EMPA Koller

LMS LMS Conference Conference Europe Europe
Munich Munich, , March March 22 & 23, 2006 22 & 23, 2006
Slide 1
Mat erials Science &Technology
Service Load Measurements
Service Load Measurements
on
on
Ropeway Vehicles
Ropeway Vehicles
Mech. Eng. ETH R. Koller
Swiss Federal Laboratories for
Materials Testing and Research
Dbendorf / Switzerland
Slide 2
1. Introduction
2. Risks in Traffic - Safety
3. Service load measurements
4. Full scale fatigue test
Contents
Contents
Slide 3
1.
1.
Introduction
Introduction
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
Slide 4
Classification of ropeways Classification 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 support
structure
Vehicle
Rope
Slide 5
Examples of common types of ropeways Examples of common types of ropeways
Tramway
Twin-Linear,
Samnaun
180 Passengers,
10 m/s
Funicular
Sierre-Crans
Montana
120 Passengers,
4.2 km, 8 m/s
Cont. circul.
aerial rope-
way
Flims-Plaun-Nagens
8 Passengers,
6 m/s
Cable lift
2 Passengers,
~ 2 m/s
Slide 6
Cabin
Hanger
Grip
Hanger frame
Main components Main components
Slide 7
Two types of cont. circulating aerial ropeways Two types of cont. circulating aerial ropeways
Permanently
attached grip
(e.g. 2-seat chair)
Detachable grip
(e.g. 8-seat cabin)
Slide 8
1. Introduction
Slide 9
6
12 12
127
135
710
0
100
200
300
400
500
600
700
800
C
a
s
e
s

o
f

d
e
a
t
h

p
e
r

1
0
9

p
a
s
s
e
n
g
e
r
s
Cable lift Ropeway Bus / Tramway Railway Automobile Aircraft
Cases of death per 10
9
passengers
(mean values 1990 1994 in Switzerland)
2.
2.
Risks in Traffic
Risks in Traffic
Source: Seilbahnen
Schweiz SBS 2006
Slide 10
1. Introduction
Slide 11
3.
3.
Service load measurements
Service load measurements
Valid harmonised European standards exist since 2005. Valid harmonised European standards exist since 2005.
EN 13796 EN 13796- -1: 1: Safety requirements for cableway installations Safety requirements for cableway installations
designed to carry persons designed to carry persons Carriers Carriers
Part 1: Grips, carrier trucks, on Part 1: Grips, carrier trucks, on- -board brakes, cabins, board brakes, cabins,
chairs, carriages, maintenance carriers, tow chairs, carriages, maintenance carriers, tow- -hangers hangers
Part 2: Slipping resistance test for grips Part 2: Slipping resistance test for grips
Part 3: Fatigue tests Part 3: Fatigue tests
Slide 12
Approval of ropeway vehicles requires static and fatigue Approval of ropeway vehicles requires static and fatigue
strength analysis. strength analysis.
Stresses and strains used Stresses and strains used
for fatigue analyses have for fatigue analyses have
to be verified by measure to be verified by measure- -
ments ments on the installation. on the installation.
An experimental fatigue test has to be passed in order to An 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:
Slide 13
Measurement runs under defined conditions according to Measurement runs under defined conditions according to
EN 13796 EN 13796- -1 1 (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 in Long time measurements under unattended conditions in
service service (not required by the standard) (not required by the standard). .
Slide 14
Load cases according to EN 13796 Load cases according to EN 13796- -1 1
Installations with Installations with detachable grips detachable grips
Entry into station guide systems Entry into station guide systems: :
Vehicles with 50% payload positioned eccentrically on the Vehicles with 50% payload positioned eccentrically on the
line support side and opposite side respectively line 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 systems Entry into station guide systems: :
Vehicles with 100% payload uniformly distributed Vehicles with 100% payload uniformly distributed
(without lateral oscillation) (without lateral oscillation). .
On the line On the line: :
Vehicles with 100% payload uniformly distributed. Vehicles with 100% payload uniformly distributed.
Slide 15
Installations with Installations with permanently attached grips permanently attached grips
The same load cases apply for installations with detachable The same load cases apply for installations with detachable
grips, but additionally grips, but additionally
Passing around sheaves Passing around sheaves: :
Vehicles with 0% payload Vehicles with 0% payload
hauling rope
sheave
Slide 16
Measurement devices Measurement devices
Wheatstone bridge
Bridge
amplifier
( )
4 3 2 1
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 U
A
Gauge 4
Gauge 2 Gauge 3
I
n
p
u
t

v
o
l
t
a
g
e
U
B
8-channel,
battery powered
data acquisition
system
Slide 17
Application examples Application examples
Long time measurements on a 12 Long time measurements on a 12- -passenger cabin passenger cabin (6 month) (6 month)
Slide 18
Typical signal behaviour in the hanger during upward travel Typical signal behaviour in the hanger during upward travel
Slide 19
Measurement setups according to Measurement setups according to
EN 13796 EN 13796- -1 1
50% payload positioned eccen-
trically on the line support side
Payload distribution on
seats () and floor ()
Slide 20
Evaluation of measured strain signals Evaluation of measured strain signals
8 strain channels of 8 strain channels of
a complete run a complete run
loaded into TEC loaded into TEC- -
Ware Ware TimeEdit TimeEdit
(upper station entry (upper station entry
marked as marked as evalua evalua- -
tion tion event). event).
Statistics for each Statistics for each
event ( event (maximum maximum
range range) provided ) provided
easily by easily by TimeEdit TimeEdit. .
Missing load cycle Missing load cycle
on the plots: on the plots:
Loading Loading - - Unloading Unloading
Slide 21
Measurement of exceptional station entries Measurement of exceptional station entries
Strains occurring in grips caused by impact of the guiding Strains occurring in grips caused by impact of the guiding
pulley of a lateral oscillating cabin at the station guide syste pulley of a lateral oscillating cabin at the station guide system m
left crest
phase: 90
right crest
phase: 270
Phase: 0 Phase: 180
Rest position
guiding
pulley
oscil-
lation
guiding pulley
station guide system
oscillation
Slide 22
Location of
strain gauges
Slide 23
1. Introduction
Slide 24
4.
4.
Full scale fatigue test
Full scale fatigue test
As a part of the approval procedure, every new vehicle design As a part of the approval procedure, every new vehicle design
as well as structural modifications have to be verified by a ful as well as structural modifications have to be verified by a full l
scale fatigue test scale fatigue test (EN 13796 (EN 13796- -3) 3). .
Parameters for detachable continuously circulating aerial
ropeways:
1. Step 2. Step
Upper load: F
o
= 2.75 g m
total
F
o
= 3.0 g m
total
Lower load: F
u
= 0.75 g m
total
F
u
= 0.5 g m
total
Load range: F = 2.0 g m
total
F = 2.5 g m
total
No. of cycles: 4.5 10
6
0.5 10
6
m
total
= m
grip
+ m
hanger
+ m
vehicle
+ m
payload
+ m
accessories
g = 9.81 m/s
2
test frequency: 2 - 5 Hz
F
F
Slide 25
Example of a full scale fatigue test at Empa Example of a full scale fatigue test at Empa

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