Auto Loading of Elements Into End Plate Welding
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AUTO LOADING OF ELEMENTS INTO END PLATE WELDING FLOWER
Submitted in the partial fulfilment of the award of
Degree BACHELOR OF ENGINEERING
Department of MECHANICAL ENGINEERING
Submitted by
G.SRAVANI (1005-11-736043
B.RADHI!A (1005-11-7360"#
UNIVERSIT$ COLLEGE OF ENGINEERING% OSMANIA UNIVERSIT$ (A.
Osmania University Main Rd, Durgabai Deshmukh Colony,
Hyderabad, elangana!"####$%
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AC!NOWLEDGEMENTS
&e are thankful to the Head of the Department 'rof%(%Sri Ram (enkateshwar sir, who help
us in doing pro)e*t work%
&e are pleased to a*knowledge 'rof% +% rishnaiah sir, 'rof% Sanke and % ChandraShekar sir for his invaluable guidan*e during the *ourse of this pro)e*t work%
&e e-tend our sin*ere thanks to Ra)kumar sir who *ontinuously helped us throughout the
pro)e*t and without his guidan*e, this pro)e*t would have been an uphill task%
&e are also grateful to other members of the ./C0.u*lear /uel Comple-1 and University
College Of 2ngineering, Osmania University0+1, team who *o!operated with us regarding
some issues%
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ABSTRACT
The 3rass flower has 4$ no of holes, in whi*h these 56 elements have to be inserted% he elements
in the tray *an be of " types7 0i1 Central, 0ii1 8nner!5, 0iii1 8nner!9, 0iv1Outer!5 and 0v1 Outer!9 type
of elements%
Steps performed are7
:;ifting the element%
:(isual inspe*tion of element%
:8nsertion of element in 3rass /lower%
:&e will be using a SC+R+ RO3O for insertion of element in the flower for whi*h we need to
develop a program in *%
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NUCLEAR FUEL COMPLE&
he .u*lear /uel Comple- 0./C1, established in the year 56$5 is a ma)or industrial unit of Department of +tomi* 2nergy,
ir*onium alloy
*ladding and rea*tor *ore *omponents are manufa*tured under one roof starting from the raw materials%8ndia is pursuing an indigenous three stage .u*lear 'ower 'rogramme involving *losed fuel *y*les of 'ressurised Heavy
&ater Rea*tors 0'H&Rs1 and ;i=uid Metal *ooled /ast 3reeder Rea*tors 0;M/3Rs1 for )udi*ious utilisation of the
relatively limited reserves of uranium and vast resour*es of thorium% 'H&Rs form the first stage of the 'ower programme
whi*h uses ?ir*aloy as *lad @ .atural Uranium as fuel% 8n addition, 8ndia is operating two 3oiling &ater Rea*tors 03&Rs1
for the last 4# years% he ?ir*aloy *lad enri*hed Uranium fuel elements and assemblies for these rea*tors are fabri*ated at
./C starting from imported enri*hed Uranium He-afluoride%
he raw material for the produ*tion of 'H&R fuel in ./C is Magnesium Di!Uranate 0MDU1% he MDU *on*entrate is
obtained from the uranium mine and milled at Aaduguda, Aharkhand, operated by Uranium Corporation of 8ndia ;imited
0U8C;1% he impure MDU is sub)e*ted to .itri* a*id dissolution followed by solvent e-tra*tion and pre*ipitation withammonia to get +mmonium Di!Uranate 0+DU1% 3y further steps of *ontrolled *al*ination and redu*tion, sinterable Uranium
Dio-ide powder is formed whi*h is then *ompa*ted in the form of *ylindri*al pellets and sintered at high temperature to get
high density Uranium Dio-ide pellets% /or 3&Rs, the enri*hed Uranium He-afluoride is sub)e*ted to pyrohydrolysis and
*onverted to +mmonium Di!Uranate whi*h is treated in the same way as natural +DU to
obtain high density uranium dio-ide pellets%
he sour*e mineral for the produ*tion of ?ir*onium is >ir*on 0>ir*onium sili*ate1 available in the bea*h sand deposits of
erala, amil .adu and Orissa and is supplied by the 8ndian Rare 2arths ;td% ?ir*on sand is pro*essed through *austi*
fusion, dissolution, solvent e-tra*tion 0to remove hafnium1, pre*ipitation and *al*ination steps to get >ir*onium o-ide%/urther, the pure >ir*onium o-ide is sub)e*ted to high temperature *hlorination, rea*tive metal redu*tion and va*uum
distillation to get homogeneous >ir*onium sponge% he sponge is then bri=uetted with alloying ingredients and multiple
va*uum ar*s melted to get homogeneous ?ir*aloy ingots whi*h are then *onverted into seamless tubes, sheets and bars by
e-trusion, pilgering and finishing operations%
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DESCRIPTION OF WELDING FLOWER
:2lements will be re*eived in a Semi ellipti*al roughs kept on a *onveyor% 56 no of elements will be kept one over
another in the trough%
:On another *onveyor, there will be a /i-ture with 3rass flower kept inside%
:he 3rass flower has 4$ no of holes, in whi*h these 56 elements have to be inserted%:he elements in the tray *an be of " types7 0i1 Central, 0ii1 8nner!5, 0iii1 8nner!9, 0iv1Outer!5 and 0v1 Outer!9 type of
elements%
:2a*h type of element has its defined lo*ation in the 3rass flower and it *annot be kept on the lo*ation defined for
another type of element%
:Currently, the elements are manually liftedB its type is identified by visual inspe*tion and inserted in its identified
lo*ation in 3rass flower% he operator is involved in this operation only for full shift of his operation%
:8n*rease in the operator effi*ien*y and better utili>ation of operator *an be a*hieved by automating the pro*ess of
element insertion in the brass flower from the rough%:his will not only in*rease the a**ura*y and improve produ*tivity, but also minimi>e the 3undle level re)e*tions by
identifying the re)e*ted element during insertion itself%
:he manpower *an also be redu*ed% One operator *an see both the welding ma*hine simultaneously% 2arlier for
running both the welding ma*hine for two shifts, operators were re=uired% .ow the same produ*tion *an be done by 4
operators% Hen*e straightway, "# redu*tion in manpower is a*hieved, whi*h is a great saving%
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/or 'H&R fuel, the *ylindri*al UO9 pellets are sta*ked and en*apsulated in thin walled tubes of ?ir*onium alloy, both ends
of whi*h are sealed by resistan*e welding using ?ir*aloy end plugs% + number of su*h fuel pins are assembled to form a fuel
bundle that *an be *onveniently loaded into the rea*tor% he fuel bundles for 'H&R 99# M&e and 'H&R "## M&e
*onsist of 56 and 4$ fuel pins respe*tively% /or 3&Rs, two types, namely - and $-$ array fuel assemblies are fabri*ated%
/or 'H&R fuel, the *ylindri*al UO9 pellets are sta*ked and en*apsulated in thin walled tubes
of ?ir*onium alloy, both ends of whi*h are sealed by resistan*e welding using ?ir*aloy end
plugs% + number of su*h fuel pins are assembled to form a fuel bundle that *an be
*onveniently loaded into the rea*tor% he fuel bundles for 'H&R 99# M&e and 'H&R "##
M&e *onsist of 56 and 4$ fuel pins respe*tively% /or 3&Rs, two types, namely - and $-$
array fuel assemblies are fabri*ated%
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NUCLEAR FISSION
&hen a nu*leus fissions, it splits into several smaller fragments% hese fragments, or fission produ*ts, are about e=ual
to half the original mass% wo or three neutrons are also emitted% he sum of the masses of these fragments is less than
the original mass% his EmissingE mass 0about #%5 per *ent of the original mass1 has been *onverted into energy
a**ording to 2insteinEs e=uation% /ission *an o**ur when a nu*leus of a heavy atom *aptures a neutron, or it *anhappen spontaneously%
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N')*+, +/ ,*+/2
+ *hain rea*tion refers to a pro*ess in whi*h neutrons released in fission produ*e an additional fission in at least one
further nu*leus% his nu*leus in turn produ*es neutrons, and the pro*ess repeats% he pro*ess may be *ontrolled
0nu*lear power1 or un*ontrolled 0nu*lear weapons1%
U94" F n G 3a55 F r69 F 4 n F 9## Me(
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8f ea*h neutron releases two more neutrons, then the number of fissions doubles ea*h
generation% 8n that *ase, in 5# generations there are 5,#9 fissions and in I# generations about
- 5#94 0a mole1 fissions%
E/*, R*)*+* F, E+ F/
5" Me( J kineti* energy of fission produ*ts
$ Me( J gamma rays Me( J kineti* energy of the neutrons
$ Me( J energy from fission produ*ts
Me( J gamma rays from fission produ*ts
6 Me( J anti!neutrinos from fission produ*ts
9## Me(
5 Me( 0million ele*tron volts1 K 5%#6 - 5# !54 )oules
C,+) M++lthough two to three neutrons are produ*ed for every fission, not all of these neutrons are available for *ontinuing the
fission rea*tion% 8f the *onditions are su*h that the neutrons are lost at a faster rate than they are formed by fission, the *hain
rea*tion will not be self!5# sustaining% +t the point where the *hain rea*tion *an be*ome self!sustaining, this is referred to as
*riti*al mass% 8n an atomi* bomb, a mass of fissile material greater than the *riti*al mass must be assembled instantaneously
and held together for about a millionth of a se*ond to permit the *hain rea*tion to propagate before the bomb e-plodes% he
amount of a fissionable materialEs *riti*al mass depends on several fa*torsB the shape of the material, its *omposition and
density, and the level of purity% + sphere has the minimum possible surfa*e area for a given mass, and hen*e minimi>es the
leakage of neutrons% 3y surrounding the fissionable material with a suitable neutron Lrefle*torL, the loss of neutrons *an
redu*ed and the *riti*al mass *an be redu*ed% 3y using a neutron refle*tor, only about 55 pounds 0" kilograms1 of nearlypure or weaponEs grade plutonium 946 or about 44 pounds 05" kilograms1 uranium 94" is needed to a*hieve *riti*al mass%
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C/,))* N')*+, F/
o maintain a sustained *ontrolled nu*lear rea*tion, for every 9 or 4 neutrons released, only one must be allowed to strike
another uranium nu*leus% 8f this ratio is less than one then the rea*tion will die outB if it is greater than one it will grow
un*ontrolled 0an atomi* e-plosion1% + neutron absorbing element must be present to *ontrol the amount of free neutrons in
the rea*tion spa*e% Most rea*tors are *ontrolled by means of *ontrol rods that are made of a strongly neutron!absorbent
material su*h as boron or *admium% 8n addition to the need to *apture neutrons, the neutrons often have too mu*h kineti*
energy% hese fast neutrons are slowed through the use of a moderator su*h as heavy water and ordinary water% Some
rea*tors use graphite as a moderator, but this design has several problems% On*e the fast neutrons have been slowed, they are
more likely to produ*e further nu*lear fissions or be absorbed by the *ontrol rod%
W U,+/' +/ P)'/'8
S*ientists knew that the most *ommon isotope, uranium 94I, was not suitable for a nu*lear weapon% here is a fairly high
probability that an in*ident neutron would be *aptured to form uranium 946 instead of *ausing fission% However, uranium
94" has a high fission probability% Of natural uranium, only #%$ is uranium 94"% his meant that a large amount of uranium
was needed to obtain the ne*essary =uantities of uranium 94"% +lso, uranium 94" *annot be separated *hemi*ally from
uranium 94I, sin*e the isotopes are *hemi*ally similar% +lternative methods had to be developed to separate the isotopes%his was another problem for the Manhattan 'ro)e*t s*ientists to solve before a bomb *ould be built% Resear*h had also
predi*ted that plutonium 946 would have a high fission probability% However, plutonium 946 is not a naturally o**urring
element and would have to be made% he rea*tors at Hanford, &ashington were built to produ*e plutonium%
S9/+/*' N')*+, F/
he spontaneous nu*lear fission rate is the probability per se*ond that a given atom will fission spontaneously!!that is,
without any e-ternal intervention% 8f a spontaneous fission o**urs before the bomb is fully ready, it *ould fi>>le% 'lutonium
946 has a very high spontaneous fission rate *ompared to the spontaneous fission rate of uranium 94"% S*ientists had to
*onsider the spontaneous fission rate of ea*h material when designing nu*lear weapons%
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INDIA:S THREE STAGE NUCLEAR PROGRAM
he adoption of the uni=ue se=uential three!stage nu*lear power programme and asso*iated te*hnologies is based on the
optimum utili>ation of the indigenous nu*lear resour*e profile of modest Uranium and abundant horium in the *ountry%
8ndias three!stage nu*lear power programme is shown pi*torially in figure% he three!stage power programme of D+2
has been planned based on a *losed fuel *y*le *on*ept, re=uiring repro*essing of spent fuel from every rea*tor% heob)e*tive is to )udi*iously utili>e mined uranium and thorium resour*es of the *ountry to a ma-imum e-tent% Uranium
has )ust #%$ fissionable U94" isotope while U94I, the balan*e dominant isotope of uranium is a fertile material% 8t
needs to be *onverted to fissile 'u946 for further use% he pro*ess of this *onversion does take pla*e in a nu*lear rea*tor
where uranium fuel is used% Uranium s fissile isotope, U94" present as a very small fra*tion in uranium, produ*es
e-*ess neutrons over and above those re=uired for maintaining a steady fission *hain rea*tion% Some of these e-*ess
neutrons invariably get absorbed in the ma)or isotope U94I and result in produ*tion of 'u946% 3y suitable rea*tor
physi*s design of a nu*lear rea*tor the produ*tion of 'u *an be optimi>ed% hus the spent fuel from thermal rea*tors
*ontains a small =uantity of 'u946, along with residual uranium 0predominantly U94I1% he spent fuel *an be
repro*essed *hemi*ally to separate plutonium, residual uranium and the fission produ*ts, et*% 'lutonium 946 is a fissilematerial and when used in /ast Rea*tors, where neutron energies are kept high 0by not slowing them through use of a
moderator as in thermal rea*tors1, is more effi*ient in produ*ing e-*ess neutrons during fission *hain rea*tion% hese
e-*ess neutrons are used by proper rea*tor physi*s design to *onvert U94I into additional 'lutonium% 3y suitable *hoi*e
of fuel type and rea*tor *onfigurations su*h /ast Rea*tors *an produ*e a little more 'u than they *onsume, hen*e breed
more fuel from spent Uranium obtained from repro*essing, thus the name N3reeder Rea*tors% Similarly, thorium is a
fertile material and has to be *onverted to a fissile material, vi>% U944 to be used for power produ*tion% + *losed fuel
*y*le approa*h as mentioned above, involving repro*essing of spent fuel to separate the useful fissile and fertile isotopes
from spent fuel and reusing them in nu*lear rea*tors has been adopted as a guiding prin*iple for our nu*lear energy
programme to ensure long term energy se*urity for the *ountry%
he se*ond stage, *omprising of /ast 3reeder Rea*tors 0/3Rs1 are fuelled by fuels based on 'lutonium mi-ed with
repro*essed Uranium re*overed by repro*essing of the first stage spent fuel% 8n /3Rs, 'lutonium 946 undergoes fission
produ*ing energy, and at the same time, produ*ing 'lutonium 946 by transmutation of Uranium 94I% Over a period of
time, growing 'lutonium inventory *an multiply the number of /3Rs 'lutonium inventory *an multiply the number of
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based /3Rs% horium 949 is not fissile and has to be *onverted to Uranium 944 by transmutation in a rea*tor for use
as a fissile material% 8n the se*ond stage, on*e suffi*ient nu*lear power *apa*ity is built through 'lutonium!based
/3Rs, horium 949 will be introdu*ed as a blanket material to be *onverted to Uranium 944% he third stage of the
programme will be using a horium 949Uranium 944 fuel *y*les in the rea*tors% Dire*t use of horium 949 as a fuel
will thus be in the third stage rea*tors% horium 949Uranium 944 fuel *y*le does not permit attra*tive breeding
*hara*teristi*s like that of 'uU *y*le but would fa*ilitate the nu*lear power *apa*ity built during se*ond stage of the
programme to be sustained for as long as horium, whi*h is =uite large in the *ountry, is available%
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URANIUM FUEL C$CLE
he Uranium *y*le *onsists of different steps right from mining in the plants in Aharkhand to the assembly of the fuel
pellets at the .u*lear /uel Comple-% &e shall lay more emphasis on the pellet manufa*turing pro*ess and the fuel
bundles assembly whi*h is the primary ob)e*tive of ./C%
M// +/ C/*/,+/
Uranium mining is the pro*ess of e-tra*tion of uranium ore from the ground% he worldwide produ*tion of uranium in
9#59 amounted to "I,46 tones% a>akhstan, Canada, and +ustralia are the top three produ*ers and together a**ount for
of world uranium produ*tion% Other important uranium produ*ing *ountries in e-*ess of 5,### tons per year are
.iger, .amibia, Russia, U>bekistan, and he Unites States of +meri*a% here are different types in whi*h uranium is
mined% Open pit mining is the pro*ess where a large portion of the earth is dug out and mining operations are done%
Underground mining is done when the uranium is present at a distan*e below the surfa*e of the earthB this generally leads
to fewer disturban*es at the surfa*e level% &e also have in!situ lea*hing and heap lea*hing where we use the advantage of
uranium *hemistry to lea*h out the uranium atoms from the sand or ro*k below the surfa*e% his pro*ess also has arestri*tion that it *an only be done when the ore is *onfined in both the hori>ontal and verti*al dire*tions as we use a lot of
*hemi*als and theses *hemi*als shouldnt pollute the surfa*e below% Sea water re*overy is another e-*iting option as there
is plenty of sea water available% Here we pla*e bo-es of large surfa*e area in the sea at a parti*ular depth for many
monthsB where these bo-es sele*tively keep absorbing uranium% &e have been doing a lot of resear*h in this field but
havent stru*k gold yet% +fter the mining operation is done we sub)e*t the mine to a series of *hemi*al pro*esses where
we dissolve the mine in sulphuri* a*id% o this we add Mno9 and *hemi*al beads whi*h absorb the uranium mole*ule%
his is what we *all MDU% &e add nitri* a*id to MDU and it undergoes solvent e-tra*tion pro*ess again and pre*ipitation
and *al*inations to finally give us uranium dio-ide% /rom the mining prospe*tive 8ndia unfortunately doesnt have a large
deposit of uranium but still mining operations are *arried out at the Aaduguda mines in Aharkhand and ummalapallemines in +ndhra 'radesh where we mine low grade uranium *ompared to global standards to redu*e the dependen*y on
the international market%
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MANUFACTURE AND LOADING OF THE FUEL ASSEMBL$
/uel rods are assembled into bundles *alled fuel assemblies, whi*h are loaded individually into the
rea*tor *ore% +s we know that the inner and outer elements have spa*er pads with different angles, the
elements that need to be pla*ed in a parti*ular ring are fi-ed% &eEve two types of fuel assemblystru*tures, namely7 56!pin assembly @ 4$!pin assembly%he design of a fuel bundle is as su*h, that
fuel pins fall on the *ir*umferen*e of *on*entri* *ir*les% 8n the 56!pin assembly, there is one pin in the
*enter, surrounded by pins% /urther the outer most layers have 59 fuel pins% 8n the 4$!pin bundle,
there is another *ir*le, whi*h 5I fuel pins around the *ir*umferen*e% Here, the pellets are of smaller
si>e% On*e the operator re*eives the desired set of fuel pellets, he uses a brass plug, whi*h already has
the design of the fuel bundle embedded into it, to sta*k the bundle% here is a design that a*ts like a
mold and has slots for loading the fuel pins, into whi*h these pins are pushed in one by one% On*e this
is done, L2nd!*ap weldingL takes pla*e%.u*lear fuel designs di*tate that the pellet!filled rods have a
pre*ise physi*al arrangement in terms of their latti*e pit*h 0spa*ing1, and their relation to otherfeatures su*h as moderator *hannels and *ontrol!rod *hannels% he physi*al stru*tures for holding the
fuel rods are therefore engineered with e-tremely tight toleran*es% hey must be resistant to *hemi*al
*orrosion, high temperatures, large stati* loads, *onstant vibration, fluid and me*hani*al impa*ts% Pet
they must also be as neutron!transparent as possible%+ssembly stru*tures *omprise a strong
framework made from steel and >ir*onium upon whi*h are fi-ed numerous grid support pie*es that
firmly hold rods in their pre*ise latti*e positions% hese are made from >ir*onium alloy and must
permit the flow of *oolant water around the fuel rod% he grid stru*tures grip the fuel rod and so are
*arefully designed to minimi>e the risk of vibration!indu*ed abrasion on the *ladding tube *alled
fretting wear%
+ll fuel fabri*ators have highly sophisti*ated engineering pro*esses and =uality *ontrol for
the timely manufa*ture of their assembly stru*tures%
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F'*) B'/)* L+/ +/ E/ P)+* W*)/
his step in fuel assembly is almost entirelyautomated% + me*hani*al arm, rea*hes out for the fuel
bundle, lifts it and pla*es it for resistan*e welding%he end plates fuse with the fuel pins at threedifferent lo*ations and these are the ones that hold the
bundle together% heseplates have hollow stru*turesfor a reason% he *oolant needs ho have properme*hani>ed *hannel for an unrestri*ted flow andhen*e provide effe*tive heat transfer% Hen*e, thesevents ensure that *oolant rea*hes ea*h fuel rod% On*ean end plate is weld, the me*hani*al arm lifts it,rotates it verti*ally by an angle of 5I# degrees and
pla*es it before the operator% he operator thenremoves the brass plug, arranges the falling out rods,
pla*es another end plate and allows the me*hani*alarm to do its )ob% he arm then pla*es it ba*k to thespot where the welding takes pla*e and leaves the
bundle there%he fuel bundle rotates three timesand is weld at three appropriate pla*es, before theme*hani*al arm takes it ba*k to the operator% heouter mold is then removed and the fuel bundle is
sending for storage% hese bundles go throughvarious =uality *he*ks on*e again, before beingshipped to the desired rea*tor%
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+ll fuel fabri*ators have highly sophisti*ated engineering pro*esses and =uality *ontrol for the timely manufa*ture of their
assembly stru*tures%
8n order to ma-imi>e the effi*ien*y of the fission rea*tion the *ladding and indeed all other stru*tural parts of the assembly
must be as transparent as possible to neutrons% Different forms of >ir*onium alloy, or ?ir*aloy, are therefore the main
materials used for *ladding% his ?ir*aloy in*ludes small amounts of tin, niobium, iron, *hromium and ni*kel to provide
ne*essary strength and *orrosion resistan*e% Hafnium, whi*h typi*ally o**urs naturally with >ir*onium deposits, needs to beremoved be*ause of its high neutron absorption *ross!se*tion% he e-a*t *omposition of the alloy used depends on the
manufa*turer and is an important determiner in the =uality of the fuel assembly% ?ir*aloy o-idi>es in air and water, and
therefore it has an o-idi>ed layer whi*h does not impair fun*tion%
S9+*, P+ ; B*+,/ P+ W*)/
B*+,/ P+
he bearing pads are 5%" mm high appendages atta*hed to the outer elements at 4 planes of the bundle in order to maintain
the gap between the hori>ontal pressure tube and the fuel bundle%
S9+*, P+
he spa*ers are used to provide ne*essary spa*ing between the fuel pin sub assembly% he spa*er pad allows for the *oolant
fluid to flow un!hindered around the fuel pins and in prevention of hot spots%
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T$PES OF ROBOTS
: Cobra s*ara robot
: Quattro parallel robots
: (iper si- a-is robots
: 'ython linear modules
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S** < +'+/
:Lifting the Element:
8dentifying the element position 0trough position1 on the *onveyor through a *amera on op of the
*onveyor%(a*uum pi*k!up of element at two positions by a SC+R+ Robot%'i*king up the element in hori>ontal
*ondition.
:Visual Inspection of element:
+nother gripper holds the element at the end and rotates it in front of the *amera in hori>ontal *ondition itself% he
element is visually inspe*ted for defe*t and its type is identified.
:Insertion of element in the Brass flower:
3undle /i-ture with brass flower is kept on another *onveyor% One more *amera is kept on the top of this *onveyoralso to e-a*tly identify the lo*ation of the /i-ture and brass flower orientation% he element is rotated and made
verti*al% /inally the element is inserted in its respe*tive lo*ation in the brass flower% Robot is ready to pi*k up
another element from the trough%Same *y*le *ontinues for this element also% his gets repeated till all the 56
elements from this tray and 5I elements from ne-t trough is loaded in the flower 0i%e% all 4$ elements re=uired to
make a /uel 3undle are loaded1% he operator puts the top 2nd plate in the Aig and lo*ks it over the elements in the
/lower and the fi-ture moves forward on the *onveyor% +nother fi-ture now *omes on its pla*e for loading and so
on%
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REFERENCES
5% Samuel