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Automated Fuel Element Wire Shearing Mechanism Design for Enhanced Efficiency

This project addresses the need for an automated process to separate fuel elements from spacer wires at the INL Materials and Fuels Complex. By designing a labor-saving mechanism, we aim to streamline the operations of loading, orientating, shearing, and chopping fuel elements. The proposed solutions include device concepts such as a canister system and specialized gear mechanisms, improving efficiency and reducing manual labor. A detailed budget and timeline for implementation are outlined, facilitating a smoother transition from conception to execution.

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Automated Fuel Element Wire Shearing Mechanism Design for Enhanced Efficiency

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  1. Automated Fuel Element Wire Shearing Mechanism Justen Bock, Christopher Johnson Alberto Castro, Richard Fries

  2. Design Review Outline • Background • Problem Definition • Fuel Element Delivery • Fuel Element Orientation • Fuel Element Wire Shearing • Fuel Element Rod Chopping • Fuel Element Waste Management • Integrated Solution Concepts • Budget/Timeline • Discussion Questions

  3. Background • Currently a technician manually loads the fuel elements into the shearing and chopping devices using the master/slave manipulator.

  4. Problem Statement Design a labor-saving process for separating fuel elements from spacer wires at the INL Materials and Fuels Complex. This includes the following operations: • Load the fuel element into a wire shearing device • Orientate the fuel element to properly position the wire • Shear and separate the wire from the fuel element • Cut the wire into pieces of three inch length • Cut the fuel element into pieces of three inch length

  5. Delivery: T-Bar • Fuel elements go on at Detail B end • Flaps recess inward as spade end is pushed on • Individual elements are advanced at Detail A end

  6. Delivery: Canister • Operator inserts fuel elements • Canister revolves • Individual fuel element ejected through bottom

  7. Orientation: 1-Tooth Gear • Fuel element goes through the Gear • Full gear used in Design Concept 1 • Partial gear used in Design Concept 2

  8. Orientation: Clapper • Claps onto the spade end of the fuel element • Wire must be one side or the exact opposite

  9. Orientation: Shackle • Bend fuel element inserted between shackles • Shackles close and force the fuel element into position

  10. Wire Shearing: Pac-Man • Rotates around rod and shears the wire • We created an experimental single shear

  11. Wire Shearing: Double Shear • Fuel element is placed in lower shear • Bottom shear comes up to push the fuel element into the top shear

  12. Rod Chopping • At Present, the plan is to use the existing chopper at INL for the fuel element rods.

  13. Waste Management: Slotted Pan • Fuel elements and wire fall on tray • Wires fall into slot • Elements slide across into box at end

  14. Integrated Solution Concept 1 • Design Includes: Canister, 1-tooth Gear and Clapper, Shackles, and the Double Shear.

  15. Integrated Solution Concept 2 • Design Includes: T-bar, 1-Tooth Gear Open, Shackle Arm, Pac-Man, and the Slotted Pan

  16. Is the submitted budget sheet correct? Alterations? Budget

  17. Timeline • Snapshot Day ……………….Dec. 01 2006 • Semester End Report Due…Dec. 14 2006 • Winter Break…………………Dec. 16 2006 • Spring Semester Begins…….Jan. 16 2007 • 2nd Design Review………….Feb. 12 2007 • Final Report Due…………….May 05 2007 • Engineering Expo……………May 12 2007

  18. Discussion Questions • Is using existing fuel element chopper an acceptable narrowing of scope? • How are the chopped fuel element sections sorted? • Did you have any ideas similar to ours? If so, what problems did you come across?

  19. Questions? Ideas, Comments, or Suggestions

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