Movement device for N SW - PowerPoint Presentation

Slide1

Movement device for NSW

T. Blaszczyk, F. Rosset, C. Sordé, M. Raymond… and various contributors from EP-ADO-PO

Review on NJD

and NSW transport

tooling

April 30

th

, 2018

Slide2

Content

Reasons for a new designLoad distribution on feet

New layout

Air pad support

Blocking JacksMovement services on NJDUse of friction padsConsequence on TractionZ-bracket designAncillary equipment Conclusions Reference documents

M. Raymond - 30th April 2018

NSW movement device

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Slide3

Reasons for a new movement device

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The increase of the

NSW weight has produced a displacement of the centre of gravity of the system {NJD + NSW}.This displacement of CoG has consequences on the feet and movement device Decrease of stability Loss of performance of the air pads coming from the high unbalance of the working pressureThe Blocking Jacks, used as permanent feet, are not anymore suitable to take the weight of the NSW, for the same reason of unbalance as mentioned aboveUnder certain conditions (see next pages), the use of the current layout of

{feet + movement device} was simply not acceptable. Decision to revisit the design of this system.

Attempt to take this opportunity to optimize it as much as possible

Slide4

Load distribution on feet

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Model of the {

NJD + NSW}F1 and F2 can represent either the feet (BJ) or the air pads, depending of the numeric data. The weight is inclined to figure out the inclination of ATLAS axisResult of calculation using the same layout than the one of the current SW(weight and CoG according ATL-M-ES-0034, 08.06.2016)For comparison the load on the air pads is distributed 59% - 41% on the current SW-A.

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New design with shifted air pads

Air pad on HO side shifted by 514 mm

But it is in conflict with ECT in Run position 

it has to be dismounted

Additional air pad support is required Contact between air pad support and A-plate to block the rotationNeed of lifting to surface before ECT is moved to Run positionRe-positioning of height sensors and Bcam targetsRe-routing of the services required for the movement deviceReplacement of the blocking jacksReplacement of the Z-bracket M. Raymond - 30th April 2018

NSW movement device4

Design

completed

,

except for Z-brackets

(finishing)

Slide6

New design with shifted air pads

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Air pads on HO side shifted by 514 mmConflict with ECT in Run position  has to be dismountedAdditional air pad support is required Contact between air pad support and A-plate to block the rotation

New Z

-bracket

New Blocking jacks

New services organisation

Slide7

New Layout

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Slide8

Layout versus stability

Reminder : with the former layout (before re-design)

Distribution of load on the various feet and depending on the tilt

Loads are given for a total weight of 104T, percentages are independent of the value of the weight

It is optimized for side A. To optimize for both sides at the time would entail to reduce the total span, therefore the distribution of load would be better balanced but stability would be less. The choice has been done to optimize the stability.The distance between air pads is increased from 1186 mm to 1701 mm.The distance between BJs is increased from 632 mm to 775 mm.

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Slide9

Detail of air pad support

No change on the Air pads at IP side

in Run

position, Air pads on HO side will be removed

Total weight ≈ 610 kg (air pad = 450 kg + support = 160kg of steel)Moveable thanks to the Z-bracketPositioning using to 2 pins Ø45Locked in position thanks to 2 bolts M16Contact with A-plate to limit deformation and movement : 3 bolts M20 with spherical join Fixation of the air pads : 4 bolts M24 from the bottomM. Raymond - 30th April 2018

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Parts are delivered

Pins are machined

Ancillary parts procured

Installation on NJD tested

Spherical bearing

Slide10

Design details

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The design has been made in order to minimize stress in the welds

Slide11

Air pad support dimensioning

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Fixed support : forks are welded on JD foot

“Compression only” as these surfaces are in compression on the A-plate

Load case : Vertical force from the air pad

Nominal higher force = 257 715 N

A safety factor of 1.4 has been applied then the load has been rounded to 365

kN

Slide12

Stress analysis

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However this data applies to trade parts and does not really make sense

(approximated model)On the full model, the higher Von Mises stress is 385 MPa(only the most loaded area is shown)On the manufactured part, Von Mises

stress is less than 254 Mpa

Choice of E355 steel

Yield stress = 355

MPa

Ultimate tensile stress ≥ 500

MPa

Slide13

Pins validation

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In complement to FEA, the Ø45 pin have been checked using

Eurocode requirements (Table extracted from Eurocode)0.330.310.780.350.650.23

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Blocking jacks

The replacement of the hydraulic Blocking jacks with adjustable steel feet has been studied long.ProsS

pan is considered too small to give confidence in acting BJ directly without air pads, therefore hydraulics is of poor benefit compared to a more simple solution.

Tilt and height adjustment could be performed with the help of air pads.

ConsEven if less complex, the system would also loose:Flexibility in the procedures Easy and immediate adjustment (even without air pads)It works well since 10 years !In additionDesign has been improved to allow a better use of the BJsShort movement on the BJs should be possible using friction pads (Permaglide)Could make much easier the tuning of the positioning

But hydraulics jacks are compulsory to balance the load

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Blocking jacks still consist in hydraulic cylinder, double acting

Slide15

Blocking jacks

View from bottom

2 blocking jacks

Jack characteristics:

Double actingLoad capacity : 593 kN @ 700 bStroke : 70 mm

Radial load up to 40 kN

Weight ~50 kg

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Technical specification: AT1-HT-CD-0001

8 hydraulic cylinders are delivered and tested

Interface plates machined

Oil will be supplied thanks to rigid and permanent piping

BJs installed under NJDs

Locking nut

Swivel head +

Permaglide

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Services layout

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Fluids are required to perform any NSW movement (oil, air, electricity)

No change compared to the current services layoutAir pads are linked to get 3 equivalent supporting points (hydraulics)Air supply is independent for each of the air padsBlocking jacks are linked to get 3 equivalent supporting points

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Services for NSW movement

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2 flexible chains provide the fluids to the movement device

Rigid pipes are used as much as possibleThe routing has been discussed and agreed with the Muon services teamLink must be done between USA15 and US15 sides  rigid pipes

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Services for NSW movement

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Pipe installation is on going at B191

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Sliding on Permaglide

This is optional but may result in a very smooth and efficient way to position accurately the NSW.

M. Raymond - 30th April 2018

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18Comprehensive tests have been performed on the movement test bench to qualify the Permaglide as friction pad.Conditions of test and results can be found on edms : ATL-HT-ER-0012 Friction factor is function of the movement speed Friction is in the range 3%-6% (speed from 0.5 mm/s to 6.5 mm/s, nominal about 3 mm/s)Movement is smooth, more than with the air padsStrong increase of the traction strength (factor 3 to 5)

Friction factor evolves rather quickly along lifetime

Lifetime = about 100 m !!

Results rather good and certainly acceptable

Stability concern

(small distance between BJs)

Difficulty to go to Large Opening

Decision was made not to propose it as the baseline but to try short and accurate movement

Slide20

Traction cylinder and Z-bracket

The displacement of HO air pads makes obsolete the current sequence for JD+SW movementZ-bracket should be moved forward by 560 mm to escape the air pad

The traction cylinder cannot be moved (otherwise it would conflict ECT)

Option 1: E

xtension of 725 mm to be added to the rod instead of the 165 mm current oneThis may entail an issue of buckling for the rod A reinforcement on the traction cylinder itself may be requiredM. Raymond - 30th April 2018NSW movement device19Option 2: Re-design of Z-bracket  the selected option !Design on going

– Goal is to reach the nominal Standard Opening position when the last hole in the rail is reached, and to avoid additional handling.

In case this could not be achieved, the Z-bracket would have to be removed and the traction cylinder connected to ECT before the movement can be

completed

The interface part exists but has never been used

Slide21

Z-bracket design

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Function Analysis :

FP1 : Provide a fix point between the rail and the traction cylinderZ-bracketAtlas railNSW (Traction Cylinder)

FP1

FP2

Air pad

FP2

:

Allow to carry the air pad on the rail

FC1

User

FC1

:

Interface with the rail

Pin Ø50 mm

Sliding pads

FC2

FC2

:

To be carry by hand by 2 users

Mass ≤ 50 kg

Traction cylinder

FC3

FC3

: I

nterface with the traction cylinder

Axis Ø40mm

FC4

FC4

:

To allow the passage of the air pad to perform the full movement without conflict

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Z-bracket current version

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Function

CommentStatusFP1Design done, FEA shows reasonable stress and deformationDoneFP2Technical proposal done, effort to move the full package might be too high for easy handling To be optimizedFC1Interface for pins is done, sliding pads still on goingOn goingFC2

Current weight is 81 Kg  out of requirement

To be optimized

FC3

Design of the interface with traction cylinder

is completed

Done

FC4

Z-bracket is high enough to avoid conflict

Done

spring

sliding part

Spring axis

nut

Slider

Slide23

Z-bracket dimensioning

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Load cases and boundary conditions

Case #1 : NSW movement toward IP side A4 pins fixed inside the railContact with friction (friction factor 0.1) between the pins and the Z-bracketHorizontal force 50 kN applied to the Z-bracket

Case #2 : NSW movement toward HO side C

4 pins fixed inside the rail

Contact with friction (friction factor 0.1) between the pins and the Z-bracket

Horizontal force 50

kN

applied to the Z-bracket

Case #3 : Handling of air pad

4

sliding pads

fixed

on the

rail

Vertical

force

2x 3.5

kN

applied to the Z-bracket

The 50

kN

force correspond to the traction cylinder capacity. The typical force during the movement is about 15

kN.

Slide24

Preliminary stress level

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Load case 2

Load case 1Stress < 113 MPaStress < 119 MPaHighest value is very local at the contact with the pin

Material : Al alloy, 6082 T6 or 7075 T6  the choice depends on the stress level after optimization of the mass.

Without surprise, the second arm is not loaded

Here also there is room for optimization

Highest stress is actually in the pin (240

MPa

)

Material is

34 Cr Ni Mo 6 steel

Yield stress ≥ 800

MPa



safety factor

≥ 3.3

Ultimate tensile stress ≥ 1200

MPa

Slide25

Preliminary stress level : load case 3

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Maximum deformation ≤ 0.06 mm

Stress ≤ 35 MPaThe Z-bracket is clearly over dimensionedOptimization of the design is required, it will be completed by the summer 2018.Note : as this part is independent of the NSW and used in UX15 only, the earliest date for 1st use is October 2019

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Ancillary equipment

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6

reflectors are used in relation with 6 Bcams to position the NSW with accuracy4 Reflector supports have been modified (out of 6) Drawings done, parts machinedSupports for height sensors2 supports out of 4 have been modifiedDesign doneProduction drawing and parts to be doneIntegration drawings to be doneStop for traction cylinderDesign doneProduction drawing and parts to be doneInterface to support the flexible chain

Design still to be doneFriction pads

Design done

Production drawings and parts to be done

Slide27

Conclusions

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The layout of the movement device has been fully re-visited because of the large shift of the NSW centre of gravity

The concept is unchanged, but friction pads could be used in complement to air padsAir pads are re-usedTraction cylinders are re-usedCam followers are re-used (lateral guidance)Sensors are re-used (pressure, height, etc)Blocking Jacks are new (and equipped with Permaglide) : delivered and testedNew interfaces have been designed

Air pad supports : deliveredZ-brackets :

design still on going

Ancillary parts :

being completed

Services routing has been designed

Services installation is on going on both NJDs

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Reference documents

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Report on stability :

ATL-HT-ER-0011, edms id. 1553984Technical specification for blocking jacks : AT1-HT-CD-0001, edms id. 1812368Production drawings of Air pad support : AT1HTMJ_0001 & AT1HTMJ_0002Layout of air pads and blocking jacks : AT1HTMJ-0003Report on Permaglide friction pads :

ATL-HT-ER-0012

Interface for Blocking jack fixation : ATUMHM__0003

Reflector supports :

AT1HTCM_0001

to AT1HTCM_0007

Calculation reports have still to be written on :

Air pad support

Z-bracket (after design completion)