r&l System for Aurora

8/12/2019 r&l System for Aurora

1/32

JUNE 2013

Version

UNITED ARAB EMIRATES

EMIRATES OF ABU DHABI

.

GALVA COAT RAISING& LOWERINGSYSTEM

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photocopying, recording, or by any information storage andretrieval system without express written permission from the company


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INDEX

- INTRODUCTION.- COMPONENTS DESCRIPTION.- HOW IT WORKS.- OPERATION MANUAL.- APPENDIX A: SYSTEM MODEL.- APPENDIX B: MOTOR DETAILS.- APPENDIX C: GEAR BOX DETAILS.- APPENDIX D : SUSPENSION SYSTEM- APPENDIX E: POWER CABLE DETAILS & JB BOXES.

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INTRODUCTION

Highmastwithraisingandloweringfacilityisdesignedtoraiseandlowerthemobile

ringautomaticallytoanacceptablelevelinordertodothemaintenanceforthelight

fittingsusingropesandmotorizedgearedwincharrangement.

High mast with raising and lowering system is easy, fast, feasible and efficient

method todo themaintenance in someplaceswhereothermethod to reach the

light

fitting

is

not

efficient

and

fraught

with

risks.

R&Lsystemsubstantially,isanelectromechanicalsystemsimpleindesigntoavoid

anymechanical/electrical failand to achieve the accuracy required for thewhole

systeminservice&maintenancepositionwithhighreliabilityandrelativelylowcost

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COMPONENTS DESCRIPTION

Raisingandloweringsystemconsistofthefollowingmainparts(subassemblies):

1. FixedheadFramesubassemblies.2. Mobileringwithlightfittingarmsandcentralizingsystem.3. Stainlesssteelropessuspensionsystem.4. Motorizeddrivesystem(motor&winch).5.

Electrical

parts

&

Connections.

/

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1.The Head Frame

TheHeadFrameconsistsofthefollowingcomponents:

- Topfiberglasscover(canopy).- Maintenancefreecastironsheaveswithbearing.- SteelhousingfortheSheaves.- NylonSheavesforguidingpowercable.- Steelhousingforthepowercablesheaves.- Plates(steel)supportinglatchingpins.- Reinforcementsteelplates(Ribs)tosupportmainsupportplate.- Steelsleeveconnectingtheassemblytopole.-

Description:

Completeassemblyofheadfromismadefromhotdippedgalvanizedsteelattached

totheshaftwithsetsofstainlesssteelgrubscrewwhichreflectsafetyandreliability

tothesystem.

On themain supportplate ishaving setsofpulleysmade of cast iron to roll the

stainlesssteel

ropes

and

Teflon

for

power

cables

which

is

designed

to

run

the

system smoothly, these pulleys supported on stainless steel spindle with self

lubricatedbearingandcertainlywithguardtopreventropesslip.

Onthesupportplate,therearethreeplatssupporting3latchingpinstogovern

latchingandunlatchingoperations

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2. MOBILE RING WITH LIGHT FITTING ARMS AND

CENTRALIZING SYSTEM

TheLight

fitting

mounting

ring

consists

of

the

following:

- ThreeLatchingArmsspacedat120onthering.- Setof3centeringspringloadedarms(irisarms)withrolleron eacharm- HotdipgalvanizedUchannelshapesteelring.- Setoflightfittingsupportarmsboltedtothering.- Removableringrestingarmabovethedoor.- Eyebolttoconnectthestainlesssteelropestothering.

Description:

Thecomplete system ismadeofhotdippedgalvanized steel,mainpurposeof

thispart is tocarry/support light fittingsand lowering it formaintenance the

coreelementof thispart is theUchannel, the latter isused to carry the light

fittingarmsbymeanofboltingandithasthethreelatchingarmstoconductthe

latchingprocess,atthetopoftheringthereisaprovisiontotighttheeyeboltin

ordertoconnectthesuspensionsystem(stainlesssteelropes) ,atthebottom

thereistheirisarmwhichplayveryimportantroleincontrollingtheeccentricity

oftheringwhileraisingandloweringwhichpreventtheswayingofthesystem.

These arms maintain the roller in direct contact with the shaft during

lowering/raisingoperation the roller ismadeof rubberanddoesnot leaveany

scratchesonthepoleduringoperation.

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3. STAINLESS STEEL ROPES SUSPENSION SYSTEM

Wireropessystem(suspensionsystem)consistsofthefollowingparts:

- Setof3stainlesssteelGr.316suspensionwireropesof4mmdiameterhaving7x19

constructions

connecting

the

mobile

ring

to

the

connecting

plate.

- Set of 2 Stainless steel Gr.316Wire Rope of 6mm Diameter having 7 x19constructions, winding on the dual drum connecting the winch to the

combiningpulley.

- Combiningpulleytoadjust/compensatethetworopescomingfromthedualdrum.

- SteelTransitionPlatewithconnectingthesetofthree4mmropes.- Ropesaccessoriesi.e.thimbles&clips.

Description:

Suspensionsystemconsistsofstainlesssteelwirestotransmittheloadexcreted

frommotortotheringinordertoraiseandlowerthesystem.

Toachievemore reliability indexof thesystem twodrumsareusedgiving two

ropes sharing equally the load, the rope size is 6mmmade of stainless steel

Gr.316 these two ropes are tied at combing pulley thereafter the pulley is

transmittingthe

load

to

the

connecting

plate

which

in

turn

transmitting

the

load

thru threestainlesssteel ropes fixed to theconnectingplatewitheyebolts,at

theendthethreeropesaretiedwiththeringbyeyeboltaswell.

Inordertostrengthentheconnectionoftheabovesaidropesastandardwayto

fixtheropesusingstainlesssteelthimblesandclipsisadopted.

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)RMOTO&WINCHMOTORIZED DRIVE SYSTEM (.4

The

Motorized

Which

Drive

system

consists

of

the

following

components:

- 1HPmotorwithbrakingdevicemadebyKEBGermanOrigin- HeliacalwormgearmadebyKEBGermanorigin- Dualsteeldrumhasatleast5windinglayersspareondrum.

Description:

The helical worm gear is fully submerged in oil for continuous lubrication;

comprehensivedetailsofthemotorareprovidedinAppendixA&B

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5. Electrical Components & Connections- BottomJunctionbox(distributionbox).

Made of cast aluminum Italian origin, Located at the door opening(compartment) connected to the topjunction box by 5 cores cable easy toaccess,arubbergasketisprovidedtoachievetherequiredIPratingwithmin.IP54ComponentsinsidethebottomJunctionBox:

Motorcircuitbreaker3phases,rating2.5to4Amps. Contactor3phases,rating7.5kw. Terminalblock. Terminals. PVCglandIP68,BrassglandIP68&shroud.

BOTTOMJUNCTIONBOX

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- Topjunctionbox(terminalbox).Mountedonthemobileringgettingpowerfromthebottomjunctionboxand

distributes thepower to the light fittings , Italianoriginmadeofaluminum

rubbergasketisprovidedtoachieveIPratingof54asminimum.

ComponentsinsidethebottomJunctionBox:

5pinwallmountedsocket32Amps. Ceramicfuses. PVCglands. Terminalsblocks.

Earth

terminal

blocks.

TOPJUNCTIONBOX

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- Limitswitches.2 Nos. of Limit switches are provided inside the door compartment as an

transducer to control the movement of the mobile to monitor efficiently

latching&unlatchingoperations.

LimitswitchisIPratedtoIP67,10A/220volts,accordingtoIEC6094751

SETOFLIMITSWITCHES(2NOS.)- Remotecontrolunit.

Comprehensiveremotecontroluniteshasall therequiredbuttonsdesigntosuit the safety concept of the system with 2m flexible cable in order tooperatethesysteminsafearea.

REMOTECONTROLUNIT

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- Mainpowersupplycable(betweentop&bottomjunctionbox).Low voltage rubber flexible cable NEXAN branded, 5 cores 4mm

2with

permissiblecurrentrating38A.

5CORERUBBERCABLE

- Powercableplug.Connectedtopowercablewhichisroutedtotopjunctionbox.

POWERCABLEPLUG

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HOW IT WORKS?

the system is used in order to domaintenance or relamping for the light

fittingused , themaintenance isdoneby lowering themobile ringat thea

levelnearthegroundtoberestedontherestingarm.

Loweringthisringisdonebyusingasetofwinchandsteelropesenergizedby

electricmotor.

While lowering and raising the mobile ring, there are three iris arms to

centralizetheringandtopreventswaying.

LATCHING/UNLATCHINGMETHODOLOGYAveryvitalpartof the raisingand loweringmechanism, ishow tohang the

head frame steady in operation condition and how to release it once

maintenanceisrequired.

Therearethreelatchingplatesconnectedinfreerotatingwaytohingeplate

which is fixed firmly to themobile ring,while themobile ring isgoingup, it

hitstheroundrodbetweenthetwosupportingplatesandpassthesaidrod,

thereafterthe

mobile

ring

must

be

lowered

down

alittle

bit

in

order

for

the

latchingplatetosnagfirmlytothesaidroundpin.

Inordertoreleasethelatching,themobileringmustberaisedupalittlebit

so the latching plate will be released then lower down in order for the

latchingplatelatchingplateto bypass theroundpinwithoutsnagging.

It couldbe considered that the latchingplate isdesigned toworkasa cam

plateinup&downdirections.

Followingpageshowingsequenceofthelatching/unlatchingprocess:

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1 Latchingplateisrestedonthepininoperationcondition

2- Raising the ring upward to release the latch

3- Continue raising upward till the pin does not block the bottom part of the latching plate,so it can rotate under its own weigh around its centroid.

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4-lower down the ring so the back side of the latching plate (cam) will bypass the pin without

latching

In a same manner following photos shows the snagging process.

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OPERATION MANUAL

1 The resting armas shown indrawingmustbe fitted,whichwillbeused to

supportthemobileringatloweredposition.

2 Openthedoorofthehighmastanddisconnectthelightfittingspowersupply

multicorecable,supplyingthepowertothetopjunctionboxonthemobilering

whichisprovidingthepowertothelightfittings.

3holdthehandyremotecontrolandstepasideapropersafedistanceabout2

3mawayfromthepolethenoperatethewinchtolowerdownthemobileringtill

itreaches

the

resting

arm

and

once

it

is

resting

on

the

arms

do

not

continue

operatingthewinchsothewirewillnotbe looseandwillstaywindedproperly

onthedrum.

4conduct the required maintenance required for the lantern and use the

auxiliarycables (plugdirectly from thejunctionboxon the ring to thejunction

boxinthepole)whichwillberoutedexternallytotestthelanternwhiletheyare

attheloweredposition

4To

raise

the

mobile

ring

again

after

doing

the

maintenance,

operate

the

winch

inreversedirectiontillyoudescrythecompensationplate(transitionplate).

5 Continue liftingwith prudence till youmake sure that the system passes

slightly the latching pin, at the same time the upper direction button on the

remotecontrolwillbedisfunctioned.

6lowerdownthemobilering littlebitbypressingthebutton inshortburstson

the

remote

control

till

the

ring

is

dangled

on

the

latching

pin

through

the

THREE

latchingplates.

(Pleaserefertosection,HOWITWORKSforbetterunderstandingforthelatching

&unlatchingprocess)

7 Connectmulticorecableagaintothepowersupply,closethedoorofthehigh

mastANDSECURE.

KEEP SAFE, IF YOU HAVE ANY DOUBT ASK!

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APPENDIX A

SYSTEM MODEL

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RAISING & LOWERING STANDARD COMPONENT

GC-RLS-200GENERAL ARRANGEMENT

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APPENDIX B

MOTOR DETAILS

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59

Helical worm gear units S

Type of construction

Foot mounted versionHollow shaft with keywayExample: S32ADM90L4

Foot mounted versionOutput shaft with keyExample: S12AVDM80G4

Shaft mounted versionHollow shaft with keywayExample: S22B DM100L4

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Masse

Mass m kgMasse GegengewichtMass of counter weight

mG kg

HubgeschwindigkeitLifting speed

v m/s

BeschleunigungAcceleration

a m/s

Wirkungsgrad bertragungselementEfficiency of transmission element Seilscheibe / cable sheave: 0.9

Wirkdurchmesser bertragungselementEffektive diameter of transmission element

d mm

GetriebebersetzungGear ratio

ikein Getriebe oder unbekannt: i=1without gearbox or unknown: i=1

Massentrgheitsmoment des AntriebsInertia of the drive

Jm kgcmMassentrgheitsmoment von Motor + Bremse + Getriebe, unbekannInertia of motor + brake + gearbox, unknown Jm=0

Massentrgheitsmoment der Last, bezogenauf MotorwelleInertia of the load, based on the motor shaft

J kgcm2i4002dmJ

=

Drehzahl des AntriebselementesSpeed of the drive element

n 1/mind

60000vn

=

Drehzahl des MotorsSpeed of motor

nm 1/min innm =

Winkelbeschleunigung des MotorsAngular acceleration of motor

m 1/s d

i2000am

=

HubkraftLifting force

Fh N ( ) gmGmFh = Beschleunigungskraft

Acceleration forceFa N ( ) amGmFa +=

Motormoment aus HubkraftMotor torque from lifting force

Tmh Nmi2000

dFhTmh

=

Motormoment aus BeschleunigungskraftMotor torque from acceleration force

Tma Nmi2000

dFaTma

=

Beschleunigungsmoment des Motors

Acceleration torque of motorTmb Nm

10000

mJmTmb

=

Gesamtdrehmoment des MotorsTotal torque of motor

Tm Nm TmbTmaTmhTm ++=

GesamtmotorleistungTotal power of motor

Pm kW30000

nmTmPm

=

C131 - Hubantrieb Hoist

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114

Motor options

B - Brake COMBISTOP spring-set twin-disc safety brake

Protection standard: IP54

connection via contacts in terminal box

adjustment provision for wear of friction linings without dismantling

torque reduction possible

Standard voltages: 230VAC, 400VAC, 24VDC

Options: Manual brake release MB

Dust- and water protection IP65

Mode of OperationThe brake is released by direct-current excitation of the brake coil (2) orby a manual release unit MB (3) which can be attached as an option.Braking is achieved in power off condition by means of spring force (1).The adjusting screws (5) are used to adjust the nominal air gap (X) incase of wear.

Technical DataBrake Mbr

[Nm]Mbred[Nm]

JB[kgcm]

P20[W]

t2[ms]

t11~[ms]

t11=[ms]

WR0.1[J*10^6]

WRmax[J*10^3]

X[mm]

Xn[mm]

hL[mm]

~kg

B02 5 2.5 1.5 0.3 25 40 70 10 7.5 5.3 0.2 0.4 106 1.4B03 10 7.5 5 3 0.7 30 55 100 15 12.5 7.5 0.2 0.5 114 2.0

B04 20 15 10 6 1.4 30 90 180 25 19.1 18 0.2 0.6 128 3.6B05 36 27 18 11 3.5 48 110 220 25 28.0 28 0.2 0.6 168 5.7B06 70 53 35 21 5.6 62 240 260 25 28.8 38 0.3 1.0 176 9.1

B07 100 75 50 30 16 65 220 400 40 35.7 49 0.3 1.0 225 15B08 150 113 75 45 30 75 320 700 50 44.2 56 0.4 1.2 235 24

B09 250 188 125 75 75 80 350 900 60 69.0 78 0.4 1.2 256 34

B10 500 375 250 150 210 130 400 1400 100 80.0 100 0.5 1.5 335 49

Mbr Static braking torque after completed run-in phaseMbred possible reduced brake torquesJB InertiaP20 Excitation rating at 20Ct2 Release time, time from connecting the current to the beginning of torque decreaset11~ Engagement delay time for AC side switching (Fig. 1,3) Time from disconnecting the current to the raise of the torquet11= Engagement delay time for DC side switching (Fig. 2) Time from disconnecting the current to the raise of the torqueWR0.1 friction work until 0.1mm abrasionWRmax permissible friction work for emergency stop from 3000 1/min (B08..B10 - 1500 1/min)X Nominal clearanceXn Clearance, at which a readjustment is recommended

The specified switching times apply to nominal clearance and nominal torque. It relates to average values and depends on the type ofrectification and coil temperature.

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APPENDIX C

GEAR BOX DETAILS

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PARTS LIST

Item Qty. Description

04 4 Spacer

02 2 Drums

03 2 U-Bolt with 4 Nuts & Wahsers

01 1 Electric Motor

Material

MS Pipe

H.D.G. Steel

---

. I .


GC-RLS-203

I I

MOTORIZED DRIVE SYSTEM

MAIN ASSEMBLY

Ref. Dwg. No.

GC/RLS/203-01

GC/RLS/203-02

GC/RLS/203-03

06 6 6mm Wire Rope

05 2 Angle Support

Stainless Steel

H.D.G. Steel GC/RLS/203-05

----

H.D.G. Steel

GC/RLS/203-04

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79

Dimensions

A - Foot mounted version

A AB A1 A2 A3 B B1 B2 H HA HB H1 H2 H3 H4 H5 L S1

S0 50 63 86 43 2 60 52-0.5 30 70-0.5 9 9 7.5 113 106.5 29 86 126 M6

S1 90 110 116 58 2 75 70-0.5 37.5 95-0.5 15 12 10 151.5 137.5 30 95 160 9

S2 110 135 144 72 3 90 85-0.5 45 120-0.5 18 15 18 191 175 40 120 191 11

S3 120 150 168 84 3.5 115 100-0.5 57.5 145-0.5 22 18 24 229.5 212 47 150 233 13.5

S4 150 185 202 101 4 135 125-0.5 70 180-0.5 25 22 35 280 259.5 57 180 280 17.5

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APPENDIX D

SUSPENSION SYSTEM

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PARTS LIST

Item Qty. Description

04 6 Eye Bolt (M12x120)

05 18 Hex Nut (M12)

06 12 Flat Washer (M12)

07 3 4mm Wire Crimping Sleeve

08 1 Sub Assembly

09 1 6mm Wire Rope

02 6 Bull Dog Grip

03 6 Thimble

01 3 4mm Wire Rope

Material

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

H.D.G. Steel

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

. I .


GC-RLS-201

I I

WIRE SUSPENSION SYSTEM

MAIN ASSEMBLY

Ref. Dwg. No.

---

---

---

---

GC/RLS/201-01

---

---

---

---

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APPENDIX E

POWER CABLE DETAILS & JB BOXES

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04 2 Limit Switch

05 1 Cable for Limit Switch

06 1 Bottom Junction Box

07 1 Cable for Remote Control

08 1 Remote Control

02 1 Cable for Top Junction Box

03 1 Power Socket

01 1 Top Junction Box

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

H.D.G. Steel

Stainless Steel

Stainless Steel

Stainless Steel

TOP JUNCTION BOX

LIMIT SWITCH

BOTTOM JUNCTION BOX

PARTS LIST

Item Qty. Description Material

. I .


GC-RLS-204

I I

ELECTRICAL PARTS & CONNECTION

MAIN ASSEMBLY

Ref. Dwg. No.

---

---

---

---

GC/RLS/201-01

---

---

---

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