Editor's Choice


Hydraulics lifts the stage at U2 concert

1st Quarter 2017 Editor's Choice Hydraulic systems & components

For U2’s 360° Tour the Belgian company, Stageco constructed three gigantic, identical stages. What made this project special was that high pressure hydraulics were used for the first time ever to assemble and dismantle the 230 ton construction. Together with Enerpac, Stageco developed a unique system based on Enerpac’s synchronous lift system to raise the modular construction to a height of 30 metres quickly and safely.

The steel stage construction consisted of a central lock which rested upon four legs, each made up of six sections. The central block was gradually lifted off the ground in 38 steps and a section was added to each of the four legs after every six or seven steps. A temporary truss containing a supporting frame at the top was made for each leg. Within each truss was a hydraulic pump unit, four high pressure lifting cylinders (350 bar), each with an applied pulling force of 20 tons and a 600 mm stroke, and four 0,5 ton low pressure (60 bar) locking cylinders, each with a stroke of 260 mm. All were attached to a supporting frame, which moved along the guide rails. The complete hoisting system for each stage therefore consisted of 16 lifting cylinders, 16 locking cylinders and four fully hydraulic units. The lifting cylinders were fitted with a pressure transducer, a built-in stroke sensor and two proximity switches. The locking cylinders were also fitted with two proximity switches. The hydraulic pump unit included individual pumps – one for the lifting cylinders and one for the locking cylinders. The pump units were controlled according to the master/slave principle from a central operating computer on the ground, which had a touch screen with images showing the position of the various hydraulic cylinders and their position within the lifting portals. The force of each lifting cylinder and each lifting portal was also displayed, along with the total force. A local PLC was installed on each platform so that the lifting platform could be operated locally if necessary.

First of all, the complete pump units were positioned in the lifting portals using a small mobile crane. At the beginning of the lifting process, the ends of the central block rested on the supporting frames with the Enerpac units. When the frame was lifted, the top beams were first raised one step hydraulically, and then locked mechanically using locking pins and the hydraulic locking cylinders. The bottom locking pins were then cleared hydraulically and the cylinders raised the load to the same height. In this way, the four hydraulic units lifted themselves in the lifting portals with the load, as it were, at a net speed of around 10 metres per hour. Lift synchronism was vital here due to the torsional stress that occurred. Stageco worked with a tolerance of 5 to 10 mm. This may seem like a lot, but it was adequate since the lifting portals were 35 metres apart. The operating computer’s display also showed that the load in the four portals remained in perfect balance. The display showed which steps in the lifting process had already been completed. The operator did, however, need to give the system a command for each step. After the claw was assembled, the pump units were lifted out of the lifting portals with a crane and the lifting portals were then removed. The system worked according to the same principle but, of course, in the opposite direction when the whole construction was later lowered and dismantled. The pump units were then back on the ground and could be stored ready for transport to the next location.

Stageco made no concessions whatsoever as far as safety was concerned. The mechanical locking of the lifting platforms, for example, was an extremely important element. Enerpac’s computer-controlled synchronous lift system also fulfilled this requirement perfectly. Every step in the lifting process was controlled, and the next step could only be performed when all the required conditions had been fulfilled. The system also gave information on the position the load was in, and how the tension was distributed during lifting. The Enerpac system measured the forces continuously and in real time. Although the operational speed was significant, Stageco considered safety to be one of the greatest advantages of this technology. Since the three stages travelled across the whole world over two years, the emphasis was also on reliability and durability. According to Stageco, another advantage was that Enerpac had an international presence and operated worldwide.

Enerpac is represented locally by BMG.

For more information contact Lauren Holloway, BMG, +27 (0)11 620 7597, laurenhy@bmgworld.net, www.bmgworld.net



Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Oil-free beer and wine processing
Pneumatic systems & components Hydraulic systems & components
The food and beverage industry depends on superior quality, 100% oil-free compressed air to eliminate the presence of unwanted oil vapour throughout the production line.

Read more...
WEG partners with Panaco in the DRC
Zest WEG Group Africa Editor's Choice News & events
The strengthened presence of WEG in the Democratic Republic of Congo (DRC), through its strategic alliance with ts value-added reseller (VAR) Panaco, has proved to be highly successful.

Read more...
Execution of the massive Azmet Reactor project DRC
Editor's Choice News & events
The Azmet Reactor project, a collaborative effort led by Viva Engineering, involved fabricating six massive reactors that were over three stories high in Gauteng, and then transporting these more than 2500 kilometres to a mine in the DRC - where all 3265 parts fitted perfectly, with not even one of the 26 900 bolts out of place. This was a massive achievement.

Read more...
The time is now to implement a motor management strategy
Schneider Electric South Africa Editor's Choice Electrical switching & drive systems & components
Motor management plays an all-important role in controlling motor energy costs in various industries, segments and applications. Research and practical experience have consistently shown that effective motor management practices can result in significant energy savings, reduced operational costs, and improved overall system reliability.

Read more...
SKF’s successful raid action in Cape Town
SKF South Africa Editor's Choice Shaft power components
Authorities, with collaborative support from SKF, recently conducted a large and highly effective raid on a very well-known bearing seller of SKF bearings in Cape Town.

Read more...
Case study on automotive quality control
Motion Tronic Editor's Choice
Motion Tronic selected high-performance PLCs and HMIs from Inovance Technology to engineer a smart catalytic converter quality control solution for the exhaust facility at Toyota South Africa Motors.

Read more...
PC-based motion control on a labelling machine
Beckhoff Automation Editor's Choice Electrical switching & drive systems & components
For 50 years, Bausch+Ströbel in Germany has been developing packaging and production systems for the pharmaceutical industries. The company’s goal is to offer the best technical and economical solutions for the challenges of modern industry. Its new ESA1025 labelling machine shows how this is achieved with PC-based control from Beckhoff as the central motion controller.

Read more...
Thrust for hybrid electric flying
Editor's Choice Electrical switching & drive systems & components
Several leading academic institutes in Germany are collaborating on the future of hybrid electric flying. The partners are researching an entirely new propulsion system for medium-range aircraft with up to 35 passengers.

Read more...
Tough couplings for tough industries
Bearing Man Group T/A BMG Editor's Choice
BMG’s extensive range of power transmission components encompasses robust products from Regal Rexnord, a leading manufacturer of critical system components that perform efficiently under rigorous demands in diverse applications.

Read more...
Hydraulic connectors with residual pressure
Editor's Choice Hydraulic systems & components
Hydraulic connections are vital in both outdoor and indoor industrial machinery. However, the hydraulics lines frequently require connecting and disconnecting for maintenance or changeover. The goal is to enable quick, easy swaps to enhance machine flexibility and productivity.

Read more...