ZDCDummy Absorber Exchange Crane Proposal

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ZDC/Dummy Absorber Exchange CraneProposal

• Paul Debbins
• Ianos Schmidt
• Univ. of Iowa - Nov. 5, 2007

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Intro

• Crane 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.

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Fixed Hinge Leaves

• Custom 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.

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Rotating Hinge Leaves

• Custom 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.

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Clever Bell Outer Frame

• Frame 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.

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ZDC Lift Frame / Linear Bearings

• These 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.

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WireFrame Front View

• Next 4 frames included to provide more details of
  the structural system.

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Wireframe Side View
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Wireframe Top View
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ZDC Fully inserted in TAN

• 5 slides animate operation. ZDC is fully
  inserted, normal operating position. For
• removal only human intervention is to disconnect
  signal/power/cal cables.

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Partial Vertical Extraction

• Twin Lead screws (not shown) located vertically
  between each end of the lift
• frame and outer frame pull ZDC from slot..

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Full Extraction
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Partial Rotation

• Clever 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.

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Clever Bell mated to Shielding Pig

• Clever Bell assembly mates on alignment pins to
  pig. Alignment blocks on side
• of TAN allow accurate pre-placement of pig.

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ZDC Fully lowered into Pig

• ZDC 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.

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Detail of Linear Bearing Mechanism

• Linear 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 dont matter as the system
• aligns itself to the TAN.

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Top View of Linear Bearing
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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.

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Issues

• TIME ! A truly organized effort and maybe magic
  required
• Approvals from CERN
• Need to absolutely verify clearances with LUMI
  people and
• tunnel people.

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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 (whos 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.

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