cask design meeting - nist
TRANSCRIPT
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20 April 2004 1
CASK Design Meeting
• DTS – Gregg Scharfstein• VBA – Randy Hammond• ICX – Stephen Smee
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20 April 2004 2
DTS
DFM TRANSPORT STAGE
• Transport• Cable Management• Alignment
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20 April 2004 3
DTS: Transport
Components of Transport• Guideways• Motion• Actuation• TelemetrySystem Requirements• Total Travel = 70.75 in [1797mm] • Full Travel in less than 30 seconds• Positional Accuracy within .020 in [0.5mm] in all directions• The Position of the DFM must be known at all times• The DFM & DTS Motor shall be removable with relative ease• Mechanisms shall be radiation hardened
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20 April 2004 4
DTS: GuidewaysThomson Accuglide Linear Guides• Recess for alignment datum• Four carriers interface Sled• Standard Accuracy Class: within .004 in [.1 mm] in all directions
over 79 in [2000 mm] travel
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20 April 2004 5
DTS: MotionThomson Precision Ball Screw• Double Nut for anti-backlash• Accuracy .004 in/ft [.33mm/m]• Maximum Angular Velocity ~330 rpm (1000 rpm safe)
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20 April 2004 6
DTS: ActuationEmpire Magnetics Stepper Motor w/
CGI Planetary Right Angle Gear Head• Motor Torque: 350 oz-in @ 1000 rpm (driving torque ~50 oz-in)• 3:1 Ratio on gear head, capable of over 1200 in-lb• Both units are radiation-hardened• Inertia Ratio ~8, Torque Ratio ~21
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20 April 2004 7
DTS: TelemetryAbsolute Position Data, Home Position & Limits• Empire Magnetics Rad-Hardened Resovler with 160:1 Harmonic
Drive Gear Head• Magnetic Reed Switch @ Reference Position• Honeywell GL Series Limit Switches• Hard Stops located .1 in [2.5mm] past extreme travel
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20 April 2004 8
DTS: Cable Management
Cabling Origins• MACS-DFM
– Upper Bundle– Lower Bundle
• DTS• VBA
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20 April 2004 9
DTS: Upper BundleUpper Bundle from MACS-DFM Bulkhead• 2 Cables ~.5in [12.7mm] in diameter• Replace current connector shell with 90-degree shells• Rotary Take-up occurs on top surface of DFM• Translation Take-up with Gortrac SS Cable Carrier
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20 April 2004 10
DTS: Upper BundleRotary Take-Up• Quick disconnect strain relief• Cable shroud keeps cable on
top surface of DFM• Bundle strain relieved before
entering cable carrier
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20 April 2004 11
DTS: Lower BundleLower Bundle from MACS-DFM Bulkhead• 8 Cables ~2in [51mm] in diameter• Replace current bulkhead with Cable Guide• Rotary Take-up occurs within Lower Shroud• Translation Take-up with Gortrac SS Cable Carrier
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20 April 2004 12
DTS: Lower BundleRotary Take-Up• Guide for cables
out of DFM• Blind-mate just
after cable shroud• Hard Stops
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20 April 2004 13
DTS: Lower BundleCables from DTS & VBA• Cables run along channel in optical bench• Join lower bundle and mate to Cask Bulkhead
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20 April 2004 14
DTS: Alignment & Removal
DTS Alignment & Removal• Optical Bench• DFM Interface Plate• DTS Motor
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20 April 2004 15
DTS: Alignment & Removal
Optical Bench Alignment to MACS• Bench sits on 3 pedestals• Horizontal Plane Alignment: within .039 in [1 mm]
– Alignment Bar• Vertical Plane Alignment: within .078 in [2 mm]
– Spec 1.4: mounting pad to beam centerline distance 817 +/- .2 mm– Pedestals have tip/tilt adjustment
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20 April 2004 16
DTS: Alignment & Removal
Optical Bench Alignment to MACS
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20 April 2004 17
DTS: Alignment & RemovalOptical Bench Alignment to MACS
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20 April 2004 18
DTS: Alignment & Removal
Optical Bench Installation & Removal• Total Weight ~ 1300 lbs• Lifting & Guide Poles
installed without reaching into Cask
• Spreader attached to crane via Chain Sling w/ Turnbuckles
• Total height neededabove floor for removal = 164”
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20 April 2004 19
DTS: Alignment & Removal
Shielding Wall Installation & Removal• Borated Poly Shielding Slab attached to 3/8” thick aluminum plate• Contains guideway for upper cable carrier• Constrained by guides attached to Cask Liner
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20 April 2004 20
DTS: Alignment & RemovalDFM Interface Plate Alignment &
Removal• Lifting Brace Assembly & Guide Poles
installed without reaching into Cask• Tapered Guide Pins provide instrument-
MACS alignment• Blind Mate can be mated/de-mated
without reaching into Cask
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20 April 2004 21
DTS: Alignment & RemovalDTS Motor Removal & Installation• Vertical installation & removal via pinion that interfaces planetary
right angle gear head• Captured Bolts allow mate/de-mate without reaching into Cask• Slack in cable for motor allows retrieval and then connector de-mate
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20 April 2004 22
Conclusion
DTS Status:• The DTS Design is 99% complete – Cask Bulkhead is the only
remaining design task• Creating Fabrication Drawings is the next phase• Sub-Systems to be tested:
– Rotary Cable Take-Up for Lower Bundle– Resolver Assembly for Absolute Position Information
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20 April 2004 23
MACS - Variable Beam Aperture
VBA
The Variable Beam Aperture (VBA) shapes the MACS neutron beam to a variable rectangular cross section.
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20 April 2004 24
Requirements
Ref: MACS Top Level Specification Revision D., Section 2.3
Required: As Designed:
• VBA Located ≤ 1500 mm from DFM reference 1445mm
• Aperture Height and Width independently variable YES
• Aperture not within line of sight of the sample YES
• Aperture accommodates (passes) full beam diameter (355mm) YES
• Shutters shall be 100mm thick YES
• Shutters shall be composed of moderating and absorbing materials YES
• Aperture shall be centered within 2mm of the DFM rot. axis TBD (easily achieved)
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20 April 2004 25
Major Features:• Chassis
• Neutron Absorbing Shutters
• Motive System / Bearings
• Telemetry
upstream
downstream
Dimensions• 500# Weight
• 42.7in. (1085mm) height
• 33.0in. (885mm) width
• 8.9in. (225mm) depth
• Aperture Range: 0.0 in to 14.25in (360mm)
Design Overview
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20 April 2004 26
Chassis
The VBA Chassis is a bolted together aluminum structure:
• Lift Points
• Mounting Plate
• Side Walls
• Pedestal
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20 April 2004 27
Neutron Absorbing Shutters
There are two horizontal and two vertical shutters
• Bolted together aluminum frame
• Nominally 100mm thick along the beam axis
• 2 degree draft angle on beam-side face
• Composed of both moderating and absorbing components.
• Assembly weighs 35#
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20 April 2004 28
Neutron Absorbing Shutters
• Aluminum chassis includes stiffening web
• 62mm upstream moderator (HDPE)
• 5+mm B4C Moderator encapsulation limits scatter
• 30mm downstream absorber (B4C)
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20 April 2004 29
Motive System / Bearings
• Radiation Hardened Stepper Motors drive dual-handed leadscrews to position the shutters
• Each shutter rides on all-steel twin ball bushings and hardened steel shafting.
• Radiation hardened lubricants are used throughout.
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20 April 2004 30
Motive System / Bearings
• Gimbaled lead nuts prevent binding
• Nylon ring brushes exclude dirt and retain grease
• Steel cap plates engage with threaded collars as full-open hardstop.
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20 April 2004 31
Motive System / Bearings
• A test rig was developed to quantify shutter sag due to bearing slop and shaft bending
• The majority of sag was determined to originate from shaft bending Ø1.25 shafting was selected for the bearing system
Guide Rod Performance / Vertical ShutterSingle Shutter for Comparison to Test Rig Data
0
0.01
0.02
0.03
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Shutter Opening (in.)
Max
. Shu
tter S
ag (i
n.)
1.0 Defl.1.25 Defl.
FEA Predictions for Steel (42.5#) Shutter Assemblies
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20 April 2004 32
Motive System / Bearings
VBA Operation
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20 April 2004 33
Telemetry
The VBA uses a conservative telemetry system
• Positive sensing of VBA open and closed positions using rad-hard reed switches
• Rad-hard absolute resolverassemblies used on both shutter pairs
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20 April 2004 34
Telemetry
Radiation Hardened Reed Switches are custom-prepared by Hermetic Switch, Inc.
• 22ga. Kapton leads
• Hermetic Switch supplied reed switch
• Brass housing
• 3M Polyurethane Potting
• Samarium Cobalt Actuating Magnet
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20 April 2004 35
Component Status
• Motors and Resolvers: ETA May 2004
• Harmonic Gear Heads: ETA June 2004
• B4C Panels: ETA May 2004
• HDPE Moderators: Complete
• Machined Components: Drawings Underway
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20 April 2004 36
Conclusion
• The MACS VBA is a mature mechanical design
• Delivery on long lead items is expected within six weeks
• Effort remains in:
-Manufacturing Drawings
-Cabling and wire routing details
-Particulars of the mate with the optical bench
-Absorbing material backfill
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20 April 2004 37
Inline Collimator Exhcanger
ICX
The Inline Collimator Exchanger (ICX) provides four discrete collimation settings for the MACS experiment.
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20 April 2004 38
ICX
• Two co-aligned collimators: – Segment-A: 60’– Segment-B: 40’– Segment A+B: 20’
• 50 µm thick SS foils are coated with 13 µm Gd2O3
• Collimators are exchanged using pneumatic actuators
• Adjustments integral to the guide bushing blocks facilitate co-alignment
• Weight ~ 300 lbSegment A
Segment B
Linear ball bushings
10B:Al Stop
Lift Rods
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Segment A
Details• Type: Radial
• Collimation: 58.1’
• Foil spacing: 3.3 mm at entrance
• Foil length: 135 mm
• Foil material: 50 µm stainless steel
• Foil coating: 13 µm Gd2O3
• Number of foils: 97
• Structural Material: 6061-T6 aluminum
• Mass: ~ 18 kg (40 lb)
• Clear aperture: 350 mmNote: design not representative of
current tensioning scheme
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20 April 2004 40
Segment B
Details• Type: Radial
• Collimation: 41.0’
• Foil spacing: 3.41 mm at entrance
• Foil length: 208 mm
• Foil material: 50 µm stainless steel
• Foil coating: 13 µm Gd2O3
• Number of foils: 97
• Structural Material: 6061-T6 aluminum
• Mass: ~ 27 kg (60 lb)
• Clear aperture: 350 mm Note: design not representative of current tensioning scheme
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20 April 2004 41
Segment A+B
Details• Type: radial co-aligned pair (Segments A
and B)
• Collimation: 23.5’
• Collimator separation: 8 mm foil to foil
• Transverse co-alignment: ± 0.05 mm RMS
• Angular co-alignment: ± 0.05° RMS
• Clear aperture: 350 mm
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20 April 2004 42
ICX Co-Alignment
Flexures
AdjustmentScrews Adjustment
Screws
Flexure
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20 April 2004 43
Bearing Block Detail
Snap Ring
Linear Ball Bushing
Grease Retainer
AdjustmentScrews
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20 April 2004 44
Misc. Details
Alignment Cube
Upper HardStop
Lower HardStop
Shim
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20 April 2004 45
ICX Lift Mechanism
Details• Bimba 2” non-rotating cylinders,
~17” stroke• Reed switches on cylinders for
position sensing• Hard stops internal to the ICX
establish in-beam and stowed positions
• Cylinders can be replaced without entry into the cask
Pneumaticcylinders
Liner
Lift Rods
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20 April 2004 46
Cylinder Interface Details
O-Ring
O-Ring
Clamp Ring
Cylinder Support
Rod guide
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20 April 2004 47
Cylinder Mount Detail
SupportTube
ShaftClamp
PneumaticCylinder
1/4-20 Thread
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20 April 2004 48
MACS Electrical System
• ICX, DTS and VBA control will be added to a new drawer in the existing DFM Rack.
• A PCI Digital I/O Card will be installed in the PC.
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20 April 2004 49
VBA Electrical System
Empire Magnetics RH-U33-S Horiz Motor
MAX 410Motor Indexer
VBA Horiz
MAX 410Motor Indexer
VBA Vert
RS422
+5V Logic
+40V Motor
Empire Magnetics RH-EMR-57 Resolver
Empire Magnetics RH-U33-S Vert Motor
Empire Magnetics RH-EMR-57 Resolver
ResolverReadout
ElectronicsMagnetic Reed
Switches
Magnetic Reed Switches
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20 April 2004 50
Empire Magnetics RH-U33-S Motor
MAX 410Motor Indexer
DTS Drive
RS422
+5V Logic
ResolverReadout
Electronics
DTS Electrical System
+40V Motor
Empire Magnetics RH-EMR-57 Resolver
Limit Switches
Reed Home Sensor
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20 April 2004 51
ICX Electrical System
PCI Digital I/O Card Located in
DFM PC
Clippard Solenoid Board
Upper and Lower Magnetic Reed
Switches
Pneumatic Cylinder
Power In