REPORT (14.12.1999) MDT-wheel Assembling at the End (Vertical) Wall in the Cavern Three holes ( see pos.12 Fig.1) will be made in each assembly unit of the MDT-wheel (see pos.1,2…9, Fig.1) for pins (see pos.14, Fig.1) Pins with the same nominal location of centers as for test horizontal assembling, but of less diameter (that allows to compensate deviations from nominal location of holes and pins as well as to move assembly units while assembling within the hole limits), are placed at the end wall (at CERN) where the MDT-wheel will be assembled. The option of pin design at the end wall is shown in Fig.2. Pin is threaded. Originally the thread is dressed with cone tip (see pos.9, Fig.2), intended for getting into the holes of MDT-wheel plate of 30mm thickness. Then the thread is used for sector fixing at the end wall. In this case cone bushing, nut and washer are used (see pos.7 and 8, Fig.2). The cone bushing (see pos.7, Fig.2) is intended for uniform distribution of sector weight among the pins (since after sector suspension some pins may be unloaded). Prior to lowering down into the cavern in hall SX 15 horizontal assembling of eight sectors and inner ring is expected. For lifting preassembled sectors from assembly fixture, their lowering down into the cavern, reloading from one crane to another and assembling at the end wall special fixtures – two stiff steel frames and stand (see Fig.3) are used. To protect from collisions with shaft walls projecting parts of the sectors are dressed with protective caps. Because of adequate strength and stiffness of the inner ring its transportation doesn’t assume significant difficulties. The sequence of MDT-wheel assembling into the cavern at the end wall (see Fig.1) is as follows: 1. Installation of inner ring (see pos.1, Fig.1) on three pins. 2. Two bottom sectors (see pos.2 and 3, Fig.1) are consistently hanged on pins and connected with each other with flange joint. 3. Next two sectors (see pos.4 and 5, Fig.1) are consistently hanged on pins and connected with two bottom sectors with flange joints. 4. Four top sectors (see pos.6,7,8 and 9, Fig.1) are consistently and from the bottom to top are placed on pins and connected with previously installed sectors and with each other. When sector pos.4 (Fig.1) is hanged and connected with sector pos.2 (Fig.1) it (and all the following sectors –pos.5,6,7,8,9) are fixed at the wall with the help of cone bushings pos.7(Fig.2). It allows more uniform distribution of sectors weight among the pins. 5. Sector spokes are fixed with each other and with the inner ring. 6. Connection of locking devices of the first and middle rings (in the direction from the center to outer frame). 7. Connection of two top flanges with half-axles (see pos.10, Fig.1), with the help of which MDT-wheel is placed on movement mechanisms. 8. MDT-wheel removal from the pins at the end wall (see pos.2) and its placement on movement mechanisms, deployed on guiding rails. The wheels are expected to be removed from the pins at the end wall with the help of screw jacks (see pos.15, Fig.1). Fig.1. Schematic diagram of MDT-wheel at the end wall (vertical) 1- inner ring; 2,3 …9 –sectors; 10- flanges with half-axles; 11-bottom element for connection with mechanism for setting inclination angle; 12-holes in plates of MDT-wheel assembly units; 13-plate of MDT-wheel assembly units; 14-pin at the end wall; 15-screw jacks. Digits in rectangles indicate the sequence of MDT-wheel assembling operations. Fig.2. Schematic diagram of installation of MDT-wheel assembly units on pins. 1- assembly unit of MDT-wheel; 2-MDT-wheel plate of 30mm thickness; 3-end wall (vertical); 4-pin; 5-pin fixing screw; 6-pin fixing dowel; 7-cone bushing; 8nut and plane washer; 9-cone tip; 10-casing of fixture for forced removal of pins from MDT-wheel 1 2 3 Fig.3. Schematic diagram of stiff steel frame and stand, intended for sectors lifting from assembly fixture, their lowering down into the cavern, reloading in the cavern from one crane to another and assembling at the end wall 1- top sector of MDT-wheel; 2-stiff steel frame (red), links spokes and top frame into stiff package – to reduce deformations while transportation; 3-stiff steel stand (violet), intended for sectors lifting from assembly fixture, their lowering down into the cavern, reloading in the cavern from one crane to another and assembling at the end wall TGC M1 Wheel Assembling at the End Wall in the Cavern For the moment the wheel is expected to be transported by truck. For these purposes the wheel will be disassembled into fragments freely placed in a truck body. These fragments will be fixed at a transport frame generating a single package. Perhaps, several packages will be required if not all fragments can be put into one body. At CERN for less work time to be spent in hall UX15 the fragments should be assembled into as large parts as possible that can be lowered down into the shaft. This partial assembling would be accomplished in hall SX15. It is expected that assembled fragment will be 1/6 of TGC M1 wheel. For assembling 1/6 part and its lowering down into the cavern through 12,6m shaft special fixture will be required – frame which design enables changing of suspension and support places. 1. In hall SX15 1/6 part of the wheel will be assembled in horizontal position on the frame. Then the frame with fixed first fragment of the wheel (I) will be lifted into vertical position. Total weight of the wheel fragment and the frame is less 6 tons. The frame with fixed fragment will be lowered down with a crane from hall SX15 to hall UX15. The frame will be put on the cavern bottom for reloading to another crane operating inside the cavern. The frame will be moved to end wall with the crane and the fragment will be hanged on pins, located at the cavern end wall. This wheel fragment is hanged on three pins. The diagram in AutoCAD v.14 format is presented (see STEP 1_TGC). 2. In parallel assembling of another 1/6 part of the wheel is possible. The second wheel fragment (II) – is adjacent part, located to the right from the one placed into the cavern. Similar operations described above will be conducted with the second fragment. The diagram in AutoCAD v.14 format is presented (see STEP 2_TGC). Thus, to reduce time for wheel assembling two frames are required (or more depending upon a number of groups of operating personnel). With the help of one frame a group of operating personnel fixes fragment to end wall in hall SX15, on another frame second group of operating personnel assembles next fragment in UX15. Then the frames exchange their places. The second fragment is hanged on pins and joint with the first fragment. Probably pins design will enable their advance into the fragment holes or these pins will have different length (to be discussed) 3. Third fragment (III) –is adjacent left part for the first part of the wheel, already placed into the cavern. Similar above described operations will be conducted. 4. Fourth fragment (IV) – is right top 1/6 part of the wheel with a part of main beam. 5. Fifth fragment (V) – is left top 1/6 part of the wheel with a part of main beam. The diagram in AutoCAD v.14 format is presented (see STEP 5_TGC). 6. Sixth fragment (VI) –is top 1/6 part of the wheel with a part of main frame. The diagram in AutoCAD v.14 format is presented (see STEP 6_TGC). When the wheel assembling at the end wall is completed the Big wheel must be put on end carriages in the cavern. Jacks are expected to be used for these purposes. They lift the wheel through the main beam. Freed pins are removed under small value of the wheel lifting. Then the Big Wheel is lowered and fixed in hinges on the end carriages. Notes TGC M1 wheel assembling at the end wall in the cavern is under discussion. Please provide the information about time limits for partial assembling in hall SX15 and final assembling in hall UX15. Is it possible to avoid partial assembling and increase time for a final assembling? Place a package with the wheel fragments into hall UX15 at once. The Big wheel will be assembled at the end wall of light fragments at once by two groups of operating personnel. FEA calculations We studied the possibility to model joint elasticity by coupling certain degrees of freedom set. FEA calculations of MDT-octant for combination ofshell-and-beam finite-element models with account of such joints are conducted. We are comparing the obtained results with previous calculations. Specified shell finite-element model of the MDT-octant which will be used for reference FEA-calculation is under work Summarizing and analysis of the calculations results of the bolted and welded joints as well as other design elements for new values of the member forces is done.