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AD-A285 826Report No. CG-D-20-94 -.
Coast Guard Mission Data Recorder (MDR)for the 47-FT Motor Lifeboat
Bert N. MaceskerRobert C. Desruisseau
Edward S. Purcell
U.S. Coast GuardResearch and Development Center
1082 Shennecossett Road-s /Groton, CT 06340-6096
FINAL REPORTAUGUST 1994
•Q
This document is available to the U.S. public through theNational Technical Information Service, Springfield, Virginia 22161
Prepared for: 3.
U.S. Department of TransportationUnited States Coast GuardOffice of Engineering, Logistics, and DevelopmentWashingtcn, DC 20593-0001
09411 1 10
,
NOTICEThis document is disseminated under the sponsorship of theDepartment of Transportation in the interest of informationexchange. The United States Government assumes no liabilityfor its contents or use thereof.
The United States Government does not endorse products ormanufacturers. Trade or manufacturers' names appear hereinsolely because they are considered essential to the object ofthis report.
The contents of this report reflect the views of the Coast GuardResearch & Development Center. This report does not consti-tute a standard, specification, or regulation.
* Technical Director, Act.ngUnited States Coast GuardResearch & Development Center1082 Shennecossett Road
"<,vws e- ' Groton, CT 06340-6096
ii
Technical Report Documentation Page1. Report No. 2. Government Accession No. 3. Recipient's Catalog No.
CG-D-20-94
4. Title and Subtitle 5. Report Date
August 1994Coast Guard Mission Data Recorder (MDR) for the 47-FT Motor Lifeboat 6. Perforrring Organization Code
7. Author(s) 8 Performing Organization Report NoBert N Macesker, Robert C Desruisseau and Edward S Purcell R&DC 16/94
9 Performing Organization Name and Address 10 Work Unit No (TRAIS)
U.S. Coast GuardResearch and Development Center 11 Contract or Grant No1082 Shennecosset2 RoadGroton, Connecticut 06340-6096 12 Type of Report and Period Covered
12 Sponsoring Agency Name and Address Final Report
Department of Transortation 14 Sponsoring Agency CodeU.S. Coast GuardOffice of Engineering, Logistics, and DevelopmentWashington. D.C. 20593-0001
15. Eup;4ementary Notes
16. Abstract
A Mission Data Recorder (MDR) was designed and built by the Coast Guard R&D Center to support theOperational Test an' Evaluation (OT&E) of the 47-FT Motor Lifeboat (MLB).
The OT&E was under the overall direction of the Motor Lifeboat Replacement Acquisition ProjectManager, Commandant (G-AMB).
The purpose of the MDR was to collect both short-term event data and long-term vessel motions data inan autonomous manner. Some significant even~ts have been recorded, including a 137-degree rollevent, during which the values of roll, pitch, yaw, engine RPM and rudder angle were recorded.
Testing of five 47-FT MLBs will continue for at least another six months. The MDR will recordsigrnifinarit ro;i events and long-term vertical acceleration data for u3e in a crew fatigue study.
17. Key Words 18. Distribution Statement
motor lifeboat capsize Document is available to the U.S. public through47-FT N4L_- accelerations the National Technical Informati.n Service,Coast Guard maneuvering ,pringfield, Virginia 22161data recording operational testing
19 Security Classif (oi thts vapart) 120. SECURITY CLASSIF. (of this page) 21. No. of Pages 22. Price
UNCJ~2LASSIFlIE D I UNCLASSIFIED
Form DOT F 1 700.7 (8/72) Reproduction of form and completed page is authorized.II
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TABLE OF CONTENTS
PAGE
INTRODUCTION ............................................ 1
" BACKGROUND 1.............................................. 1
Concept Development 1..................................... 1- Various Development Efforts .............................. 4
Prototype Testing at Station Cape Disappointment ........ 6
DISCUSSION .............................................. 6
MDR Functional Overview ................................. 6MDR Installations ....................................... 12
Installation Schedule ............................... 12MDR Hardware Installation ........................... 12
MDR Post Processing ..................................... 20Events Recorded ..................................... 20
Data Offloading ................................. 20Area of Recorded Operations (AROs) ...................... 22Animation Routine ................................... 22
CONCLUSIONS ............................................. 26
Discussion of Events Recorded During the OT&E .............. 26Motion Statistics ....................................... 29Area of Recorded Operations ............................. 30Recommended Phase 2 OT&E Evaluations of the
47-FT Preproduction MLBs .............................. 30
REFERENCES ............................................. 31
APPENDIX A - 47201 DATA RESULTS ......................... A-i
APPENDIX B - 47202 DATA RESULTS ......................... !3-i
APPENDIX C - 47203 DATA RESULTS ......................... C-I
APPENDIX D - 47204 DATA RESULTS ......................... D-1
APPENDIX E - 47205 DATA RESULTS .............................. E-1I
APPENDIX F - 47200 DATA RESULTS ......................... F-i
APPENDIX G - LIST OF HARDWARE AND SOFTWARE .................. G-I
v
LIST OF ILLUSTRATIONS
Figurp Paae
1 Geographic Locations of Preproduction andPrototype MLBs for the 47-FT OT&E ................. 2
2 Information Requiremen .s for a Mission DataRecorder .............................................. 5
3 Major Components Inside the Mission DataRecorder .......................................... 7
4 Mission Data Recorder Rotating Memory Buffer ..... 9
5 Functional Overview of the Mission DataRecorder ............................................. 10
6 Installation of Mission Data Reccrder on AftFuel Cover Plate .................................... 13
7 Starboard Photo-Optical RPM Sensor as Installedon the 47-FT MLB .................................. 15
8 Micro-Switch Measures Shaft Directionon the 47-FT MLB .................................... 16
9 String Potentiometer installed in the Lazaretteof the 47-FT MLB .................................... 17
10 Mission Data Recorder Wiring Layout andBulkhead Penetrations ............................... 18
11 MDR System Wiring Diagram ........................... 19
12 Event Summary Plot Key .............................. 21
13 Mission Data Recorder Data Retrieval System ..... 23
14 Area of Recorded Operation (ARO) Plot Key ........ 2.,..
15 Display of the BOATVU Animation ProgramPicture Screen ............................... 45
16 Key to Interpretation of Virtual Instruments ... 7
vi
LIST OF TABLES
I Mission Data Recorder Performance Characteristics. 11
II Motion Events Recorded by the Mission DataRecorder ............................................. 20
vii
ACKNOWLEDGEMENTS
The cooperation of each of the five stations tasked with testingthe preproduction 47-FT Motor Lifeboats is gratefully acknowl-edged. Although a nearly autonomous mission data recorder (MDR)device was developed, some additional responsibility had to begiven to each station (on top of their already busy workschedule) to support the MDR data collection. Appreciation isexpressed to the sponsor (C-NRS), particularly CDR M. Lewandowskiand CDR J. McGuiness, for taking an active interest and providingencouragement to fully develop the MDR. Additionally,appreciation is expressed to Mr. G. Hayward for introducing us toa datalogger that could do the job and for all of his hardwareand software contributions. GESAC, Inc. is also acknowledged fortheir support in developing an animation capability.Acknowledgement is due to LCDR D. E. Milburn who originallyconceived many of the ideas for the MDR before his transfer fromthe R&D Center. Acknowledgement is due to ETC T. Brion and BM2D. Harding, both members of the MDR installation team. ETC Brionhas taken on the responsibility of retrieving MDR data on aroutine basis and organizing the voluminous data collected.
viii
EXECUTIVE SUMMARY
A Mission Data Recorder (MDR) was designed and built by the CoastGuard R&D Center to support the Operational Test anC Evaluation(OT&E) of the 47-FT Motor Lifeboat (MLB).
The OT&E was conducted by G-NRS to evaluate the etfectiveness andsuitability of five 47-FT MLBs placed at various stations underoperation by normal Coast Guard crews, as opposed to theprototype, which had a special Test Team.
The purpose of the MDR was to collect both short-term motionevent data and long-term vessel motions data in an autonomousmanner, similar to an aircraft flight data recorder.
Some significant events were recorded during the first six-monthOT&E period, including a 137-degree roll by one of the boats. Apermanent record of the event and its surrounding time frame wasobtained, showing roll, pitch, yaw, engine RPM and rudder 3n_ •.On two occasions where severe roll occurred, the engine o. ý-heside toward the roll stalled, and was re-started in about oneminute. A computer screen animation of the event was alsodeveloped, to assist in debriefing and training of the crew.
The MDR also records the LORAN position of the boat every tenminutes. The Coast Guard Electronic Engineering Center's program,"Geographical Display Operations Computer," was used to plot MDRposition data. A computer screen chart overlay, showing theboat's positions over a one-month period, was used to produce achart plot of its operational area.
R&DC will continue to waoritor MDR data for an additional sixmonths in F795 to obtain lonq-term statistics on verticalaccelerations for usi in a crew fatigue study. Significant rollevents will also be recorded to assist in post-event analysis andcrew training.
ix!x
INTRODUCTION
The 47-FT Motor Lifeboat (MLB) design was developed by the U.S.Coast Guard and Textron Marine Systems. The 47-FT MLB isdesigned as a heavy weather rescue boat with self-rightingcapabilities. The self-righting capability of 3 47-FT MLB isessential since it can expect to encounter violent motions inthe surf with an occasional severe roll or even 360 degreerollover in the course of conducting operations.
The Coast Guard is planning to procure about one hundred of thesecraft to replace the aging 44-FT MLBs. Prior to full-scaleproduction, five preproduction boats are undergoing anOperational Test & Evaluation (OT&E). The five Coast Guardstations involved with the OT&E are:
Station Cape May, Cape May, NJ 47201Station Oregon Inlet, Rodanthe, NC 47202Station Tillamook, Garibaldi, OR 47203Station Umpqua River, Reedsport, OR 47204Station Gloucester, Gloucester, MA 47205
Figure 1 illustrates the relative geographic locations of the47-FT MLBs.
The objective of the OT&E as defined in the OT&E Plan [1] is toevaluate the effectiveness and suitability of the Coast Guard47-FT MLB. The OT&E results will be provided to the Coast GuardAcquisition Review Council (CGARC) to support decision-makingpolicies regarding the decision to go ahead with full productionof a 47-FT MLB fleet.
The R&D Center was tasked to develop a Mission Data Recorder(MDR) to autonomously record operating hours, motion environment,operational profile, and capture any significant events such as aboat rollover. The task of developing an MDR, which addressesone of the six OT&E evalua,-ion components [1], is the subject ofthis report.
BACKGROUND
Concet;DeveJiQpmenY~
Prior to the construction of the preproduction boats an extensiveDevelopmental Test & Evaluation (DT&E) was performed on theprototype 47-FT MLB (47200). The R&D Center conducted a varietyof technical tests including seakeeping, maneuvering, tructuralloading, etc., the results of which can be found ir. the reportentitled "Technical Characteristics Verification of the Prototype47 FT MLB" [2]. The prototype performed exceedingly well. in mostof the technical areas tested. However, maneuvering problemswere identified with the original design of employing largecanted rudders. These rudders were very efficient arid sometimestended to induce excessive roll. This phenomena was revealed in
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the unpredictable behavior exhibited in high speed turns andbroaching in following seas during the DT&E. After a number oftest iterations with different skeg/rudder configurations, acombination of smaller vertical rudders and no skeg were chosenas being optimal. The conversion from the 2.7 square foot cantedrudders to 1.9 square foot vertical rudders is believed to haveeliminated the excessive transient rolls during high-speedmaneuvers and improved the handling characteristics with respectto the maneuvering problem identified. The long term investmentinvolved in replacing the 44-FT MLBs with a capable replacementdictates the need for continued monitoring of the motion andmaneuvering performance of the preproduction boats. This isnecessary in case )ther problems or variations of the originalproblem are revealed during the OT&E. The MDR was developed toaccomplish this monitoring function.
Two main objectives were established from the start of thisproject to collect motions data on the 47-FT MLB. They were asfollows:
# The primary objective for the MDR is to have the ability toreconstruct a severe dynamic event such as a rollover whenan established threshold is exceeded.
# The secondary objective for the MDR is to collect data todevelop motion and underway time histories.
Cost was an additional constraint because MDR systems had to bedeveloped for five MLBs.
A sixth MDR has recently been installed on the 47200 prototype,as well. Although the prototype is slightly different internallyit has the same Deep Vee hull and diesel engines as thepreproduction boats. Since the Motor Lifeboat Replacement TestTeam located at the National Motor Lifeboat School completedtheir evaluations of the prototype, it has gone into operationaluse with Coast Guard Station, Cape Disappointment, WA.
The MDR was developed to function like an aircraft flightrecorder "black box". The concept was to use a self-containedsensor package and data-logger to record the motions and controlsettings on the 47-FT MLB. The recorded data is played backafter an incident to help reconstruct what dctually happened.The minimum amount of information required to perform thisfunction resulted in the selection of the following measurementparameters:
MoQtion Pdrdmter
# heave acceleration# pitch angle# roll angle# yaw angle (heading)
3
+ rudder position* port engine RPM# starboard engine 21PM# port shaft direction (reverse or forward)* starboard shaft direction (reverse or forward)
BQt's Position
* latitude and longitude
Figure 2 illustrates the desired information characteristics ofthe MDR. The minimum performance requirements which wereestablished at the star-, f this project for the MDR were definedas follows:
* minimum autonomous operating time of 120 hours (30 days X 4hours underway per day)
* storage of a minimum of 4 roll motion events# status indicators to display MDR operating and memory status
to crew# 20 Hz sampling rate* data readout in ASCII column format# minimum 8 bit resolution
Various DevelopmentEffft P
SMD C.2mputer: The datalogger s'ý±ected for use as the heart ofthe MDR was a low power Tattletale Model 5. The Model 5 wasoutfitted with 2 Mbytes of expanded solid state memory to storethe data collected on the 47-FT MLBs. The datalogger uses astreamlined version of the BASIC programming language calledTTBASIC.
MDR__Hardware: The MDR hardware, including circuit hoards,housing, and interfaces were designed and fabricated by the R&DCenter. The sensors used were selected off-the-shelf items.
MDR__g•nting: Vibration isolation mounts were designed in-houseto Isolate the MDR from the propeller-induced structurebornevibrations. The mounts were tested at a vibration laboratoryusing a 1200 lb. shaker table. An MDR foundation plate wasdesigned in-house to attach to each of the MLB's aft fuel coverplates using the existing bolt holes with Jonger bolts.
B ATMAJ: A computer animation capability was developed to playback computer generated images of virtual instruments and asolid wire-frame rendition of the 47-FT MLB's recorded motions.This program was adapted fiom an existing animation program todefray developmental costs.
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Fe___tDi.vl-eve1:. A data retrieval scheme using a hand-heldcomputer and communications software package was developed by theR&D Cen.er to off-load dct& through an RJ-1l RS232 interface.
A listing of hardware and software used in carrying out this
project is provided in Appendix G for information.
Protype__Te_siitinua _tation Cape Disappointmn_
A prototype MDR was developed and tested on the 47-FT MLB (47200)on 7 April 1993 at Station Cape Disappointment, WA. The originalapproach was to record the RPM and rudder position directly fromthe MLBs tachometers and rudder angle indicator. The attempt toread voltages directly from these sensors resulted in the MDRsystem loading down the boats sensors causing inaccuratereadings. In order to completely divorce the MDR system from the47-FT MLB's electronics, a rudder-position transducer and photo-optic tachs were used in the final configuration.
The MDR motion sensors were tested on 47200, together with theR&D Center's motion package used for seakeeping testing. The47200 went through several maneuvers including turning circlesand various wave encounters. During these maneuvers the MDR'sthreshold was artificially triggered to record several minutesworth of data. The peak-to-peak excursions measured by the MDRsensors and separate motions package were consistent,
DISCUSSION
MDR FunctionalQy-eryview
The MDR was designed to operate autonomously with minimal crewparticipation. The MDR remains in a low power 'stand-by-mode"and charges up its battery when the 47-Fm MLB is on shore-tie.After a relay detects a shore-tie power disconnect, it turns onand begins data collection. The shore-tie is normallydisconnected just before the boat gets underway. This enablesthe MDR to monitor the boat's motions from the moment it leavesthe dock until it returns. After the shore-tie is reconnectedthe MDR resumes its low power "stand-by mode" and charges up itsbattery for the next mission.
The MDR houses the computer board, 2 Mbyte expanded memory board,battery charger, and 12V6Ah gell cell battery. The MDR has fourinternal sensors. Two electronic, pendulum-type sensors are usedto measure roll and pitch angles of motion. A 4g accelerometermeasures heave motions and a fluxgate compass is used to measureyaw angle. Figure 3 illustrates the major components inside theMDR.
6
Missioie Data Recorder Physical Layout
(COVER - looking at inside of cover)
System Tachometer Circuit
1-4 .1. 1 -Green
fl~tRery Charger IISVAC IEYOC
ACDsu
(BTO -e TWkn onInoMRbx
Figure 3ReMajoy opnnsIsd h iso aaRcre
The MDR economizes storage space by recording data continuouslyin a revolving buffer at a 20 Hz sampling rate. When the MDR ison, the program collects 10 channels of information for a cycleof 10 minutes. During the 10-minute cycle, the MDR programcontinuously checks the roll sensor and determines if a thresholdhas been exceeded or not. If no event has been detected afterthe I0-minute cycle expires, the memory pointer goes to thebeginning of the buffer and begins to collect new data. However,if an event is detected, the 10 minutes of information is eavedas pre-event data. The program's progressive memory pointermoves to a different location and stores an additional twominutes of post-event data. Figure 4 illustrates this conceptusing bench test data where a roll threshold was set to 60degrees. At sample number 2085, the roll sensor detects a valuethat exceeds the threshold. The memory pointer goes to 300Kbytes (15,000 samples x 2 bytes x 10 channels) to initiate the 2minute post-event cycle. A threshold software filter was addedto eliminate the possibility of triggering on an artificial eventsuch as a spurious voltage spike or extreme verticalacceleration.
The data in the 10 minute buffer is statistically reduced beforethe buffer is overwritten in the case of a non-event, saving thefollowing:
* date and time* heave RMS, heave average, highest heave value detected,
lowest heave value detected* pitch RMS, pitch average, highest pitch value detected,
lowest pitch value detected* roll RMS, roll average, highest roll value detected, lowest
roll value detected* average port shaft RPM* ships position (lat/long)
If the shore-tie disconnect is not replaced and the internal 12Vbattery falls below 8.5 Volts, the system assumes a "sleep-mode"to retain recorded data. When this occurs, the MDR data can onlybe recovered by executing a hard reset. The internal MDR batterywill collect three to five days of continuous data acquisitionwithout recharging.
Figure 5 illustrates the program's operation. Further detailsincluding MDR schematics and program listings can be found in the47-FT Motor Lifeboat Mission Data Recorder Development Manual[3]. The general performance characteristics of the MDR arelisted in Table I.
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TABLE IFISTON DATA RECORDER PERFORMANCE CHARACTERISTICS
heave acceleration +/- 4g dynamic rangepitch angle +/- 175 deg range of motionroll angle +1- 175 deg range of motion*heading +/- 0.5 deg accuracy (gimbaled to +1- 45 deg)port/stbd shaft RPM +/- 30 accuracyrudder 0-150 deg range of motionport/stbd shaft directionLORAUN lat/lcng**
Operatio-nal Parmtr
autonomous operation of 110 days @ 4 hrs underway per daystorage of 5 events (12 minutes each)20 Hz sampling ratestores 10 minute statistical summariesstatus lights indicate memory condition
less than $8000.00 per unit (hardware costs only, asconstructed by the R&D Center)
* MDR lab tests demonstrate box can accurately track a 360 degreeroll. MDR software can be configured to trigger off any sensoror combination of sensors to capture a specific motionphenomenon.
** Program can be adapted to decode GPS signals.
1i
MDR Installatlons
Installation Schedule
The MDRs were installed on the five preproduction boats when theybecame available. The boats were put in "Charlie" status forthree days to install the MDR hardware and software, calibratethe sensors, and perform checkout tests with the boat underway.The initial MDR installation and checkouts were performed asfollows:
MLU INSALLATION SCHEDULE MDR Ng_, RQLL THRE_.SHOLD
47201 27-30 SEP 1993 MDR No.1 30 degrees47202 25-29 OCT 1993 MDR No.2 45 degrees47203 16-18 NOV 1993 MDR No.3 45 degrees47204 21-24 JAN 1994 MDR No.4 45 degrees47205 31 JAN - 3 FEB 1994 MDR No.5 45 degrees
47200 14-16 MAY 1994 MDR No.6 60 degrees
A set of second visits were required to upgrade rudder sensorsthat were having mechanical problems with the rudder sensorstring pots and to generally check the system integrity. Thesevisits were performed as follows:
MU VYISISCHEDULE
47201 3/11/9447202 2/27/9447203 3/24/9447204 2/25/9447205 trip not required......................................................
47200 trip not required
MDR Hardwar Installation
The MDR box was installed on the aft fuel cover plate in thesurvivor's compartment approximately 14½ feet forward of the aftperpendicular and three feet above baseline. This install ationsite is located near the center of gravity of the 47-FT MLB. Aone-half inch thick aluminum foundation plate interfaces with theexisting bolt hole pattern on the cover plate. Four mounts wereused to isolate high frequency vibrations including propeller-induced structureborne vibrations. This was necessary because ofthe importance placed on the MDR measuring rgid body motions ofthe 47-FT MLB and not unrelated boat vibrations. Figure 6presents a photograph of this installation.
Two banner photoelectric; polarized retro-reflective sensors wereinstalled on the port and starboard cardan shafts to recordengine RPM. The cardan shaft is located between the engine and
12
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reduction gear of the 47-FT MLB's vee drive system. The sensorsare mounted on the outboard framing near frame 6. Reflectivetape was adhered to the cardan shaft in-line with each sensor.These RPM sensors draw power from the boat's 12V DC panel anddraw a maximum of 25 milliamps. Figure 7 presents a photographof a photoelectric tach as installed on the 47-FT MLB.
Two micro-switches were installed in each reversing gear box tomeasure throttle or shaft direction. The switches are engaged bythe cam at the end of the linkage inside the box. A signal issent to a digital I/O port on the MDR and is assigned a negativevalue if the shafte are in reverse. Figure 8 presents aphotograph of a micro-switch installed on a 47-FT MLB.
A ruggedized string potentiometer was installed in the Lazaretteto measure the rudder position. The rudder angle sensor is asealed string pot which has a stainless steel leader attached tothe rudder post. Figure 9 presents a photograph of the ruddersensor attached in the Lazarette.
The MDR measures the boat's position through a 'Tee' connectorinstalled in the back of the LORAN set which is located in theenclosed bridge. The 47-FT MLB has two LORAN unite. One islocated in the enclosed bridge and one is up on the f lyingbridge. The MDR program extracts latitude and longitudeinformation every 10 minutes from the NMEA 0183 interface on theLORAN-C sets. The pcsit±on sampling rate i? not frequent enoughfor detailed track reconstruction. However, this information isused for plotting Areas of Recorded Operations (AROs) using thenewly developed Geographical Display Operations Center (GDOC)software which is undergoing testing.
Several bulkhead penetrations had to be made to accommodate theMDR system. In the first installation on the 47201 at StationCape May, water-tight stuffing tubes were used. In the remaininginstallations the existing Multiplug penetrations were utilizedto eliminate the need to drill any holes through the bulkheads.Figure 10 illustrates the bulkhead penatretions required andgeneral wiring layout. Figure 11 illustrates a system wiringdiagram.
The installations took three days, required three R&D Centerpersonnel, and required that the boat be in "Charlie" status.The wiring and hardare installation normally took two days. Thethird day waa required to calibrate the sensors and "store" thevalues into the MDR's Read Only Memory (ROM). The MDR was arti-ficially triggered for each boat, dockside, to collect baselinedata on the motion sensors. Typically the roll and pitch readingsdeviated from zero (level plane) no more than 1 to 2 degrees atthe most. A system check was performed by setting a temporarythreshold value to 10 degrees and then taking the boat out formaneuvers to trigger the recording of roll events. These datawere analyzed to determine if all channels were working properly.
14
MDRphoto-optictachometer
i~i,,,,ii:•Re tro-reflective
.:.i;i~i?!i!?i............ ..ta p e
Figure 7. Starboard Photo-Optical RPM Sensor as Installedon the 47-FT MLB
15
Throttle transfer unit
Figure 8. Micro-Switch Measures Shaft Direction on the47-FT MLB
16
Wire attached to MDR iudder transducerport tiller tie rod
Figure 9. String Potentiometer Installed in the Lazarette of
the 47-FT MLB
17
Rude ngeU. S. :,UAST GUARD S 47201Sensor •,
MDR
RJ-1 I ComputerInteuface Box
Laatt Microswitch P~# Panal
RPM Loran Receiver
L e ne Survivors Machinery Forward
Room Compartment Space Compartment
Figure 10. Mission Data Recorder Wiring Layout and BulkheadPenetrations
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MDR Post Pr_=essing
Table II summarizes the motion events that have been recorded asof 12 June 1994. A sample of a full report is contained inreference [5], available on request.
TABLE II
MOTION EVENTS RECORDED BY THE MISSION DATA RECORDER
Station Event Time/Date
Station Cape May 13:35 on 12/15/9313:33 on 2/18/9410:38 on 3/3/9413:43 on 5/12/94
Station Tillamook 17:31 on 6/12/94
Station Oregon Inlet 13:44 on 12/1/9313:59 on 12/1/9314:12 on 12/1/9313:26 on 12/2/93
Station Umpqua River no events detected
Station Gloucester no events detected
Appendices A through F contain the results of the data analysisfor the 47201, 47202, 47203, 47204, 47205, and 47200,respectively. Each Appendix contains a summary table for eachevent recorded, the resulting time histories, snapshots ofanimations if performed, accumulated statistical results to date,and ARO plots.
Each event recorded and analyzed has a summary plot whichpresents the 12-minute time histories of the 7 MDR sen ors. Thisis illustrated in Figure 12. A closer inspection is made aroundthe event in a 25-second time history expanded plot which depictsthe 5 seconds before and 20 seconds after the event.
D - ffad i ng.
A number of options were considered for offloading data from theMDR. A direct modem line to the MDR was considered notpracticable because of the slow transmission rate (9600 baud) ofthe datalogger and because of the logistics involved in gettingphone lines on-board the 47-FT MLBs at each station.
Unfoitunate]y, there was no cellular phone coverage at the moreremote stations. Even if a cordless system were available to all
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of the stations, the costs associated with transmitting this muchdata would have been high. The method chosen to off-load MDRdata was to send a hand-held computer with a batch routine on arotating basis to each station. This is performed periodicallyto off-load the data or reset sensor thresholds.
Unlesa a significant motion event is recorded, the R&D Centerroutinely mails a hand-held computer to off-load the MDR data andto reset the internal clock. The crew is asked to connect thehand-held computer to the phone Jack located in the survivor'scompartment. The general setup is demonstrated in Figure 13.The crew member initiates the batch program which automaticallyoff-loads the 2 MByte file, resets the roll sensor threshold, andclears the memory. The data is stored in a 4 Mbyte RAM memoryPCMCIA card. The crew member must enter the time and date to theprompts on the screen. It takes about one hour to perform thistask. The hand-held computer is then mailed back to the R&DCenter.
Area of Recorded O rations (AROs)
The Area of Recorded Operations (AROs) is defined as the latitudeand longitude locations recorded by the MDR for the purposes ofthis report. This is not to be confused with Areas ofResponsibility (AORs). The MDR records position fixes every 10minutes when the MLBs are underway. The navigational informationis decoded from the LORAN set in the enclosed bridge.
A program was written to convert the MDR ASCII output to a formatcompatible with the Geographical Display Operations Computer(GDOC). This program was developed by the Coast Guard ElectronicEngineering Center. The MDR position data are displayed asscatter plots over vector charts about each of the six stations.The level of detail can be improved by zooming in. Raster chartscan also be utilized and read from a CD-ROM drive. The level ofdetail provided with the vector charts was considered adequatefor this study. The user can click on any of the data points todisplay a window containing the date and time for that recordedlocation. Figure 14 provides a key to the interpretation of theMDR ARO plots.
Animion RQutin_
A post-processing routine was developed to animate the datacollected with the MDR. The program is called BOATVU. Userdocumentation can be found in the BOATVU User's Manual [4]. Theprogram plays back event data through instrument gauges and dialson the computer screen. These virtual instruments represent thsboat parameters recorded ,ith the MDR. A wireframe 3D renditionof the 47-FT MLB can simultaneously be displayed with theoperating instrument gauges. Figure 15 illustrates the MDR data
22
a))
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25
animation capabilities. The MLB animation is based on the MDRmotion data of roll, pitch, yaw, and heave. Figure 16 provides akey to interpreting the virtual instrument displays. Theaccelerometer data is integrated twice to estimate the verticaldisplacement.
Wave information is not collected with the MDR. QualitativeInformation on wave characteristics can be derived f.om eitherNational Data Buoy Center (NDBC) spectra or from eyewitnessaccounts from the MLB coxswain or crew. Although wavecharacteristics are not actually measured, a user definedsinusoidal wave can be synchronized to the MLB animation. Asingle moving sinusoidal waveform can be defined by itsamplitude, wavelength, frequency, and phase and its direction inthe X-Y plane. The MLB wireframe model can be translated to anyinitial starting location with respect to the wave.
Heave displacement was calculated through a double integration ofthe accelerometer time history data. The accelerometer dataalong with roll and pitch are low-pass filtered around 1 Hz. A 1Hz second order Butterworth Filter is used to eliminate unwantednoise while retaining sufficient rigid-body motion informationfor the animation routine. The heave acceleration is transformedfrom the boat cocrrdinate system to the inertial system and aconstant lg factor is removed to account for constantacceleration due to gravity. A moving average technique was usedto minimize bias problems encountered in the acceleration data.In general, the animation package must be used with discretionand is only good for providing a gross approximation to therecorded motions.
CONCLUSIONS
Discuasasinno•fEvents onecrded During the OT&
47201 at _$ti na_¢ . May:
The MDR captured several 30-degree roll events from 47201 thatwere not very remarkable. These were collected on 15 December1993, 18 February 1994, and 12 May 1994. These data arepresented in Appendix A for consistency. However, the 47201 didexperience a 53-degree roll on 3 March 1994 which was moreinteresting. The data collected on this event are presented inTable A-3 and Figures A-10 through A-18. Although this was onlya 53-degree roll, the MLB spent nearly four seconds past 45degrees. This was a pitch event as much as a roll event. Justas the 47201 began the 53-degree roll sequence, it rapidlypitched down to a maximum of 35 degrees. This is illustrated inFigures A-13 and A-18. As evident in Figure A-13, 47201 hoveredaround 50 degrees of roll to starboard for about three seconds.Snapshots of the animated roll event sequence are shown inFigures A-19 through A-23. The 47201's starboard engine stalled
26
oQ2
CC
C3-
00
E0 5yE E
Cl) m~cj :3Uc ~CDm CflO) 4-
L M.I!3 2;;4jj i7E( +
Co 00
:a Co
27-
immediately after a roll event was detected. It took nearly oneminute to restart the engine and to match the port RPMtachometer. This is illustrated in Figure A-16.
47202 at Station Oregon Inlet:
At Station Oregon Inlet, 47202's MDR recorded three events on 1December 1993. They were at 1344, 1359, and 1412, all within ahalf-hour of one another. The first event was not a true eventas defined by the 45-degree roll threshold established for the47202 MLB. The data collected for this event are presented inTable B-1 and Figures B-2 through B-5. The recording of thisevent was triggered by several consecutive high roll sensorvalues which exceeded the threshold setting. However, thesevalues are the result of the roll sensor's damping limitations.Although a software filter in the MDR program is used to minimizethe recording of non-events, the MDR will occasionally recordthem. The trade-off to record the occasional non-eventovershadowed the alternative of desensitizing the roll detectionscheme too muon. The actual maximum roll in this case wasapproximatelT ?3 degrees to starboard. This is illustrated inthe roll time history plot in Figure B-5.
The data recorded for the second event on 1 December at 1359 arepreserted in Table B-2 and in Figures 13-6 through B-14. The47202 experienced a 47-degree roll to port as shown in FigureB-9. Both port and starboard engine RPM were near cruising speedbefore, during, and a few seconds after the event. Just prior tothe recorded event, the rudder was rapidly moved from 25 degreesstarboard to 13 degrees port, then hard to starboard. This isshown in Figure B-14. From Figure B-9, it is evident that theMLB experienced a series of 10 to 30-degree rolls immediatelyafter the 47-degree roll.
Once again in the third event recorded the same day at 1412, aset of consecutive motions from different directions caused therecording of a non-event. These data are presented in Table B-3and in Figures B-15 through B-18. The approximate maximum rollrecorded was 30 degrees to starboard as illustrated in FigureB-18.
There have been only a few noteworthy roll motion events in thecourse of this phase of the 47-FT OT&E. The most severe rollevent was recorded on 47202. The 47202 rolled to 137 degrees andspent 5.25 seconds past 90 degre3s. These data are presented inTable B-4 and in Figures B-19 through 8-25. According to the"Class C Marine-Related Mishap Report" from Station Oregon Inlet,the 47202 was deliberately placed by the coxswain, starboard sidebeam to a set of well-developed waves. The 47202 decreased toclutch speed just beforv the roll event and experienced a quick39-degree roll to starboard followed by a slow port roll to 137degrees. Snapshots of th-e animated roll event sequence are shownin Figures B-26 through B-29. Some of the time history plots
28
from this event are included in this report for completeness butmore detail can be found in the original event report inReference [5]. In this particular case, because the vessel wasat clutch speed and making only a couple of knots headway Justbefore the event, it was essentially a static test of the boat'srighting capability to a ten-foot plunging, breaking wave (asreported by the coxswain). The MLB performed as designed and thelarge righting arm at 140 degrees prevented the MLB from rollingcompletely over.
Both engines increased RPM immediately after this event.However, the port engine quickly lost RPM and fell below clutchspeed. This is illustrated in Figure B-25. It took nearly oneminute to restart the engine and match it to the starboardengine. This is the second case where one of the two enginesfailed after a significant roll event and where it would takenearly a minute to recover. The recording of this event on the47202 has provided the first opportunity to capture the data froma roll of this magnitude in actual operating conditions.
47203 at Station TI llamook:.
One motion event was recorded on 47203 on 12 June 1994. Thesedata are presented in Table C-i and in Figures C-2 through C-15.The 47203 experienced several 10-degree rolls in the minutepreceding the event detection. The MLB experienced a 10-degreeroll to port before slowly rolling to starboard to a maximum of72 degrees as illustrated in Figure C-5. After the MLB reachedthis maximum roll value, it rapidly righted itself to an evenkeel in less than 2.3 seconds. A snapshot of the roll animationsequence is presented in Figures C-16 through C-20. Forapproximately two minutes before the event was detected, bothengines were running at near cruising speed. Both engines werereduced rapidly to clutch speed approximately 10 seconds beforethe event sequence began. During the roll sequence, the engineRPM was quickly increased to 1800 and 1600 port and starboardRPM, respectively, and returned to near clutch speed for abouttwo minutes. In this severe motion event, the engines remain on-line immediately after the roll event. The only differenceunique to this event was that the engines were throttled upduring the roll-over sequence. This is illustrated in FiguresC-14 and C-15.
Motion Sta istics
The motion statistics for each boat are summarized for theaverage roll, pitch, heave, and RPM data into monthly values.These are presented in the Appendices of the respective MLB(Appendices A-F). The data have also been processed on a averagedaily basis which may provide a better "flavor" for the differentlevels of motions recorded by the boats at different geographicallocations. These data are available upon requesL. Heave RMSwhile underway averaged around 0.1 g. The average of the highest
29
recorded heave values for the majority of the boats was around0.15 g's except for the 47201 located at Station Cape May, NJ,which recorded lower values around 0.11 g's. The highest pitchaverages were recorded on the 47203 at Station Tillamook, OR.The highest roll RMS averages were also found in the datarecorded on the 47203.
Area of Recorded Operationfl
The AROs are presented in the Appendices of the respective MLB.A perimeter was drawn around the recorded position data toindicate the bounds to each boat's underway locations.
Recommended Phase 20OT&E Evluations of tha 47-FT Preproduc LionMLBs
It needs to be emphasized that the MDR as presently developedonly records the response of the MLB to environmental forces.The evaluations made of the events recorded so far are one-sided.The input to the event picture can only be established fromsubjective eyewitness accounts from the crew and possible wavespectra data from distant NDBC wave buoys. In Phase 2 of theOT&E, the R&D Center will continue to collect motion events withthe MDR and will interview the coxswains by presenting theanimations and data on events recorded to elicit feedback todevelop an improved picture of what happened. The interviewswill also uncover whether or not the R&D Center should re-evaluate the MDR's definition of what an event is in order tocapture other more important boat maneuvering concerns that thecoxswains have experienced in the course of this phase of theOT&E.
30
REFERENCES
[1] Operational Test and Evaluation Plan for the 471 MotorLifeboat
[2] Technical Characteristics Verification of the Prototype47-FT MLB, Coast Guard R&DC Final Report No. CG-D-02-92,October 1991
(3] 47' Motor Lifeboat Mission Data Recorder DevelopmentManual - Version 2, R&D Center Unpublished Document,Available upon Request
[4] BOATVU User's Manual, by GESAC, Inc. for the US Coast GuardR&D Center, Available upon Request
[5] Enclosure (1), "47 FT MLB/MDR Event Report, 47202, 12/2/93"to RDC ltr 3900/749209 to G-NRS dtd 21DEC93
31/32
APPENDIX A
472UI DATA RESULTS
A-1/2
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TABLE A-I. 47201 EVENT SUMMARY TABLE
Summary of Data Collected w- th the MDR
Bcat: 47201Date: 15 DEC 93Dock Departure (Shore-tie Disconnected):Time of Event: 13:35:06Location: Not RecordedMaximum Rol! Angle DetecteL: 31 deg.,eesTime Spent Past 90 Degrees: N.A.Time Spent Past 45 Degrees: N.A.
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TABLE A-Il. 47201 EVENT SUMMARY TABLE
Summary of Data Collected with the MDR
Boat: 47201Date: 18 FEB 94Dock Departure (Shore-tie Disconnected): 7:23Time of Event: 13:33:11Location: 38.56.97N, 07453.46WMaximum Roll Angle Detected: 30 degreesTime Spent Past 90 Degrees: N.A.Time Spent Past 45 Degrees: N.A.
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TABLE A-III. 47201 EVENT SUMMARY TABLE
Summary of Data Collected with the MDR
Boat: 47201Date: 03 MAR 94Dock Departure (Shore-tie Disconnected): Not RecordedTime of Event: 10:38:59Location: Not RecordedMaximum Roll Angle Detected: 53 degreesTime Spent Past 90 Degrees: N.A.Time Spent Past 45 Degrees: 3.6 secondsStbd Engine RPM:* Before Event - 1900 RPM* During Event - decreasing rapidly* After Event - engine stalled for about 1 minutePort Engine RPM:* Before Event - 1900 RPM* During Event - decreasing rapidly* After Event - 900 RPMRudder Angle:* Before Event - -2 degrees* During Event - 4 degrees* After Event - changed rapidly to 16 degrees to portHeading:* Before Event - 310 degrees+ After Event - 240 degreesPitch: 35 degrees (bow down)
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TABLE A-IV. 47201 EVENT SUMMARY TABLE
Summary of Data Collected with the MDR
Boat: 47201Date: 12 MAY 94Dock Departure (Shore-tie Disconnected): Not RecordedTime of Event: 13:43:48Location: Not RecordedMaximum Roll Angle Detected: 30 degrees (triggered off a 30
degree roll, but a maximum roll post-event was detected atbeing 32 degrees.)
Time Spent Past 90 Degrees: N.A.Time Spent Past 45 Degrees: N.A.
Note: The port RPM tach was not operating during the eent.
A--29
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A--37/3
APPENDIX B
47202 DATA RESULTS
B-I/2
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TABLE B-I. 47202 EVENT SUMMARY TABLE
Summary of Data Collected with the MDR
Boat: 47202Date: 01 DEC 93Dock Departure (Shore-tie Disconnected): 07:28Time of Event: 13:44:19Location: 35 deg, 47.38 min. lat.; 75 deg, 31.51 min. long.Maximum Roll Angle Detected: APPROXIMATE 28 degrees *Time Spent Past 90 Degrees: N.A.Time Spent Past 45 Degrees: N.A.
* This is not a true event as defined by the 45° thresholdsetting on the 47202. The recording of this event was triggeredby several consecutive spurious values which exceeded thethreshold setting. This occurred in -ne region defined in the 25second roll plot. The firs. 4 %) seconds of the beginning of thebuffer were lost as evident in the time history plots for thisevent.
B- 1
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0 0i
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B-8 ~ -
TABLE B-II. 47202 EVENT SUMMARY TABLE
Sununary of Data Collected with the MDR
"Boat: 47202Date: 01 DEC 93Dock Departure (Shore-tie Disconnected): 07:28Time of Event: 13:59:58Location: 35 deg, 47.30 min. lat.; 75 deg, 31.13 min. long.Maximum Roll Angle Detected: 47 degrees to PortTime Spent Past 90 Degrees: N.A.Time Spent Past 45 Degrees: 0.6 seconds
P-9
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[ .. . . .. ... .. . . . ... .. . . ... .. ... . . .. .... . . ... . .. . ... . .. . .. . . .. . .. . .. .. .. ...... ... .. ... ..... . . ... .. . ... .. .. ... ... .. . . .. . . . . ... .. . .... . . .....
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TABLE B-Ill. 47202 EVENT SUMARY TABLE
Summary of Data Collected with the MDR
Boat: 47202Date: 01 DEC 93Doc% Departure (Shore-tic Disconnected): 07:28Time of Event: 14:12:12Location: 35 deg, 47.30 min. lat.; 75 deg, 31.13 min. long.Maximum Roll Angle Detected: 30 degrees*Time Spent Past 90 Degrees: N.A.Time Spent Past 45 Degrees: N.A.
* This is not a true event as defined by the 450 roll thresholdsetting on the 47202. The recording uf this event was triggeredby several consecutive spurious values which exceeded thethreshold setting.. Only the roll data is plotted to demonstratethat this was a 30 degree roll.
B-19
0 0
88 -8 -
CY))
c 70
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0N (f) Cf C 0 00
liIxAPR ~ dJd VdJ
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lid 11imeA pflJVYddd VY &H s
ciC)
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B-22
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CCI.114
-2 3
TABLE 3-IV. 4'."102 Sll*?ý,tARY TABLE
Summary of Data Collectid with Lhs MDR
Roat: 47202Date: 02 DEC 93Dock Departure (Shore-tle Disconnocted): 12:34Time of Event:: 13:26Location: 35 deg, 46.58 miai. lat.; 75 deg, 32.16 min. lung.Maximum Roll Angle Detected: 137 6egrees to PortTime Spent Past 90 Degrees: 4.25 secondsTime Spent Past 45 Degrees: 6.45 secondsetbd Engine RPM:
Before Event decreasing frotr, 1700 to 750 RPMDuring Event 750 RPMAfter Event increasing from 750 to 1700 RPM
Port Engine RPM:Befors Event - decreasing from 1700 ' 750 RPMDuring Event 750 RPMAfter Event - decreesing to 300 RPM
Rudder Angle:Before Event - 23 degrees starboardDuring Event - 2 degrees starboardAfter Event - 31 degrees port
Heading:Before Event- 320 degreesAfter Event - 320 degrees
Pitch: Bow down
Note: A more detailed analysis and description of this event canbe found ir Reference [5].
B-24
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APPENDIX C
47203 DATA RESULTS
C-1/2
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TABLE C-I. 47203 EVENT SUMMARY TABLE
Summary of Data Collected with the MDR
Boat: 47203Date: 12 JUN 94Dock Departure (Shore-tie Disconnected): 13:32Time of Event: 17:31Location: 45 deg, 33.27 min. let.; 123 deg, 54.32 min. long.Maximum Roll Angle Detected: 72 degreesTime Spent Past 90 Degrees: N.A.Time Spent Past 45 Degrees: 2.80 secondsStbd Engine RPM:
Before Event -, decreasing from 1620 to 1000 RPM(just prior to event)
During Event - 1600 RPMAfter Event - decreasing from 1600 to 950 RPM
Port Engine RPM:Before Event - decreasing from 1850 to 850 RPM
(just prior to event)During Event - 1800 RPMAfter Event - decreasing from 1800 to 900 RPM
Rudder Angle:Before Event - 5 degrees portDuring Event - 0 degreesAfter Event - changing rapidly to 30 degrees starboard
Heading:Before Event - 360 degreesAfter Event - 320 degrees
Pitch: Bow up
Note: Ship's position captured 28 minutes before event; boat wasunderway for 4h hours.
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APPENDIX D
47204 DATA RESULTS
D-1/2
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APPENDIX E
47205 DATA RESULTS
E-1/2
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APPENDIX F
47200 DATA RESULTS
(Data was not ccllected on the 47200during this phase of the evaluation)
F-1/2
APPENDIX G
LIST OF HARDWARE AND SOFTWARE
MDR MAJOR PARTS LIST
1. Container for Mlasion Data Recorder -- Hoffman Enclosure part# A-1287JFGQR 57.65.
2. Computer/Data Acquisition System -- Tattletale Model 5Computer with 2--Meg RAM board from Onset Computer Corp., POBox 3450, Pocasset, MA 02559-3450, 508-563-9000.
3. Yaw Angle Sensor -- KVH model CI00 Compass Engine Part # 54-0044 KVH Industries, Inc., 110 Enterprise Center, Middletown,RI 02840, (401) 847-3327.
4. Roll & Pitch Angle Sensor -- Humphrey model CP17-0601-1Pendulum sensor. Humphrey Inc., 9212 Balboa Avenue, SanDiego, CA 92123, (619) 565-6631.
5. Vertical Acceleration Sensor -- +/-4G Accelerometer model141. Setra Systems Inc., 45 Nagog Park, Acton, MA 01720,(508) 263-1400.
3. Rudder Angle Sensor -- two manufacturers:
a. Magnetek Position transducer model # PSA-40A-5K(AI79)from Magnetek, 650 Easy Street, S~mi Valley, CA 9?065,(805) 581-3985.
b. CELESCO Position Transducer, Model # PT8101-0040-111-3110from Celesco Transducer Products, Inc., "'800 DeeringAvenue, PO Box 7964, Canoga Park, CA 91309-7964,(818) 884-686C.
7.. RPM Pick Up Sensor -- BANNER Model QI9SN6LP Polarized RetroSensor. From Banner Engineering Corp., 9714 10th Avenue No.,Minneapolis, MN 55441, (612) 544-3164.
S. Battery -- 12V, 6Ah Part # JC1260, from Johnson Controls.
9. Battery Charger -- 12V 250mA Type GRCI2250CDF from JohnsonControls.
1. TTBASIC MDF Prograim
1. BOATrVl developed by GESAC, Inc., for Coast Guard R & D Center.2. GDOC developed by CG LECEN.3. MATLAS, The Math Works, Inc.4. AXUM, TriMetrix, Inc.
G-3
