1. ZDC Remote Handling Tool Structure and Force Analysis P. Debbins University of Iowa December 10, 2009

2. From March 6, 2009: Rotational arm, TAN anchors, and rotational geometries Were determined to be free of interference and fully qualified for loads encountered. Vertical elevation sub-system was not fully developed. Rotational Arm Rotational Arm Anchor Actuator Anchor Vertical Elevation System Holes in Tunnel Floor to locate Sarco – Completed May 2009 Tapped Holes in TAN for Anchors and adjustment bars – Completed May 2009

3. Vertical Displacement Maximum displacement at load point is 0.034 inches From March 6, 2009

4. Horizontal Displacement Maximum horizontal displacement is 0.01 inches From March 6, 2009

5. Vertical Elevation system is now Specified and analyzed for loads and displacements resulting in determining payload placement accuracy Rotational geometry is unchanged and Spatial occupancy of system is smaller than the envelope used to establish clearances; non-interference with tunnel environment and TAN is preserved.

6. Vertical Elevator Layout Vertical Lifting Motor Frame Overhead Beam Frame Sidewall Payload Carrier Beam Vertical Lift Screw Rotational Spindle (Rot Arm Articulation) Linear guide rail for Carrier Beam 90’ Brace – shown this side only Merkur M1 Screw Jack (1 of 2)

7. Payload Carrier Beam End Blocks: single Machined piece Beam tubes and X-webbing are welded from 5mm steel plate stock, water jet cut to form Material: S235J steel. This is stocked at CERN (also available in the US) Fabrication: End blocks are machined Oversize and without attachment holes or screw jack placement features. Welded internal beam structure is Fabricated separately. End blocks are Welded on secured by jig. Final machining of as-fabricated beam ensures parallelism and dimensional accuracy of features. Design conducted with consultation of machine and weld shops

8. Frame Overhead Beam Construction methodology is identical to The Carrier Beam

9. Frame Sidewall Material and Construction same as other elements, except spindle Spindle – 4140 steel

10. Elevator Frame Components assembled with M12 bolts. Post fabrication of mating surfaces to establish mating planes; possible to shim allowing frame to be assembled with high geometric precision, and not be able to shift out of alignment Steel structures painted with Americote 741 over Dimecote primer

11. Top View Payload Carrier Beam End Block Bishop-Wisecarver Dual-Vee Guide wheel #3 size (4 per side) Max loads: (radial 5900N Axial 1590N) per wheel. Bishop-Wisecarver V-guide rail (inox) Guide rail mount plate. Mount plate bolted to Frame sidewalls Consultation with factory establishes that system can be set up for zero free play. Krytox 227 lubricant (radiation hard). These guides are highly resistant to jamb from foreign matter

12. Load Calculations All load calauclations and FEA loads are based on the worst case of the more massive full Copper Bar Absorber assembly

15. Models generated for FEA incorporate intermittent gaps to reflect the skip welded pattern of fabrication Welded joint No Weld

16. FEA of Carrier Beam http://www.physics.uiowa.edu/~pdebbins/ZDC_TOOL/Carrier_Beam_FEA.pdf.pdf

25. Payload – Carrier Beam Mating Structures Carrier Beam “HAD” Payload Upper Mate Lower Mate Chamfer acommodates +/- 10mm misalignment in all directions 15mm bores When mated – pin Locks sections together Auxiliary holes allow Fixation of payload to Emergency removal tool EM section is double pinned to Prevent “rocking” in Z axis

26. Pivot Roller Bearings SKF JL 26749 F/710 Bering thrust flange Flange applies pre Load to bearing – Secured with Castellated nut, Which is wired to Prevent loosening

27. Payload Displacement Free Play of pre-loaded Roller bearings and Bishop Wisecarver guide Wheels is negligible at the Loads presented. Distortion of Carrier Beam Also disregarded (0.2mm)