重型工业升降机的自动化索具设计外文文献

Contents lists available at ScienceDirect Automation in Construction journal homepage Automated rigging design for heavy industrial lifts SeyedMohammadAmin MinayHashemia SangHyeok Hanb Jacek Olearczykc Ahmed Bouferguened Mohamed Al Husseine Joe Kosaf aDepartment of Building Civil and Environmental Engineering Concordia University Montr al QC H3G 1M8 Canada bDepartment of Building Civil and Environmental Engineering Concordia University Montr al QC H3G 1M8 Canada cDepartment of Civil and Environmental Engineering University of Alberta Edmonton Alberta T6G 1H9 Canada dCampus Saint Jean University of Alberta Edmonton Alberta T6C 4G9 Canada eDepartment of Civil and Environmental Engineering University of Alberta Edmonton Alberta T6G 1H9 Canada fNCSG Engineering Ltd 28765 Acheson Road Acheson Alberta T7X 6A8 Canada A R T I C L E I N F O Keywords Rigging assembly Modules Mathematical model Automated system 3D visualization A B S T R A C T Modular based heavy industrial construction projects typically involve the use of mobile cranes to lift and place large heavy prefabricated modules These modules must be lifted vertically raised evenly and maintained in a level position during the lift in order to prevent them from defl ecting and more importantly to mitigate safety issues regarding potential rigging failure In this respect a comprehensive crane lift study at the planning stage of the project is required to ensure the lifts are successful and to improve safety and productivity One of the most tedious and time intensive tasks involved in conducting the lift study is the design of the rigging assem blies which are the link between the crane hook and the module In practice however this task is performed manually and relies heavily on guesswork which is error prone and time consuming especially when the center of gravity is off set from the center of the module Poorly designed rigging assemblies are only detected at the job site when the module does not raise evenly at the beginning of the lift which then results in wasted time and productivity loss as the assembled components have to be unrigged and properly adjusted To overcome these limitations this paper proposes an automated mathematical based rigging assembly design system that consists of i collecting module and available rigging component information ii the solver analysis which calculates the sling angles and performs the calculations required to balance the module iii the rigging assembly designer which determines the required capacity of the rigging components and selects the suitable riggings from the database iv rigging assembly design alternatives and v the 3D visualizer which creates a 3D model of the designed rigging assembly This framework enables lift engineers to create rigging assembly designs more precisely and expeditiously The methodology is validated in a case study 1 Introduction Modularization is a growing trend in construction thanks to its ef fi ciency in terms of time cost and quality improvement 1 This mode of construction thus is the solution of choice for heavy industrial pro jects especially oil refi nery facilities in the province of Alberta Ca nada In these projects hundreds of modules are prefabricated in a controlled environment transported to the job sites lifted from their pick locations and fi nally erected in their planned position These modules which have N lifting points 4 to 16 lifting points depending on the module length can typically be classifi ed as pipe racks cable trays and building modules 2 Furthermore the modules can weigh up to 160 t and can measure up to 24 ft 7 3 m wide 138 ft 42 m long and 27 5 ft 8 4 m 3 In order to prevent the modules from tilting they are required to be lifted vertically and evenly from extensions of the module s columns which are located on the top of the modules Lifting the modules un evenly can potentially result in defl ection of the module and more importantly an uneven distribution of the load throughout the rigging assembly increases the risk of rigging failure and corresponding safety issues At this juncture it should be noted that rigging failure is one of the major causes of crane accidents According to a study based on the Occupational Safety and Health Administration OSHA database 28 1 of fatal crane accidents that happened in the United States https doi org 10 1016 j autcon 2020 103083 Received 3 October 2019 Received in revised form 10 December 2019 Accepted 7 January 2020 Corresponding author E mail addresses s minayh encs concordia ca S MinayHashemi sanghyeok han concorida ca S Han jaceko ualberta ca J Olearczyk ahmed bouferguene ualberta ca A Bouferguene malhussein ualberta ca M Al Hussein joe kosa J Kosa Automation in Construction 112 2020 103083 0926 5805 2020 Published by Elsevier B V T between 2002 and 2012 were caused by failure of wire ropes slings and hoist lines The other causes of fatal crane accidents were overturn tips 8 6 collapse 11 4 ground conditions 3 6 power line contact 5 6 overloading unstable 26 signal communication error 9 4 and other causes 7 3 4 Rigging assemblies are generally used to not only build a physical connection between the crane s hook and the modules but also to determine how the load is distributed from the lifting points to the crane s hook Suitably designed rigging assemblies have a vital role in the success of the lift and can ensure the modules are lifted safely and effi ciently Traditional rigging assemblies as shown in Fig 1 are a combina tion of spreader bars slings and shackles that are used to transfer pairs of loads from the lifting pick points of the module to the crane s hook using triangular slinging arrangements The term level is used in this paper to refer to the various heights of the assembly where rigging components are used as shown on the left side of Fig 1 The number of levels in traditional rigging assemblies varies based on the number lifting points on the module It should be noted that this paper focuses on overcoming the limitations of designing traditional rigging assem blies through the use of an automated procedure that integrates rigging analysis calculations with 3D visualization As mentioned earlier above unevenly lifting a module not only contributes to safety issues due to potential rigging failure but also increases the risk of damage to the structural components of the module To solve this issue in practice the assembled rigging compo nents need to be unrigged and properly adjusted to balance the load which leads to a decrease in lifting productivity due to wasted design and lifting time In this respect designing a rigging assembly that en sures the module is lifted evenly and maintained in a level position during the lift is paramount The design process used to assemble a rigging system consists of the following tasks i calculating the re quired capacity of each rigging component based on the module in formation such as its weight dimensions center of gravity COG position and number of lifting points ii selecting suitable rigging components from their capacity charts based on the required capacities and dimensions iii calculating the total weight of the rigging as sembly that is used in crane selection and iv creating a 3D model of the rigging assembly to identify whether the selected rigging compo nents can actually be used together size compatibility of the selected rigging components The developed 3D model as a part of a more comprehensive 3D lift study is then used to ensure that the module and rigging assembly do not collide with the crane s boom and or site ob stacles Manually performing these tasks especially when the COG is off set from the center of the module COM is a tedious and error prone process relying heavily on guesswork and it can take anywhere from 0 5 to 4 h per module depending on the number of lifting points on the modules as well as the engineer s experience To overcome these lim itations this paper proposes an automated mathematical based rigging assembly design system that consists of i collecting module and available rigging component information ii the solver analysis which calculates the sling angles and performs the required calculations for balancing the module iii the rigging assembly designer which de termines the required capacity of the rigging components and selects the suitable riggings from the database iv rigging assembly design alternatives and v the 3D visualizer which creates a 3D model of the designed rigging assembly The proposed system is developed in the AutoCAD platform using Application Programming Interface API 2 Literature review A signifi cant amount of research has been published in the area of heavy lift studies to address issues regarding crane selection 3 5 7 crane lift path planning 8 11 and crane operation simulation 12 15 However research on the development of design frameworks for crane rigging assemblies has received less attention in both aca demia and industry despite their importance in terms of safety and effi ciency In practice rigging assembly design is time consuming and error prone which is associated with safety issues and decreases in productivity One common slinging arrangement for lifting those modules referred to as 4 point pick modules consists of attaching four diagonal slings directly from the lifting points to the hook In the ideal scenario where the COG is exactly at the geometric center of the module the lengths of the slings used to transfer the load from the module to crane hook in a 4 point pick scenario need to be exactly equal assuming the pick points are distributed symmetrically with respect to the COG In practice however because the COG is likely to be off set from the geometric center of the module the length of the slings needs to be adjusted in order to have a balanced transfer of the load which ensures that the lifted module stays level at all times In previous work Sam 16 developed a spreadsheet to determine the load distribution between the four slings considering the position of COG and sling lengths The scope of Sam s study is limited to 4 point pick modules unless an independent and separate analysis is done for those modules with more than four lifting points and they are lifted with multiple cranes Moreover the alignment of the lifting lugs which are the most vulnerable places of the module 17 is important in this confi guration Each of the lifting lugs located on the top of the legs of the modules must be in plane toward the COG If the lifting lugs are aligned toward X axis direction the load is not applied on the shackles in line due to the angle that slings make with the shackles which re ferred to as side loading 18 In that case the working load limit of the shackle must be reduced based on the angle of sling with shackle ac cording to its supplier s manual The working load limit of the shackle may be reduced to as low as 50 of its full capacity in side loading applications 19 Considering the uncertainties in the position of COG length of slings and the angle of slings with shackles Anderson 18 suggests designing the lifting lugs shackles and slings in a way that two of them are able to carry the entire load The lifting points of modules may be located at the bottom of the Fig 1 Traditional rigging assembly S MinayHashemi et al Automation in Construction 112 2020 103083 2 modules Lifting from the bottom however involves risk due to in stability if the module s COG is too high e g the module may be dumped in the course of its motion In this respect for 4 point pick modules that must be lifted from the bottom an analysis is necessary using criteria for Lyapunov stability or asymptotic stability as was suggested by Longman and Freudenstein 20 They defi ned an ex pression for the margin of stability in which the disturbance forces caused by crane hook motion during the lift can be tolerated Their methodology cannot be applied in the case of modules with more than four lifting points In terms of the assembly and disassembly operations of rigging confi gurations suffi cient research works are not existed yet In this respect this paper looks at only the assembly and disassembly operations in other fi elds For example Hu and Zhou 21 proposed automated manufacturing systems using a petri net based discrete event control to respond to splitting to and merging from diff erent subprocesses respectively As a continuous work Hu et al 22 in troduced a resource distributed control system to develop automated manufacturing systems based on the application of petri nets and dis crete event system As described in the previous section compared to the other research areas regarding heavy lift studies crane selection crane lift path planning crane operation simulation etc there are relatively fewer studies and or practical reports in terms of methods to support the design of rigging components However there are a few commercial software programs that can help in designing rigging assemblies Industry academic research collaborations have led to the development of computer aided heavy lift planning systems in order to assist lift engineers in the planning phase of the heavy lift projects A computer aided rigging CAR system was developed by Brown ii they may result in wasted assembly time on site since actual rigging components e g slings spreader bars and shackles are represented by the software programs as simple solid geometries which are not capable of indicating size incompatibilities between rigging components that may result in the components not being able to be assembled in real life iii the lengths and angles of slings and number of shackles in the rigging may not be computed accurately due to the result of the reason ii and iv the rigging confi gurations in the software cannot be designed to load more than four lifting points of the modules In order to overcome these limita tions this paper presents a mathematical based rigging assembly design system that automates the design of rigging assemblies for a large number of modules generally used in heavy industrial construction projects The proposed system consists of i collecting module in formation ii automating the rigging analysis calculations iii reporting the result of the analyses and iv visualizing the rigging assembly in a 3D environment Moreover the results of the proposed framework provide rigging assembly information e g overall heights and weights which is an essential input to complete the crane selec tion crane lift path planning and crane operation simulation success fully and effi ciently 3 Proposed methodology The proposed methodology for an automated mathematical based rigging assembly design system is illustrated in Fig 3 The required input data which must be entered manually by the user consists of i module information including dimensions weights and the COG po sition ii availability of rigging components in inventory such as shackles spreader bars slings and turnbuckles iii user defi ned con straints such as maximum acceptable angle of drop slings and iv the crane hook s width There are three main design criteria 1 The module must be lifted evenly and maintained in a level position during the lift In other words the lifted module must be parallel to the ground otherwise the load is unevenly distributed throughout the rigging as sembly and consequently potential rigging failure and module de fl ection may occur 2 The angle between the drop slings slings at the fi rst level of the rigging assembly attached to the lifting points and the module must be perpendicular so that only vertical tension forces are applied on the module s columns to prevent the module from bending 3 The selected rigging components must meet the minimum required capacity Failure to meet each of these three criteria could put the safety of the lift in jeopardy Based on the input and criteria the pro posed methodology to design a rigging assembly for each of the mod ules consists of a framework including three elements i the solver that performs two tasks which include calculating the sling angles at each level of the rigging assembly through solving a system of nonlinear equations and fi nding the optimal size and number of shackles which are attached to slings to increase their lengths in order to satisfy criteria 1 and 2 iii the rigging assembly designer which calculates the required capacity of the rigging components based on the module in formation and selects suitable rigging components that meet the re quired capacity from the data considering their availability in the in ventory and iii the 3D visualizer which creates a 3D model of the rigging assembly in the AutoCAD platform using AutoCAD Application Programming Interface API Creating the 3D model is an essential step to identify size compatibility of the selected rigging components which indicates whether or not the selected rigging components can be used together If an incompatibility issue is encountered the user may choose to put constraints on the availability of the rigging components that cause the error and start the design over again or to perform the required modifi cations manually Moreover as mentioned earlier the developed 3D model is used to ensure that the module and rigging assembly do not have collision risks among crane s boom and or site obstacles The 3D visualizer collects the required data from both the database and the results of the rigging analyses The collected data is then used in the process of inserting and positioning the rigging com ponents that are stored as AutoCAD 3D blocks in the database Finally the outputs of the system are rigging designs can be more than one single design that include a list of selected rigging components total height and weight of the rigging assembly and proposed percentage capacity of the rigging components in accordance with alternatives of the rigging assembly designed by the proposed methodology It should b