EMPA Koller[1]

8/12/2019 EMPA Koller[1]

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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006

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Materials Science & Technology

Service oad Measurementservice oad Measurementsonn

Ropeway Vehiclesopeway VehiclesMech. Eng. ETH R. Koller

Swiss Federal Laboratories for

Materials Testing and Research

Dbendorf / Switzerland


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Slide 2


1. Introduction

2. Risks in Traffic - Safety3. Service load measurements

4. Full scale fatigue test

ContentsContents


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Slide 3


1.1. IntroductionIntroduction

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

Current installations in Switzerland:Current installations in Switzerland:

Source: Seilbahnen Schweiz SBS 2006


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Slide 4


Classification of ropewaysClassification of ropeways

A.Doppelmayr:Denkanstsse, Wolfurt 1997

ROPEWAYS

Funiculars Aerial cableways Cable lifts

Principle of a funicular

Vehicle (car)

Track

Haul rope

Principle of a cable lift

Cable

Grip

Tow-hanger

Principle of an aerial ropeway

Line supportstructure

Vehicle

Rope


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Slide 5


Examples of common types of ropewaysExamples of common types of ropeways

TramwayTwin-Linear,

Samnaun

180 Passengers,

10 m/s

FunicularSierre-Crans

Montana

120 Passengers,

4.2 km, 8 m/s

Cont. circul.

aerial rope-

way

Flims-Plaun-Nagens8 Passengers,

6 m/s

Cable lift2 Passengers,

~ 2 m/s


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Slide 6


Cabin

Hanger

Grip

Hanger frame

Main componentsMain components


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Slide 7


Two types of cont. circulating aerial ropewaysTwo types of cont. circulating aerial ropeways

Permanently

attached grip(e.g. 2-seat chair)

Detachable grip

(e.g. 8-seat cabin)


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Slide 8


1. Introduction




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Slide 9


6 12 12

127 135

710

0

100

200

300

400

500

600

700

800

Cas

esofdeath

per109p

assengers

Cable lift Ropeway Bus / Tramway Railway Automobile Aircraft

Cases of death per 109 passengers(mean values 1990 1994 in Switzerland)

2.2. Risks in TrafficRisks in Traffic

Source: SeilbahnenSchweiz SBS 2006


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Slide 10


1. Introduction




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Slide 11


3.3. Service load measurementsService load measurements

Valid harmonised European standards exist since 2005.Valid harmonised European standards exist since 2005.

EN 13796EN 13796--1:1: Safety requirements for cableway installationsSafety requirements for cableway installations

designed to carry personsdesigned to carry persons CarriersCarriers

Part 1: Grips, carrier trucks, onPart 1: Grips, carrier trucks, on--board brakes, cabins,board brakes, cabins,

chairs, carriages, maintenance carriers, towchairs, carriages, maintenance carriers, tow--hangershangers

EN 13796EN 13796--2:2: Safety requirements for cableway installationsSafety requirements for cableway installationsdesigned to carry personsdesigned to carry persons CarriersCarriers

Part 2: Slipping resistance test for gripsPart 2: Slipping resistance test for grips

EN 13796EN 13796--3:3: Safety requirements for cableway installationsSafety requirements for cableway installationsdesigned to carry personsdesigned to carry persons CarriersCarriers

Part 3: Fatigue testsPart 3: Fatigue tests


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Slide 12


Approval of ropeway vehicles requires static and fatigueApproval of ropeway vehicles requires static and fatigue

strength analysis.strength analysis.

Stresses and strains usedStresses and strains used

for fatigue analyses havefor fatigue analyses have

to be verified by measureto be verified by measure--

mentsments on the installation.on the installation.

An experimental fatigue test has to be passed in order toAn experimental fatigue test has to be passed in order to

prove the fatigue strength of the vehicle's structure.prove the fatigue strength of the vehicle's structure.

Two approaches of service load measurements are used:Two approaches of service load measurements are used:


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Slide 13


Measurement runs under defined conditions according toMeasurement runs under defined conditions according to

EN 13796EN 13796--11 (speed, loading, position of the loading, distance(speed, loading, position of the loading, distance

between vehicles, etc.)between vehicles, etc.)

Long time measurements under unattended conditions inLong time measurements under unattended conditions in

serviceservice (not required by the standard)(not required by the standard)..


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Slide 14


Load cases according to EN 13796Load cases according to EN 13796--11

Installations withInstallations with detachable gripsdetachable grips

Entry into station guide systemsEntry into station guide systems::

Vehicles with 50% payload positioned eccentrically on theVehicles with 50% payload positioned eccentrically on the

line support side and opposite side respectivelyline support side and opposite side respectively (without(without

lateral oscillation)lateral oscillation), the most unfavourable situation is, the most unfavourable situation is

applicable.applicable.

Entry into station guide systemsEntry into station guide systems::

Vehicles with 100% payload uniformly distributedVehicles with 100% payload uniformly distributed

(without lateral oscillation)(without lateral oscillation)..

On the lineOn the line::

Vehicles with 100% payload uniformly distributed.Vehicles with 100% payload uniformly distributed.


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Slide 15


Installations withInstallations withpermanently attached gripspermanently attached grips

The same load cases apply for installations with detachableThe same load cases apply for installations with detachable

grips, but additionallygrips, but additionally

Passing around sheavesPassing around sheaves::

Vehicles with 0% payloadVehicles with 0% payloadhauling rope

sheave


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Slide 16


Measurement devicesMeasurement devices

Wheatstone bridge

Bridge

amplifier

( )4321

4

4

3

3

2

2

1

1

B

A

4

k

R

R

R

R

R

R

R

R

4

1

U

U

+=

+=

Gauge 1

Output voltage UA

Gauge 4

Gauge 2 Gauge 3

Inputvoltage

UB

8-channel,

battery powereddata acquisition

system


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Slide 17


Application examplesApplication examples

Long time measurements on a 12Long time measurements on a 12--passenger cabinpassenger cabin (6 month)(6 month)


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Slide 19


Measurement setups according toMeasurement setups according to

EN 13796EN 13796--11

50% payload positioned eccen-

trically on the line support side

Payload distribution on

seats () and floor ()


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Slide 20


Evaluation of measured strain signalsEvaluation of measured strain signals

8 strain channels of8 strain channels of

a complete runa complete run

loaded into TECloaded into TEC--

WareWare TimeEditTimeEdit(upper station entry(upper station entry

marked asmarked as evaluaevalua--

tiontion event).event).

Statistics for eachStatistics for eachevent (event (maximummaximum

rangerange) provided) provided

easily byeasily by TimeEditTimeEdit..

Missing load cycleMissing load cycle

on the plots:on the plots:

LoadingLoading --UnloadingUnloading


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Slide 21


Measurement of exceptional station entriesMeasurement of exceptional station entries

Strains occurring in grips caused by impact of the guidingStrains occurring in grips caused by impact of the guiding

pulley of a lateral oscillating cabin at the station guide systepulley of a lateral oscillating cabin at the station guide systemm

left crest

phase: 90

right crest

phase: 270Phase: 0 Phase: 180

Rest position

guiding

pulley

oscil-

lation

guiding pulley

station guide system

oscillation


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Slide 22


Location of

strain gauges


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Slide 23


1. Introduction




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Slide 24


4.4. Full scale fatigue testFull scale fatigue test

As a part of the approval procedure, every new vehicle designAs a part of the approval procedure, every new vehicle design

as well as structural modifications have to be verified by a fulas well as structural modifications have to be verified by a fulll

scale fatigue testscale fatigue test (EN 13796(EN 13796--3)3)..

Parameters for detachable continuously circulating aerial

ropeways:

1. Step 2. Step

Upper load: Fo = 2.75 g mtotal Fo = 3.0 g mtotalLower load: Fu = 0.75 g mtotal Fu = 0.5 g mtotal

Load range: F = 2.0 g mtotal F = 2.5 g mtotalNo. of cycles: 4.5 106 0.5 106

mtotal = mgrip + mhanger+ mvehicle + mpayload + maccessoriesg = 9.81 m/s2

test frequency: 2 - 5 Hz

F

F


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Slide 25


Example of a full scale fatigue test at EmpaExample of a full scale fatigue test at Empa

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EMPA Koller[1]