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Design of a Ski Lift Inspection & Maintenance System

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Design of a Ski Lift Inspection & Maintenance System Design of a Ski Lift Inspection & Maintenance System May 9, 2018 ─ Katie Barthelson, Shallu Darhele, Miguel Mitra, Pritika Sondhi INSPEX - “Because ski lift inspections shouldn’t be a slippery slope” 1 Table of Contents Table of Contents 2 1.0 Context Analysis 5 1.1 Ski Resorts and Ski Lifts 5 1.2 Operating Costs 5 1.3 Components 6 1.4 Regulations 8 1.5 Inspection Requirements, Frequency, and Methods 9 1.6 Failure Analysis 12 1.7 Economics of Ski Lift Maintenance 20 1.8 Accident/Incident Statistics 23 1.8.1 Passenger Statistics 23 1.8.2 Occupational Statistics 24 1.8.3 Reliability 25 1.9 Economics of Increased Inspections 27 2.0 Stakeholder Analysis 27 Ski Resorts 28 Maintenance and Inspection Personnel 28 Visitors 28 Parts Manufacturers 28 Regulators 29 NSAA 29 Insurance Companies 29 Other 30 3.0 Gap Analysis and Problem Statement 33 3.1 Gap Analysis 33 3.2 Problem Statement 34 4.0 Need Statement 34 5.0 Concept of Operations 35 General Concept of Operation for the Current Method 35 Proposed Concept of Operations 35 Image Processing for the Aerial and Tower Platforms 37 2 6.0 Design Alternatives 37 Current Method 37 Aerial Platform 38 Tower-based Platform 42 Cameras for Design Alternatives 43 7.0 Requirements 44 7.1 Inspection System Requirements 44 7.1.1 Mission Requirements 44 7.1.2 Functional Requirements 44 7.1.3 Design Requirements 45 7.2 Simulation Requirements 45 7.2.1 I/O Requirements 45 7.2.2 Time I/O Requirements 45 7.2.3 Cost I/O Requirements 46 7.2.4 Accuracy I/O Requirements 46 7.2.4 Availability I/O Requirements 46 8.0 Simulation Design 47 8.1 Time 48 8.2 Cost 49 8.3 Accuracy 49 8.4 Safety 50 8.5 Availability 51 9.0 Design of Experiment 51 10.0 Results 52 11.0 Analysis 55 11.1 Utility Analysis 55 11.2 Analytic Hierarchy Process 56 11.3 Sensitivity Analysis 57 11.4 Cost Versus Utility Analysis 58 12.0 Business Model 59 12.1 Motivation and Business Thesis 59 12.2 Business Model 59 12.3 Market Analysis 60 12.4 Marketing and Sales Strategy 61 3 12.5 Market Competition and Competitive Advantage 61 12.6 Business Costs 62 12.3 Revenue Projection 64 13.0 Verification and Validation 65 13.1 Verification 66 13.2 Validation 68 14.0 Future Work: Predictive Analytics 69 14.0 Project Plan 70 14.1 Statement of Work 70 14.2 Work Breakdown Structure (WBS) 73 14.3 Project Schedule 74 14.4 Critical Path 76 14.5 Budget 78 14.6 Project Risk Mitigation 79 15.0 References 80 16.0 Appendix 82 16.1 Colorado Cause and Failure codes 82 16.2 Simulation Code 83 4 1.0 Context Analysis 1.1 Ski Resorts and Ski Lifts Ski resorts are popular recreation destinations developed specifically for skiing, snowboarding, and other winter sports. Although the primary season for a ski resort is winter, ski resorts are now operating their lifts 12 months a year to expand operations for summer sports such as mountain biking. Ski areas are mountainous areas with pistes (ski runs), ski trails, and a ski lift system. The NSAA categorizes U.S. ski areas by region: Pacific Northwest, Pacific Southwest, Rocky Mountain, Midwest, Northeast, and Southeast. Pennsylvania, Maryland, Virginia and West Virginia are all part of the southeast region. The United States consists of a total of 521 ski resorts with 4 operating in Virginia [1]. During the 2015/16 ski season, the number of customers at ski resorts varied between 50,000 and 499,000 for downhill snowsports [2]. Ski resorts use ski lifts as their primary mode of uphill transportation. A ski lift is a motor-driven conveyor system used to safely and reliably transport skiers and sightseers up a slope to the top of a run. Ski lifts typically consist of a series of bars or seats attached to an overhead moving cable. A total of 2,705 ski lifts are operated across the US with 18 operating in Virginia [1]. These lifts vary in type, consisting of traditional double, triple and quad chair lifts, gondolas, surface lifts, rope tows, and aerial tramways [3]. The case study for operational analysis is Bryce Resort in Basye, Virginia. It has five surface lifts and two aerial lifts that service 8 runs. The area has 25 acres of skiable terrain and a vertical drop of 500 feet [23]. Bryce Resort was chosen as the case study because their double chair aerial lift is one of the oldest ski lifts in the country and it is one of the closest ski resorts to George Mason University. Skylark Drone Research is investigating the use of unmanned aerial vehicles (UAVs) to inspect ski lift towers. The purpose of this analysis and system design is to examine the viability of using UAVs as a potential design alternative for an 5 inspection system in comparison to other alternatives. Some ski resorts operate on US Forest lands where the use of drone systems is banned, but Bryce Resort does not fall under US Forest Service rules. There is a non-FAA regulated airfield nearby with low frequency local traffic that does not interfere with UAV operation over the lift area. However, inspection personnel would need to obtain a waiver or an FAA 14 CFR Part 107 license to operate a UAV for commercial use. 1.2 Operating Costs The cost of operating a ski lift is based on multiple variables because ski areas and resorts are both capital and labor intensive. Operating expenses include direct labor, maintenance and repairs, property/other taxes, land use fees, and insurance. The average operating expenditure in the Southeast was $13.8 million for the 2015/2016 season [4]. The largest expense category is direct labor accounting for 24% in overall expenditures with an average of $7.9 million per ski area in the 2015-16 season [4]. Lift operations account for 4.1% of expenses and the average maintenance and repair cost was $735,000 in the 2015-16 season accounting for 2.3% of overall expenditures. It takes an average of $423,500 to inspect a ski lift per year [5]. Examples of operating costs include the cost of: ● Installation of ski lifts based on type, configuration, and installation method ● Running base lodges, which house a variety of services, and their maintenance ● Purchase, replacement, and labor costs of snow grooming tractors which move and recondition the snow each night ● Purchase and energy cost of snowmaking equipment ● Energy costs required to run equipment and lifts, and to heat the base facilities 6 ● Labor costs for lift and grooming operators, rental shop technicians, instructors and patrollers, accounting, road maintenance personnel, marketers, snowmakers, IT, and administrative support. [6]. The cost of the most recent ski lift installed at Bryce Resort in 2012 was $1.5 million alone. Ski resorts are dependent on the mechanical soundness of their ski lift components and safety systems in order to operate their businesses. Any mechanical breakdown could cause closure of the slopes, strand passengers, and cost their business millions. 1.3 Components The major components of a ski lift, defined in Table 1, are the haul rope, terminals, towers, carriers, and safety systems. Components Description Haul Rope The lift cable that moves the carrier up the hill while supporting its weight and passengers Terminals Houses the motor, gearbox, auxiliary engine and drive and safety circuitry Major Towers All other lift towers in line with the haul rope that are not drive/return terminals Components Carriers The device on/in which customers ride (chairs, gondola cabins, tram cabins, T-bars) Safety Devices used to detect a cable coming off the sheave wheels Systems or to trigger breaking during rollback. Table 1: Major Ski Lift Components [7] Ski lift towers are made of the components shown in Figure 2 that help support the haul rope and carrier. The tower head consists of the crossarm, sheave train, and support assembly. The haul rope, supported specifically by the support assembly, is covered by the brittle bars and cable catcher in the event of deropement. For bicable systems, there is both a haul rope and a stationary track 7 rope to support the weight of the carrier. The track rope is supported on the tower by the saddle, which prevents excessive movement. Figure 2: Components of the ski lift towers described in this section [8] Table 3 below defines the subcomponents by component type. The power components generate and supply the energy for ski lifts to function. The mechanical components consist of the parts involved in the moving mechanism of the ski lift. The safety components ensure the ski lift is fail safe by activating when a failure in the system occurs. Another important component is the communications line (comm line) which carries data signals from each tower’s safety and operating circuitry between the base and the summit and mountain dispatch. If the comm line breaks, a signal is sent to the terminal to indicate a fault, and problems related to the low voltage control system may occur. 8 Power Components Mechanical Components Safety Components Components Description Components Description Components Description Large wheel located at both ends Backup power to Anti-Rollback A type of brake that prevents Auxiliary Bullwheel of the lift used to change the main motor Device ski lift from rolling backwards directions of the haul rope Controls speed Drive (Low Arm at the top of the tower to A device connected to a safety and amount of Voltage Control Cross Arm which the sheave train is Brittle Bar circuit that breaks if a cable voltage going to System) attached comes off the sheave wheel the main motor Transfer power Catches the haul rope if it The main brake used to stop the Gearbox from the motors Service Brake Cable Catcher comes off preventing the rope lift during daily operations.
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