Qilu Network Lightning News February 14 news "Drive!" With song Jianjun, deputy station chief of the Zhongtianmen Ropeway Management Station, issuing a driving instruction, ChangJiangbo, the mechanical and electrical section of the Zhongtianmen Ropeway Management Station, immediately pressed the red driving button on the control cabinet, and the "ropeway" with 6 gondolas hung began to run, the station cart was normal, the automatic disconnection was normal, the rope force value was displayed normally, and the tension tension value was displayed normally. ... Just as the Zhongtianmen ropeway in operation, functions, displays, etc. were readily available on this "ropeway".
This "ropeway" is the first off-hook full-featured simulation teaching ropeway in China developed by the Zhongtianmen Ropeway Management Station of Taishan Ropeway Operation Center for more than 7 months.
"We went from conception to design, from material preparation to component 'manufacturing', from assembly to commissioning, in about a year. This 'ropeway' is completed independently by our mechanical and electrical personnel from conception to physical objects. Song Jianjun, the "chief designer" of the off-hook full-featured simulation teaching ropeway, said.
Problem-oriented, teaching simulation ropeway "unique"
"To carry out this ropeway, we mainly have two considerations. One is to simulate some equipment failures, and then to improve the practical ability of our mechanical and electrical employees, in the final analysis, it is a purpose, that is, to improve our equipment management capabilities. Ge Zunrui, director of the Taishan Ropeway Operation Center, said when talking about the original intention of developing the simulated ropeway, "We couldn't do it on the running ropeway, so we had the idea of making a simulated ropeway ourselves." ”
Since 2013, the Taishan Ropeway Operation Center has established the idea of "improving the emergency handling capability of equipment failures" in equipment management. Because the two ropeways in Zhongtianmen and Taohuayuan are long, the height difference is large, and there are many tourists, once the ropeway equipment failure occurs, emergency rescue is very difficult. In order to ensure the safety of tourists, it is necessary to move the safety gate forward, while ensuring the last line of defense, that is, emergency rescue, it is necessary to comprehensively improve the emergency handling capacity of ropeway equipment failure, after the ropeway ropeway equipment fails and stops, the fault point can be detected in the shortest possible time, and then the fault can be solved and the ropeway operation can be restored.
At that time, the two ropeways of Zhongtianmen and Taohuayuan had entered the aging period, equipment failures were becoming more and more frequent, and experienced old employees were leaving one after another, and new young employees lacked practical experience, so it was urgent to improve their vocational skills. Under the guidance of this line of thinking, the Taishan Ropeway Operation Center has successively improved the emergency response plan for 32 emergencies covering the field of ropeway mechanical and electrical equipment, and carried out nearly 200 fault simulation and emergency disposal drills for 6 major systems such as drive equipment, disconnection and station transmission equipment, braking and tensioning system, carrier equipment bracket line equipment, safety detection and control system.
Since 2019, the Taishan Ropeway Operation Center has begun to implement the three major improvements of "management, ability and efficiency", of which the professional ability improvement of mechanical and electrical personnel is the top priority. With the "post training and business competition" as the main form of mechanical and electrical professional ability education and training in full swing, the assessment of practical operation ability has become the norm.
In practice, whether it is a ropeway station or an individual employee, whether it is equipment failure simulation or professional education and training, it always feels that there is a lack of specific grippers, and it is not systematic and comprehensive enough, resulting in pertinence and effectiveness that are not strong enough.
After repeated brainstorming, the idea of "making a teaching ropeway" was formed in Song Jianjun's mind. "If there is a ropeway that can be used for teaching, the fault that cannot be simulated in the real ropeway can be simulated on the teaching ropeway, and by making the various execution elements of the teaching ropeway by yourself, everyone will have an in-depth re-learning and re-study process of the principle, operation mode and design idea of the unhook-up ropeway, which will be a great impetus to our mechanical and electrical professional ability." Song Jianjun's idea has been fully affirmed and strongly supported by the leaders of the Taishan Ropeway Operation Center.
Just do it. Under the leadership of Song Jianjun, starting in May 2021, the mechanical and electrical employees of Zhongtianmen and Taohuayuan formed several teams and began to act separately, and a concentrated research on "building" a simulated ropeway opened the curtain.
Do-it-yourself, teaching simulation ropeway "turned out"
The R&D team's goal was very clear, which was to make a simulation model that was exactly the same as the real disconnect cableway function. Although everything was difficult at the beginning, they decided to start with the most difficult roper, because this is the core technology of the cableway, and it is also the technical difficulty that the simulation ropeway needs to be overcome first, so they decided to make a simulated cable socket first.
The working principle of the gripper is very clear to the team members, but relying on their own model, no one has tried it in China. They first found out the installation diagram of various unhanging rope grabbers, studied and analyzed which form was more suitable for production, and finally chose the combination of the shape structure of the Zhongtianmen rope grabber plus the stainless steel pressure spring. In order to verify the feasibility and facilitate processing, first of all, the nylon material was manually polished according to the size of 8 to 1, and after adding the compression spring, the jaws could clip a pencil, which greatly boosted everyone's morale and proved that the team's research and development direction was correct and feasible. A 3D printer was purchased for this purpose, and through learning, it quickly printed a more scientific size of the roper parts. But because of the material, after many times of opening and closing, cracks and fractures will appear in the stressed part, although the thickness is increased to improve the structure but still can not avoid cracking, all the teams consider the use of sand turning process to make copper parts, but in the details is always difficult to meet the requirements, and then explore the use of lost wax method, because the device is too small, the temperature loss is too fast, in the key jaw position of the rope gripper is still unable to meet the needs, can only give up another way to carry out. In the end, stainless steel machining was chosen to make it. In order to reduce the processing cost, the team used CAD to draw the parts well, and the other party directly processed them according to the drawings. Through continuous testing and improvement, the rope holder was finally successfully made.
After the gripper was completed, the team immediately set out to overcome the second difficulty: the production of the cart system in the station. Carriage rope in the line and in and out of the station is connected with the wire rope, the wire rope movement with the rope together, but in the station, the rope is separated from the wire rope, the rope puller in the station movement depends on the station cart system, the power of the cart system comes from the wire rope, through the friction wheel and the wire rope direct contact and driven rotation, through the belt friction wheel to conduct power to the pulley, and through a belt to conduct to more pulleys, Pulley through the coaxial tire to push the rope gripper running on a fixed track, in the production process, choose what to pulley and belt to effectively conduct the power down, without too much loss, but also consider the installation position and size, in the corner, how to achieve the curve pusher, install the ropeway prototype, in the corner to tighten the wheel space is too small to achieve, with the synchronous motor and the mechanism is complex can not be implemented, and finally the team thought of the coupling, with the coupling to achieve the power transmission of the curve, Solves the biggest challenge of the cart system. At this point, the two biggest difficulties in research and development have been overcome by the team's unremitting and repeated exploration experiments.
The production of carriages is also a difficult point. The carriage is a very conspicuous and brilliant place in the whole system, and it is also easy to cause problems. The carriage began to be made of direct splicing with aluminum plates, and then gradually installed angle guards, edge guards, glass, sealing strips, carriage doors, compartment door switch mechanisms, suspensions, shock springs and other components in the later stage, and each increase greatly improved the practicality and aesthetics.
Although the unhooking simulation teaching ropeway is small, but it is a complete disconnection ropeway, the normality of the ropeway not only depends on the quality of each component, but also depends on the installation and debugging of the entire ropeway system, especially as the first ropeway, there is no experience to learn from, no data can be referred to, everything is constantly groping and exploring, and as a whole system, the problem often appears or is found after the combination, and it is necessary to repeatedly improve the debugging to ensure the normal operation of the ropeway.
For example, in the test, it was found that the relative height and position of the walking rail, balance rail, wire rope, and pulley must be ensured, and which position is not suitable will cause additional wear or caton in operation, which needs to be carefully adjusted.
Fully functional, teaching simulation ropeway "complete"
At present, the electrical part of the analog ropeway has 46 fault alarms and functions such as emergency stop button, working stop button, forward and reverse interlock, and logical fault of the station and fault of the pit stop area, and the mechanical part has 12 functions such as the positive and reverse automatic disconnection system of the rope, the acceleration and deceleration system in the carriage station, and the touch screen function display includes 15 items such as rope speed, inverter voltage value, cable force value, tension tension value, etc., which can really be described as "although the sparrow is small, it is complete".
Remarkable results, teaching simulation ropeway "domestic first"
In the exploration and practice of more than half a year, the teaching simulation ropeway development process has become a platform for learning and displaying the mechanical and electrical employees of taishan ropeway operation center, which has greatly exercised the hands-on ability of mechanical and electrical employees.
More importantly, with the further digestion and absorption of the principles and technologies of passenger ropeway equipment, the Taishan Ropeway Operation Center will continue to add new functions, set up new faults, and carry out new fault disposal training on teaching simulation ropeways according to different needs. At the same time, the latest ropeway technology is simulated on the teaching simulation ropeway, the reliability of the new technology transplantation is improved, and the only teaching simulation ropeway in China is strived to play the greatest "practical" role.
Lightning News reporters Wang Xun and Zhang Tiancheng reported from Tai'an