200people on the technical team
The scope of the contract is divided into Clusters, encompassing services of the same type of work:
- Cluster I: maintenance of electrical systems.
- Cluster II: maintenance of mechanical systems.
- Cluster III-Trades: performing “Minor Works” (small tasks in the different trades: plumbing, locksmithing, decoration, other)
- Cluster IV- Elevated transport, PCI, elevators, MANAGEMENT, BMS, and energy control.
In addition to these services, maintenance and operation of the Temperature Control System and Fire Protection and Energy are included, as are projects involving remodeling and facility modification. It is a maintenance contract with SLAs where response times must be met for the different types of maintenance needed, where the technical and human resources available are carried out comprehensively by Ferrovial Services
Contract in Getafe, Madrid: Technology applied to the factory
Ferrovial Services’ Management Team in the Getafe Airbus Factory maintenance contract has created a robot to facilitate and improve preventive maintenance at crane bridge sites. The robot was created with the aim of addressing the difficulties of accessing rail beams, thus improving preventive maintenance work, reducing costs, and minimizing occupational hazards.
This robot, called the Robotic Lane Inspector for Crane Bridges, abbreviated IcaRo in Spanish, can be remotely controlled in its inspection work. This way, the robot records through an HD camera, enabling improvements to preventive maintenance by inspecting the condition of the rails through which the bridge beam runs. Crane bridges are essential tools for productive development in any industrial environment, and as such, they are critical assets that must have minimum downtime.
The idea for this robot arose from the difficulties encountered in accessing certain areas of the beams when performing preventive maintenance of the crane bridges at the Getafe Airbus plant. The maintenance team suspected that the rail could have broken welding, as the sound of the wheels changed when crossing the bridge. The robot helped remotely display where the problem was located and its severity, and they could then determine the plan of action for making the appropriate changes.
ICaRo is a robot created for a specific purpose in a given task, but it has the versatility of being able to adapt to other mediums. It could therefore be reprogrammed to the scale of other accessories or improvements studied as the device runs. The main benefit of this device is the operational improvement to the preventive maintenance work, as the robot enables seeing the entire length of the rail, which may sometimes be difficult or impossible for accessibility reasons. In addition, another of the advantages of using it are lowering costs by spending less time on inspection, minimizing occupational hazards, and a lower impact on the customer’s production process.
A robot with a unique design
For the robot’s design, the most common rail heights and beam widths found at this sort of facility were considered. The size of the wheels, in addition to the adjustable guides, give the robot adequate robustness to move forward safely through the paths where the height of the work is very high. Also, the flexibility of the chassis allows it to navigate dirt and obstacles it may come across during inspection. The set has a built-in HD camera that connects to a PC via wifi, where the status of the rails is displayed and recorded for further reporting and image processing. Controlling the robot is done with the same PC terminal via Bluetooth, using the keyboard to determine its movement, speed, and distance traveled. With the camera’s HD recording, the inspector may check:
- How clean the rail is.
- The status of the welding between the rail and the support beam.
- Any metal waste to determine potential effects on the crane bridge wheels or track.
- The status of the guide profile and joints between different sections of the track.