gaining efficiency in container handling operation
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Seminar Nasional Teori dan Aplikasi Teknologi Kelautan (SENTA 2012) 5 Desember, 2012, Surabaya, Indonesia
P. HANGGAGraduate School of Engineering, Kyushu UniversityDepartment of Maritime Transportation, ITS - Surabaya
T. SHINODADepartment of Marine Systems Engineering, Kyushu University
GAINING EFFICIENCY IN CONTAINER HANDLING OPERATION WITH REGENERATIVE POWER CHARGING SYSTEM
Climate change issue Container terminal operator need to come up with ideas Some handling equipment are used more frequently than the other
Crucial question :
How is environment-friendly technology has been applied?Which part of operation need attention?
How to measure the implementation?
Background
Page 2
Application : Hybrid Straddle Carrier
Page 3
RechargableBattery
Engine Generator
Inverter fortraveling(Left side)
Inverter fortraveling(Right side)
Braking unit Resistor
Inverterfor hoist
Travelingmotor(Right side)
Travelingmotor(Left side)
Hoist motorConverter
Diesel-electric S/C system diagram
Type : Diesel Electric with inverterAcceleration Capability : 30 seconds to reach 20 km/hTraveling capability : 23 km/h (with load),
27 km/h (without load)Hoist/Lowering speed : 280 mm/sec (with load)
400 mm/sec (without load)Other characteristic : Equipped with battery to store
regenerative energy by motion
• Straddle Carrier is the most commonly used for In-Yard operation in medium and large sized container terminal
• Widely used in several major port in USA, Korea, Germany and Japan as a complement to conventional diesel-mechanic S.C
Diesel Electric Type
Engine
A.C Generator
Inverter
Motor
Reduction
Wheel
Diesel Mechanical Type
Engine
Torque Converter
Transmission
Differential
Reduction
Wheel
PART I : METHODOLOGY
1. Designing S/C movement pattern2. Installation of electric data logger in S/C
3. Conversion of electric data into real value
How to measure the impacts of Hybrid S/C operation in energy saving Movement pattern were designed for experimental purposes
Motions of S/C categories (with load and without load)Hoisting phaseStarting phaseCruising phaseBraking phaseLowering phase
Designing The Experiments (Movement pattern)
Page 5
Traveling stateHandling state
Measuring the electrical output easily separate the output from various range of machinery equipment
Designing The Experiments (Data logger)
Page 6
Voltage data logger is installed in the S/C Output performances from continuous
and temporal activity is are recorded in data logger (HIOKI LR8400-20 )
Recorded data in voltage is exported to CSV data
SCV data is converted into real value and analysed
‐2.00
‐1.00
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1.00
2.00
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0 20 40 60 80 100 120
Scale of M
easuerem
ent (Volt)
Time (s)
Battery
Fuel Cons.
Generator Engine Speed
Traveling Motor Speed
STARTING PHASE
‐6.00
‐4.00
‐2.00
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2.00
4.00
6.00
8.00
10.00
20 40 60 80 100 120 140 160
Scale of M
easuerem
ent (Volt)
Time (s)
Battery Fuel Cons.Traveling Motor Speed Generator Engine Speed
CRUISING PHASE‐1.00
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1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41
Scale of M
easuerem
ent (Volt)
Time (s)
Brake pedal angle
Battery
Fuel Cons.
Traveling Motor Speed
Generator Engine Speed
BRAKING PHASE
Example of Waveform Analysis
Page 7
Note : Recorded Time interval = 0.2 seconds, Output = voltage resolution of 0.5 mV in the 10 V
Cursor for partial measurement
Traveling motor speed
Fuel Cons.
Generator Engine Speed
Battery
Calculation Output of Partial Measurement
Lifting Motor Speed
Lifting Traveling
Converted the waveform to show the relation in real value and divided the analysis into lifting & traveling process Measured the value for each channel output by ACV (average channel value)
Data Conversion to Real Value
Page 8
Remarks:n = total number of data itemsdi = data on channel number i∆t = sampling period
Integration of shaded portionsAveraging value
Converting value
M = Max measurement rangeO = Max output voltageACV = Average Channel Value
PART II : MOVEMENT ANALYSIS
1. Traveling Analysis2. Hoisting/Lowering Analysis
3 kinds of traveling experiments were conducted- Exp_1 is for changing in travel speed - Exp_2 is for changing in acceleration but maintain traveling motor speed with a container load- Exp_3 is similar with Exp_2 only without a container load to S/C.
Traveling Analysis – Fuel Consumption
Page 10
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
100 150 200 250 300 350 400 450 500 550 600 650
Fuel
Con
s (L
/h)
Travelling Motor Speed (RPM)
Starting_Exp_2_Load
Cruising_Exp_2_Load
Braking_Exp_2_Load
Starting_Exp_1
Cruising_Exp_1
Braking_Exp_1
Starting_Exp_2_No_Load
Cruising_Exp_2_No_Load
Braking_Exp_2_No_LoadBraking
Effect of driver action on throttle to maintain speed
Effect of load shows difference on fuel consumption except for braking phase
Regenerative energy : energy recovery mechanism which slows a vehicle or object down by converting its kinetic energy into electric power and the stored saved in a storage battery and used later to power the motor for another use, such as hoisting, powering air conditioner in the control room and lights.
Traveling Analysis – Regenerative Energy
Page 11
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
0 100 200 300 400 500 600 700 800 900
Bat
tery
Usa
ge (-
)/ C
harg
ing
(+) (
A)
Travelling Motor Speed (RPM)
Starting_Exp_2_Load
Cruising_Exp_2_Load
Braking_Exp_2_Load
Starting_Exp_1
Cruising_Exp_1
Braking_Exp_1
Starting_Exp_2_No_Load
Cruising_Exp_2_No_Load
Braking_Exp_2_No_Load
Charging
Usage
Gain energy in cruising phase.Hypothesis:-push/pull action to throttle-effect of inertia-vibration of load
Experiments shows good agreement in annotating the relation between braking and gaining energy
Impact of Traveling Speed (Pre-Analysis)
Page 12
STARTING PHASE CRUISING PHASE
BRAKING PHASEStarting Cruising Braking Total
10 -6.4 2.0 1.4 -3.020 -2.7 2.2 4.6 4.025 -7.0 5.6 7.8 6.310 -3.2 2.7 4.7 4.320 -0.7 2.7 6.3 8.325 -8.8 5.1 9.2 5.610 -5.4 1.7 1.8 -1.920 -1.4 2.3 3.1 3.925 -7.2 4.6 9.0 6.4
置き①
置き②
置き③
Speed (km/h)Pattern
Battery Usage (-)/ Charge (+) (A)
Higher Traveling Speed produce more battery charging, mainly during braking
Charging
Usage
Charging
Measuring correlation between lifting speed and fuel consumption as well as to battery usage/charging with variability in hoisting speed and stacking position
Hoisting/Lowering Analysis
Page 13
‐8.00
‐6.00
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2.00
4.00
6.00
8.00
10.00
0 5 10 15 20 25 30 35 40 45
Scale of M
easuerem
ent (Vo
lt)
Time (s)
Battery Lifting Motor Speed Fuel Cons.
‐8.00
‐7.00
‐6.00
‐5.00
‐4.00
‐3.00
‐2.00
‐1.00
‐
1.00
2.00
3.00
4.00
0 5 10 15 20 25 30 35
Scale
of M
easuerem
ent (Vo
lt)
Time (s)
Battery Lifting Motor Speed Fuel Cons.
1st HOISTING
LOWERING
2nd HoistingAdjustment to Container Stack
2nd Hoisting
1st Hoisting
1st Hoisting
2nd HOISTING
0.00
1.00
2.00
3.00
4.00
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7.00
8.00
9.00
-250 -150 -50 50 150 250 350 450 550 650
Fuel
Con
s (l/
h)
Lifting Speed (rpm)
Lowering
First Hoisting
Second Hoisting
Lowering and Hoisting operation shows good agreement with normal performance parameter and assumption
Hoisting/Lowering Analysis – Fuel Consumption
Page 14
Lowering 1st Hoisting 2nd Hoisting
Intriguing phenomena : Increase in fuel cons during 2nd Hoisting
Hypothesis : Data might be distorted as 2nd Hoisting is conducted while traveling
2nd Hoisting
1st Hoisting
Strong correlation between lifting speed and alternate performance parameter of battery utilization
Future issue : Can regenerative energy (lowering) be used to compensate energy usage during hoisting?
Hoisting/Lowering Analysis – Regenerative Energy
Page 15
y = ‐0.095x ‐ 1.246R² = 0.771
y = ‐0.092x ‐ 1.058R² = 0.993
‐20.00
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0.00
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10.00
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‐250.00 ‐200.00 ‐150.00 ‐100.00 ‐50.00 ‐ 50.00 100.00 150.00 200.00
Battery U
sage
(A)
Lifting Speed (RPM)
Lifting Up
Lifting Down
Lowering
Hoisting
Charging
Usage
energy are regenerated by lowering operation
This preliminary study proposes methodology to assess and measure the efficiency of hybrid straddle carrier (Hybrid S/C) in the form of fuel consumption and gained regenerative energy by motions.- Combination of data logging instrument, logger utility software and spreadsheet is
used to capture electronic output- Electric data is successfully converted using the proposed ACV calculation
Analyzed data show good agreements in relation between traveling speed / lifting speed with either fuel consumption and battery charging- Regenerative energy can be gained through the following operation
- Traveling - Braking phase with more traveling speed- Lowering operation
Future research will focus on :- Assessing appropriate driving method and movement cycle (GPS and Video
Camera)- Comparing operational performance of Hybrid S/C and Conventional S/C
Conclusion
Page 16
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