ZDC Remote Handling ToolStructure and Force Analysis

P. Debbins

University of Iowa

December 10, 2009

From March 6, 2009: Rotational arm, TAN anchors, and rotational geometriesWere determined to be free of interference and fully qualified for loads encountered. Vertical elevation sub-system was not fully developed.

Rotational Arm

Rotational Arm Anchor Actuator Anchor

Vertical Elevation System

Holes in Tunnel Floor to locate Sarco – Completed May 2009

Tapped Holes in TAN for Anchors and adjustment bars – Completed May 2009

Vertical Displacement

• Maximum displacement at load point is 0.034 inches

From March 6, 2009

Horizontal Displacement

• Maximum horizontal displacement is 0.01 inches

From March 6, 2009

Vertical Elevation system is nowSpecified and analyzed for loads anddisplacements resulting in determiningpayload placement accuracy

Rotational geometry is unchanged and Spatial occupancy of system is smaller than theenvelope used to establish clearances; non-interference with tunnel environment and TAN is preserved.

Vertical Elevator Layout

Vertical Lifting Motor

Frame Overhead Beam

Frame Sidewall

Payload Carrier Beam

Vertical Lift Screw

Rotational Spindle(Rot Arm Articulation)

Linear guide railfor Carrier Beam

90’ Brace – shown this side only

Merkur M1 Screw Jack(1 of 2)

Payload Carrier Beam

End Blocks: singleMachined piece

Beam tubes and X-webbing are welded from 5mm steel plate stock, water jet cut to form

Material: S235J steel. This is stocked atCERN (also available in the US)

Fabrication: End blocks are machined Oversize and without attachment holesor screw jack placement features.Welded internal beam structure is Fabricated separately. End blocks are Welded on secured by jig. Final machiningof as-fabricated beam ensures parallelismand dimensional accuracy of features.Design conducted with consultation of machine and weld shops

Frame Overhead Beam

Construction methodology is identical toThe Carrier Beam

Frame Sidewall

Material and Construction same as other elements, except spindle

Spindle – 4140 steel

Elevator Frame Components assembled withM12 bolts.

Post fabrication of mating surfaces to establishmating planes; possible to shim allowingframe to be assembled with high geometric precision, and not be able to shift out of alignment

Steel structures painted with Americote 741 over Dimecote primer

Top View

Payload Carrier Beam End Block

Bishop-Wisecarver Dual-VeeGuide wheel #3 size (4 per side)Max loads: (radial 5900NAxial 1590N) per wheel.

Bishop-WisecarverV-guide rail (inox)

Guide rail mount plate.Mount plate bolted toFrame sidewalls

Consultation with factory establishes that system can be setup for zero free play. Krytox 227 lubricant (radiation hard).

These guides are highly resistantto jamb from foreign matter

Load Calculations

All load calauclations and FEA loads are based on the worst caseof the more massive full Copper Bar Absorber assembly

Models generated for FEA incorporate intermittent gaps to reflect the skip welded pattern of fabrication

Welded joint

No Weld

FEA of Carrier Beam

http://www.physics.uiowa.edu/~pdebbins/ZDC_TOOL/Carrier_Beam_FEA.pdf.pdf

Payload – Carrier Beam Mating Structures

Carrier Beam

“HAD” Payload

Upper Mate

Lower Mate

Chamfer acommodates+/- 10mm misalignmentin all directions

15mm bores

When mated – pinLocks sections together

Auxiliary holes allowFixation of payload toEmergency removaltool

EM section is double pinned to Prevent “rocking” in Z axis

Pivot Roller Bearings

SKF JL 26749 F/710

Bering thrust flange

Flange applies preLoad to bearing – Secured with Castellated nut, Which is wired to Prevent loosening

Payload Displacement

Free Play of pre-loadedRoller bearings and Bishop Wisecarver guideWheels is negligible at theLoads presented.

Distortion of Carrier BeamAlso disregarded (0.2mm)