human/hardware-in-the-loop testbed of cargo transfer operations at sea dr. tom zhao mr. frank leban...
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![Page 1: Human/Hardware-in-the-Loop Testbed of Cargo Transfer Operations at Sea Dr. Tom Zhao Mr. Frank Leban BMT Designers & Planners NSWC Carderock Division Joint](https://reader035.vdocuments.site/reader035/viewer/2022062321/56649e855503460f94b86ec3/html5/thumbnails/1.jpg)
Human/Hardware-in-the-Loop Testbed
of Cargo Transfer Operations at Sea
Dr. Tom Zhao Mr. Frank Leban
BMT Designers & Planners NSWC Carderock Division
Joint Seabased Theatre Access Workshop February 8 ~ 10, 2005
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OutlineOutline Background
Testbed Development and Integration
– Software Architecture
– Subsystem Modules
– Integrated Virtual Environment
Uses of the Testbed
– Control System Performance
– Engineering Design and Evaluation
Summary & Discussion
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ONR funded an Advanced Technology Demonstration (ATD) of the Advanced Shipboard Crane Motion Control System (1999-2002)
• Demonstrated the feasibility of implementing a motion compensating control system on an existing crane
• Modern digital machinery controller installed to support computer interface (MacGREGOR CC2000)
• CC2000/Sandia National Lab algorithm combination = Pendulation Control System (PCS)
Pendulation Control System BackgroundPendulation Control System Background
Technology successfully demonstrated pier-side. Pendulation controlled. At-sea testing would be needed to explore full capability of PCS.
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Pendulation Control System BackgroundPendulation Control System Background
Pier-side testing of the
Pendulation Control System
on board the S.S. Flickertail
State at Cheatham
Annex in 2002.
1/16th-scale crane model
demonstrating motion
compensating control
algorithm developed by
Sandia National Laboratory
under ONR-funded ATD.
The S.S. Flickertail State, while moored skin-to-skin to the S.S. Cornhusker State, transfers a container using the Pendulation Control System.
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• JLOTS 04 New Horizons indicated that LO/LO throughput needs to be improved even in calm sea conditions. Too much time spent in connecting to and positioning containers on deck.
• Investigate alternative payload motion sensing technologies.
• Develop twin-, quad-, and team-mode (coordinated multi-crane lift) operation with PCS to support full utilization of crane capabilities.
• Investigate enhanced Crane Operator Display for situational awareness and PCS status monitoring.
Further PCS Development & Technology Further PCS Development & Technology InitiativesInitiatives
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Testbed Project ObjectiveTestbed Project ObjectiveTo build a physics-based, high fidelity testbed for engineering testing and evaluation of emerging concepts in cargo transfer operations at sea
Desired Capabilities - • Hydrodynamics simulation of multiple vessels
• Ship-mounted crane machinery dynamics
• Advanced crane control systems
• Mooring lines and fenders
• Hardware-in-the-loop simulations
• Human-in-the-loop simulations
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Software ArchitectureSoftware Architecture PC-based, real-time simulation system
Software and hardware subsystem modules
Open-architecture and object-oriented design
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Crane Machinery DynamicsCrane Machinery Dynamics
Hagglunds TG3637
pedestal crane in the
SS Flickertail State
Modeled as a rigid
multibody system
Pulled by hoisting,
luffing, tagline, and
liftline cables
Slew motion and twin
crane rotation
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The Equations of MotionThe Equations of Motion
0;,
;,,;,;,
,
,
ptq
ptqqKptquptqM
qDqtqCuTq
A set of differential-algebraic equations based
on Lagrangian Mechanics
Using an efficient O(n) formulation to achieve
real-time computation performance
Requires <10% CPU power of Intel Pentium 4
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Winch Actuator DynamicsWinch Actuator Dynamics Internal-state based, non-lumped drive system
models to represent winch actuator dynamics
Useful information for sensory feedback design
Validated against field test data
Control card
Joystickcommands
(V)
current
solenoids Pump/Motor
(A)
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Drive System Model ValidationDrive System Model Validation
0 5 10 15 20 25 30 35-150
-100
-50
0
50
100
150
Time (sec)
Hois
t W
inch
Rate
(d
eg
/s)
Measured and Simulated Responses (6.5v)
Hagglunds Test Data (hoist66)
Model Output
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Coupled Ship MotionsCoupled Ship Motions
Real-time computations in time-domain
Multiple vessel configuration at very close
proximity at slow speed of advance
Coupled hydrodynamics
}{, othersWD
t
FFdtK
xCdxtKxA
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Time-Domain InteractionsTime-Domain Interactions Other external forces include current, wind, wave-
drift, mooring lines, fenders, anchor/chain, and
viscous roll damping
Specify one or two wave spectra simultaneously
(Bretschneider, Ochi-Hubble, JONSWAP)
“shielding algorithm” based on theory of turbulent wakes
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Hydro Implementation ComparisonHydro Implementation Comparison
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0.0 0.5 1.0 1.5 2.0 2.5
Lighter surge, sway, heave
Lines: Frequency domainPoints: Time domain
(rad/sec)
Mo
tio
n A
mp
/Wav
e A
mp
surge
heave
sway
0.0
0.5
1.0
1.5
2.0
2.5
3.0
0.0 0.5 1.0 1.5 2.0 2.5
TACS surge, sway, heave
Lines: Frequency domainPoints: Time domain
(rad/sec)
Mo
tio
n A
mp
/Wav
e A
mp
heave
surge
sway
0.0
0.5
1.0
1.5
2.0
0.0 0.5 1.0 1.5 2.0 2.5
Lighter roll, pitch, yaw
Lines: Frequency domainPoints: Time domain
(rad/sec)
roll
yaw
pitch
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
0.0 0.5 1.0 1.5 2.0 2.5
TACS roll, pitch, yaw
Lines: Frequency domainPoints: Time domain
(rad/sec)
pitch
roll
yaw
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Control SystemsControl Systems Crane machinery controlled by an external unit,
in addition to the crane manufacturer’s devices
Hardware-in-the-loop approach treating any
external control unit as a “black box”
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Sensory SystemsSensory Systems GPS-aided Inertial Navigation System (INS) to
sense six degrees-of-freedom ship motions
Incremental and absolute encoders to measure
crane boom and slew positions and speeds
Swing sensors to estimate in-plane and out-of-
plane payload pendulation angles
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Visual and Audio SystemsVisual and Audio Systems Visualization was implemented based on a cross
platform C/C++ OpenGL API
Visual display was provided to the crane
operator via a 4-meter eLumens visual dome
A second visual channel via a HMD is available
for team scenario such as signalman training
Efficient collision algorithm to detect possible
contacts between moving bodies in real-time
Audio cueing is generated based on winch
actions and detected collisions
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Integrated Virtual EnvironmentIntegrated Virtual Environment
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Control System Performance Control System Performance EvaluationEvaluation
Boom aligned with ship centerline and boom
angle at about 25 degrees from horizontal
Sinusoidal ship motions:
– roll of 3 degrees at a period of 13.9 seconds
– pitch of 0.5 degrees at a period of 16.7 seconds, and
– heave of 5.7 feet at a period of 17.2 seconds
Pendulation motion was resolved into the ship-
fixed coordinate system of surge, sway, heave,
pitch, roll, and yaw
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Closed-loop PCS PerformanceClosed-loop PCS Performance - No Joystick Inputs- No Joystick Inputs
The PCS enabled the testbed to significantly
reduce the payload pendulation
Introduced small yaw motion, i.e., some energy
flows from translational to rotational modes
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Closed-loop PCS PerformanceClosed-loop PCS Performance - With Simulated Operator Input - With Simulated Operator Input
Driving with pre-recorded joystick inputs: boom-
up, hoist-up, then slew about 90 degrees
Plotted horizontal pendulation as observed
vertically downwards from the boom tip
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Engineering Design and EvaluationEngineering Design and Evaluation Testbed for engineering designs and evaluations,
with the option of human-in-the-loop and/or
hardware-in-the-loop
Application scenarios:
– Specify subsystem design parameters such as required
sampling frequencies of encoders
– Determine communication protocol for the integrated
system such as maximum allowed system time-delay
– Evaluate new designs of mooring lines or fenders and
best configuration for deployment arrangement
– Study utility of using commercial dynamic positioning
systems in notional Seabasing support ships
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Impact of System Time-DelayImpact of System Time-Delay
w/o PCS
Generally, the performance of a control system is
expected to degrade with increasing time delay
Using the testbed to find out an appropriate value
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Impact of Encoder Sampling FrequencyImpact of Encoder Sampling Frequency The more demanding the requirement, the higher
the cost. It also limits the number of candidate
subsystems that may be selected.
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Summary and DiscussionsSummary and Discussions
Physics-based, high fidelity M&S
Real-time and fast time simulations
Human-in-the-loop and hardware-in-the-loop
Visual and audio cueing for quality virtual
environment presence
Open-architecture and object-oriented design
Graphical user interface
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Summary and DiscussionsSummary and Discussions
An asset for exploration of concepts for skin-to-skin
cargo transfers at sea while underway in sea states
4 or greater
Engineering tool for specification and testing of
subsystem performance and interfaces
“Training” tool for introduction and evaluation of
new technologies with human interaction
“System of systems” approach - Flexible, modular,
expandable, reusable, and interoperable
Cost-effective and timely
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Questions?Questions?