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8/12/2019 EMPA Koller[1]
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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 1
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 2
Materials Science & Technology
1. Introduction
2. Risks in Traffic - Safety3. Service load measurements
4. Full scale fatigue test
ContentsContents
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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 3
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 4
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 5
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 6
Materials Science & Technology
Cabin
Hanger
Grip
Hanger frame
Main componentsMain components
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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 7
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 8
Materials Science & Technology
1. Introduction
2. Risks in Traffic - Safety3. Service load measurements
4. Full scale fatigue test
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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 9
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 10
Materials Science & Technology
1. Introduction
2. Risks in Traffic - Safety3. Service load measurements
4. Full scale fatigue test
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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 11
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 12
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 13
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 14
Materials Science & Technology
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
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 16
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 17
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 19
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 20
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 21
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 22
Materials Science & Technology
Location of
strain gauges
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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 23
Materials Science & Technology
1. Introduction
2. Risks in Traffic - Safety3. Service load measurements
4. Full scale fatigue test
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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 24
Materials Science & Technology
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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LMSLMS ConferenceConference EuropeEuropeMunichMunich,, MarchMarch 22 & 23, 200622 & 23, 2006
Slide 25
Materials Science & Technology
Example of a full scale fatigue test at EmpaExample of a full scale fatigue test at Empa
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