1. RADIATION SOURCE Design Review Dmitry Gudkov BE-BI-ML

2. RADIATION SOURCE General description of the device The device is used for commissioning of the BLMs in the tunnels. The clip (the unit fixed on the BLM) is connected to the safe lead box (the source storage box) by a flexible hose. The source is attached to the metallic cable pushed by the electric motor through the hose in order to achieve the final position inside the clip which is fixed on the BLM. The operator remotely controls the movement of the source keeping safe distance (5 m) from the source. Once the control of the BLM is done the source is pulled back by the electric motor and stored inside the safety storage lead box. Quantity of cycles (in-out) between two services - 4000, means 4000 BLMs can be checked. 1.Clip attached to the BLM 2.Radiation source trolley 3.Lead box 4.Operator with remote control unit 5.Hose 6.Cable 1 2 3 4 5 6 5 m

3. Problems of the existing devices Movable parts 1.Main problems are the jamming of the source inside the hose during the operation and wear of the wire due to friction in the regions where the hose is bent. The hose rigidity should be increased while the friction between the hose, the source housing and the wire should be reduced; 2.Design of the source housing should be modified in order to reduce the friction; 3.Larger wire should be used (the motor allows the use of larger wire); 4.The metallic tube inside the ”garage” should be modified, bigger bending radii to be implemented; possibly increase the length of the ”garage” to reduce the friction; 5.All the connections of the hoses to the “garage” should be revised, the robustness in these regions should be increased; 6.All the movable parts are replaced during the maintenance; 7.Desirable length of the hose is 1 m bigger (should be ~3 m) 8.The function allowing the pulling of the source manually in case of jamming should be considered. Clip and safety switches 1.Safety switch on the clip is not protected from outside (it can cause it’s damage) can be protected by metallic sheet with t=0.1..0.2 mm; N. B. The end switch on the clip causes the biggest problem. In case the switch does not work when the source achieves the end position, the electric motor continues to push the cable. This can cause cable damage (uncoiling). Uncoiling of the cable causes it’s jamming in the electric motor. 2.Check if the clip available on market can be implemented; the clip used at the present moment is heavy and requires the force application by the operator about 100 times/shift. Consider ergonomic clamp. 3.Different safety switches to be revised in order to improve the reliability of the system.

4. Trolley 1.The metallic trolley should be kept but can be modified (holes or slots for hose extraction can be added). 2.Softer wheels are required, possibility of blocking the rotation of each wheel should be implemented; 3.Wood panel to be replaced by plastic or aluminium (?); 4.Cover support (when the cover is opened) should be enhanced; 5.The battery replacement (every 2..3 years) should be possible without dismantling of the panel (?); 6.Tow bar (side tractor connection) on both sides of the trolley; 7.Keep continuous dose instrument inside the trolley. Problems of the existing devices Remote control panel 1.Cable connector for remote control panel on both sides of the trolley; 2.Cable connector on the remote control panel should be on the other side; 3.Increase the length of the cable; 4.Increase the rigidity of the cable near the remote control panel (cable is heavy, it bends around the connector; 5.Consider a possibility of reduction of the weight and size of the remote panel, the weight of the cable. Other 1.Keep cables and hose inside the trolley or cover it differently for protection during transport and storage;

5. Cable, Source housing, Tube In order to avoid the cable damage the nylon coated solution is proposed: In order to reduce the friction between the source and the hose, the pivot can be used: source sleeve Pivot (ø5) cable Cable ø2.3 mm Bending radii 120 mm Bending radii on the tube inside the lead box are increased to 120 mm: 250 Cable ø2.3 mm COMMENT: The source should be protected by 100 mm of lead minimum

6. a1. The existing tube configuration seems ok, 100 mm of “direct” distance: Cable, Source housing, Tube

7. 1 1.The safety switch is moved from the end cable position (old version of the irradiator) to the wall of the lead box. 2.Two fractions of cable are used. Interconnection between the long cable and short cable fraction which holds the source is used to activate the safety switch. 3.No need to calculate exact length of the cable. 4.Two safety switches are used at the position “source in the box” 5.Mechanical lock Cable (to reel) 2 Source safety box 3 3 4 ø5

8. Cable, Source housing, Tube Safety switch is moved to the side of the lead box due to lack of the vertical space:

9. Hose 1 1.Rigid tube is used to guide the cable from the lead box to the wall of the trolley. 2.The hose – tube interface is located outside the trolley on the wall 3.Spring is used to increase the hose rigidity in the interconnection region 2 swivel 3 COMMENT: Safety switch should be integrated (motor is blocked when there is no hose connected)

10. Hose 1 2 1.Rod attached to the hose 2.Switch

11. Clip. Enhanced “classic” clip 1.Hose rigidity is increased (spring is used) 2.Internal surface of the hose is protected by the cover 3.Two safety switches are used at the position “source in clip” 4.Clip can rotate around the hose (swivel) 5.Switch housing part can be used with different types of clips 1 2 3 4 5 COMMENT: The distance between the end switched and the final position of the source should be approximately 20..30 mm - to be checked

12. Clip. Enhanced “classic” clip COMMENT: The distance between the end switched and the final position of the source should be approximately 20..30 mm - to be checked

13. Clip. Click-type 1.50% lighter than “classic” clip 2.Only one movement is necessary to attach the clip to the BLM 3.Felt sheet can be used to reduce the friction during the connection of the clip and protect the BLM from scratches 4.Easy access from the back side of the quad 5.Switch housing is the same for all the clip types (including “classic”) 2 3 4 5 COMMENT: Check this solution with all possible types and locations of BLMs

14. Cable storage 1.The use of reel allows to store up to 5 m of cable 2.Screw shaped cable slot for smooth cable collection 3.Reel moves transversally to provide constant cable orientation (ball screw transmission is used) 4.Torque spring is used for cable retractionTorque spring 1 2 3 4 65 ø90

15. Modifications of trolley 1 2 3 4 5 1.Tow bar (side tractor connection) on both sides of the trolley 2.Gas springs are used for smooth opening of the cover and keep it opened 3.Welded eyes (x 4) for fixation during transport by a truck 4.Spring forced castors for smooth transport inside the tunnel 5.Swivel-block mechanisms on each castor

16. Gas springs Norelem 26200-0615150X150 Tow bar (same as already installed, drawings are needed to produce the 2 nd ) Modifications of trolley Weldable Eye Norelem 07720-1000 Spring loaded castor (phenolic group mat.) Swivel lock mechanism Mounting dimensions (check if the existing holes can be used)

17. Modifications of trolley 1.Access to the batteries is provided by sliding the panel out the trolley by 280 mm 2.Continuous dose instrument inside the trolley 3.Batteries can be replaced without full dismantling od the device 2 batteries 1 3 COMMENTS: 1.Battery charger should be integrated (fixed on the movable platform) 2.Solution to avoid tumbling of the trolley to be designed

18. Modifications of trolley COMMENTS: 1.Battery charger should be integrated (fixed on the movable platform) – patch panel 2.Solution to avoid tumbling of the trolley to be designed – center of mass 1 2

19. 1.Cable connector for remote control panel on both sides of the trolley; 2.Cable connector on the remote control panel should be on the other side; 3.Increase the length of the cable; 4.Increase the rigidity of the cable near the remote control panel (cable is heavy, it bends around the connector; 5.Consider a possibility of reduction of the weight and size of the remote panel, the weight of the cable (radio/cable) Other 6. Keep cables and hose inside the trolley or cover it differently for protection during transport and storage; Remote control panel and cable 1 1 6 250 x 150 x 80 2 2 5 COMMENT: 2nd cable connector is not needed

20. Manual pulling of the cable PULL 1.The operator can not approach the trolley if the source is outside the lead box 2.The cable is locked between the rollers of the electric motors 3.The only place from where the cable can be pulled is between the motor and the lead box 4.Another cable can be attached in this place so the operator can pull the cable without approaching the trolley 1 5 m to operator 2 3 4

21. Prototyping Test bench phase 1: cable with nylon coating and switch housing parts: 1 2 3 1.Hose 2.Tube 3.Switch housing Results: -10500 cycles completed (corresponding to 10500 BLMs) -No visible wear of cable, hose, tube or switches -No change in cable dimensions -Stability of work during 2 weeks if tests

22. Prototyping Test bench phase 2: cable collection device, moving inside the long hose: 1 2 1.Cable reel (cable length/travel 3.5 m) 2.Hose 3.Switch housing 3 3

23. Schedule and future actions 1.Detailed design of the approved solutions 2.2D drawings 3.Production of parts for test bench 2 4.Production of 1 (+1) x Irradiator 5.Tests of Irradiator Next steps Design Status 3D modelProduction drawings 85%75%