target area overhead crane: -updated layout -fault analysis -recommendations for remote handling...
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Target Area Overhead Crane:- Updated Layout- Fault Analysis
- Recommendations for Remote Handling (ITER)
R. Rinaldesi, K. Kershaw – HE Group
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Updated layout
Main characteristics:
• Capacity: 40 ton• Span: increased from 22600 mm to 25100 mm• Lifting height: 24 m• Lifting speed: reduced from 10 m/min to 5 m/min• FEM classification: A4 - M4 (exception for gearbox)
Aug. 1st 2013Target Area Overhead Crane
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Updated layout
Hook lateral approach:
Aug. 1st 2013Target Area Overhead Crane
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Updated layout
Hook lateral approach:
Aug. 1st 2013Target Area Overhead Crane
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Updated layout
Hook longitudinal approach:
Aug. 1st 2013Target Area Overhead Crane
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Updated layout
Overall height:
Aug. 1st 2013Target Area Overhead Crane
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Updated layout
Wheel loads:
Aug. 1st 2013Target Area Overhead Crane
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Updated layout
Festoon along one walkway:
Aug. 1st 2013Target Area Overhead Crane
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Fault AnalysisMechanical Faults
Hoist (lifting movements)
Aug. 1st 2013Target Area Overhead Crane
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Fault AnalysisMechanical Faults
Hoist (lifting movements)
Aug. 1st 2013Target Area Overhead Crane
Fault Probability
Effect
Intervention
Duration of intervention on
crane *Preventive action
Price increas
e
Breakdown
position
Parking
zone
Main motor -short-circuit between phases
Medium
Emergency motor is switched on and operations can continue at a lower speed (20% of nominal speed)
- - -
Incoming fault can be identified during inspections (temperature measurement)
~20.000 € (2nd motor
with diff. Unit)
Gearbox – fracture of shaft, gear or key
Very low (1 case at CERN due to intensive use at a load exceeding capacity)
Drop of load is avoided by emergency brake; load slips ~40 cm before being stopped with a deceleration of 1 m/s2. Intervention of personnel is required to manually lay the load on the ground
Yes (load
laying)
Yes (gearb
ox repair)
- Load laying: 4 hours
- Gearbox repair: 4 days
- Additional inspections: noise measurement and oil analysis
- Oversizing: gearbox designed as if it would be used in a heavy-duty crane (continuous use at full load)
~15.000 €
(heavy-duty
gearbox)
Gearbox/ Rope drum– seized bearing
Very low (never happened at CERN)
No hoist movement is possible (load stuck)
Yes (gearbo
x repair)
- 4 days
- Additional inspections: noise measurement
- Oversizing: gearbox is designed as if it would be used in a heavy-duty crane (continuous use at full load)
-
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Fault AnalysisMechanical Faults
Hoist (lifting movements)
Aug. 1st 2013Target Area Overhead Crane
Fault Probability
Effect
Intervention
Duration of intervention on
crane *Preventive action
Price increas
e
Breakdown
position
Parking
zone
Service brake
Low
Drop of load is avoided by emergency brake; load slips ~40 cm before being stopped with a deceleration of 1 m/s2. Intervention of personnel is required to manually lay the load on the ground
Yes (load
laying)
Yes (brake replacemen
t)
- Load laying: 4 hours
- Brake replacement: 4 hours
- -
Rope drum
Very low (1 case in HE history due to assembly fault)
Drop of load is avoided by emergency brake; load slips ~40 cm before being stopped with a deceleration of 1 m/s2. Intervention of personnel is required to manually lay the load on the ground
Yes (load
laying)
Yes (rope drum repair
)
- Load laying: 4 hours
- Rope drum replacement: 5 days
- Additional inspections: non-destructive tests
-
Rope Low
The entire load is sustained by the second rope (swaying); the load can be safely laid on the ground
- Yes 1 day (no exposure to radiation)
Incoming fault can be identified during visual inspections
-
*: intervention time doesn’t include lead time to have spare parts available
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Fault AnalysisMechanical Faults
example of fully redundant hoist
Aug. 1st 2013Target Area Overhead Crane
Courtesy of Meloni Tecno-Handling srl
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Fault AnalysisMechanical Faults
Cross and Long travel (horizontal movements)
Aug. 1st 2013Target Area Overhead Crane
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Fault AnalysisMechanical Faults
Cross and Long travel (horizontal movements)
- All the 4 wheels are motorized with self-braking motor+gearbox
- Motors and brakes are independently controlled
- In normal conditions only 2 motors are working; the other 2 motors are not
used and their brakes are left open
Aug. 1st 2013Target Area Overhead Crane
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Fault AnalysisMechanical Faults
Cross and Long travel (horizontal movements)
Aug. 1st 2013Target Area Overhead Crane
Fault Probability
Effect
Intervention
Duration of intervention on
crane *Preventive action
Price increas
e
Breakdown
position
Parking
zone
Motor -short-circuit between phases
Medium
One wheel is blocked; both emergency motors are switched on and able to push the crane and complete the operation
- Yes4 hours (no exposure to radiation)
Incoming fault can be identified during inspections (temperature measurement)
~15.000 € (2
additional
motors and
gearboxes;
oversize of
motors)
Gearbox/Wheel – fracture of shaft, gear or key
Very low
The wheel becomes loose; one emergency motor is switched on and operations can continue
- - -Additional inspections: noise measurement and oil analysis
-
Gearbox/ Wheel - seized bearing
Very low
One wheel is blocked; both emergency motors are switched on and able to push the crane and complete the operation
- Yes 1 dayIncoming fault can be identified during inspections (noise measurement)
-*: intervention time doesn’t include lead time to have spare parts available
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Fault AnalysisElectrical Faults
- Cubicles (both power and control) are located in a separate room
- The following equipment is on-board of the crane:
Junction boxes
Encoders / Laser (position detectors)
Weighing system
Cameras
- The only fault that will need access of personnel is a defect on wiring:
intervention time is about 1 hour (with spare wires already installed)
Aug. 1st 2013Target Area Overhead Crane
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Recommendations for Remote Handling (ITER)
Consider RH compatibility from earliest stage of development cycle Prefer vertical load transfer during installation and removal Use of a crane provides compliance in 5 d.o.f. (helps self alignment) Provide for self alignment (into position and with handling equipment) –
typically use of cones Keep operations simple Recovery techniques vital
Provide space for handling trajectories and for vision Provide visual clues for gross alignment motions Protect sensitive equipment
Aug. 1st 2013Target Area Overhead Crane
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Recommendations for Remote Handling (ITER)
ITER Monorail Crane (Neutral beam remote handling system)
Aug. 1st 2013Target Area Overhead Crane
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Recommendations for Remote Handling (ITER)
ITER Monorail Crane (Neutral beam remote handling system)
Aug. 1st 2013Target Area Overhead Crane
Twist-locks
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Recommendations for Remote Handling (ITER)
ITER Monorail Crane (Neutral beam remote handling system)
Aug. 1st 2013Target Area Overhead Crane