={1},
  pages={1--16},
  year={2023},
  doi={10.4173/mic.2023.1.1},
  publisher={Norwegian Society of Automatic Control}
};