Seminar Nasional Teori dan Aplikasi Teknologi Kelautan (SENTA 2012) 5 Desember, 2012, Surabaya, Indonesia

P. HANGGAGraduate School of Engineering, Kyushu UniversityDepartment of Maritime Transportation, ITS - Surabaya

T. SHINODADepartment of Marine Systems Engineering, Kyushu University

GAINING EFFICIENCY IN CONTAINER HANDLING OPERATION WITH REGENERATIVE POWER CHARGING SYSTEM

Climate change issue Container terminal operator need to come up with ideas Some handling equipment are used more frequently than the other

Crucial question :

How is environment-friendly technology has been applied?Which part of operation need attention?

How to measure the implementation?

Background

Page 2

Application : Hybrid Straddle Carrier

Page 3

RechargableBattery

Engine Generator

Inverter fortraveling(Left side)

Inverter fortraveling(Right side)

Braking unit Resistor

Inverterfor hoist

Travelingmotor(Right side)

Travelingmotor(Left side)

Hoist motorConverter

Diesel-electric S/C system diagram

Type : Diesel Electric with inverterAcceleration Capability : 30 seconds to reach 20 km/hTraveling capability : 23 km/h (with load),

27 km/h (without load)Hoist/Lowering speed : 280 mm/sec (with load)

400 mm/sec (without load)Other characteristic : Equipped with battery to store

regenerative energy by motion

• Straddle Carrier is the most commonly used for In-Yard operation in medium and large sized container terminal

• Widely used in several major port in USA, Korea, Germany and Japan as a complement to conventional diesel-mechanic S.C

Diesel Electric Type

Engine

A.C Generator

Inverter

Motor

Reduction

Wheel

Diesel Mechanical Type

Engine

Torque Converter

Transmission

Differential

Reduction

Wheel

PART I : METHODOLOGY

1. Designing S/C movement pattern2. Installation of electric data logger in S/C

3. Conversion of electric data into real value

How to measure the impacts of Hybrid S/C operation in energy saving Movement pattern were designed for experimental purposes

Motions of S/C categories (with load and without load)Hoisting phaseStarting phaseCruising phaseBraking phaseLowering phase

Designing The Experiments (Movement pattern)

Page 5

Traveling stateHandling state

Measuring the electrical output easily separate the output from various range of machinery equipment

Designing The Experiments (Data logger)

Page 6

Voltage data logger is installed in the S/C Output performances from continuous

and temporal activity is are recorded in data logger (HIOKI LR8400-20 )

Recorded data in voltage is exported to CSV data

SCV data is converted into real value and analysed

‐2.00 

‐1.00 

‐

1.00 

2.00 

3.00 

4.00 

5.00 

6.00 

7.00 

8.00 

0 20 40 60 80 100 120

Scale of M

easuerem

ent (Volt)

Time (s)

Battery 

Fuel Cons. 

Generator Engine Speed 

Traveling Motor Speed 

STARTING PHASE

‐6.00 

‐4.00 

‐2.00 

‐

2.00 

4.00 

6.00 

8.00 

10.00 

20 40 60 80 100 120 140 160

Scale of M

easuerem

ent (Volt)

Time (s)

Battery  Fuel Cons.Traveling Motor Speed Generator Engine Speed 

CRUISING PHASE‐1.00 

‐

1.00 

2.00 

3.00 

4.00 

5.00 

6.00 

7.00 

8.00 

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

Scale of M

easuerem

ent (Volt)

Time (s)

Brake pedal angle

Battery

Fuel Cons. 

Traveling Motor Speed 

Generator Engine Speed

BRAKING PHASE

Example of Waveform Analysis

Page 7

Note : Recorded Time interval = 0.2 seconds, Output = voltage resolution of 0.5 mV in the 10 V

Cursor for partial measurement

Traveling motor speed

Fuel Cons.

Generator Engine Speed

Battery

Calculation Output of Partial Measurement

Lifting Motor Speed

Lifting Traveling

Converted the waveform to show the relation in real value and divided the analysis into lifting & traveling process Measured the value for each channel output by ACV (average channel value)

Data Conversion to Real Value

Page 8

Remarks:n = total number of data itemsdi = data on channel number i∆t = sampling period

Integration of shaded portionsAveraging value

Converting value

M = Max measurement rangeO = Max output voltageACV = Average Channel Value

PART II : MOVEMENT ANALYSIS

1. Traveling Analysis2. Hoisting/Lowering Analysis

3 kinds of traveling experiments were conducted- Exp_1 is for changing in travel speed - Exp_2 is for changing in acceleration but maintain traveling motor speed with a container load- Exp_3 is similar with Exp_2 only without a container load to S/C.

Traveling Analysis – Fuel Consumption

Page 10

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

100 150 200 250 300 350 400 450 500 550 600 650

Fuel

Con

s (L

/h)

Travelling Motor Speed (RPM)

Starting_Exp_2_Load

Cruising_Exp_2_Load

Braking_Exp_2_Load

Starting_Exp_1

Cruising_Exp_1

Braking_Exp_1

Starting_Exp_2_No_Load

Cruising_Exp_2_No_Load

Braking_Exp_2_No_LoadBraking

Effect of driver action on throttle to maintain speed

Effect of load shows difference on fuel consumption except for braking phase

Regenerative energy : energy recovery mechanism which slows a vehicle or object down by converting its kinetic energy into electric power and the stored saved in a storage battery and used later to power the motor for another use, such as hoisting, powering air conditioner in the control room and lights.

Traveling Analysis – Regenerative Energy

Page 11

-15.00

-10.00

-5.00

0.00

5.00

10.00

15.00

0 100 200 300 400 500 600 700 800 900

Bat

tery

Usa

ge (-

)/ C

harg

ing

(+) (

A)

Travelling Motor Speed (RPM)

Starting_Exp_2_Load

Cruising_Exp_2_Load

Braking_Exp_2_Load

Starting_Exp_1

Cruising_Exp_1

Braking_Exp_1

Starting_Exp_2_No_Load

Cruising_Exp_2_No_Load

Braking_Exp_2_No_Load

Charging

Usage

Gain energy in cruising phase.Hypothesis:-push/pull action to throttle-effect of inertia-vibration of load

Experiments shows good agreement in annotating the relation between braking and gaining energy

Impact of Traveling Speed (Pre-Analysis)

Page 12

STARTING PHASE CRUISING PHASE

BRAKING PHASEStarting Cruising Braking Total

10 -6.4 2.0 1.4 -3.020 -2.7 2.2 4.6 4.025 -7.0 5.6 7.8 6.310 -3.2 2.7 4.7 4.320 -0.7 2.7 6.3 8.325 -8.8 5.1 9.2 5.610 -5.4 1.7 1.8 -1.920 -1.4 2.3 3.1 3.925 -7.2 4.6 9.0 6.4

置き①

置き②

置き③

Speed (km/h)Pattern

Battery Usage (-)/ Charge (+) (A)

Higher Traveling Speed produce more battery charging, mainly during braking

Charging

Usage

Charging

Measuring correlation between lifting speed and fuel consumption as well as to battery usage/charging with variability in hoisting speed and stacking position

Hoisting/Lowering Analysis

Page 13

‐8.00 

‐6.00 

‐4.00 

‐2.00 

‐

2.00 

4.00 

6.00 

8.00 

10.00 

0 5 10 15 20 25 30 35 40 45

Scale of M

easuerem

ent (Vo

lt)

Time (s)

Battery  Lifting Motor Speed Fuel Cons. 

‐8.00 

‐7.00 

‐6.00 

‐5.00 

‐4.00 

‐3.00 

‐2.00 

‐1.00 

‐

1.00 

2.00 

3.00 

4.00 

0 5 10 15 20 25 30 35

Scale

 of M

easuerem

ent (Vo

lt)

Time (s)

Battery  Lifting Motor Speed Fuel Cons.

1st HOISTING

LOWERING

2nd HoistingAdjustment to Container Stack

2nd Hoisting

1st Hoisting

1st Hoisting

2nd HOISTING

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

-250 -150 -50 50 150 250 350 450 550 650

Fuel

Con

s (l/

h)

Lifting Speed (rpm)

Lowering

First Hoisting

Second Hoisting

Lowering and Hoisting operation shows good agreement with normal performance parameter and assumption

Hoisting/Lowering Analysis – Fuel Consumption

Page 14

Lowering 1st Hoisting 2nd Hoisting

Intriguing phenomena : Increase in fuel cons during 2nd Hoisting

Hypothesis : Data might be distorted as 2nd Hoisting is conducted while traveling

2nd Hoisting

1st Hoisting

Strong correlation between lifting speed and alternate performance parameter of battery utilization

Future issue : Can regenerative energy (lowering) be used to compensate energy usage during hoisting?

Hoisting/Lowering Analysis – Regenerative Energy

Page 15

y = ‐0.095x ‐ 1.246R² = 0.771

y = ‐0.092x ‐ 1.058R² = 0.993

‐20.00

‐15.00

‐10.00

‐5.00

0.00

5.00

10.00

15.00

20.00

‐250.00  ‐200.00  ‐150.00  ‐100.00  ‐50.00  ‐ 50.00  100.00  150.00  200.00 

Battery U

sage

 (A)

Lifting Speed (RPM)

Lifting Up

Lifting Down

Lowering

Hoisting

Charging

Usage

energy are regenerated by lowering operation

This preliminary study proposes methodology to assess and measure the efficiency of hybrid straddle carrier (Hybrid S/C) in the form of fuel consumption and gained regenerative energy by motions.- Combination of data logging instrument, logger utility software and spreadsheet is

used to capture electronic output- Electric data is successfully converted using the proposed ACV calculation

Analyzed data show good agreements in relation between traveling speed / lifting speed with either fuel consumption and battery charging- Regenerative energy can be gained through the following operation

- Traveling - Braking phase with more traveling speed- Lowering operation

Future research will focus on :- Assessing appropriate driving method and movement cycle (GPS and Video

Camera)- Comparing operational performance of Hybrid S/C and Conventional S/C

Conclusion

Page 16