1. ZDC/Dummy Absorber Exchange Crane Proposal Paul Debbins Ianos Schmidt Univ. of Iowa - Nov. 5, 2007

2. 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.

3. 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.

4. 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.

5. “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.

6. 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.

7. WireFrame Front View Next 4 frames included to provide more details of the structural system.

8. Wireframe Side View

9. Wireframe Top View

11. 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.

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

13. Full Extraction

14. 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.

15. “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.

16. 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.

17. 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 don’t matter as the system aligns itself to the TAN.

18. Top View of Linear Bearing

19. 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.

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

21. 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.