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Document Sample
Service Load Measurements
on
Ropeway Vehicles
Mech. Eng. ETH R. Koller
Swiss Federal Laboratories for
Materials Testing and Research
Dübendorf / Switzerland
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 1
Contents
1. Introduction
2. Risks in Traffic - Safety
3. Service load measurements
4. Full scale fatigue test
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 2
1. Introduction
Current installations in Switzerland:
• 59 Funiculars
• 217 Tramways
• 116 Cont. circulating aerial tramways
• 329 Chair lifts
• 1037 Cable lifts (ski lifts)
Total installations: 1758
Total track length: 1900 km
Total difference of altitude: 500 km
Total capacity: 2 Mio passengers/h
Source: Seilbahnen Schweiz SBS 2006
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 3
Classification of ropeways
ROPEWAYS
Funiculars Aerial cableways Cable lifts
Haul rope Grip
Vehicle (car)
Cable
Tow-hanger
Track
Principle of a funicular Principle of a cable lift
Rope
Line support
structure
Vehicle
Principle of an aerial ropeway A.Doppelmayr:
Denkanstösse, Wolfurt 1997
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 4
Examples of common types of ropeways
Funicular Tramway
Sierre-Crans Twin-Linear,
Montana Samnaun
120 Passengers, 180 Passengers,
4.2 km, 8 m/s 10 m/s
Cont. circul.
aerial rope- Cable lift
way 2 Passengers,
Flims-Plaun-Nagens ~ 2 m/s
8 Passengers,
6 m/s
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 5
Main components
Grip
Hanger
Hanger frame
Cabin
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 6
Two types of cont. circulating aerial ropeways
Permanently
attached grip
(e.g. 2-seat chair)
Detachable grip
(e.g. 8-seat cabin)
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 7
1. Introduction
2. Risks in Traffic - Safety
3. Service load measurements
4. Full scale fatigue test
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 8
2. Risks in Traffic
Cases of death per 109 passengers
(mean values 1990 – 1994 in Switzerland)
800
710
Cases of death per 10 passengers
700
600
500
9
400
300
200 127 135
100
6 12 12
0
Cable lift Ropeway Bus / Tramway Railway Automobile Aircraft Source: Seilbahnen
Schweiz SBS 2006
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 9
1. Introduction
2. Risks in Traffic - Safety
3. Service load measurements
4. Full scale fatigue test
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 10
3. Service load measurements
Valid harmonised European standards exist since 2005.
EN 13796-1: Safety requirements for cableway installations
designed to carry persons – Carriers
Part 1: Grips, carrier trucks, on-board brakes, cabins,
chairs, carriages, maintenance carriers, tow-hangers
EN 13796-2: Safety requirements for cableway installations
designed to carry persons – Carriers –
Part 2: Slipping resistance test for grips
EN 13796-3: Safety requirements for cableway installations
designed to carry persons – Carriers
Part 3: Fatigue tests
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 11
Approval of ropeway vehicles requires static and fatigue
strength analysis.
Stresses and strains used
for fatigue analyses have
to be verified by measure-
ments on the installation.
An experimental fatigue test has to be passed in order to
prove the fatigue strength of the vehicle's structure.
Two approaches of service load measurements are used:
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 12
Measurement runs under defined conditions according to
EN 13796-1 (speed, loading, position of the loading, distance
between vehicles, etc.)
Long time measurements under unattended conditions in
service (not required by the standard).
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 13
Load cases according to EN 13796-1
Installations with detachable grips
Entry into station guide systems:
Vehicles with 50% payload positioned eccentrically on the
line support side and opposite side respectively (without
lateral oscillation), the most unfavourable situation is
applicable.
Entry into station guide systems:
Vehicles with 100% payload uniformly distributed
(without lateral oscillation).
On the line:
Vehicles with 100% payload uniformly distributed.
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 14
Installations with permanently attached grips
The same load cases apply for installations with detachable
grips, but additionally
Passing around sheaves:
Vehicles with 0% payload sheave
hauling rope
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 15
Measurement devices
Wheatstone bridge
8-channel,
battery powered Gauge 1 Gauge 4
Input voltage UB
data acquisition
system
Gauge 2 Gauge 3
Bridge
Output voltage UA
amplifier
U A 1 ∆R1 ∆R2 ∆R3 ∆R4
= ⋅ − + −
U B 4 R1
R2 R3 R4
k
= ⋅ (ε 1 − ε 2 + ε 3 − ε 4 )
4
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 16
Application examples
Long time measurements on a 12-passenger cabin (6 month)
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 17
Typical signal behaviour in the hanger during upward travel
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 18
Measurement setups according to
EN 13796-1
50% payload positioned eccen- Payload distribution on
trically on the line support side seats (⅔) and floor (⅓)
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 19
Evaluation of measured strain signals
8 strain channels of
a complete run
loaded into TEC-
Ware TimeEdit
(upper station entry
marked as evalua-
tion event).
Statistics for each
event (maximum
range) provided
easily by TimeEdit.
Missing load cycle
on the plots:
Loading - Unloading
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 20
Measurement of exceptional station entries
Strains occurring in grips caused by impact of the guiding
pulley of a lateral oscillating cabin at the station guide system
oscil-
lation
station guide system
guiding
pulley
oscillation
Rest position
left crest right crest
guiding pulley
phase: 90° phase: 270°
Phase: 0° Phase: 180°
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 21
Location of
strain gauges
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 22
1. Introduction
2. Risks in Traffic - Safety
3. Service load measurements
4. Full scale fatigue test
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 23
4. Full scale fatigue test
As a part of the approval procedure, every new vehicle design
as well as structural modifications have to be verified by a full
scale fatigue test (EN 13796-3).
Parameters for detachable continuously circulating aerial
ropeways:
F
1. Step 2. Step
Upper load: Fo = 2.75 · g · mtotal Fo = 3.0 · g · mtotal
F Lower load: Fu = 0.75 · g · mtotal Fu = 0.5 · g · mtotal
Load range: ∆F = 2.0 · g · mtotal ∆F = 2.5 · g · mtotal
No. of cycles: 4.5 · 106 0.5 · 106
mtotal = mgrip + mhanger + mvehicle + mpayload + maccessories
g = 9.81 m/s2
test frequency: 2 - 5 Hz
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 24
Example of a full scale fatigue test at Empa
LMS Conference Europe
Munich,
Munich, March 22 & 23, 2006 Materials Science & Technology
Slide 25
