Satamanosturin dynamiikan reaaliaikasimulointi

Työn tavoitteena oli mallintaa satamanosturin dynamiikkaa mahdollisimman tarkasti kuvaava yksinkertaistettu malli Simulink-ohjelmalla, jonka jälkeen malli käännettiin edelleen reaaliaikasimulaattorille soveltuvaan muotoon. Nosturin malli yksinkertaistettiin käsittämään kolme osaa: Nosturin rungon, nostovaunun ja kontin. Voimista mallinnettiin pyörien kontaktivoimat, köysivoimat sekä siirtovoima. Reaaliaikasimulaattorina käytettiin Opal-RT:n RT-LAB reaaliaikasimulointiohjelmistoa, sekä tavallisia PC-tietokoneita. Simulointiin liitettiin myös 3D-animaatio, jolla nosturin liikkeet saatiin visualisoitua. Animoitava grafiikka luotiin WorldUp-ohjelmistolla ja liitettiin RT-LAB-simulaatioon RT3D-rajapinnan ja WorldUp Player:n avulla. Työn tuloksena saatiin satamanosturin dynaamista käyttäytymistä kuvaava Simulink-malli, jota on mahdollista käyttää reaaliaikaisessa simuloinnissa. Mallia testattiin RT-LAB reaaliaikasimulaattorissa, ja simuloinnista saatuja tuloksia verrattiin Adams:lla simuloituihin tuloksiin. Saatujen tulosten perusteella mallia voidaan pitää onnistuneena. Myös RT-LAB reaaliaikasimulaattori visualisointeineen vaikuttaa toimivalta kokonaisuudelta.

Liikesimulaattorialustan kehittäminen virtuaaliprototyypin avulla

Työn tarkoituksena oli kehittää kuuden vapausasteen liikesimulaattorialusta virtuaaliprototyypin avulla siten, että alustan dynamiikka mallinnetaan Adams-ohjelmistolla ja ohjaus- ja säätöpiiri Matlab Simulink:llä. Tarkoituksena oli tutkia dynaamisen mallin ja säätöteknisen mallin yhdistämistä ja niiden yhteen toimimista. Tarkoituksena oli myös selvittää tulevaisuudessa rakennettavan Stewart:n alustan mekaniikan mitat ja hydraulikomponenttien koot. Työssä tutkittiin alustan käyttäytymistä halutulla liikealueella, nopeuksia joita saavutetaan ja mekaanisia rajoitteita. Työn tuloksesta on tarkoitus rakentaa fyysinen prototyyppi liittyen KONSI-projektiin, jossa kehitetään satamanosturisimulaattori nosturiohjaajan koulutuksen tueksi. Malli tullaan kytkemään Teppo Lehtisen diplomityönä tehtyyn satamanosturi kontin simulointimalliin ja koko järjestelmän on tarkoitus toimia reaaliaikaisena.

Real-Time Simulation of Mobile and Industrial Machines Using the Multibody Simulation Approach

This thesis introduces a real-time simulation environment based on the multibody simulation approach. The environment consists of components that are used in conventional product development, including computer aided drawing, visualization, dynamic simulation and finite element software architecture, data transfer and haptics. These components are combined to perform as a coupled system on one platform. The environment is used to simulate mobile and industrial machines at different stages of a product life time. Consequently, the demands of the simulated scenarios vary. In this thesis, a real-time simulation environment based on the multibody approach is used to study a reel mechanism of a paper machine and a gantry crane. These case systems are used to demonstrate the usability of the real-time simulation environment for fault detection purposes and in the context of a training simulator. In order to describe the dynamical performance of a mobile or industrial machine, the nonlinear equations of motion must be defined. In this thesis, the dynamical behaviour of machines is modelled using the multibody simulation approach. A multibody system may consist of rigid and flexible bodies which are joined using kinematic joint constraints while force components are used to describe the actuators. The strength of multibody dynamics relies upon its ability to describe nonlinearities arising from wearing of the components, friction, large rotations or contact forces in a systematic manner. For this reason, the interfaces between subsystems such as mechanics, hydraulics and control systems of the mechatronic machine can be defined and analyzed in a straightforward manner.

Pukkinosturin pääkannattimen uudelleen muotoilu

Tässä työssä tutkittiin eräässä nosturipatentissa esitettyjä innovatiivisia pääkannatinratkaisuja suurissa telakkapukkinostureissa. Erityisesti keskityttiin tuulen paineesta tuleviin kuormituksiin ja niiden pienentämiseen. Käytännössä haluttiin selvittää kuinka nosturin rakennelaskelmissa käytettävää tuulen vastuskerrointa voitaisiin pienentää ja onko patentissa esitetty rakenne toteuttamiskelpoinen. Työssä myös vertaillaan yhden ja kahden pääkannattimen vahvuuksia sekä heikkouksia, koska Konecranes monien kilpailijoiden sijaan suosii yhdenpääkannattimen ratkaisua suurissa telakkapukkinostureissa. Innovatiivisessa telakkapukkinosturi patentissa nosturi on ideoitu kahdenpääkannattimen nosturiksi, jossa alavaunu on sijoitettu pääkannattimien väliin. Pääkannattimeen on suunniteltu erilliset hyllyt sekä ylä- että alavaunun kiskoille, joilla vaunut kulkevat. Patentissa esitettiin, että pääkannattimeen tehtävillä pyöristyksillä voitaisiin tuulen vastuskerrointa pienentää merkittävästi. Lujuuslaskelmien avulla saatiin selvitettyä pääkannattimen koko sekä painoarvio, jos käytettäisiin patentin esittämiä ratkaisuja. Näin saatiin selkeästi painavampi pääkannatin verrattuna nykyiseen Konecranesin käyttämään ratkaisuun. Lisäksi patentin esittämää profiili sekä Konecranesin nykyisin käyttämälle pääkannattimen profiilille tehtiin virtausanalyysit. Virtausanalyysin tuloksista ei voitu selvästi todeta, kumpi pääkannatin profiileista olisi parempi ratkaisu. Pyöristykset eivät näyttäneet tuovan selvää hyötyä vastuskertoimen pienentämiseen. Jatkotutkimuksena profiilien pienoismalleille tulisi tehdä tuulitunnelikokeet, jolla saataisiin tarkat sekä vertailu kelpoiset muotokertoimet tutkittaville pääkannattimen profiileille.

Improving Dynamic Characteristics of Open-loop Controlled Log Crane

The improvement of the dynamics of flexible manipulators like log cranes often requires advanced control methods. This thesis discusses the vibration problems in the cranes used in commercial forestry machines. Two control methods, adaptive filtering and semi-active damping, are presented. The adaptive filter uses a part of the lowest natural frequency of the crane as a filtering frequency. The payload estimation algorithm, filtering of control signal and algorithm for calculation of the lowest natural frequency of the crane are presented. The semi-active damping method is basedon pressure feedback. The pressure vibration, scaled with suitable gain, is added to the control signal of the valve of the lift cylinder to suppress vibrations. The adaptive filter cuts off high frequency impulses coming from the operatorand semi-active damping suppresses the crane?s oscillation, which is often caused by some external disturbance. In field tests performed on the crane, a correctly tuned (25 % tuning) adaptive filter reduced pressure vibration by 14-17 % and semi-active damping correspondingly by 21-43%. Applying of these methods require auxiliary transducers, installed in specific points in the crane, and electronically controlled directional control valves.

Effects of modern variable frequency drive on the reliability of an old crane induction motor

The work aims to analyze the possibilities of utilizing old crane driving AC induction motors in modern pulse-width-modulated variable frequency drives. Bearing currents and voltage stresses are the two main problems associated with modern IGBT inverters, and they may cause premature failure of an old induction motor. The origins of these two problems are studied. An analysis of the mechanism of bearing failure is proposed. Certain types of bearing currents are considered in detail. The most effective and economical means are chosen for bearing currents mitigation. Transient phenomena of cables and mechanism of over voltages occurring at motor terminals are studied in the work. The weakest places of the stator winding insulation system are shown and recommendations are given considering the mitigation of voltage stresses. Only the most appropriate and cost effective preventative methods are chosen for old motor drives. Rewinding of old motors is also considered.

Technology roadmap for new sales support and management system for crane manufacturing company

Sales configurators are essential tools for companies that offer complicated case specifically crafted products for customers. Most sophisticated of them are able to design an entire end product on the fly according to given constraints, calculate price for the offer and move the order into production. This thesis covers a sales configurator acquisition project in a large industrial company that offers cranes for its customers. The study spans the preliminary stages of a large-scale software purchase project starting from the specification of problem domain and ending up presenting the most viable software solution that fulfils the requirements for the new system. The project consists of mapping usage environment, use cases, and collecting requirements that are expected from the new system. The collected requirements involve fitting the new sales system into enterprise application infrastructure, mitigating the risks involved in the project and specifying new features to the application whilst preserving all of the admired features of the old sales system currently used in the company. The collected requirements were presented to a number of different sales software vendors who were asked to provide solution suggestions that would fulfil all the demands. All of the received solution proposals were exposed to an evaluation to determine the most feasible solutions, and the construction of evaluation criteria itself was a part of the study. The final outcome of this study is a short-list of the most feasible sales configurator solutions together with a description of how software purchase process in large enterprises work, and which aspects should be paid attention in large projects of similar kind.

Trolley R&D project for a small portal log yard crane

This master’s thesis was done for Andritz Inc. Atlanta Georgia. The purpose of the thesis was to develop a new trolley for a small portal log yard crane. In the beginning of the thesis the basic principles of the systematic design processes have been described, along which the design work of the trolley has proceeded. The second literature part consists of the design and dimensioning of the welded steel structures under fatigue loading. The design work of the trolley consists of the engineering and the selection of the mechanical components and the design of the load carrying structure for the trolley. The realization of the steel structure of the trolley is based on the fatigue and static dimensioning. The fatigue dimensioning is grounded in the life expectations estimated for the trolley and the static dimensioning is based on the CMAA guidelines. The computer aided element method was utilized in the design of the steel structure. The effective notch method and the hot spot method were used in the fatigue calculations. The trolley structure was carried out by using the sheet metal parts in order to manufacture the structure as effective and low cost way as possible. The corner stone of the dimensioning of the trolley structure was the utilization of the open profiles made of welded or cold formed sheet metals, which provide better weldability, weld inspection, access for repairs and corrosion protection. As a last part of the thesis a new trolley traveling system was developed. The distribution of the wheel loads of the trolley bogies on the main girder was also studied, which led to an innovative suspension arrangement between the trolley leg and the bogie. The new bogie solution increases the service life of the main girder of the crane and improves the stability of the bogies. The outcome of the thesis is an excellent trolley structure from the weight and the service life point of view.

Compliance of crane electrics with electrical safety standards and codes

Master’s thesis focuses on the questions of crane electrics compliance with electrical safety standards. Overview and short comparison of the world’s effective standards in the field is made in order to understand their demands. Basic concepts of a proper electrical circuit design are presented. Characteristics, construction and operation principles of overcurrent protective devices are studied in details. Electrics of the basic crane is designed according to the assumed customer’s demands, compliance with the requirements of the standards is checked. Solutions to achieve better compliance in some issues are proposed. Accent is made on the National Electrical Code (NEC) and standards by Underwriters Laboratories (UL) latests demands. Requirements of the International Electrotechnical Commission (IEC) are also taken into account.

Embedded controller system in crane application

The thesis studies possibility of using embedded controller in a crane application and furthermore defines requirements when designing such a controller. Basic crane control architectures are considered and compared. Then embedded controller product life cycle is described: considering such issues like microcontroller selection, software/hardware design and application development tools. Finally, available embedded controller is described and used for implementing crane control.

Welding development of crane main girder

Konecranes Corporation manufactures huge steel structures in 16 factories worldwide, in which the environment and quality varies. The company has a desire to achieve the same weld quality in each factory, regardless of the manufacturing place. The main subject of this master’s thesis was to develop the present box girder crane welding process, submerged arc welding and especially the fillet welding. Throughput time and manufacturing costs can be decreased by welding the full penetration fillet weld without a bevel, changing present groove types for more appropriate ones and by achieving the desired weld quality on the first time. Welding experiments of longitudinal fillet welding were made according to the present challenges, which the manufacturing process is facing. In longitudinal fillet welding tests the main focus was to achieve full penetration fillet weld for 6, 8 and 10 millimeters thick web plates with single and twin wire submerged arc welding. Full penetration was achieved with all the material thicknesses, both with single and twin wire submerged arc welding processes. The main problem concerning the weld was undercutting and shape of the weld bead. The question about insufficiency of presently used power sources with twin wire was risen up during testing, due to the thicknesses that require high welding current. Bigger power source is required when box girders are welded nonstop, if twin wire is used. For single wire process the penetration was achieved with significantly less amperage than with twin wire.

Taxonomy, species richness and biogeography of Finnish crane flies (Diptera, Tipuloidea).

Biodiversity is unequally spread throughout terrestrial ecosystems. The highest species richness of animals and plants is encountered around the Equator, and naturalists observe a decrease in the number of creatures with increasing latitude. Some animal groups, however, display an anomalous species richness pattern, but these are exceptions to the general rule. Crane flies (Diptera, Tipuloidea) are small to large sized, non-biting nematoceran insects, being mainly associated with moist environments. The species richness of crane flies is highest in the tropics, but these insects are species rich and abundant in all biogeographic realms, boreal and arctic biomes included. The phylogeny and systematics of crane flies are still at an early stage and somewhat controversial. New species are constantly discovered even from temperate Europe, faunistically the best known continent. Crane flies have been rather neglected group of insects in Finland. The history of Finnish crane fly taxonomy and faunistics started in 1907, the year when Carl Lundström published his two first articles on tipuloids. Within roughly 100 years there have been only a handful of entomologists studying the Finnish fauna, and the species richness and natural history of these flies have remained poorly understood and mapped. The aim of this thesis is to clarify the taxonomy of Finnish crane flies, present an updated and annotated list of species and seek patterns in regional species richness and assemblage composition. Tipula stackelbergi Alexander has been revised (I). This species was elevated to a species rank from a subspecific rank under T. pruinosa Wiedemann and T. stackelbergi was also deleted from the list of European crane flies. Two new synonyms were found: T. subpruinosa Mannheims is a junior synonym of T. freyana Lackschewitz and T. usuriensis Alexander is a junior synonym of T. pruinosa. A new species Tipula recondita Pilipenko & Salmela has been described (II). Both morphology and COI (mtDNA) sequences were used in the assessment of the status of the species. The new species is highly disjunct, known from Finland and Russian Far East. A list of Finnish crane flies was presented, including the presence of species in the Finnish biogeographical provinces (III). A total of twenty-four species were formally reported for the first time from Finland and twenty-two previously reported species were deleted from the list. A short historical review on the studies of Finnish crane flies has been provided. The current list of Finnish species consists of 338 crane flies (IV, Appendix I). Species richness of all species and saproxylic/fungivorous species is negatively correlated with latitude, but mire-dwelling species show a reversed species richness gradient (i.e. an increase in the number of species toward north). Provincial assemblages displayed a strong latitudinal gradient and faunistic distance increased with increasing geographical distance apart of the provinces. Nearly half (48 %) of the Finnish crane flies are Trans-Palaearctic, roughly one-third (34 %) are West Palaearctic and only 16 and 2 % are Holarctic and Fennoscandian, respectively. Due to the legacy of Pleistocene glaciations, endemic Fennoscandian species are problematic and it is thus concluded that there are probably no true endemic crane flies in this region. Finally, there are probably species living within Finnish borders that have hitherto remained unnoticed. Based on subjective assessment, the number of “true” (i.e. recorded + unknown species) species count of Finnish crane flies is at minimum 350.

Intelligent mapping of stresses in a hydraulic crane

Continuous loading and unloading can cause breakdown of cranes. In seeking solution to this problem, the use of an intelligent control system for improving the fatigue life of cranes in the control of mechatronics has been under study since 1994. This research focuses on the use of neural networks as possibilities of developing algorithm to map stresses on a crane. The intelligent algorithm was designed to be a part of the system of a crane, the design process started with solid works, ANSYS and co-simulation using MSc Adams software which was incorporated in MATLAB-Simulink and finally MATLAB neural network (NN) for the optimization process. The flexibility of the boom accounted for the accuracy of the maximum stress results in the ADAMS model. The flexibility created in ANSYS produced more accurate results compared to the flexibility model in ADAMS/View using discrete link. The compatibility between.ADAMS and ANSYS softwares was paramount in the efficiency and the accuracy of the results. Von Mises stresses analysis was more suitable for this thesis work because the hydraulic boom was made from construction steel FE-510 of steel grade S355 with yield strength of 355MPa. Von Mises theory was good for further analysis due to ductility of the material and the repeated tensile and shear loading. Neural network predictions for the maximum stresses were then compared with the co-simulation results for accuracy, and the comparison showed that the results obtained from neural network model were sufficiently accurate in predicting the maximum stresses on the boom than co-simulation.