GE BIKE Operating Instructions Manual
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GE BIKE Operating Instructions Manual

GE BIKE Operating Instructions Manual

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BIKE
Operating Instructions

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Summary of Contents for GE BIKE

  • Page 1 BIKE Operating Instructions...
  • Page 2 BIKE Operating Instructions Legal Note This document may not be copied, redistributed or republished for any reason whatsoever, without the written permission of GE Inspection Robotics. Page ii...
  • Page 3 BIKE Operating Instructions Document Information File name BikeManual.docx Version Item number Date 2017-11-06 Manufacturer GE Inspection Robotics Technoparkstrasse 1 8005 Zürich Switzerland Telephone +41 44 275 25 75 info@inspection-robotics.com www.inspection-robotics.com Change History Date Edition Authors Modifications Pages 2017-11-06 V0.1 Create 2017-11-21 V1.0...

  • Page 4: Table Of Contents

    Crawler removal from a ferromagnetic surface ................ 4-2 Interconnection ..........................5-1 Connectors and fittings .......................... 5-1 Umbilical tube interconnection to the BIKE Crawler ..............5-2 Control Station ............................5-3 Auxiliary equipment ..........................5-3 Connection to the main power supply .................... 5-4 System start ...........................
  • Page 5 Contact ................................ 13-1 13.2 Replacement Parts ..........................13-1 Appendix A Specifications ........................A-1 BIKE ................................. A-1 Control Station ............................A-1 Umbilical ............................... A-1 Appendix B List of parts and options ....................B-1 Appendix C CE Declaration of Conformity ..................C-1...

  • Page 6: System Overview

    Ultrasonic probe (option) Front (Steering) Drive Unit Front fisheye Camera Rear Drive Unit Led arrays (8 at each side of the camera) Magnetic wheels (4) LH: Left hand RH: right hand HAND Figure 1. BIKE – Main components (view from the front)
  • Page 7 Led arrays (4 at each side of the Front (Steering) Unit Drive camera) Rear Drive Unit Top plate interface for cable fixing Ring bolt for safety line Auxiliary connector (special applications) Ultrasonic connector module (option) Figure 2. BIKE – Main components (view from the back)
  • Page 8 BIKE Operating Instructions Main Control panel Tactile touchscreen Control Pad (Joystick) Control Pad slot Figure 3. Integrated Control Station 2 (ICS2)
  • Page 9 BIKE Operating Instructions Figure 4. Pump Unit (option for BIKE UT)

  • Page 10: Overview Of Manual

    BIKE Operating Instructions Overview of Manual This manual provides all the necessary information to operate and maintain the BIKE, a mobile tele-operated crawler platform. This document does not include: NDT (Non Destructive Test) work instructions ▪ Finding evaluation, assessment or reporting instructions.

  • Page 11: Safety

    Operating instructions provide important information on the operation of the BIKE system. Read the operating instructions carefully before starting work! It is a component of the product and must be kept accessible to the personnel in the immediate vicinity of the BIKE system.

  • Page 12: Symbols Used

    General safety instructions related to BIKE These operating instructions are intended for the safe operation of the BIKE only. For operation of additional cameras or NDT instruments, not described in this manual, please refer to the respective operating manuals.
  • Page 13 BIKE is NOT ATEX compliant. The manufacturer has developed a controller and a gas sensor able to immediately switch off the BIKE in the presence of hazardous gases. Please contact the Sales Representative if you have interest in this solution.
  • Page 14 Power cords and adapters must be compliant to local and general safety regulations. Use power supply connected to earth Disconnect the power for any electrical work on the BIKE equipment Connect power after all devices are connected (Crawler and Control Station) Do not open the sealed board panels of the Control Station, no inside parts require maintenance.
  • Page 15 Caution must also be taken when trying to remove foreign parts attracted to the magnets, and when the BIKE must be removed from a ferromagnetic surface. Always manage to use the provided rubber mat to deploy or detach the crawler from a ferromagnetic surface.
  • Page 16 BIKE Operating Instructions WARNING The crawler is tele-operated. If the crawler is not in line of sight, the operator can only see the crawler environment through the Front and Rear fisheye cameras. A person close to the crawler (and out of sight) can be injured by the consequence of an unexpected event or movement.

  • Page 17: Operator Responsibilities

    Operating Instructions Operator responsibilities As the BIKE system is used in the commercial field, the operator is subject to the statutory obligations to work safety. In addition to the work safety instructions in this operating manual, the safety, accident prevention and environmental protection regulations applicable to the BIKE system must be complied with.
  • Page 18 ➢ ensures adequate workplace lighting as per locally safety regulations, but at least 750 lx, and regularly checks the lighting is maintained to the same level. ➢ in the case of demonstrations, the BIKE system is restricted to an area with sufficient safety distance to third parties and effectively prevents ingress of unauthorized persons Furthermore, the operator must ensure that the BIKE is: ➢...

  • Page 19: Personal Protective Equipment (Ppe)

    Personal protective equipment (PPE) Personal protective equipment is used to protect persons from impairment of safety and health at work. During the various work on and with the BIKE system, the personnel must carry personal protective equipment: ✓ as referred to separately in the individual sections of this operating manual ✓...
  • Page 20 BIKE Operating Instructions Respiratory protections Respiratory protection protects workers against insufficient oxygen environments, harmful dusts, fogs, smokes, mists, gases, vapours, and sprays. Protective clothing Protective clothing is tight-fitting workwear with low tear strength, with narrow sleeves and without protruding parts.

  • Page 21: Environmental Aspects

    BIKE Operating Instructions Environmental aspects NOTICE Environmental hazard due to incorrect handling of environmentally hazardous substances! Incorrect handling of environmentally hazardous substance, especially incorrect waste disposal, can cause considerable environmental damages. ➢ The following information regarding the handling of environmentally hazardous substances and the corresponding waste disposal shall always be observed.
  • Page 22 BIKE Operating Instructions Process water / Coupling water Used coupling water is regarded as industrial water and may contain substances that must not be directly discharged into the environment. During replacing or disposal of the water, it must be ensured that it is disposed of according to the local regulations.

  • Page 23: Product Overview And Functionalities

    Product overview and functionalities Intended use The main purpose of the BIKE is remote inspection of metallic structures The BIKE includes two fisheye cameras by default. The operator can drive the crawler to the location of interest and perform an inspection with a specific probe or instrument attached to the BIKE.

  • Page 24: Operational Overview

    BIKE Operating Instructions Operational overview Operator working Inspected area area Figure 5. Visual overview of BIKE application Control Station (ICS2) Couplant container Cable bundle in tube & Inspection Umbilical (UT version represented) camera cable BIKE Cable length 10 to 30 m (on...
  • Page 25 BIKE Operating Instructions BIKE Any required maintenance or assembly on the BIKE, must be done in a convenient safe and clean area. Control Station The operator shall position the Control Station in an ergonomic and safe location. The Control Station must be protected from splashing water or rain.

  • Page 26: Principle Dimensions

    BIKE Operating Instructions Principle Dimensions Figure 6. Front view (height measured with umbilical connected) Figure 7. Side view (height measured without umbilical connected)

  • Page 27: Crawler Movement Capabilities

    & 254 & 300 Figure 8. Movement capabilities along cylindrical shape axis Measurements are in mm. The curvatures shown in Figure 8 represent the minimum curvatures required to move the BIKE forwards or backwards, without steering. Edge between two flat surfaces...
  • Page 28 ➢ the minimum curvature required to move straight with low steering, outside a cylindrical shape (&254), The BIKE is also able to pass through 90° corners (edges) shown in the same figure. To steer, the BIKE can turn the full Front Drive Unit. A gimbal joint helps When the Steering Unit turns 90°...

  • Page 29: System

    Joystick Integrated Control Station case Power cord with C13 connector Integrated Control Station case The full standard equipment is packed in two hard shell cases. Part references are listed in Appendix B. Component description Figure 12. BIKE Crawler box closed...
  • Page 30 BIKE Operating Instructions BIKE Umbilical tube (option 30 m cable on reel) Rubber mat Pump Unit (option) Couplant tube (Pump inlet) Power cord Figure 13. BIKE crawler box opened (Pump) Figure 14. Integrated Control Station 2 closed...
  • Page 31 Power Switch LED indicators for 48V and 12V DC Fuse for the 48V DC output Connection to Crawler (Umbilical) Encoder out socket (not used for BIKE) Ethernet socket Push button to shutdown the computer (blue light indicator: computer on) Reset pushbutton...
  • Page 32 ADJUST mode pushbutton switch (straight move Forward / Backwards) MANOEUVRE mode pushbutton switch (free move – straight, turn) Not used for this application Not used for this application Mini Joystick Figure 17. Umbilical tube, 10m with ultrasonic cables and couplant tube (version for BIKE UT)
  • Page 33 BIKE Operating Instructions Figure 18. Cable reel with Umbilical from Control Station (version for standard BIKE)

  • Page 34: Handling

    Follow unpacking and handling instructions. Use protective gloves. Review the chapter 1.3 General safety instructions related to BIKE and in particular the dangers related to the strong magnetic wheels, page 1-5. Consider the following steps to unpack the BIKE: ➢...

  • Page 35: Crawler Removal From A Ferromagnetic Surface

    Specific care must be taken to remove the BIKE when it adheres to a ferromagnetic surface The risk is much higher if you try to remove the BIKE without rubber mat as it strongly adheres to a ferromagnetic surface. As the operator might strongly pull up the BIKE to detach it, he can be surprised by the sudden collapse of the magnetic forces when he succeeds in detaching it from the surface.

  • Page 36: Interconnection

    BIKE Operating Instructions Interconnection Connectors and fittings Push-pull connectors The cylindrical push-pull connectors include a self-latching system to ease the mate and un-mate of the connectors. To connect the cylindrical push-pull connectors: • Line up the red dot on the connector shell with the red index mark on the socket •...

  • Page 37: Umbilical Tube Interconnection To The Bike Crawler

    Always lay cables and connectors in clean areas Roll cables and attach them with a binder when they are not used Umbilical tube interconnection to the BIKE Crawler ➢ Connect the connector [1] to the socket [2].

  • Page 38: Control Station

    Figure 24. Control pad connection Control Station Auxiliary equipment Connect all other devices required. For the BIKE UT, connect the probe cables to the Ultrasonic Data Acquisition Unit and the fitting of the couplant tube to the Pump Unit.

  • Page 39: Connection To The Main Power Supply

    BIKE Operating Instructions Connection to the main power supply If a power strip is used, it must be compliant to local and international regulations. We recommend the use of a standard power cord with latched C13 connector, provided with the Control Station, to ensure a reasonable protection against dust.

  • Page 40: System Start

    ➢ Commute the Power Switch to ON position. ➢ Wait until the screen displays the window of the ICS Launcher program. ➢ Click on the BIKE icon to launch the application, and wait for the main. ➢ Press the RESET button to activate the 48v DC power.

  • Page 41: Main Screen

    It includes a button to reset the value Communication Displays status and includes a soft button to reset the faults Fault Shifts the position of the three views (BIKE position / orientation simulation, front and Cycle views rear camera) Motion modes...
  • Page 42 BIKE Operating Instructions Select a mode by pushing the respective switch on the Control Pad or the soft version on the Touchscreen. Forwards Backwards Figure 26. Movements with the Control Pad The View menu proposes to display a new window called On Screen Joystick.

  • Page 43: System Stop

    BIKE Operating Instructions System stop Emergency treatment DANGER In the case of imminent danger, power supply to the crawler must be shut down immediately. Press the emergency-stop from the Control Station Unlatch the Emergency stop with a twist of the button, to release it when you want to restart, and press the RESET button.

  • Page 44: Operation

    ➢ Proceed to the BIKE interconnection as per chapter 5.2. ➢ Make sure the safety line and umbilical tube plate are firmly attached ➢ Check the environment is safe for the BIKE (no ferromagnetic parts that can interfere with the wheels) In the operator work area: •...

  • Page 45: Navigation

    ➢ The crawler can pass convex and concave corners of up to 90 degrees (steps, flanges), however limitations can occur (specific geometry, surface roughness, .and cleanliness ➢ If there are different ways to pass an obstacle (with different BIKE orientations), select the path where the gravity will less affect the adhesion to the structure.

  • Page 46: Packing

    ➢ If the crawler is on a ferromagnetic structure, deposit the rubber mat in a place where you can drive the crawler and easily detach it. ➢ Define a clean and ergonomic working place where you can deposit and clean the BIKE components, including the cables. Reserve a specific place for the crawler, to ensure no ferromagnetic parts will be attracted by the magnetic wheels.

  • Page 47: Storage And Shipments

    Do NOT clean not with direct compressed air – or water pressure acting on to the encoder unit or any bearing. Use gloves to protect your hands when cleaning Storage and Shipments The BIKE system shall be stored in a clean and dry location: Temperature: -20°C to 70°C. Humidity: 95%.

  • Page 48: Maintenance

    Check there is no play in the magnetic wheels, clean with a brush with brass wires Functional check As described in 8.3 10.2.2 Yearly or after 200 hours of operation Inspection of BIKE system by GE IR, is recommended after 200 hours of operation or 12 months, whichever is the sooner. 10-1...

  • Page 49: Troubleshooting

    BIKE Operating Instructions Troubleshooting Problem Cause Remedy The crawler does not move, Emergency stop Release Emergency stop and Control Station power is click the soft Clear Fault turned on, Motor Drive LEDs button are off The crawler does not move,...

  • Page 50: Disposal

    ➢ liable to treatment of special refuse and must only be disposed by authorized specialist companies! Local authorities and waste disposal companies provide information on the environmentally friendly disposal. NOTICE The BIKE can be returned to us. To learn the exact procedure, contact our support service. 12-1...
  • Page 51 BIKE Operating Instructions 12-2...

  • Page 52: Technical Support

    BIKE Operating Instructions Technical Support 13.1 Contact For fault rectification or technical support, contact the manufacturer’s support service: support@inspection-robotics.com GE Inspection Robotics Ltd Technoparkstrasse 1 8005 Zürich Switzerland 13.2 Replacement Parts Replacement parts are listed in Appendix B. To provide a speedy service we require the following information: 1) Contact person and access data (telephone.

  • Page 53: Appendix A Specifications

    4 integrated drives with 48V brushless DC Drive units motors 48V via umbilical cable from external supply Power Supply station Motor controller GE Inspection Robotics motor controller Communication Gigabit Ethernet Protection class of the case that contains the IP67 Crawler...

  • Page 54: Appendix B List Of Parts And Options

    Pos. in Description container qty. Model Case Hard case 1650 (polypropylene) with wheels and 1650-BIKE "BIKE" [A] extendable handle, black, IP67, ext. dimensions: 80.1 x 52.1 x 31.7 cm, customized foam BIKE #N/A – Crawler 1118-1-0032 2.2a – Ultrasonic module...

  • Page 55: Appendix C Ce Declaration Of Conformity

    EN ISO 7010:2012 EN 55011 Notice The BIKE Standard and BIKE UT are devices for remote inspection of ferromagnetic structures (example: vessels, pipes, metallic walls of industrial constructions). We, GE Inspection Robotics Ltd, hereby declare under sole responsibility that the equipment named above has been designed and documented to comply with all applicable essential requirements of the above regulations and standards.

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