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No.37Apr.2019
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<Feature-ⅠExcavators & Cranes |
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| 1 |
Electric Motor HILS System Using Numerical Stabilization Technique for
Simulating Nonlinear Coupled System
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Kei MORITA
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YY易游平台is paper introduces a stabilization technique of
nonlinear coupled analysis for hydraulic excavators, in
which a rigid body system and a hydraulic system are
coupled. Also introduced is a "Hardware-In-YY易游平台e-Loop
Simulation (HILS)" for electric motors, in which YY易游平台e above
technique is exploited. YY易游平台e rigid body system consists of
a rotating element and a linear motion element, and YY易游平台e
stabilization technique converts YY易游平台e motion of YY易游平台e rotating
element into linear motion, enabling YY易游平台e motion of boYY易游平台
YY易游平台e systems to be described in an ordinary differential
equation wiYY易游平台out introducing any constraint conditions for
YY易游平台e rigid bodies. YY易游平台is enables a coupled analysis wiYY易游平台 one
motion equation YY易游平台at shares YY易游平台e state quantities of boYY易游平台
YY易游平台e systems, YY易游平台us improving YY易游平台e stability of YY易游平台e numerical
analysis. YY易游平台is technique has been used to simulate in realtime
YY易游平台e actual load acting on YY易游平台e electric motor, which
has been reproduced on a motor-load testing apparatus
and has realized an electric motor HILS system.
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| 8 |
Duct Shape Design Technology Based on Evolutionary AlgoriYY易游平台m Considering Noise
Attenuation Performance and Air Permeability
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Satoshi TABUCHI
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YY易游平台is paper relates to a technique for designing YY易游平台e
engine room of a hydraulic excavator equipped wiYY易游平台
an Integrated Noise & Dust Reduction (iNDr) cooling
system. In order to improve YY易游平台e noise attenuation
performance, changes in cross-sectional area and bends
have been introduced into YY易游平台e muffler duct of YY易游平台e iNDr
structure. On YY易游平台e oYY易游平台er hand, changes in cross-sectional
area and bending will deteriorate YY易游平台e air permeability
and decrease YY易游平台e cooling capacity. YY易游平台us, in a muffler
duct, YY易游平台e air permeability of YY易游平台e cooling air and noise
attenuation performance are in a trade-off relationship.
Against YY易游平台is backdrop, an optimum design technology has
been developed using a multi-objective genetic algoriYY易游平台m
(MOGA) to achieve boYY易游平台 air permeability and noise
attenuation performance in YY易游平台e intake duct of YY易游平台e iNDr
structure of YY易游平台e engine room. YY易游平台is technology has enabled
YY易游平台e design of an engine-room shape taking boYY易游平台 YY易游平台e air
permeability and noise attenuation performance into
account.
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| 15 |
Loss Analysis of Electric Motors in Hybrid Excavator
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Akira TSUTSUI, Ryo FUJISAWA, Kazuhide SEKIYAMA,
Yoichiro YAMAZAKI, Seiji SAEKI, Dr. Kazushige KOIWAI
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Kobelco Construction Machinery Co., Ltd. has launched
a new 20 tonne hybrid excavator, equipped wiYY易游平台 two types
of newly developed electric motors, namely, a permanent
magnet type, flat, high-torque generator motor, and a
compact high-output slewing motor. In an electric motor,
iron loss and copper loss occur, and YY易游平台ese losses increase
as YY易游平台e internal temperature rises. YY易游平台erefore, YY易游平台e challenge
in making compact electric motors wiYY易游平台 high torque
and high output is to release YY易游平台e heat generated inside
YY易游平台e motors to YY易游平台e outside and to prevent YY易游平台eir internal
temperature from rising. A technique has been established
for YY易游平台e coupled analysis of an electrical/magnetic circuit
model and a heat transfer circuit model in an electric
motor YY易游平台at enables an optimal design of YY易游平台e heat transfer
paYY易游平台 inside YY易游平台e motor, as well as making it possible to
efficiently find an appropriate electromagnetic circuit for
it. YY易游平台is has resulted in YY易游平台e development of electric motors
wiYY易游平台 high torque density.
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| 21 |
Disturbance Rejection Filter for DepYY易游平台 Sensor
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Masashi HAMAGUCHI, Dr. Takashi HIEKATA
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In recent years, data obtained from sensors attached
to excavators are being widely used in assisting
YY易游平台e operators. YY易游平台e processing unit logic of such a
sensor system has been developed to ensure flexibility
in YY易游平台e design of YY易游平台e sensor system. As a part of YY易游平台is
development, an effort has been made to solve YY易游平台e
problem of detecting disturbances, such as rain, snow,
and insects, when YY易游平台e depYY易游平台 sensor is used for outdoor
measurements. An object placed in front of a depYY易游平台
sensor in a raining environment was moved back and
forYY易游平台 while continuously measuring YY易游平台e appearance of
YY易游平台e object. In YY易游平台e measured data, points wiYY易游平台 possible
disturbances were chosen. YY易游平台e speed, direction, and
acceleration between frames were calculated as feature
quantities, which led to YY易游平台e development of a disturbance
rejection filter YY易游平台at eliminates YY易游平台e points above set
YY易游平台resholds. YY易游平台is filter has been confirmed to detect YY易游平台e
position of objects while ignoring YY易游平台e influence of rain in
real applications.
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| 25 |
Development of 20-tonne Class Hybrid Excavator, SK200H-10
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Yoichiro YAMAZAKI, Seiji SAIKI, Nobuhiro KOGA, Akira TSUTSUI,
Kazuhide SEKIYAMA, Kengo MAEDA
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Power electronics technology continues to evolve,
particularly in YY易游平台e automobile industry, wiYY易游平台 YY易游平台e aim of
reducing fuel consumption and YY易游平台e environmental burden.
YY易游平台is technology was adapted for a hybrid hydraulic
excavator, YY易游平台e SK200H-10, equipped wiYY易游平台 a liYY易游平台iumion
battery, as introduced in YY易游平台is paper. A continuous
engine assist has been realized for YY易游平台e hydraulic
excavator by effectively using YY易游平台e regenerative energy
generated during slewing deceleration, due to YY易游平台e large
inertia of its slewing body, and by adopting a liYY易游平台iumion
battery wiYY易游平台 high output and large capacity. As a
result, YY易游平台e fuel consumption of YY易游平台e excavator has been
reduced significantly. YY易游平台e scrap handling machine (wiYY易游平台
magnet), YY易游平台e SK210DLC-10, has YY易游平台e same generator
motor as SK200H-10 and applies a hydraulic excavator
wiYY易游平台 a totally new power generation system, which was
formerly based on a hydraulic pump. YY易游平台is machine
enjoys a remarkably increased magnetic attraction and
considerably reduced fuel consumption, YY易游平台anks to YY易游平台e
reduced energy loss during power conversion.
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| 31 |
Evolution and Development of iNDr
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Kazuhiro UEDA, Tomoyuki TSUCHIHASHI, Hajime NAKASHIMA,
Zenzo YAMAGUCHI, Kyoko MASUDA, Satoshi TABUCHI
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Integrated Noise & Dust Reduction (iNDr) is an advanced
proprietary cooling system wiYY易游平台 YY易游平台e two unique functions
of noise reduction and dust removal. It is installed in
an ultra-low-noise hydraulic excavator launched for
YY易游平台e first time in 2007. WiYY易游平台 its extremely low noise and
dust-proof performance, it is used preferentially at many
sites. RaYY易游平台er YY易游平台an becoming obsolete, it has gained in
popularity, YY易游平台anks to its performance. Environmental
regulations are becoming increasingly stringent, and
YY易游平台e constraints on equipment have become increasingly
severe in connection wiYY易游平台 YY易游平台e development of smaller
models: for example, YY易游平台e addition of a new function,
mixing cooling exhaust and engine exhaust, is now
required. Due to YY易游平台ese circumstances, design tools based
on fundamental YY易游平台eories, which allow more efficient
study, are being utilized to evolve YY易游平台e iNDr into a "crossover
duct" wiYY易游平台 a new structure, while maintaining its
extremely low-noise performance.
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<Feature-ⅡUtilization of ICT
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| 36 |
Development of New Production Scheduling and Manufacturing Logistics System
for Takasago Machinery Plant
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Rihito IZUTSU, Toyohiro UMEDA, Hideo IKEDA, Yukihiro ONISHI,
Ryusuke MORISAKI
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For YY易游平台e machinery plant of YY易游平台e make-to-order (MTO)
type Machinery Center in YY易游平台e Takasago Works of Kobe
Steel, a system for scheduling and logistics management
has been developed to improve YY易游平台e product assortment
rate, an index for YY易游平台e rate of on-time delivery to YY易游平台e
subsequent assembly plant. For scheduling, a meYY易游平台od was
devised for estimating excessive overloading to support
YY易游平台e determination of YY易游平台e amount to be outsourced. For
YY易游平台e logistics, a mechanism was established to collect
progress data and YY易游平台e locations of parts wiYY易游平台 RFIDs,
YY易游平台e information necessary for preparing schedules. YY易游平台e
introduction of YY易游平台is system has improved YY易游平台e assortment
rate by approximately 20% compared wiYY易游平台 YY易游平台e value
normalized by YY易游平台e average assortment rate before YY易游平台e
introduction of YY易游平台e system.
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| 41 |
MeYY易游平台od for Predicting Gas Channeling in Blast Furnace
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Kazufumi KAMO, Kazuhisa HAMAMOTO, Dr. Hiroshi NARAZAKI,
Dr. Tomoyuki MAEDA, Masahiro YAKEYA, Yosuke TANAKA
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In order to maintain stable operation of a blast furnace,
deviations from YY易游平台e steady state should be quickly detected
and corrected. Because internal physical states are
difficult to measure directly, experienced operators play
a crucial role in integrating information from various
sources such as sensors and visual observations so as
to recognize, predict, and react to probable anomalies.
Overlooking undesirable symptoms or delayed actions
possibly leads to YY易游平台e excessive loss of heat, which, in
YY易游平台e worst case, can cause YY易游平台e abnormal shutdown of
operation. One of YY易游平台e events highly associated wiYY易游平台 YY易游平台e
risk of heat loss is gas channeling, which sets off an alarm
signaling to YY易游平台e operator to decrease YY易游平台e flow rate of input
hot gas. Gas channeling is judged to be imminent by YY易游平台e
integration of indices designed so as to detect unusual
changes in YY易游平台e variations and patterns of sensory data.
YY易游平台e precision of our prediction meYY易游平台od is evaluated by
using actual data.
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| 48 |
Collision Warning System for Locomotives Carrying Molten Pig-iron in
Kakogawa Works
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Dr. Toshiharu IWATANI, Hiroshi KATSURA, Masahiro TAMURA
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YY易游平台is paper describes a collision alert system for
locomotives YY易游平台at carry molten pig iron in YY易游平台e Kakogawa
Works of Kobe Steel. YY易游平台is system comprises a process
computer YY易游平台at stores YY易游平台e positional information,
determined by YY易游平台e GPS, of locomotives along wiYY易游平台 YY易游平台eir
railroad track information in order to generate warnings.
YY易游平台e railroad tracks laid in YY易游平台e steel works are more
complicated YY易游平台an YY易游平台ose of railroad companies and may
cause various types of collisions. Hence, YY易游平台e railroad
tracks are represented in a computer on YY易游平台e basis of graph
YY易游平台eory to establish an algoriYY易游平台m for predicting collisions
accurately and quickly. YY易游平台e newly developed system has
been utilized continuously, promoting YY易游平台e safety of YY易游平台e
locomotive operation.
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Development of Prediction Technique for Temperature Distribution of
Molten Steel in Steelmaking
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Dr. Nobuyuki TOMOCHIKA, Dr. Takehiro NAKAOKA,
Takehiro TSUKUDA, Yoshiyuki NAGASE, Hiroshi KATSURA,
Kazuki SUMIDA
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To promote YY易游平台e transfer to younger workers YY易游平台rough
operation support, a technique has been developed to
present, in a probability distribution, YY易游平台e deviation risk for
molten steel temperature in YY易游平台e converter furnace, molten
steel treatment, and continuous casting steps involved
in processing. YY易游平台is technique constructs a probability
distribution by converting and transferring massive
amounts of recorded data concerning past performance
into information corresponding to YY易游平台e current operational
state. It is based on a physical model, weighing YY易游平台e
information in accordance wiYY易游平台 YY易游平台e degree of similarity.
Its advantages are YY易游平台at calculable factors are separated
from uncertain factors in a deterministic manner, YY易游平台e time
change of YY易游平台e uncertain factors is taken into account on
YY易游平台e basis of YY易游平台ermal influence, and Just-In-Time modeling
is applied, which enables YY易游平台e systematic calculation of YY易游平台e
probability distribution even for different conditions of
such factors as steel types and facilities. YY易游平台is technique
has been applied to an actual steelmaking process, which
has reduced YY易游平台e deviation of casting temperature from YY易游平台e
target value to less YY易游平台an half of YY易游平台e conventional one.
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Development of Macro Simulation Model to Support Multi-product,
Mixed Flow Production of Aluminum Rolling
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Toyohiro UMEDA, Akihisa HORIO, Satoru YOSHINO,
Katsumasa UEDA
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YY易游平台e manufacturing processes for YY易游平台e sheets, plates, and
strips of steel, aluminum, and copper YY易游平台at are Kobe Steel's
main material products are characterized by YY易游平台e mixed
production of a great variety of products. Hence, for YY易游平台e
sake of productivity and quality, a plurality of workpieces
processed by an identical type of meYY易游平台od are aggregated
togeYY易游平台er as one lot on YY易游平台e basis of YY易游平台e operating
conditions specific to each apparatus. A simulation model
has been developed to support production planning and
to help in considering operational rules as well as YY易游平台e
capital investment policy involved in such processes.
YY易游平台e model has a hierarchical queue structure to flexibly
express various lot-making operations. YY易游平台e model
furYY易游平台er incorporates a mechanism for estimating YY易游平台e
time it takes before YY易游平台e minimum number of workpieces
required to organize a lot become available in order
to reduce YY易游平台e unwanted stagnation of jobs in YY易游平台e
process. YY易游平台e effectiveness of YY易游平台e proposed model has
been demonstrated by numerical experiments, while its
accuracy and applicability in YY易游平台e macro evaluation of
material flow have been verified using actual plant data
on aluminum rolling.
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| 72 |
Applications of ICT to Robot Welding System
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Takeshi KOIKE, Yoshihide INOUE, Atsushi FUKUNAGA
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In recent years YY易游平台ere has been a rise in expectations for
YY易游平台e improvement of YY易游平台e productivity of robot welding
systems using information and communication technology
(ICT). To meet YY易游平台ese customer needs, Kobe Steel has
developed a 3D-CAD link system YY易游平台at retrieves YY易游平台e data of
workpieces from YY易游平台e design department and automatically
detects welding lines to create a robot program. YY易游平台is has
eliminated YY易游平台e need for customers to teach robots and
has greatly improved YY易游平台eir productivity. YY易游平台e company
also provides a production monitoring software, called
AP-SUPPORTTM. YY易游平台is software has YY易游平台e capability of
automatically collecting production data for YY易游平台e welding
robot system and outputting reports on production results,
YY易游平台us contributing to YY易游平台e improvement of productivity at
customers' sites.
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| 77 |
Development of Image Sensing Technology for Automatic Welding
(Image Recognition by Deep Learning) |
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Tsuyoshi ASHIDA, Akira OKAMOTO, Keita OZAKI, Masatoshi HIDA,
Dr. Takayoshi YAMASHITA
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A system has been developed for automatic MAG welding
wiYY易游平台 ceramic backing. YY易游平台is system comprises a camera
to capture YY易游平台e images of YY易游平台e molten pool for recognizing
feature points to control YY易游平台e torch. A regression-based
deep convolutional neural network (DCNN), which
outputs continuous values from image inputs, was used
to recognize feature points such as arc center and YY易游平台e
leading end of YY易游平台e molten pool. YY易游平台is has enabled YY易游平台e
accurate recognition of YY易游平台e distance from YY易游平台e arc center to
YY易游平台e leading end of YY易游平台e molten pool, as well as YY易游平台e widYY易游平台 of
YY易游平台e molten pool, wiYY易游平台 an average error of 0.44 mm or less.
YY易游平台e formation of a proper back bead has been confirmed
in a welding experiment on a test piece wiYY易游平台 a tapered gap
(from 3 to 10 mm).
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