X. Jiang
Please Note
38 records found
1
Simulation-Based Multi-Objective Optimization for Offshore Wind Installation Scheduling
Integrating Population-Based Metaheuristics into Discrete Event Simulation Tool ’Metis’
Unsupervised Fault Diagnosis and Remaining Lifetime Estimation for the Predictive Optimization of Offshore Wind Turbine Maintenance
Design of a deep learning framework for unlabeled offshore wind turbine SCADA data
The framework identifies historical failure events through reconstruction-based anomaly detection and the construction of a health indicator. By clustering detected anomalies, associated failure modes are inferred, allowing classification of future fault types. Using the estimated moments of failure as guidance, it then learns degradation trends in the reconstruction feature space and performs RUL prediction.
Given the complexity of offshore environments and the unpredictable nature of wind turbine faults, the framework is first validated in a controlled setting using NASA's C-MAPSS simulated aircraft engine dataset. The results are competitive and align well with those reported in related studies. Subsequent application to real-world OWT SCADA data demonstrates the practical feasibility of the approach. However, challenges such as data imbalance, obscured features due to SCADA data quality issues, and propagation of errors between model components complicate implementation and reduce prediction reliability.
Despite these challenges, the proposed framework successfully extracts health-relevant insights, enabling predictive maintenance optimization and contributing to more informed data-driven decision-making in offshore wind operations. ...
The framework identifies historical failure events through reconstruction-based anomaly detection and the construction of a health indicator. By clustering detected anomalies, associated failure modes are inferred, allowing classification of future fault types. Using the estimated moments of failure as guidance, it then learns degradation trends in the reconstruction feature space and performs RUL prediction.
Given the complexity of offshore environments and the unpredictable nature of wind turbine faults, the framework is first validated in a controlled setting using NASA's C-MAPSS simulated aircraft engine dataset. The results are competitive and align well with those reported in related studies. Subsequent application to real-world OWT SCADA data demonstrates the practical feasibility of the approach. However, challenges such as data imbalance, obscured features due to SCADA data quality issues, and propagation of errors between model components complicate implementation and reduce prediction reliability.
Despite these challenges, the proposed framework successfully extracts health-relevant insights, enabling predictive maintenance optimization and contributing to more informed data-driven decision-making in offshore wind operations.
Hybrid land/pontoon crane
Development of a removable connection system
An initial literature research is performed in order to obtain a variety of connecting options which have the potential of forming the basis of a new removable connection system, optimized for crane-to-pontoon configurations. Subsequently, creating a unique rating system, specifically for crane-to-pontoon connection systems, led to a substantiated selection process for the most feasible option among the potential connecting options. The turnbuckle option obtained the highest ranking and was therefore selected to proceed the design process with.
Developing the turnbuckle option into a complete connection system and accomplishing all defined aims led to an encounter with various engineering challenges. An integral design process led to the discovery of a proficient combination of components, which overcome the challenges and provide satisfaction with respect to the aims of the project.
The parameters of the developed conceptual design are finally quantified in order to prove feasibility and efficiency. Applicable design parameters are found which pass the safety requirements, while minimizing the material consumption. With these parameters, the removable design is compared to conventional real case connection systems in terms of cost-efficiency, which resulted in the observation that multiple millions of euros in long-term savings are anticipated per deployed crane due to the removability feature.
...
An initial literature research is performed in order to obtain a variety of connecting options which have the potential of forming the basis of a new removable connection system, optimized for crane-to-pontoon configurations. Subsequently, creating a unique rating system, specifically for crane-to-pontoon connection systems, led to a substantiated selection process for the most feasible option among the potential connecting options. The turnbuckle option obtained the highest ranking and was therefore selected to proceed the design process with.
Developing the turnbuckle option into a complete connection system and accomplishing all defined aims led to an encounter with various engineering challenges. An integral design process led to the discovery of a proficient combination of components, which overcome the challenges and provide satisfaction with respect to the aims of the project.
The parameters of the developed conceptual design are finally quantified in order to prove feasibility and efficiency. Applicable design parameters are found which pass the safety requirements, while minimizing the material consumption. With these parameters, the removable design is compared to conventional real case connection systems in terms of cost-efficiency, which resulted in the observation that multiple millions of euros in long-term savings are anticipated per deployed crane due to the removability feature.
The cost of vessel chartering significantly contributes to the overall cost of operating and maintaining an offshore wind farm. By selecting the optimal fleet mix for executing the maintenance, the vessel chartering cost can be reduced, reducing the operation and maintenance costs of the offshore wind farm. This reduces the levelized cost of energy from the offshore wind farm. This report developed a simulation and optimization model based on mixed integer linear programming to determine the opti-mal fleet mix for executing the maintenance tasks by minimizing the vessel acquisition cost. The Monte Carlo simulation is implemented to statistic an optimal strategy for chartering the vessels.
Chapter 1 introduces the offshore wind farm (OWF) and its operation and maintenance (O&M) activi-ties. Chapter 2 provided a literature review on the latest progress of the offshore wind farm’s operation and maintenance. Chapter 3 provides a simulation model for component wear, maintenance require-ment generation, and maintenance task execution. The process of optimization is explained in detail. Chapter 4 presents the mathematical model of the optimizer, which arranges the vessels and executes maintenance tasks. Chapter 5 presents a case study based on the latest progress data. The Monte Carlo simulation yields the optimal initial purchased fleet mix derived based on the Monte Carlo simu-lation. Finally, Chapter 6 gives the conclusion and recommendations for future studies. ...
The cost of vessel chartering significantly contributes to the overall cost of operating and maintaining an offshore wind farm. By selecting the optimal fleet mix for executing the maintenance, the vessel chartering cost can be reduced, reducing the operation and maintenance costs of the offshore wind farm. This reduces the levelized cost of energy from the offshore wind farm. This report developed a simulation and optimization model based on mixed integer linear programming to determine the opti-mal fleet mix for executing the maintenance tasks by minimizing the vessel acquisition cost. The Monte Carlo simulation is implemented to statistic an optimal strategy for chartering the vessels.
Chapter 1 introduces the offshore wind farm (OWF) and its operation and maintenance (O&M) activi-ties. Chapter 2 provided a literature review on the latest progress of the offshore wind farm’s operation and maintenance. Chapter 3 provides a simulation model for component wear, maintenance require-ment generation, and maintenance task execution. The process of optimization is explained in detail. Chapter 4 presents the mathematical model of the optimizer, which arranges the vessels and executes maintenance tasks. Chapter 5 presents a case study based on the latest progress data. The Monte Carlo simulation yields the optimal initial purchased fleet mix derived based on the Monte Carlo simu-lation. Finally, Chapter 6 gives the conclusion and recommendations for future studies.
Predicting the fatigue life of SPCs involves several critical steps, with local mechanical analysis acting as a pivotal bridge that significantly impacts overall fatigue life estimation. This analysis assesses overall cable behaviours, such as stiffness, and detailed component behaviours, such as stress and strain conditions. The accuracy of the local mechanical analysis crucially influences the ultimate fatigue life estimation. Currently, large safety factors are employed in engineering to compensate for uncertainties due to insufficient understanding of local mechanical behaviours. Therefore, there is a need for a modelling method that can accurately estimate the local mechanical behaviour of SPCs.
This PhD project is dedicated to developing an effective modelling method for the local mechanical analysis of SPCs. An extensive literature review on SPC configurations, design processes, and methods for determining mechanical behaviours is presented in Chapter 2. This chapter focuses on prevalent loadings of tension and bending and discusses the complexity of SPC structures, particularly due to their unbonded, multi-layer, helical component nature and associated stick-slip issues. Two approaches—analytical and numerical—are used to capture these behaviours, with numerical methods preferred for their ability to handle complex structures. However, these methods struggle with efficiency when detailed analysis is necessary. The balance between accuracy and efficiency in developing an effective numerical model hinges on resolving three specific issues: constructing appropriate finite element, managing contact issues, and establishing suitable boundary conditions.
Chapter 3 addresses the aforementioned challenges. First, it introduces an element combination—beam plus surface elements—to simulate the helical metals within SPCs, a method previously validated for accuracy and efficiency. This combination undergoes further verification in subsequent chapters. Secondly, the contact issue, particularly the initial residual stress from extruded polymers during manufacturing, is tackled using contact damping to simulate its effects, enhancing model efficiency and convergence. Lastly, the challenge of setting appropriate boundary conditions is addressed through periodic boundary conditions derived from the homogenization method, applied to a repetitive unit cell (RUC) whose length is reduced to increase computational efficiency. The resulting model, referred to as the RUC model, is applied to SPC samples and validated against test data on tension and bending.
The effectiveness of the RUC model under tension is confirmed in Chapter 4 through material tests and a tension test on a DPC sample. The model demonstrates superior performance in terms of accuracy and efficiency compared to traditional full-scale models. Similarly, Chapter 5 validates the RUC model under bending conditions using tests on both three-core DPC and single-core SPCs. The model is verified against traditional full-scale models, affirming its robustness.
Subsequently, Chapter 6 explores the RUC model’s application in analyzing the combined effects of tension and bending on DPCs. The study extends to parametric analysis of internal components and helical pitch lengths, providing crucial insights for cable design.
Finally, Chapter 7 concludes the dissertation by summarizing the key findings and offering recommendations for further research building on the current study. Additionally, it outlines guidelines for employing the proposed model in practical scenarios
...
Predicting the fatigue life of SPCs involves several critical steps, with local mechanical analysis acting as a pivotal bridge that significantly impacts overall fatigue life estimation. This analysis assesses overall cable behaviours, such as stiffness, and detailed component behaviours, such as stress and strain conditions. The accuracy of the local mechanical analysis crucially influences the ultimate fatigue life estimation. Currently, large safety factors are employed in engineering to compensate for uncertainties due to insufficient understanding of local mechanical behaviours. Therefore, there is a need for a modelling method that can accurately estimate the local mechanical behaviour of SPCs.
This PhD project is dedicated to developing an effective modelling method for the local mechanical analysis of SPCs. An extensive literature review on SPC configurations, design processes, and methods for determining mechanical behaviours is presented in Chapter 2. This chapter focuses on prevalent loadings of tension and bending and discusses the complexity of SPC structures, particularly due to their unbonded, multi-layer, helical component nature and associated stick-slip issues. Two approaches—analytical and numerical—are used to capture these behaviours, with numerical methods preferred for their ability to handle complex structures. However, these methods struggle with efficiency when detailed analysis is necessary. The balance between accuracy and efficiency in developing an effective numerical model hinges on resolving three specific issues: constructing appropriate finite element, managing contact issues, and establishing suitable boundary conditions.
Chapter 3 addresses the aforementioned challenges. First, it introduces an element combination—beam plus surface elements—to simulate the helical metals within SPCs, a method previously validated for accuracy and efficiency. This combination undergoes further verification in subsequent chapters. Secondly, the contact issue, particularly the initial residual stress from extruded polymers during manufacturing, is tackled using contact damping to simulate its effects, enhancing model efficiency and convergence. Lastly, the challenge of setting appropriate boundary conditions is addressed through periodic boundary conditions derived from the homogenization method, applied to a repetitive unit cell (RUC) whose length is reduced to increase computational efficiency. The resulting model, referred to as the RUC model, is applied to SPC samples and validated against test data on tension and bending.
The effectiveness of the RUC model under tension is confirmed in Chapter 4 through material tests and a tension test on a DPC sample. The model demonstrates superior performance in terms of accuracy and efficiency compared to traditional full-scale models. Similarly, Chapter 5 validates the RUC model under bending conditions using tests on both three-core DPC and single-core SPCs. The model is verified against traditional full-scale models, affirming its robustness.
Subsequently, Chapter 6 explores the RUC model’s application in analyzing the combined effects of tension and bending on DPCs. The study extends to parametric analysis of internal components and helical pitch lengths, providing crucial insights for cable design.
Finally, Chapter 7 concludes the dissertation by summarizing the key findings and offering recommendations for further research building on the current study. Additionally, it outlines guidelines for employing the proposed model in practical scenarios
This proposed concept has so far not been investigated in academic research. Therefore, this thesis aims to create a general understanding of the system and its characteristics. Based on the example of Port Talbot in the UK, it should be examined how the concept can be implemented in a location. Furthermore, a response analysis of the system is done in SIMA for the single blade installation to understand which motions characterise the integration task and which environmental conditions limit the operation. Those operational limits are then implemented in a Python model of the complete integration sequence to conduct an operability analysis which should also give estimates for the required installation time and costs of the system when subject to wind and wave loads. Based on the findings of those studies, the technical and economic feasibility of the concept should be investigated.
The study has found that the wave-induced floater motions are mainly governing the systems motions during the single blade installation, which leads to very strict operational limits for the waves during the mating procedure. The technical feasibility of the proposed system is given if it is not subject to large tides and if a sufficient control mechanism is implemented for the installation. The operability analysis has shown that the system can be economically feasible if smaller projects should be implemented. For large projects, it is likely more feasible to invest into the port infrastructure.
...
This proposed concept has so far not been investigated in academic research. Therefore, this thesis aims to create a general understanding of the system and its characteristics. Based on the example of Port Talbot in the UK, it should be examined how the concept can be implemented in a location. Furthermore, a response analysis of the system is done in SIMA for the single blade installation to understand which motions characterise the integration task and which environmental conditions limit the operation. Those operational limits are then implemented in a Python model of the complete integration sequence to conduct an operability analysis which should also give estimates for the required installation time and costs of the system when subject to wind and wave loads. Based on the findings of those studies, the technical and economic feasibility of the concept should be investigated.
The study has found that the wave-induced floater motions are mainly governing the systems motions during the single blade installation, which leads to very strict operational limits for the waves during the mating procedure. The technical feasibility of the proposed system is given if it is not subject to large tides and if a sufficient control mechanism is implemented for the installation. The operability analysis has shown that the system can be economically feasible if smaller projects should be implemented. For large projects, it is likely more feasible to invest into the port infrastructure.
In order to optimize the fleet size and mix problem for an offshore wind farm based on a simulation method, this thesis has performed a few research steps. Firstly, a literature view on the modeling methods of fleet size and mix problems for offshore wind farms is finished. Different modeling methods and different factors considered in the model are viewed. Then, two simulation models, the open-loop simulation model and the feedforward simulation model, are introduced, including the model inputs, model agent and process, and model outputs. Afterward, the simulation-optimization methodology is introduced and the optimization algorithm used in this research is introduced. Next, one case study using two models separately for a long-term optimization and a short-term optimization is executed and followed by the results of these two simulation models as well as the comparison of the results from them.
This thesis aims to combine the optimization method with a simulation model for offshore wind farms, which can be regarded as a decision support tool for fleet size and mix problems and is expected to be a practical technology for the operator/researcher of the offshore wind farm in the future. ...
In order to optimize the fleet size and mix problem for an offshore wind farm based on a simulation method, this thesis has performed a few research steps. Firstly, a literature view on the modeling methods of fleet size and mix problems for offshore wind farms is finished. Different modeling methods and different factors considered in the model are viewed. Then, two simulation models, the open-loop simulation model and the feedforward simulation model, are introduced, including the model inputs, model agent and process, and model outputs. Afterward, the simulation-optimization methodology is introduced and the optimization algorithm used in this research is introduced. Next, one case study using two models separately for a long-term optimization and a short-term optimization is executed and followed by the results of these two simulation models as well as the comparison of the results from them.
This thesis aims to combine the optimization method with a simulation model for offshore wind farms, which can be regarded as a decision support tool for fleet size and mix problems and is expected to be a practical technology for the operator/researcher of the offshore wind farm in the future.
Studies have shown that the costs and wind farm availability are sensitive to the fleet composition and were commonly used as criteria in offshore wind fleet optimization models. Offshore wind greenhouse gas emissions were shown to be sensitive to the offshore wind fleet composition as well but thus far not used as criteria for fleet composition decision-making. This study aims to develop an offshore wind O&M multi-objective fleet optimization model that includes GHG emissions as the third criterion for the fleet composition. The model is rendered as a deterministic MIP problem. An epsilon constraint method-inspired approach is proposed to reformulate the multi-objective into a set of perturbed single-objective models, which can be solved using a commercial MIP solver. ...
Studies have shown that the costs and wind farm availability are sensitive to the fleet composition and were commonly used as criteria in offshore wind fleet optimization models. Offshore wind greenhouse gas emissions were shown to be sensitive to the offshore wind fleet composition as well but thus far not used as criteria for fleet composition decision-making. This study aims to develop an offshore wind O&M multi-objective fleet optimization model that includes GHG emissions as the third criterion for the fleet composition. The model is rendered as a deterministic MIP problem. An epsilon constraint method-inspired approach is proposed to reformulate the multi-objective into a set of perturbed single-objective models, which can be solved using a commercial MIP solver.
Parametric Optimization of Dynamic Power Cable Configurations
For Floating Offshore Wind Applications
Inter-Array Cable installation
Optimization of the support vessel fleet composition
The cable installation process involves a complex set of operations, each necessitating a crew to be present on the foundations. Support vessels play a central role in routing of these crews and their equip- ment to these foundations.This thesis introduces an innovative approach that integrates operational scheduling and crew routing into a single formulation for optimizing the fleet of walk-to-work vessels. This hybrid model combines elements of a continuous-time rich multi-visit multi-period Vehicle Routing Problem with a time-varying Resource Constrained Project Scheduling Problem. It also factors in the substantial impact of weather conditions on offshore operations by accounting for variable weather win- dows in each scheduling period.
The formulated model is rigorously verified and validated to ensure it closely mirrors real-world sup- port vessel behavior. Although it slightly underestimates fuel consumption, this discrepancy is deemed acceptable given its minor role in the overall objective. Sensitivity analyses highlight the critical impor- tance of accurate performance data for the cable laying vessel, which significantly influences the model’s outcomes. However, the model is found to be most effective for modeling a single cable string compris- ing 6-8 turbines, with scalability issues arising when attempting to expand beyond this scope.
A focused case study delves into the impact of various weather conditions and inter-array distances on the optimal vessel composition. The study evaluates two types of walk-to-work vessels, individually and in combination. Results reveal that, under the assumption of zero downtime, the industry norm of chartering cheaper vessels is cost-effective, while the pricier vessel results in a 10% costlier solu- tion. As weather conditions worsen, a composition of costlier vessels proves more cost-effective over the scheduling horizon. Such conditions are to be expected in far offshore locations, especially on the cheaper vessels, which have lower workability limits. The study identifies potential cost reductions of up to 25%, with even marginal downtime conditions yielding 10-20% reductions to the industry standard. Moreover, delays imposed on the cable laying vessel are significantly reduced when utilizing a compo- sition that includes at least as one of the more expensive vessels.
In summary, this thesis establishes a foundation for optimizing support vessels in offshore wind installa- tion. The presented model introduces a novel framework, combining multi-visit routing with time-varying resource scheduling, while considering shared vehicles and coupled routing and scheduling over a multi- period horizon. For regions prone to harsh weather conditions, such as those further offshore and during winter months, it is advised to utilize more expensive vessels that have higher workability limits and bet- ter performance figures. Additionally, there appears to be limited justification for simultaneous use of multiple vessels during the cable installation, as the added costs do not seem to outweigh the marginal improvements in installation duration. Future research should focus on refining solution methods for the proposed formulation and incorporating crew transfer vessels into the fleet composition. ...
The cable installation process involves a complex set of operations, each necessitating a crew to be present on the foundations. Support vessels play a central role in routing of these crews and their equip- ment to these foundations.This thesis introduces an innovative approach that integrates operational scheduling and crew routing into a single formulation for optimizing the fleet of walk-to-work vessels. This hybrid model combines elements of a continuous-time rich multi-visit multi-period Vehicle Routing Problem with a time-varying Resource Constrained Project Scheduling Problem. It also factors in the substantial impact of weather conditions on offshore operations by accounting for variable weather win- dows in each scheduling period.
The formulated model is rigorously verified and validated to ensure it closely mirrors real-world sup- port vessel behavior. Although it slightly underestimates fuel consumption, this discrepancy is deemed acceptable given its minor role in the overall objective. Sensitivity analyses highlight the critical impor- tance of accurate performance data for the cable laying vessel, which significantly influences the model’s outcomes. However, the model is found to be most effective for modeling a single cable string compris- ing 6-8 turbines, with scalability issues arising when attempting to expand beyond this scope.
A focused case study delves into the impact of various weather conditions and inter-array distances on the optimal vessel composition. The study evaluates two types of walk-to-work vessels, individually and in combination. Results reveal that, under the assumption of zero downtime, the industry norm of chartering cheaper vessels is cost-effective, while the pricier vessel results in a 10% costlier solu- tion. As weather conditions worsen, a composition of costlier vessels proves more cost-effective over the scheduling horizon. Such conditions are to be expected in far offshore locations, especially on the cheaper vessels, which have lower workability limits. The study identifies potential cost reductions of up to 25%, with even marginal downtime conditions yielding 10-20% reductions to the industry standard. Moreover, delays imposed on the cable laying vessel are significantly reduced when utilizing a compo- sition that includes at least as one of the more expensive vessels.
In summary, this thesis establishes a foundation for optimizing support vessels in offshore wind installa- tion. The presented model introduces a novel framework, combining multi-visit routing with time-varying resource scheduling, while considering shared vehicles and coupled routing and scheduling over a multi- period horizon. For regions prone to harsh weather conditions, such as those further offshore and during winter months, it is advised to utilize more expensive vessels that have higher workability limits and bet- ter performance figures. Additionally, there appears to be limited justification for simultaneous use of multiple vessels during the cable installation, as the added costs do not seem to outweigh the marginal improvements in installation duration. Future research should focus on refining solution methods for the proposed formulation and incorporating crew transfer vessels into the fleet composition.
A facility location model for uncrewed surface vessels in the maritime survey industry
The impact of remote and autonomous operations on logistical decision-making regarding harbor facility locations
...
Assessment is performed by simulating stress distribution within the problematic joint structure and assessing high-cycle fatigue damage accumulation around its welds. Loading conditions affecting crane upper arm are established through multi-body dynamic simulations, which are meant to replicate operation of a lemniscate crane. Multi-body dynamic model is verified for its accuracy using available crane operation measurement data. Loads are acquired within the time domain and include temporal effects of luffing, slewing and hoisting operations as well as pontoon motion.
Fatigue analysis is performed to evaluate damage accumulation within the tubular joint structure of the crane upper arm. A detailed shell finite element model is established to acquire time-dependent stress responses. During stress evaluation stage - a particularly large stress concentration has been observed at the joint brace saddle position. To assess which method best simulate damage accumulation in the joint structure - three specific fatigue assessment approaches are tested: nominal stress approach, hot-spot stress approach and multi-axial fatigue approach. Nominal and hot-spot stress approaches are evaluated and compared to determine how inclusion of stress concentration effects into fatigue assessment influence damage accumulation results. Result comparison has shown a large disparity in results with hot-spot stress approach, indicating that the method capable of determining locations of dangerous stress accumulation, in relation to what has been observed in the real structure.
Evaluation is performed to determine whether multi-axial fatigue assessment is needed to improve calculation results of fatigue damage accumulation.
Based on stress direction properties within the analysed structure - most favorable multi-axial fatigue assessment approach (capable of analysing proportional stress responses) is used. Multi-axial fatigue assessment method results are then compared with results of conventional hot-spot stress approach to evaluate the differences in damage accumulation rate. Analysis results have shown that both methods are capable of determining locations of critical points with present disparity within magnitude of damage accumulation. This indicates that hot-spot stress fatigue approach, which uses Von Mises stress, is more conservative out of two methods. Fatigue analysis has also presented that original joint structure is inherently flawed, as its stress concentration locations are not easily accessible without crane disassembly and its structural capacity has been underestimated during design stage.
Finally methods for extending operational life of crane upper arm structure are evaluated. Three methods for reducing stress within the structure are assessed: increase of structural capacity, stress redistribution and load reduction. Increase of structural capacity is performed by adjusting thickness of relevant joint elements, with optimal thickness being established using a sensitivity analysis algorithm, which simultaneously acquires combined thickness setup for multiple joint elements - making the joint capable of surviving predetermined fatigue life. Stress redistribution approach is implemented by producing an alternative upper arm joint design, which could be exchanged with the problematic original joint during crane refurbishment. Load reduction approach is performed to investigate whether it would be possible to increase fatigue life of the original joint structure without affecting work efficiency, by only adjusting crane motion profile within multi-body dynamic simulation environment. All three methods are quantified and compared through fatigue damage factor results acquired using multi-axial fatigue assessment method. Result comparison has shown that joint redesign is the most preferred approach due to its ability to efficiently improve fatigue life of the structure without significant structural weight increase, while exposing any potential points for crack initiation to locations easily accessible for inspection and repair. ...
Assessment is performed by simulating stress distribution within the problematic joint structure and assessing high-cycle fatigue damage accumulation around its welds. Loading conditions affecting crane upper arm are established through multi-body dynamic simulations, which are meant to replicate operation of a lemniscate crane. Multi-body dynamic model is verified for its accuracy using available crane operation measurement data. Loads are acquired within the time domain and include temporal effects of luffing, slewing and hoisting operations as well as pontoon motion.
Fatigue analysis is performed to evaluate damage accumulation within the tubular joint structure of the crane upper arm. A detailed shell finite element model is established to acquire time-dependent stress responses. During stress evaluation stage - a particularly large stress concentration has been observed at the joint brace saddle position. To assess which method best simulate damage accumulation in the joint structure - three specific fatigue assessment approaches are tested: nominal stress approach, hot-spot stress approach and multi-axial fatigue approach. Nominal and hot-spot stress approaches are evaluated and compared to determine how inclusion of stress concentration effects into fatigue assessment influence damage accumulation results. Result comparison has shown a large disparity in results with hot-spot stress approach, indicating that the method capable of determining locations of dangerous stress accumulation, in relation to what has been observed in the real structure.
Evaluation is performed to determine whether multi-axial fatigue assessment is needed to improve calculation results of fatigue damage accumulation.
Based on stress direction properties within the analysed structure - most favorable multi-axial fatigue assessment approach (capable of analysing proportional stress responses) is used. Multi-axial fatigue assessment method results are then compared with results of conventional hot-spot stress approach to evaluate the differences in damage accumulation rate. Analysis results have shown that both methods are capable of determining locations of critical points with present disparity within magnitude of damage accumulation. This indicates that hot-spot stress fatigue approach, which uses Von Mises stress, is more conservative out of two methods. Fatigue analysis has also presented that original joint structure is inherently flawed, as its stress concentration locations are not easily accessible without crane disassembly and its structural capacity has been underestimated during design stage.
Finally methods for extending operational life of crane upper arm structure are evaluated. Three methods for reducing stress within the structure are assessed: increase of structural capacity, stress redistribution and load reduction. Increase of structural capacity is performed by adjusting thickness of relevant joint elements, with optimal thickness being established using a sensitivity analysis algorithm, which simultaneously acquires combined thickness setup for multiple joint elements - making the joint capable of surviving predetermined fatigue life. Stress redistribution approach is implemented by producing an alternative upper arm joint design, which could be exchanged with the problematic original joint during crane refurbishment. Load reduction approach is performed to investigate whether it would be possible to increase fatigue life of the original joint structure without affecting work efficiency, by only adjusting crane motion profile within multi-body dynamic simulation environment. All three methods are quantified and compared through fatigue damage factor results acquired using multi-axial fatigue assessment method. Result comparison has shown that joint redesign is the most preferred approach due to its ability to efficiently improve fatigue life of the structure without significant structural weight increase, while exposing any potential points for crack initiation to locations easily accessible for inspection and repair.