Drives and actuators help train crane operators

Servo drives and electromechanical actuators used in a simulator for training crane operators working on offshore oil and gas platforms, and in container ports.

Servo drives and electromechanical actuators from Parker Hannifin are being used in a simulator for training crane operators working on offshore oil and gas platforms, and in container ports.

Developed and made by Drilling Systems in Bournemouth, the Krane SIM-6000 can reproduce various normal and emergency scenarios, letting trainees master all aspects of crane operation in a safe but realistic environment.

To construct this virtually perfect replication simulator, the firm uses real-time digital computing techniques with standard crane controls and functions, plus synchronised visual information, to create a realistic simulation.

Trainees can learn to perform all the necessary crane movement operations in controlled conditions and quickly gain a wide knowledge of crane and cargo manipulation without the risks and costs normally associated with on-site training and work experience.

Although Drilling Systems has a history of developing simulators for various industries, the Krane SIM-6000 is claimed to be the first to use real time motion control at such an advanced level.

Richard Blashill, Crane Division Manager, said: "Crane operation, especially on offshore platforms, is extremely complex and our simulator has accurately to recreate all types of sea, wind and weather conditions on a variety of rig types, including jackup, tension leg, semi-sub and concrete platforms, all of which react differently and affect the motion of the crane and thus the operator's experience in often unpredictable ways".

To meet these motion control requirements, Parker Hannifin provided three Compax 3 drives controlled via Profibus, with an Ethernet link to a dedicated PC controller.

Each drive operates one of three Electro-Thrust electric cylinders; these devices operate independently, with two cylinders lifting the simulation rig at opposite ends, while the third provides horizontal motion to create the potential for full movement through x, y and z axes.

The electric cylinders provide speeds up to 1.0m/s, with a maximum travel of up to 2.4m, and incorporate C7 class ballscrew drives, so they can operate under the heavy loads of up to 1200kg imposed by the Krane SIM-6000.

Just as importantly, the combination of high performance, torsionally stiff actuators and the closed loop servo system means the simulation rig responds instantly to control signals and changes in conditions caused by trainee operator input or programmed by a system trainer.

Blashill said: "The closed-loop servo system enables us to create extremely subtle changes in the orientation of the rig, quickly and smoothly in real time, while features such as internal regeneration circuitry and external resistor connections on the Compax 3 drives make it even simpler to configure the system to redistribute power to each actuator as it is required, to produce the most realistic wave motion and strength".

"In addition, the robust nature of the actuators mean they require only minimal maintenance, helping us to ensure that our systems get the maximum usage with the lowest possible operating costs for our customers".

"We chose Parker to provide the drives and actuators for the Krane SIM-6000 for several reasons".

"We have dealt with Parker on previous projects and know its products are reliable and that the company has the ability to provide us with a high level of local technical support".

"Its engineers are both responsive and helpful, and have worked closely with us to develop a system that meets and, in many respects, surpasses our expectations".

"Following the success of the offshore crane simulator, we are already working on a further generation of dockside container crane simulators that use Parker's stand-alone process controllers".

The Krane SIM-6000 has recently completed rigorous testing procedures and is now available for training.

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