Observatory Automation Project Detailed Design Review D il d D i - PowerPoint PPT Presentation

Appendix T OAP Dome Drive DDR Presentation Observatory Automation Project Detailed Design Review D il d D i R i Electric Dome Drive System y (EDDS) Steven Bauman Contributors: Sarah Gajadhar, Grant Matsushige, Ivan Look Derrick Salmon Ralph Taroma Larry Ivan Look, Derrick Salmon, Ralph Taroma, Larry Roberts, Casey Elizares, Tyson Arruda, William Cruise, Tom Vermeulen, Jim Thomas, DeeDee Warren, Karun Thanjavur Warren, Karun Thanjavur Version 1.1 July 9, 2010 T1

Appendix T OAP Dome Drive DDR Presentation T2

Appendix T OAP Dome Drive DDR Presentation Scope Scope � Design solution to replace the hydraulic power unit and operate the dome drive system with electronically controlled motor units. � Remotely control the system under the guidelines provided by the OAP project � Meets the specifications and requirements formed M h ifi i d i f d for the dome drive electrical upgrade. � Detailed design changes to the existing system, D t il d d i h t th i ti t mechanical interfaces, safety considerations, anticipated costs and estimated manpower anticipated costs and estimated manpower resources. T3

Appendix T OAP Dome Drive DDR Presentation Hydraulic Hydraulic Hydraulic Hydraulic power unit power unit T4

Appendix T OAP Dome Drive DDR Presentation Scope Scope � Design solution to replace the hydraulic power unit and operate the dome drive system with electronically controlled motor units. � Remotely control the system under the guidelines provided by the OAP project � Meets the specifications and requirements formed M h ifi i d i f d for the dome drive electrical upgrade. � Detailed design changes to the existing system, D t il d d i h t th i ti t mechanical interfaces, safety considerations, anticipated costs and estimated manpower anticipated costs and estimated manpower resources. T5

Appendix T OAP Dome Drive DDR Presentation Requirements Dome Drive Requirements needed for OAP � Remotely controlled dome drive operation � The dome drive must be capable of being operated remotely in a “safe” reliable manner from Waimea. � NO possible remote control from Waimea when in manual mode at the summit. � Remote monitoring and status information � The electronic drive system shall provide necessary status and system information. � Phase 2 will provide a status page for motor controller system status and monitoring. � Manual Control � The drive system control panel must allow local control of the drive system with the same or y p y improved safety features. � Preventative Maintenance � The dome drive system shall provide access to all serviceable components and minimize the need for scheduled maintenance. � Improved Reliability � The new electronic dome drive system should increase the reliability and minimize repairs. � Safe Interlocking � The dome drive system shall provide safety interlocking to prevent unauthorized remote y p y g p control of the drive system. It shall protect personal and other critical systems when/if other systems shutdown or malfunction � Lock out of the system for maintenance. T6

Appendix T OAP Dome Drive DDR Presentation •Modify 5 th floor spacer room to allow for more space around the p motor. •Alterations will improve maintenance and repairs in the maintenance and repairs in the future. T7

Appendix T OAP Dome Drive DDR Presentation Replacement Actuator Parker Hannifin Pneumatic actuator actuator 122psi operating pressure T8

Appendix T OAP Dome Drive DDR Presentation Solenoid valve • 4-way valve • 1 pressure port, 2 cylinder ports, 1 exhaust port exhaust port • Built in surge suppression • 80% reduction in • 80% reduction in power use • Only draws 2 watts of power • 100-240/AC or DC DC • Rain tight, dust tight, and Ice resistant resistant. T9

Appendix T OAP Dome Drive DDR Presentation Proof of concept The Daycrew assembled and assembled and bench tested a similar two port actuator and solenoid valve with valve with 122psi operating p g pressure to verify and validate the validate the design idea. T10

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Appendix T OAP Dome Drive DDR Presentation Dome Drive Unit Components SHP wheel SHP Main shaft assembly Brevini Gear assembly assembly reduction box d i b Hydroland Hydraulic motor T12

Appendix T OAP Dome Drive DDR Presentation New Motors and Adapter Exploded adapter Baldor kit view RPM AC 20 HP 20 HP motor 1750RPM 3 3PH 60HZ Brevini Nema 250 TC Motor adapter fl flange T13

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Appendix T OAP Dome Drive DDR Presentation T16

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Appendix T OAP Dome Drive DDR Presentation Motor Integration Drive unit modifications Valve off the supply and Valve off the supply and 1) 1) 6) Drain the gearbox 6) Drain the gearbox return hydraulic lines 7) Rotate the gearbox 90 ˚ Drain and remove the 2) with the input shaft up. with the input shaft up. lines from the hydraulic l f h h d l 8) Rebolt the gearbox motor and cap them. 9) Replace the gearbox oil p g Remove hardware and 9) 3) 3) the hydraulic motor 10) Install electric motor to Remove hardware and 4) the new adapter kit the motor adapter assy the motor adapter assy. 11) Install the hardware 5) Unbolt the Gearbox from and motor/adapter on the SHP main shaft assy. the gearbox the gearbox T18

Appendix T OAP Dome Drive DDR Presentation T19

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Appendix T OAP Dome Drive DDR Presentation Location of Dome Drive cabinet Cabinet details • Nema 1 enclosure with fans and filters. • Self standing cabinet with legs S lf t di bi t ith l or other means of support. • Wheels or casters incorporated for transportation. p • Cabinet fitted with Main molded case circuit breaker (MCB) door and or side panel disconnect disconnect. • The cabinet will be located in front of the wall, the ladders will be relocated. T21

Appendix T OAP Dome Drive DDR Presentation Dome Drive Motor Controller Cabinet • Power distribution terminal block for three (3) branch circuit each with: • 50 Amp molded case circuit breaker (MCB) for inverse fault protection (loss of line or line short circuit line when drive is regenerating) . • Thermostatically controlled drive input contactor to prevent power up at below -10 deg C . • 3% Input line reactors • ZD22H420-EL drive • Output motor load reactors O *Grant will discuss the controls of the system T22

Appendix T OAP Dome Drive DDR Presentation Heat Mitigation strategy B � Heat dissipation estimates � Heat dissipation estimates � Motors At Full Speed (3.4HP @ 60 ˚ /min) ~ 95 Watts � Meets requirement criteria, no requirement for mitigation iti ti � Motor Controllers At Full Speed (3.4HP @ 60 ˚ /min) ~ 256 Watts � Worst case estimate, difficult to estimate due to W i diffi l i d intermittent operation __________________________PLAN __________________ C C • A) V A) Vent the motor controller heat into the visitor’s t th t t ll h t i t th i it ’ gallery. Sealed room with no other heat sources. • B) Add a standard ventilation fan above the visitors staircase door to vent the room air volume into the t i d t t th i l i t th staircase • C) Add a small Thermatron or Lytron heat exchanger using the building glycol system to the bottom of the i th b ildi l l t t th b tt f th Baldor cabinet. T23

Appendix T OAP Dome Drive DDR Presentation Monitoring and Status Information Phase 2 Motor Controller Example status page for monitoring the system g g � Stores data about the Stores data about the functionality and health of the drive system � The Outputs can be Th O t t b monitored such as; speed, torque, voltage, current, etc. Communication Method � Serial interface communication (RS232) expansion board (RS232) expansion board � Feedback information for status via and RS232 cable and Pearle device device. T24

Appendix T OAP Dome Drive DDR Presentation Time and resource estimates – Implementation plan Baldor Cabinet Build Room Modifications Actuator Integration and Test Prepare the visitor’s Finalize pneumatic lines Award P.O. for gallery, relocate the and location of the Baldor package ladders, terminate solenoid valve. Modify the rod clevis brackets wiring Date: ~7/16/2010 Date: ~7/28/2010 Date: ~8/5/2010 Shut off supply and Develop and/or Install Baldor begin design return lines, remove old provisions for lifting and assembly of actuator, modify as the gear reduction cabinet cabinet needed install new needed install new box and motor actuator Date: ~7/19/2010 Date: ~8/12/2010 Date: ~8/4/2010 Review cabinet Test actuator function, Remove the door run dome with new design, approve for casting and/or walls actuator, install final build and ship and modify as needed remaining actuators Date: ~8/19/2010 Date: ~9 ‐ 1 ‐ 2010 Date: ~8/26/10 *Some tasks can be preformed in parallel.* T25