ZDC/Dummy Absorber Exchange CraneProposal

Paul Debbins

Ianos Schmidt

Univ. of Iowa - Nov. 5, 2007

IntroCrane attempts to allow rapid removal of ZDC and insertion of copper absorber with

minimal human intervention. Especially that no intervention is required while components are not fully inserted into either TAN or shielding container.

Emphasis placed on industrial products and minimum custom fabrications. Serves to speed up assembly time and design approval, as industrial parts are qualified by the manufacturer

The images presented are generated from fully developed 3D CAD models of the TAN, ZDC and Tunnel, so the design is well evolved from conceptual drawings.

Some components are not shown to avoid cluttering the images, however they have been specified and their first integration into the model appear to stay within space constraints and load capabilities. These are drive systems, fastening components and control components

Next four slides animate the sequential installation of the structure.

Fixed Hinge LeavesCustom Component – 12 mm steel – welded fabrication

Bolted (possibly also welded) to TAN. These can be manufactured and installed

independently of other systems as work on TANS needs immediate attention.

Rotating Hinge LeavesCustom component – 12 mm steel

Pivot on bushing with fixed leaf

Alignment pins locate when seated

on fixed leaves as shown here.

Can be installed anytime after

fixed leaves.

“Clever Bell” – Outer FrameFrame manufactured from an industrial structural and robotic component system.

No lead time on components, assembly also rapid.

Outer frame pivots relative to rotating leaves on

a bushing at the top end of the rotating leaf.

ZDC Lift Frame / Linear BearingsThese are also from the same family of industrial components. Frame articulates

rigidly with both EM and HAD modules. Lift frame is captive in the outer frame

with a pair of linear bearings which move vertically and constrain movements

in X and Y axes. Frame attaches rigidly to ZDC and is above LUMI monitor.

WireFrame Front ViewNext 4 frames included to provide more details of the structural system.

Wireframe Side View

Wireframe Top View

ZDC Fully inserted in TAN5 slides animate operation. ZDC is fully inserted, normal operating position. For

removal only human intervention is to disconnect signal/power/cal cables.

Partial Vertical ExtractionTwin Lead screws (not shown) located vertically between each end of the lift

frame and outer frame pull ZDC from slot..

Full Extraction

Partial RotationClever Bell assembly is rotated slightly upward and out toward transport side of

tunnel. Motion is again by a pair of lead screws which span between each set of

fixed and rotating leaves.

“Clever Bell” mated to Shielding PigClever Bell assembly mates on alignment pins to pig. Alignment blocks on side

of TAN allow accurate pre-placement of pig.

ZDC Fully lowered into PigZDC lower into pig. Human intervention then to disconnect ZDC from crane.

Pig is removed, pig containing copper bars put in place, affixed to crane and

procedure reversed. Copper bar module must be built to duplicate the manner

in which ZDC attaches to lift frame.

Detail of Linear Bearing MechanismLinear bearings are in integral part of the component system. The captive motion

they provide means the ZDC will move in the TAN slot aligned with the tilt of

the TANS relative to gravity. TANS with different tilts don’t matter as the system

aligns itself to the TAN.

Top View of Linear Bearing

Control System

Does not need to be complex. Human

operator via camera with scales attached to

moving parts. System has hard stops at each

end which do not involve banging the ZDC.

Limit switches to cut motor current is operator

is asleep.

Issues

TIME ! A truly organized effort and maybe magic required

Approvals from CERN –

Need to absolutely verify clearances with LUMI people and

tunnel people.

Cost Estimate!Clever Bell outer and lift frames – $1500

Lead screws, motors, switches – $6000

Fixed/Rotating leaf system – $2000

Control System – $1500

Storage Pig - ?

Copper Bar Assembly (who’s responsible,

were the originals stolen?) ?

This does not include labor to put together and set up and test device.

These costs are for 1 crane. 2 need to be built. 50% contingency would be min.