Winch Drum Research Articles

New Measuring and Data Transmission Equipment for Operational Oceanography at the Gelendgik Black Sea Test Site of Institute of Oceanology of the RAS

The design and principles of operation of the bottom multi-modem station MDS-II, located in the coastal zone (depth of location — 25 m) of the northeastern part of the Black Sea at the Gelendzhik Test Site of IO RAS are described. The station is connected to the coastal center by means of a bottom fiber-optic cable, through which power is supplied to the station, and online transmission of measurement data takes place. The station is an underwater server to which one can connect a measuring device and get a real-time access to it, as well as remotely control on its operation. The design of an automatic stationary station for vertical sounding (SSVS) of water column, which is also used at the Gelendzhik Test Site, is also described. This station is installed close to the MDS-II multi-modem station and is connected to one of its modems. The station consists of a bottom electric winch installed on the seabed and a floating module (probe) on a cable line wound around the winch drum. When the command ʺsoundingʺ is given, the cable unwinds and the floating module, equipped with temperature and pressure sensors, floats and measures the water temperature profile from the bottom layer to the sea surface. Then the cable is winding on a drum, and the floating module returns to the bottom layer. A prototype of a new SSVS is being developed, which will allow sounding of the water layer with a thickness of up to 100 m. It will be equipped with a multi-parameter probe that makes joint measurements of hydrophysical and bio-optical parameters.

The Production of Marine Iron Objects in Europe Following the First Industrial Revolution: The Akko Tower Shipwreck Test Case

Four ferrous objects, a winch, a heart-shaped shackle, a deadeye strap with a futtock plate, and a stud-link chain controller, that were retrieved from the Akko Tower shipwreck were studied by different methods, including conventional metallography, light microscopy, scanning electron microscopy with energy-dispersive spectroscopy, optical emission spectroscopy, microhardness measurements, and the novel field multi-focal metallography (FMM), in order to determine their composition, microstructure, and manufacturing methods. The results of FMM agree well with conventional destructive metallography. The winch drum was made of grey cast iron and its shaft was wrought iron; the heart-shaped shackle and the deadeye strap with a futtock plate were wrought iron; and the stud-link chain controller was grey cast iron similar in composition and microstructure to the winch. All the wrought iron items revealed a similar composition and microstructure. Based on the composition, microstructure, and manufacturing processes of the four items, it is suggested that they were manufactured in the mid-nineteenth century. The high quality of these items indicates that they were produced using controlled processes, probably in the same workshop.

Mathematical Model of Flexible Link Dynamics in Marine Tethered Systems Considering Torsion and its Influence on Tension Force

Abstract The rigidity in bending of a flexible link (is an important characteristic that should be considered during regular service conditions. The tension and bending with torsion of wire ropes are also significant factors. This study proposed a method to calculate the vectors of the generalised forces of bending of flexible links. One of the causes of torsional stresses in the power plant of underwater tethered systems is the interaction with ship equipment, such as spiral winding on the winch drum, friction on the flanges of the pulleys or winch drums, and bends on various blocks and rolls that cause torsion. The source of torsional stresses in the FL may also be related to manufacturing, storage, transportation, and its placement on the ship’s winch drums. Torsion can lead to a decrease in the tensile strength due to load redistribution between power elements, or even a violation of their structure. In some cases, torsion significantly affects the movement of the underwater tethered system as a whole. The development of a mathematical model to describe the marine tethered systems dynamics, taking into account the effect of torsion, is important and relevant. The mathematical model of the marine tethered systems dynamics was improved and solved by accounting for the generalised forces of the torsion rigidity of the flexible link, using an algorithm and computer program. The influence of the bending and torsional rigidity of the FL on its deflection and tensile strength were considered based on the example of two problems. The developed program’s working window image shows the simulated parameters and the initial position of the flexible link. The results show that torsion has almost no effect on the shape of the a flexible link’s deflection in the X0Z plane, but leads to a deviation from the X0Z plane when calculating the static deflection of the flexible link. When the carrier vessel is stationary and the submersible vehicle has no restrictions on movement and has positive buoyancy, torsion leads to a three-dimensional change in the shape of the flexible link both in the X0Z plane and in the X0Y plane. The tension force of the flexible link along its length is distributed unevenly, and the torsion of the flexible link can lead to significant changes in its shape, the trajectory of towed objects, and the forces acting on the elements of the marine tethered systems

Experimental evaluation of dimension-stable synthetic fibre rope under investigation of spooling test on the multilayer winch drum

Synthetic fibre rope has been a promising solution in ocean exploring applications benefiting from its excellent mechanical properties and high-strength lightweight. However, spooling on the multilayer winch with fibre rope was noticed as a severe problem as a consequence of its nonlinear lateral stiffness property. Substantially increased layers of winding packages caused the deformation of rope. Therefore, a modified rope evolved from applications in fisheries with tight dimensional stability and resistance to deformation under compression is seen as an alternative selection. In this research, characteristics of a 24 mm high module polyethylene (HMPE) dimension-stable marine handling rope subjected to various tension are investigated by a series of full-scale spooling experimental tests on a specially designed test winch at a diameter ratio of D/d = 600/24. The results compared with another spooling experiment conducted in 2021 using an HMPE rope without a core but at the same D/d ratio reveal that the modified rope could induce greater loads than the former. Besides, analytical and numerical calculations will be discussed to assess the accuracy of experimental measurements. Further, a novel winding model is proposed to estimate the deformation of rope shape, evaluate the performance of rope winding and adjust rope spooling adaptability.

DEVELOPMENT OF THE SCHEME OF THE RIGGING AND ASSEMBLY INSTALLATION

In the conditions of reconstruction or technical re-equipment of grain storage and processing enterprises, there are cases of absence or impossibility of using the necessary universal lifting and transport means, in particular, construction tower or selfpropelled jib cranes at the installation sites. In such situations, they resort to the construction of specialized rigging and installation installations, which are based on the use of rigging and installation mechanisms, rigging devices and rigging equipment. The given sequence of actions, definitions and calculations at the same time practically excludes the adoption of unfounded and erroneous decisions. Most often, such installations are located near the facade walls of buildings, equipped with installation slots and loading and receiving platforms, hoists and cargo winches. Choose the design, location and means of fastening the mounting beam or boom. The load capacity of the winch, from among those in the distribution, is specified and accepted. Determine the required multiplicity of the hoist, its efficiency, the amount of tensile and breaking forces in the load rope. Choose the type and diameter of the rope, as well as its length. Determine the rope capacity of the cargo winch drum and specify its technical characteristics. Choose the location and method of securing the winch. If necessary, calculate the mass of the ballast counterweight. Choose the location and method of attachment of the diverter block, determine the amount of force exerted by this block on the building structure or anchor. Choose the type of anchor and, if necessary, calculate its stability. If it is necessary to pull the load from the front wall of the building or structure, calculate the pulling force and choose the necessary winch or hoist for this. The effort to pull the cargo from the receiving platform into the premises and the technical means required for this are determined.

A retrofitting control system design suitable for deep borehole drilling using legacy draw-works mechanical brake hardware

Deep drilling operations are typically needed when producing deep wells for hydrocarbon exploitation or geothermal energy applications. Since a notable portion of existing deep drilling rigs are still fielding manually operated draw-works (hoist) drum mechanical brake actuators, their usage puts notable constraints on the quality of borehole production and corresponding production rates. By retrofitting such mature drilling rigs with a suitable brake actuator servo mechanism, completely automatic drilling operation can be facilitated, thus also achieving borehole production efficiency improvements and meeting the increasingly stringent requirements on drilling control system performance. To this end, this paper presents the development of an automatic drilling control system based on an electrical servoactuator of the draw-works mechanical brake, with the control system arranged in the so-called cascade control system structure, and an automatic tuning procedure having been devised as well. Its robustness has been tested by means of root locus plots and simulation analysis of dominant closed-loop dynamics effects. The proposed control system has been verified by means of simulations first, which has been followed by a thorough experimental verification on an actual deep drilling rig retrofitted with electrical servodrive based-actuator of the winch drum mechanical brake. Field results have indicated that the proposed control system can maintain the drill-bit normal force within ± 10% of the target value during normal operation, with penetration rate variations typically being two to three times smaller compared to the case of human operator controlling the drilling process.

Experimental investigation of spooling test on the multilayer oceanographic winch with high-performance synthetic fibre rope

Compared with steel wire ropes, synthetic fibre ropes have a better performance in deep sea and gradually replaced the former in subsea launch and recovery systems. However, serious damage will be introduced to the winch structure when synthetic fibre ropes wound in multiple layers on the winch drum. In order to comprehensively explore the relationship between the mechanical properties of the winch drum barrel and the synthetic fibre rope, biaxial strain gauges and laser profile scanners have been used to monitor the oceanographic winch using a high-modulus polyethylene (HMPE) rope with the length of 13000 m. The full-size test rig was first introduced as an attempt to quantify the effect of winding fibre rope and evaluate the stresses on the winch with multilayer winding fibre rope. The results reveal that a loss elimination effect on rope windings may occur during the spooling experiment of fibre rope owing to the hysteresis property of the fibre, which differs significantly from the results published previously. Moreover, a more concise winding model is developed to estimate the spoolingand deformation states of the synthetic fibre rope, which can well simulate the cross-section deformation of the wound HMPE rope.

유한요소해석과 실험에 의한 유압 윈치 드럼의 응력 계산 및 수명 예측

유한요소해석과 실험에 의한 유압 윈치 드럼의 응력 계산 및 수명 예측

Determination of parameters of cable drums of capstanshunting winches

The article considers the problem of determining the rational geometric parameters of friction cable drums of capstan shunting winches. The basic technical means for performing shunting works within the cargo yards of railway stations and industrial enterprises are given. Today, shunting locomotives are the most common means of shunting works at railway stations and cargo yards of industrial enterprises. However, using them is not economically feasible for small amounts of shunting. Both sheave-type and capstan shunting winches are often used to move individual cars or groups of cars along the freight front. In the capstan shunting winches, a frictional drum of infinite coiling length is used, which rotates around a horizontal axis. It is established that the known sources give only the theoretical principles of the operation of drums of infinite coiling length and do not contain any practical recommendations for the design and operation of capstan shunting winches. The article provides a theoretical study of the forces of friction that occur between the drum and the cable, as well as between the cable lines when drums with different profiles of working surfaces are used. It was found that in shunting winches, the coefficient of friction of the rope along the drum can increase by 2.5 times, as a result of which it is necessary to increase the curvature of the profile of the drum. Also, friction forces between adjacent branches of a cable wound on a winch drum are considered. On the basis of the conducted study, recommendations on the type and geometrical parameters of cable drums of capstan shunting winches are proposed, which are aimed at extending the service life of traction cables of these mechanisms.

A Flexible Chain Proposal for Winch-Based Point Absorbers

Ocean wave power is a promising renewable energy source. It has, however, been difficult to find a cost-effective solution to convert wave energy into electricity. The harsh marine environment and the fact that wave power is delivered with large forces at low speed make design of durable mechanical structures and efficient energy conversion challenging. The dimensioning forces strongly depend on the wave power concept, the wave energy converter (WEC) implementation, and the actual power take-off (PTO) system. A WEC with a winch as a power take-off system, i.e., a winch-based point absorber (WBPA), could potentially enable a low levelized cost of energy (LCOE) if a low-cost, durable and efficient winch that can deal with peak loads can be developed. A key challenge for realizing such a winch is to find a force transmitting solution that can deal with these peak loads and that can handle up to 80 million cycles during its life. In this article, we propose a design solution for a force transmitting chain with elastomer bearings connecting the links of the chain. With this solution no sliding is present, and the angular motion is realized as elastic shear deformations in the elastomer bearings when the chain is wound onto the winch drum. The elastomer bearings were designed for low shear stiffness and high compression stiffness, and the links were designed primarily to minimize the number of joints in the chain. Thereby, the maximum allowed relative angle between the links when rolled up over the drum should be as large as possible within practical limits. Finite element-based topological optimization was performed with the aim to increase the link strength to weight ratio. A test rig for a first proof of concept testing has been developed, and preliminary test results indicate that this chain concept with elastomer bearings can be a potential solution for a durable chain and should be analyzed and tested further for fatigue and sea operations.

СТАНЦИЯ АВТОМАТИЧЕСКОГО ВЕРТИКАЛЬНОГО ЗОНДИРОВАНИЯ ПРИБРЕЖНОЙ ЗОНЫ МОРЯ НА ОСНОВЕ ДОННОЙ ЛЕБЕДКИ

This model provides a periodic measurement of temperature profiles from the bottom layer to the water surface in a programmable mode using temperature and pressure sensors placed in a single streamlined body (probe). The probe is connected by a thin resistant cable to the bottom block of the station, including a winch and an electronic unit. This cable provides power to the probe sensors, and transmits data to the station’s solid-state memory. Initially, the cable is wound on the winch drum, and the probe is located near the bottom block of the station. The probe has positive buoyancy. When turning on the winch to unwind the cable, the probe starts to go up. After it reaches the water surface and stays there for a short time, the winch turns back, the cable is wound onto the drum, and the probe is pulled down until it reach the bottom block. Measurements of parameters are carried out when the probe moves up and down with fine-scale vertical resolution. During regular use of the station in the water area of the IO RAS Gelendzhik Research Site on the Black Sea, the measurement data will not only be recorded in the station’s memory, but also promptly transmitted to the coastal center via a cable laid across the sea floor. This cable will also provide power to the station. Preliminary laboratory and field tests of the main components of the station are conducted. In the developed version, the station is designed for long-term monitoring of the hydrological structure of the marine coastal zone in operative mode. It may be retrofitted with bio-optic and hydrochemical sensors for environmental monitoring of reservoirs, the depth of which does not exceed 50-100 m.

PROBLEMS OF MEASURING OF MOTION PARAMETERS OF THE DRILL STRING

The current methods of measuring of parameters of the movement of the drill string are reviewed. The as-sessment of these methods from the point of view of metrology and the effectiveness of the application of measuring equipment is given. There are presented the block diagrams of devices for measuring the parameters of movement of the drill string on the angle of rotation of the drill winch drum with automatic correction of measurement errors arising due to changes in the radius of cable winding on winch drum, when winding from one layer to another. Diagrams of mechanical and electrical devices for automatic correction of measurement errors are presented.

Real-time simulation of cable pay-out and reel-in with towed fishing gears

Achieving real-time simulation of fast cable pay-out and reel-in manoeuvres with towed fishing gears is a challenging task. This work presents two new simulation methods based on simplified cable models for this kind of application. First, three numerical techniques are proposed to enhance a classical spring-based cable model, increasing its computational efficiency in manoeuvres that involve reeling the cable around a winch drum. Second, the development of an efficient multibody modelling approach based on natural coordinates is reported. The performance of these methods was assessed with two realistic examples. The numerical experiments involved different values of cable axial stiffness and spatial discretization levels, since these parameters were found to have a major impact on computational efficiency. The proposed methods achieved real-time performance in the simulation of systems modelled with up to a few thousand variables. Each modelling approach has advantages and limitations that must be considered when addressing a given application.

Test and Analysis of A Skidding Winch Drum with Combined Shaped Groove

Test and Analysis of A Skidding Winch Drum with Combined Shaped Groove

Precision cable winch level wind for deep ice-coring systems

AbstractIn deep ice-coring, as in many other disciplines, a winching system is involved in the overall operation of the drilling activities. The need to efficiently store the cable on the winch drum is well recognized, and the ‘orthocyclically wound’ approach is often used. This is accomplished by means of a ‘Lebus groove’, along with a level winding scheme of some description. The level wind is usually implemented in one of several ways using some mechanism to synchronize the position of the level wind with the point where the cable meets the winch drum. A novel method using a feedback control system is presented in this paper, introducing a virtually error-free approach to the surprisingly difficult task of level winding.

Analysis and Control on Winch Rope-Aligning Motion of Well Testing Truck

On basis of the rope- aligning motion analysis of the winch drum, this paper indicates the reason of the misalignment in the outer layer and edge of the drum by the current rope- aligning scheme, puts forward the rope- aligning scheme of the position following control on the rope- aligning device, and accordingly designs an automatic rope- aligning system. It is proved from the practice that the system is safe and reliable with the automatic tracking, automatic compensation, neat alignment of the steel wire rope, and stable performance, which provides the favorable guarantee for the safe operation of the winch.

Stabilization of Load’s Position in Offshore Cranes

It is often desirable to keep the load of an offshore crane in a fixed point in space despite the movement of its base. To solve the problem of stabilizing the load’s position, the authors have proposed application of the hoisting winch drum’s drive and an auxiliary system. The auxiliary system enables independent moving of a selected point of the hoisting rope in two perpendicular planes. In this paper, two methods for determining the drive functions of the auxiliary system and the hoisting winch’s drum ensuring stabilization of an offshore crane’s load are presented. Both methods are based on a simplified model of a crane and allow compensation for a pseudo-harmonic base motion. In order to take into account the deviations of base motion from the assumed and avoid over simplifications, the second, more sophisticated model is developed. This model is proposed to be applied in closed-loop control systems with a PID controller. Results of sample numerical simulations are included that proved useful information about the developed methods and models for stabilization of an offshore crane’s load.

Finite Element Optimization Design of the Drum of Storage Winch

In order to make the structure design of winch drum reasonable and reduce the gross mass of winch, the main components of storage winch were optimize designed on the premise of not affecting the safety use of storage winch. By applying the SoildWorks software, the storage winch model was established, and finite element analysis for the model was also carried out by Simulation. The maximum principal stress of drum under the most dangerous operation condition was obtained, and wall thickness of drum, web thickness, web position and hub thickness were all optimized. After the optimization analysis, it was found that the maximum stress on the drum decreased but then increased along with the increase of the wall thickness of drum. Meanwhile, the unreasonable structure was improved and the gross mass of drum of storage winch was reduced. Furthermore, the more reasonable structure design was achieved. The study provided important theoretical basis for the product design.

Dynamic simulation of wire rope with contact

We present a dynamic simulation of a wire rope involving both contacts with a winch drum and hydraulic systems using the finite element method. Rapid winch operation often causes disorderly winding of the wire rope, which is an important quality problem. Dynamic simulation is, therefore, required for design of the hydraulic winch system on construction machinery. The wire rope is modeled using by truss elements considering large displacement motion. The contact between the wire rope and the winch drum is modeled using by variable-length truss elements and bilinear spring elements. An improved Newton method is proposed for nonlinear dynamic analysis. Simulation results show that some lever operations result in rope looseness and intense pressure fluctuation.

Dynamic Simulation of a Wire Rope with Contact

We present a dynamic simulation of a wire rope involving both contact phenomena with a winch drum and hydraulic dynamics using a finite element method. Rapid winch operation often causes a disorderly winding of wire rope, which is important on quality of wire rope. Dynamic simulation is, therefore, required for a design of hydraulic winch system on the construction machinery. The wire rope is modeled using by truss elements considering large displacement motion. The contact between the wire rope and a winch drum is modeled using by variable-length truss elements and bilinear spring elements. Simulation results show that some lever operation cause the rope looseness and intense pressure fluctuation. Moreover, we propose a slow-stop winch system and verify the system performance by the simulation.