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DCal Insertion Tooling

DCal Insertion Tooling. DCal Insertion Tooling. DCal Insertion System feature following main components 1. One rotator : cylindric welded structure 2800 mm diameter, 1500 mm long, 1800 kg. Function : load detectors, and rotate them to right Phi angle.

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DCal Insertion Tooling

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  1. DCal Insertion Tooling

  2. DCal Insertion Tooling • DCal Insertion System feature following main components • 1. One rotator : cylindric welded structure 2800 mm diameter, 1500 mm long, 1800 kg. Function : load detectors, and rotate them to right Phi angle. Design : this is roughly a « squirrel cage » than can be opened into two half cylinders in order to be be loaded. One half cylinder will be used as a handling device. This part will be qualified for loading by the contractor. • 2. One rotator base rectangular structure, 3800 x 1800 mm, 1500 kg Function : support of rotator. set up in X, Y, Z, before connection to bridge. • 3. Connection bridge Function : removable connection from IT to cradle

  3. DCal Insertion Tooling : some features Rollers taken from EMCal IT Feet from EMCal IT and balls system for set up of location Centering devices for 2 half squirrel cages

  4. EMCal IT components to re-use on Dcal IT

  5. EMCal IT components to re-use on Dcal IT

  6. EMCal IT components to re-use on Dcal IT

  7. DCal Insertion Tooling : some features Configuration for 0°, 20°, 40° : « inside miniframe, short configuration » U aluminium rails not welded, removables Configuration for 60° : outside from miniframe, 60° U rails are longer than other ones

  8. General Configuration 4 different spacings 2 different levels

  9. Some changes versus EMCal • The PHOS compatibility leads to use 4 different spacing (instead of 2 for EMCal+extension ), for the aluminium rails used for transport and mounting of Supermodules : • C-0-20-40 : 1318 mm • Extension 60° : 316 mm • A-0-20 : 1562 mm • A-40 : 1111 mm • These 4 different spacings impact on some components of Insertion Tooling, which require different sizes. • Request of minimum height for accessibility to PHOS lead to 2 different levels for aluminium rails, and a specific system of shuttle/carriage which is a significant part of total cost.

  10. Insertion scenario for DCal (A+C) + PHOS DCal support structure without bridge A bridge located between IT and cradle is used instead of the « nose » of EMCal IT, for transfert of detectors from rotator to cradle. DCal support structure with bridge

  11. Transport from IT to experimental location CSide A Side Special A40

  12. Dimensions 2952 1667

  13. Insertion scenario for DCal (A+C) + PHOS 2- Loading C-side DCal Supermodule into Insertion Tooling. Shuttle Supermodule 180°

  14. Insertion scenario for DCAL A+C & PHOS 3- Moving C-side DCal Supermodule inside ALICE. Connection between rails C side and Supermodule shuttle

  15. Insertion scenario for DCAL A+C & PHOS 3- Insertion of C-side DCal Supermodule. Final position of Cside DCal SM C side Supermodule Removal of SM shuttle Supermodule shuttle Shuttle in rotator

  16. Insertion scenario for DCAL (A+C) sides & PHOS 4- Loading PHOS module into Insertion Tooling. 180°

  17. Insertion scenario for DCAL (A+C) & PHOS 5- Insertion PHOS module inside ALICE. Final position

  18. Insertion scenario for DCAL (A+C) & PHOS 6- Loading A-side DCal Supermodule into Insertion Tooling. 180°

  19. Insertion scenario for DCAL (A+C)sides & PHOS 7- Insertion of A-side DCal Supermodule. Final position

  20. Modifications from EMCal to DCal IT • No nose mounted on rotator : lack of room (mini frame), this point leads to design a removable bridge structure. • Rotation of rotator is achieved with a geared device, instead of a chain device, in order to avoid issues, that occured for insertion of EMCal extension last January, when center of gravity of the load is far from rotation axis of rotator. Discussions on the way to minimize cost of this subsystem, by exemple machining by water cutting. • Motion of detectors will be done with a motorized (hydraulic) shuttle instead of the EMCal hydraulic piston wich cannot be re-used because it is too bulky : miniframe, lack of room.

  21. Modifications from EMCal to Dcal IT Rotation by gear system instead of chain system

  22. Motorized shuttle to transport detectors 3 gear stages with total reduction ratio 1:27 Motorization with hydraulic motor using same hydraulic power unit than EMCal IT

  23. Motorized shuttle to transport detectors • Pro • Insertion process can be operated by a single operator on A side. • Operation is faster than EMCal system : DCal insertion time should be EMCal time / 2. • Can be used for removal of EMCal supermodules when EMCal will be dismounted. • Moderate cost impact : hydraulic motor 160 €, total cost < 4 k€, less if some components are machined in lab’s workshop. • No more complexity than EMCal system. • Drawbacks • A shuttle can be used only for a given spacing of rails. As there are 4 different spacings, 4 different shuttles are required. Fortunately, most of parts are common, and for a shuttle to an other one, 3 different components need to be changed. • Half a day should be required to convert the motorized shuttle from one rail spacing to an other spacing.

  24. Motorized shuttles to transport detectors C-0-20-40, 1613 mm wide 60° Extension, 611 mm wide A-0-20, 1857 mm wide A-40, 1406 mm wide

  25. FullITwith load

  26. TOP VIEW

  27. Overview of DCal + PHOS when completed

  28. Status

  29. Cost estimations • 4 possible contractors for rotator + its base (deliverey 3 months after order) • MEUNIER(former contractor for EMCal IT) 35 k€ without large gear • SACMO (never trade with them) 49 k€ without large gear • ACE(present contractor for DCal support structure) quotation late week 24 • MECATLANTIC(some previous business with them) 19 k€ without large gear • Large gear alone, with traditionnal milling process : 11 k€ • Large gear alone with water cutting process : 5 k€ • U shaped Aluminium rails : ordered by Nantes, delivered, 5.2 k€ • 3 Shuttles/carriages : 35 – 40 k€ • 18 Standard carriages (C side) 18 k€ • Motorized shuttle < 4 k€

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