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EN
Identification of an accurate and simple model of a complex underactuated crane dynamics for varying operational conditions is a crucial step towards designing and implementation of real-time monitoring and control systems to enhance crane safety and operational efficiency. This paper considers a non-parametric data-driven identification of an overhead crane dynamics using symbolic regression techniques to find compromise between model complexity and predicted output accuracy. A grammar-guided genetic programming (G3P) combined with l0 sparse regression is applied with two different variants of grammar to automatically construct a nonlinear autoregressive exogenous (NARX) model of different forms, termed extended and polynomial models. The proposed method is compared with a linear parameter-varying ARX (LPV-ARX) model. Identification is performed on experimental data obtained from a laboratory-scale overhead crane. The identified models are compared in terms of prediction accuracy, model’s complexity measured using number of model terms, and execution time. The regularized G3P method outperformed the LPV-ARX model in terms of model predictive output accuracy. The G3P with the extended grammar resulted in more accurate crane velocity prediction models than the models with the polynomial grammar. The payload sway prediction model with the polynomial grammar was less complex in all measured metrics while there was no statistical significance in the accuracy when compared to the models with extended grammar.
EN
The girders of the crane or the jib of the crane are situated at high heights, which prevents the free and continuous measurement of their stresses. Unfortunately, these elements are most exposed to high stress and damage during their use. The article presents the research methodology with the use of the magnetic metal memory method of the overhead crane girders. Diagnostic tests utilizing the crane movement mechanisms to move the magnetometric sensor along the tested surface of the girder were proposed to improve and automate measurements. The article attempts to investigate effect of the device load and speed of Hp measurements with a magnetometric sensor.
PL
Dźwigary suwnicy usytuowane są na dużych wysokościach, co uniemożliwia swobodny i ciągły pomiar ich naprężeń. Niestety elementy te są najbardziej narażone na duże obciążenia i uszkodzenia podczas ich użytkowania. W artykule przedstawiono metodykę badań z wykorzystaniem metody magnetycznej pamięci metalowej dźwigarów suwnic. Zaproponowano badania diagnostyczne wykorzystujące mechanizmy ruchu suwnic (wózek wciągarki) do przemieszczania czujnika magnetometrycznego po badanej powierzchni dźwigara w celu usprawnienia i zautomatyzowania pomiarów. W artykule podjęto próbę zbadania wpływu obciążenia urządzenia i prędkości pomiarów Hp za pomocą czujnika magnetometrycznego.
3
Content available remote Oprogramowanie do symulatora wirtualnej suwnicy
PL
Przedstawiono najistotniejsze elementy nowego oprogramowania komputerowego do zmodyfikowanego symulatora suwnicy. Krótko scharakteryzowano sposób komunikacji użytkownika symulatora z obiektami suwnicy oraz sposób wyświetlania obrazu ze środowiska. Przedstawione oprogramowanie jest istotnym elementem modyfikowanego symulatora, gdyż to od niego zależy realizm i płynność symulacji prowadzonej przez użytkownika.
EN
The article presents the most important elements of a new computer software functioning in a modified overhead crane simulator. The article briefly defines the ways of communication between the overhead crane simulator’s user and the overhead crane objects and display of images from the virtual environment. The software hereby presented is a crucial element of the modified simulator, as it impacts realism and fluency of the simulation process conducted by the user of the simulator.
EN
The safety and efficiency of material handling systems involve periodical inspections and evaluation of transportation device technical conditions. That is particularly important in case of industrial cranes, since they are subjected to a large impact load and mechanical stresses acting on the crane's structure and equipment. The paper considers the possibility of a crane structure inspection using the metal magnetic memory (MMM) method. As an advanced non-destructive technique, this method can be employed for inspection of crane structure during operation, which leads to reduce the down time costs and increase the safety confidence in the monitoring process. The MMM technique is effective for early identification of the possible defect location and detecting the micro-damage in ferromagnetic structures through detecting the stress concentration areas. The basic principle of MMM method is the self-magnetic flux leakage signal that correlates with the degree of stress concentration. This method allows detecting early damage of ferromagnetic material through performing measurement in the earth magnetic field, without the use of a special magnetizing device. The paper presents the experimental results carried out on the double-girder overhead travelling crane with hoisting capacity 1000 kg. The influence of the load variation and duration time on the intensity of the self-magnetic flux leakage signal is analysed and discussed.
EN
Material handling systems, as an important part of different type of manufacturing processes, face the same challenges as manufacturing industries pushed nowadays forward by innovative ideas and technologies to the next level loudly announced as industry 4.0. Development of the next generation of automated manufacturing systems involves advanced approaches to material handling systems design and their close integration with the higher levels of manufacturing and production control and management, e.g. manufacturing execution systems (MES), enterprise resource planning (ERP). In the presence of increasing demands for manufacturing process optimization, the role of supervisory level of material handling systems is much more advanced today, ensuring not only data acquisition, visualization, monitoring, supervisory control, as well as synchronization with the higher control levels (FEM, ERP), but also providing functionality for supporting maintenance and decision-making processes to reduce downtimes, operations and maintenance costs. The article deals with the integration of control and maintenance functions in the hierarchical control system of a crane. The supervisory system for supporting control and proactive maintenance is prototyped at the laboratory overhead travelling crane. The article presents the controlmeasurement equipment and intelligent software tools implemented in the supervisory control and data acquisition (SCADA) system to aid decision-making process in proactive maintenance. The overview of the main components of the supervisory control and proactive maintenance subsystems is provided, and their respective role in control, supervision, and proactive maintenance is explained. The crane’s supervisory control includes the stereovision-based subsystem applied to identify the crane’s transportation workspace, determine the safety and time-optimal point-to-point trajectory of a payload. The proactive maintenance module consists of the human machine interface (HMI) supporting decision-making process, intelligent tools for upcoming downtime/ failure prediction, and the crane’s girder inspection using the metal magnetic memory technique.
EN
We introduce a control strategy to solve the regulation control problem, from the perspective of trajectory planning, for an uncertain 3D overhead crane. The proposed solution was developed based on an adaptive control approach that takes advantage of the passivity properties found in this kind of systems. We use a trajectory planning approach to preserve the accelerations and velocities inside of realistic ranges, to maintaining the payload movements as close as possible to the origin. To this end, we carefully chose a suitable S-curve based on the Bezier spline, which allows us to efficiently handle the load translation problem, considerably reducing the load oscillations. To perform the convergence analysis, we applied the traditional Lyapunov theory, together with Barbalat’s lemma. We assess the effectiveness of our control strategy with convincing numerical simulations.
PL
Przedstawiono najważniejsze wytyczne do budowy symulatora suwnicy w wersji przenośnej. Symulator powstanie na bazie laboratoryjnego prototypu opracowanego w CIOP-PIB. W artykule zaprezentowano również założenia do modyfikacji symulatora w aspekcie zgodności z minimalnymi wymaganiami programu szkoleniowego opracowanego przez UDT. Urządzenie umożliwi wspomaganie praktycznego szkolenia operatorów suwnic prowadzonego przez ośrodki szkoleniowe.
EN
Presented are crucial indications to build a mobile crane simulator. The simulator will be build on the basis of a laboratory version of crane simulator prototype created in CIOP-PIB. The article also presents principles of its modifications concerning its compatibility with minimal requirements of training programme by UDT. The simulator will allow the supported of practical training of crane operators conducted by training centers.
EN
The dynamic model of a long payload motion in vertical plane containing the payload axis, suspended on two ropes on two co-operating winches is presented in the paper. The method of mathematical description of the model and its solving method are presented. The model is preliminary verified by comparison between simulation and experimental tests of payload oscillations done for immovable position of ropes suspension points. The results of verification and other simulation tests are presented as well.
EN
Reduction of transient and residual payload swing in crane systems is a key control objective to guarantee the safety and efficiency requirements. The fast and accurate payload positioning with swing suppression within the acceptable range to avoid accidents is the challenging problem due to the underactuated nature of crane systems. Since the actuated motion causes undesirable payload swing, the efficient control method should be developed to ensure fast and precise payload positioning and meet the safety requirements. The standard model predictive control method is not suitable for underactuated mechanical systems. In this article the two, soft and hard-constrained antisway predictive control strategies are compared in experiments carried out on a laboratory scaled overhead travelling crane. The both control schemes are developed based on the linear parameter-varying model of a planar crane system. The recursive least square algorithm with parameter projection is used to estimate the model parameters. The soft-constrained optimization problem is solved using the particle swarm optimization algorithm with the inertia weight linearly decreasing during iteration. The metaheuristic optimizer is applied to determine the sequence of optimal control increments subject to the hard constraint of the control input and soft constraint of the payload swing. The comparison of hard and soft-constrained predictive controllers is carried out on a laboratory stand for different payload deflection constraints.
EN
This article presents three independent concepts of use high-level technique with it adaptation and implementation concerning overhead travelling crane device type. The main objective of this statement applies a solution for device workspace mapping, payload anti-sway control techniques strategy use and possibility of reliable steel construction health monitoring. In the first chapter, the vision system technology for obstacle in workspace visualization was presented. The main idea depends on use stereovision system with sets of camera mounted under the crane’s trolley which movement with the crane shifts. The stereo pictures, after digital processing, were used for develop so-called dense disparity map. The described architecture allows achieving information about device surroundings and obstacle position in the workspace. As the final result was presented three-dimensional map of the device workspace with obtained result accuracy discussion. The second type of described problem developed in chapter two concern the crane control methodology of designing the anti-sway system for payload stabilizing during the crane movement. The oscillation of a payload adversely affects the accuracy of performed transportation tasks and may present a safety hazard to employees, transferred payload and surrounding objects. The invented and described method mainly base on so-called soft computing methods. The next part of the article-focused attention of problem concerning health monitoring cranes construction as other equipment’s as well. The problem concerns usually the large industrial cranes carry out transportation operations in the presence of a large impact load and mechanical stresses acting overall crane’s structure. The safety and efficiency of crane operations can be improved through providing the continuous structural health monitoring as well in on-line and off-line mode. The main idea allows using Metal Magnetic Memory technique for supervising and estimating steel construction actual condition. All tests and considerations were conducted on the scaled physical model of overhead travelling crane with hosting capability 150 kg
11
Content available Robust predictive control of an overhead crane
EN
The predictive control scheme is developed for an overhead crane using the generalized predictive procedure applied for the discrete time linear parameter-varying model of a crane dynamic. The robust control technique is developed with respect to the constraints of sway angle of a payload and control input signal. The two predictive strategies are presented and compared experimentally. In the first predictive control scheme, the online estimation of the parameters of a crane dynamic model is performed using the recursive least square algorithm. The second approach is a sensorless anti-sway control strategy. The sway angle feedback signal is estimated by a linear parameter-varying model of an unactuated pendulum system with the parameters interpolated using a quasi-linear fuzzy model designed through utilizing the P1-TS fuzzy theory. The fuzzy interpolator is applied to approximate the parameters of a crane discrete-time dynamic model within the range of scheduling variables changes: the rope length and mass of a payload. The experiments carried out on a laboratory scaled overhead crane confirmed effectiveness and feasibility of the proposed solutions. The implementation of control systems was performed using the PAC system with RX3i controller. The series of experiments carried out for different operating points proved robustness of the control approaches presented in the article.
12
Content available remote Problemy dotyczące eksploatacji konstrukcji wsporczych suwnic pomostowych
PL
W artykule przedstawiono problemy związane z eksploatacją i oceną trwałości konstrukcji wsporczych suwnic pomostowych, na przykładzie różnych przypadków uszkodzeń lub nadmiernych drgań rzeczywistych konstrukcji. Przeanalizowano m.in. przykład estakady, przy projektowaniu której przyjęto ryzykowne założenia obliczeniowe w celu zmniejszenia zużycia materiału, co doprowadziło do potrzeby wzmocnienia konstrukcji. Wspomniano również o zagadnieniach zmęczenia konstrukcji.
EN
The problems related to the exploitation as well as to the assessment of the durability of the overhead cranes supporting structures based on the various examples of their failures or excessive vibration has been presented in this article. The example of the crane runway designed very sparingly (based on very tentative calculations to reduce material consumption, which resulted in the need for reinforcement) has been analyzed. The issues of the construction fatigue life have been also mentioned.
EN
The large industrial cranes carry out transportation operations in the presence of a large impact load and mechanical stresses acting on the crane’s structure. The safety and efficiency of crane operations can be improved through providing the continuous structural health monitoring of crane’s equipment and components. Advanced non-destructive techniques can be employed for inspection of cranes during operation, that leads to reduce the down time costs and increase the safety confidence in the monitoring process. Magnetic flux leakage methods of non-destructive inspection are widely utilized in identification of damaged areas in steel structures. However, the traditional magnetic flux leakage techniques are more appropriate in detecting cracks, but not sensitive to the detection of micro-defects. Metal magnetic memory is a relatively novel method of detecting the micro-damage in ferro-magnets due to the stress concentration. This method proved its effectiveness in early identification of the possible defect location. However, the method is preferable to off-line inspection due to the presence of operational variations in on-line measurements that can cause false indications of damage. In this paper, the problem of continuous inspection of crane’s frame using the metal magnetic memory method is considered. The influence of operational variations on the self-magnetic flux leakage signal is investigated and quantitatively analysed based on the experimental results obtained on a laboratory-scaled overhead travelling crane.
EN
The article presents a simulator used for interactive simulation of virtual overhead crane use and the results of studies performed to assess its functionality in simulating the sense of touch. The simulator was created using Virtual Reality techniques and is operated by two real steering panels. The prepared simulator was used for tests in which overhead crane operators and training instructors participated. The study enabled the authors to assess the usefulness of the simulator in the training of future overhead crane operators and the possibility to simulate the sense of touch. The results of tests showed that training with the use of the overhead crane simulator will improve the practical skills of future operators, and the simulator is a useful tool for staging possible accidents that cannot be performed in reality for safety reasons.
PL
W artykule przedstawiono charakterystykę symulatora do interaktywnej symulacji pr o-cesu użytkowania wirtualnej suwnicy oraz wyniki z przeprowadzonych testów sprawdzających jego funkcjonalność w aspekcie symulacji wrażenia dotyku. Symulator wykonano w technice wirtualnej rzeczywistości VR i jest sterowany za pomocą dwóch rzeczywistych paneli sterowniczych. Tak opracowany symulator został użyty w testach z udziałem operatorów suwnic i instruktorów szkoleniowych. Test pozwolił ocenić przydatność wykonanego symulatora w szkoleniach przyszłych operatorów suwnic oraz w symulowaniu wrażenia dotyku. Wyniki przeprowadzonego szkolenia wskazują, że szkolenia z użyciem symulatora suwnicy pozwolą na zwiększenie umiejętności praktycznych przyszłych operatorów, a także prezentowanie inscenizowanych zdarzeń wypadkowych, których ze względów bezpieczeństwa nie można prowadzić w warunkach rzeczywistych.
15
Content available remote Stan techniczny stalowej hali przemysłowej a aspiracje jej użytkowników
PL
Przedmiotem artykułu jest analiza stanu technicznego konstrukcji stalowej hali przemysłowej zlokalizowanej w Chinach, której celem była ocena możliwości zamiany suwnic na nowe o większej nośności. W artykule przedstawiono ocenę stanu technicznego obiektu i analizę statyczno-wytrzymałościową.
EN
The subject of this paper is a technical state analysis of a steel structure of industrial hall located in China. The main purpose of the analysis was the assessment of possibility of overhead crane replacement with a new ones of increased capacities. In the paper the technical state assessment and static - strength analysis of the object was presented.
16
Content available remote Problemy eksploatacyjne podtorzy suwnicowych na terenach szkód górniczych
PL
W artykule przedstawiono problemy eksploatacyjne podtorzy suwnicowych w hali żelbetowej posadowionej na terenach szkód górniczych. Na podstawie inwentaryzacji geodezyjnej podtorzy suwnicowych sprawdzono ich prostoliniowość i możliwość rektyfikacji. Oceniono wpływ pomierzonych odchyłek na nośność podstawowych elementów konstrukcji wsporczej hali w aspekcie jej dalszej bezpiecznej eksploatacji.
EN
The paper presents exploitation problems of crane girders in seven bay industrial hall located on mining damage area. Detail geodesic checking was performed due to rectilinearity and possibility of corrections. The influence of imperfections and damages on the safety of structure was evaluated.
17
Content available Napędy przemiennikowe suwnicy chwytakowej
PL
W artykule opisano struktury i właściwości napędów mechanizmów suwnicy chwytakowej. Umożliwiają one przemieszczenie transportowanego elementu w trzech osiach: x (jazda mostem), y (jazda wózkiem) oraz z (podnoszenie - opuszczanie). Układy napędowe wyposażone są w silniki asynchroniczne klatkowe zasilane z przemienników częstotliwości. Sterowanie pracą suwnicy wspomagane jest sterownikiem PLC. Zamieszczono przebiegi czasowe podstawowych wielkości elektromechanicznych dla napędów suwnicy przy podnoszeniu i opuszczaniu ciężaru oraz podczas jego transportu poziomego wzdłuż osi x i y. Do rejestracji przebiegów wykorzystano oprogramowanie narzędziowe DriveWindow dedykowane do parametryzacji oraz monitorowania pracy przekształtnikowych układów napędowych firmy ABB.
EN
The paper describes the structure and properties of the overhead crane drives. They allow the movement of the transported item in three axes: x (driving the bridge), y (driving the trolley) and z (lifting - lowering). Drive systems are equipped with squirrel cage induction motors powered by frequency converters. Control of the crane is supported with PLC. The temporal waveforms of the basic quantities of electro-mechanical drives for lifting and lowering the weight and during its horizontal transport along the x and y axis are presented. DriveWindow software tool was used to record the signals. This software is dedicated to the parameterization and monitoring of the ABB drive systems.
Logistyka
|
2015
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nr 3
1994--2002, CD 1
PL
W pracy przedstawiono rozwiązanie umożliwiające ciągły pomiar odkształceń wybranej belki podsuwnicowej suwnicy pomostowej a tym samym monitorowanie bezpieczeństwa jej pracy. Przewidywany okres eksploatacji suwnicy wynosi zazwyczaj 30 lat. Jeżeli ten okres jest przekraczany, kluczową kwestią staje się zapewnienie bezpieczeństwa eksploatacyjnego. Oparte jest ono na systemie światłowodowym z interrogatorem optycznym i siatkami Bragg’a. Miejsce instalacji czujników światłowodowych wybrano na podstawie symulacji numerycznych belki kładki opartych na metodzie elementów skończonych. Przeprowadzono weryfikację otrzymanych wyników za pomocą metody tensometrii oporowej. Zaproponowano wykorzystanie wyników ciągłych pomiarów odkształceń konstrukcji suwnicy jako rzeczywistych warunków brzegowych (w rozwiązaniu zagadnienia odwrotnego) w symulacjach numerycznych MES umożliwiającymi analizę zachowania się całej konstrukcji.
EN
Footbridge is analyzed using Fiber Bragg Gratings sensors. The expected lifetime of the crane is usually 30 years. If this period is exceeded, it is crucial to ensure operational safety. The paper presents a solution for continuous measurement of deformations of selected beams of the footbridge, and thus monitor the safety of its work. It is based on a system of optical interrogator and fibre Bragg grating sensors . The place of installation of optic fibre sensors were chosen based on numerical simulations of the gantry beam, based on the finite element method. A verification of the obtained results was conducted with the method of resistive strain gauge and a new method of metal magnetic memory was used as well. Uncertainty had been determined using optical fibre sensors and resistive strain. The use of the results of continuous measurement of the deformation of the bridge as the actual boundary conditions (in solving the reverse issues) was proposed in numerical simulations and FEM, for the analysis of the behaviour of the whole structure.
PL
Opracowanie obejmuje zestawienie znanych rozwiązań materiałowych oraz metod ulepszania powierzchniowego kół jezdnych suwnic, celem wydłużenia ich czasu zdatności eksploatacyjnej. Omówiono stosowane metody regeneracji kół jezdnych technologią napawania. Stwierdzono, że odpowiednio dobrany materiał, obróbka powierzchniowa i regeneracja, umożliwiają wydłużenie czasu użytkowania kół jezdnych. Odpowiedni dobór materiałów na koła jezdne i technologii ich ulepszania i regeneracji, wpływają na zmniejszenie kosztów eksploatacji urządzenia. Regeneracja kół jezdnych techniką napawania staliwem węglowym i stopowym, pozwala uzyskać odpowiednie ich parametry użytkowe i żywotność. Artykuł ma charakter przeglądowy. Jego celem jest usystematyzowanie i przeprowadzenie syntezy istniejących rozwiązań w zakresie materiałów i technologii umożliwiających wydłużenie żywotności kół jezdnych suwnicy.
EN
The paper is reviewing and discuss a known materials and methods used in practice to improve the surface of crane wheels. The aim is to extend the operational suitability of their time. Also has been discussed the methods used to regenerate wheels surfacing technology. It was state, that choosing the appropriate material, surface treatment and recovery, it is possible to extend the operational use of wheels. Proper selection of materials for the wheels and their improvement and regeneration technologies, influence to reduce the cost of the device exploitation. Wheels regeneration with use the surfacing technique including carbon and alloy cast steel, allows for appropriate their performance and service life. Article has an overview character. Its purpose is to systematize and carry out the synthesis of existing solutions in the field of materials and technologies that allow the wheels extend the operation life of the crane.
EN
The method of controlling an overhead crane with respect to the variation of operating conditions and control constraints is developed using a model predictive control (MPC) and fuzzy interpolation applied in linear parameter varying (LPV) approach to crane dynamic modelling. The proposed control approach is based on the assumption that operating conditions vary within the known range of scheduling variables, and the parameters of a crane dynamic model can be interpolated by a quasi-linear fuzzy model designed through utilizing the P1-TS fuzzy theory. Hence, a crane dynamic is approximated through interpolation between a set of local linear models determined through identification experiments at the local operating points selected within the bounded intervals of scheduling variables. For the modelling assumptions, the control algorithm is developed based on a generalized predictive control (GPC) procedure taking into consideration the constraints on sway angle of a payload and control signal. Feasibility and applicability of the proposed control technique were confirmed during experiments carried out on a laboratory-scaled overhead crane. The results of experiments are presented and compared with performances of a fuzzy logic-based scheduling control scheme.
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