1. MICE Partial Return Yoke Mechanical Design
23 September 2013
Stephen R. Plate
Brookhaven National Laboratory
9/23/2013

2. Outline Mechanical Requirements and Features Assembly Technique
Obstructions
Engineering Calculations
Cost Estimate – Outside Fabrication
9/23/2013

3. Mechanical Requirements and Features
Minimize impact on existing structures and equipment
Magnets, Detectors
False floor
Mezzanine
Service-way cabling to ISIS
Sliding platforms
Comply with crane lift limit of 8 tonnes
Bolted connections
Maximize reconfiguration possibilities for later phases of project
Eliminate possibility of changes in magnetic properties due to welding
Provide greater fit-up allowances during installation
Access to solenoids and AFC
Increased access through yoke using very recent 6-piece design
9/23/2013

4. PRY SHIELDING CONSTRUCTION OVERVIEW
(Mezzanine placeholder)
Load-sharing cross bars
(4 of 8 shown)
5700 kg at 120mm thk
(one backer + one plate section)
PRY SHIELDING CONSTRUCTION OVERVIEW
Steel framework
False Floor
downstream
Splice joints
(will become flanged)
Avoid service-ways
Location templates (temp tooling)
9/23/2013

5. Assembly Technique – major operations
Locate/drill holes using footprint template
Assemble south side framework in place under mezzanine
Install shield sections #1 and #2, and new middle access section #5 with backing plates
Install shield sections #3 and #4, and new middle access section #6 with backing plates ...
(See following illustrations - NORTH side shown for convenience)
9/23/2013

6. Clearance to back of channel
Hoist ring
Install Section 1
Clearance to back of channel
Machined surfaces
on channel
mate to pink bar
Hoist ring spacer provides correct tilt
Section 2 is similarly installed
9/23/2013

7. Install Section 3 (and 4)
Lower hoist rings removed; guide blocks installed
(also shown on isometric, Slide #4)
Plate guided into engagement during lowering
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8. Install Restraint Bars
All beam-to-channel connections will also be bolted
9/23/2013

9. (Assembly Technique – continued)
… Install Virostek plate extensions
Install spectrometer solenoids and AFC
Build and install shielding on north side, same technique as south side
Install north/south load-sharing cross bars
9/23/2013

10. Obstructions/Interferences
Identification has been on-going several months
Identified all now: spectrometer solenoid tie-downs, mezzanine and its column supports, vacuum ports, AFC access, etc.
Work continues with input from J. Tarrant to modify the shielding and/or add required apertures to model as required.
Magnetic analysis is done for each modification (H. Witte) as appropriate
Construction drawings to follow
9/23/2013

11. DESIGN CHANGE Access to AFC
SOLENOID
SOLENOID
AFC
9/23/2013

12. Engineering Calculations
Magnetic forces
vector ~8660 N, each of 4 shield sections
North side in trench shown
Dead weight
25,810 kg total
9/23/2013
Overturning moment

13. Moment Reaction, worst location
9/23/2013

14. Need Reaction Moment Overturning moment = 29.7x103 N-m [263x103 in-lb]
Must be self-supporting before cross bars are attached
To counteract safely, maintain compression of vertical beam legs with floor. Determine force required to do this; check with ANSYS Workbench
RESULT
4 anchor bolts/leg, spaced 234 mm [9.21 in] apart, embedded 240 mm [9.5 in]
RAL must provide adequate strength surface (5000 psi concrete floor or grouted support plates anchored to floor)
9/23/2013

15. Deflection under loads of gravity and magnetic forces, with cross bars attached
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16. (Play video)
9/23/2013

17. Cost Quotes / Estimates
Shield plates, machined, 1008 steel
From American Alloy Steel, Syracuse, NY, USA
Material cost = $5600, each of eight plates
Machining cost = $2850, each of eight plates
Backing plates (4-pc design), mat’l only = $625 each of eight plates
TOTAL = $72,600
Delivery: weeks
Shield plates, machined??, 1006 steel
From JFE, Kurashiki, Japan
Material + machining(??) cost = $6800, each of eight plates
TOTAL = ( est)*8 = $59,400
Delivery: 16 weeks
Shield plates, machined, 1006 steel
From Tesla Engineering, UK
TOTAL = £74,227
Delivery: 21 weeks
Framework, both sides – estimate only (unburdened)
Labor 580 $110/hr = $63,800
Material = $17,000 (steel + aluminum + hardware)
TOTAL = $80,800
9/23/2013

18. Work to complete
Finalize modifications to shielding plates to avoid interferences, etc.
Reposition legs
Reposition drilled/tapped holes
Insert in Virostek plate extension for slide-out of spectrometer solenoids (allow rise of solenoid by 50 mm)
Slot(s) for tracker waveguides
6-piece design change for AFC access
Structural Framework
Shorten framework legs for installation of surveyed and grouted floor plates (accommodate uneven floor)
Reposition/shorten restraint bars on South side (interference with mezzanine)
Begin and complete manufacturing drawings in CY13
Shorten legs for installation of surveyed and grouted floor plates (accommodate uneven floor)
9/23/2013

19. BACK-UP INFORMATION
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20. 9/23/2013

21. Floor bolting calculations, Page 1
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22. Floor bolting calculations, Page 2
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23. Floor bolting calculations, Page 3
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24. Floor bolting calculations, Page 4
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25. Floor bolting calculations, Page 5
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26. Floor bolting calculations, Page 6
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