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ATLAS-MDT/RPC-ASSEMBLY LIFTING FRAME (CERN) AMP-AQ-02

22 June 2005 Page 1 of 12

NIKHEF Reference no.: AMP-AQ-02

TIS/EDMS NO.: R1946

MECHANICAL ANALYSIS OF THE R.P.C./M.D.T. LIFTING FRAME FOR TRANSPORT IN ATLAS

A.Korporaal, C.Snippe

PRODUCTION VERSION

Abstract

The purpose of the mechanical calculation is to investigate stress and safety factors in the lifting frame used to transport the

R.P.C. and M.D.T. chambers together into the ATLAS pit at CERN. These lifting frames have to comply with the

CERN SAFETY CODE D1 (Rev.) The numerical analysis was done by the

I-DEAS Finite Element Analysis software.



SUMMARY:

As one of the experiments, intergrated in de Large Hadron Collider (LHC) at CERN near Geneva, the ATLAS-detector will be operational in 2006. The detector is assembled with several sub-experiments with characteristic unique subdetectors. The Resistive Plate Counters (R.P.C.) and Monitored Dr)ift Tube muonchambers (M.D.T.) become as a set transported together into the ATLAS-pit. For the outer (96) R.P.C./M.D.Ts, it is planned to do this operation with a lifting device This lifting device have to be according CERN safety code as noted in EDMS 335726 Rev. D1 LIFTING EQUIPMENT Publication date: January 1997 This means that all equipment must be labeled and CE- certified delivered to the client.

CONSULTED STANDARDS:

EN 291-1 - SAFETY OF MACHINERY Basic concepts-General principles for design

Part 1: Baic terminology, methodelogy

EN 291-2 - SAFETY OF MACHINERY Basic concepts-General principles for design Part 2: Technical principles and specifications.

EN 1050 - SAFETY OF MACHINERY Principles for risk assessment



DATA OF SUPPLIERS/COMPANIES OF PRODUCTS MENTIONED ON

DWG.: AMP-AQ-02

PARTS 01,02,03,04,06 and 07 are CE-certified/labeled and delivered by:

MENNENS Amsterdam. Postbox 8051 1005 AB Amsterdam. Fax : +31 (0)20 6840067 Email: [email protected] Internet: http://www.mennens.nl

PART 05 is PRODUCED/ DELIVERED by:

Van HALTEREN METAAL. MARCONIWEG 2 3752 LS Bunschoten-Spakenburg. Fax : +31 (0)33 2983674 Internet: http://www.vanhalterenmetaal.nl Van Halteren Metaal B.V.'s quality system is certified acc. ISO 9002/AQAP 120 by Det Norske Veritas (certificate nr. QSC - 3252, rev.1)

PART 05 is TESTED by:

MENNENS Amsterdam. Postbox 8051 1005 AB Amsterdam. Date of test: 02 February 2004 Distinguishing mark nr. 1: NF-827 (Frame + lifting parts) Distinguishing mark nr. 2: NF-828 (Frame + lifting parts) Two frames are tested in total.

PART 05 is CE-certified by:



Figure 1 SITUATION

LENGTH OF PARTS (see figure 1) L1 = 4315/2 = 2158 mm ; L2= 2320/2 = 1160 mm; L3= 2450 mm ; L4= 2158 mm ; L5= 3265 mm WEIGHT OF PARTS MDT/RPC TRANSPORT FRAME 3000 N. MDT 3750 N. RPC 3750 N. LIFTING FRAME (all parts incl.) approx. 2000 N.

( ) .N3125300037503750200041

F 1V =+++=

== 37,41;24502158tan aa == 74,61;1160

2158tan bb

== 26,28;21581160tan gg

N472937,41SIN

3125SIN

FF 1VCHAIN === a

N3549.COS.FF CHAINH == a

N3126COS.FF H1H == g N1680SIN.FF H2H == g



There will occur 3 different loads on the frame: (See figure 1 and 2)

1. Compression forces (FH1 and FH2) in the hollow sections L= 2*L1= 4315 mm and L=2*L2=2360 mm.

2. A bending moment (Mb1) will occur because of the weight of the hollow section. 3. A bending moment (Mb2) (Fh*a) will occur because of the distance from the chain

connection and gravity axis of both hollow sections. NOTE: Because of the moments and compression force we have to check for BUCKLING-effects. Figure 2 LOADS / CALCULATION

Calculation on (Euler) buckling on CENTRIC LOADED BEAMS. As first try we choose for a hollow section tube 60.60.4 ; Material: Fe37-2-DIN59411 Ix=Iy= 47,07 x 104 mm4 ; Area= 8,96 x 102 mm2 ; Mass= 6,76 kg/m Wbending= 15,68 x 103 mm3 ; E= 21x104 mm4 ; Lbuckling=L1*2= 4315 mm ; a= 90mm

Maximum buckling stress allowed:

.92,2210.96,810.07,47

2

4

yx mmii ===BU 4315 188,5 Euler elastic range.

22,92L

il = = =

22

42

2

_

2,585,1881021..

mmNxE

bu ===2 pl

ps



Caused by moment fig. 2-02:


Caused by the compression force FH1

On top of the beam the maximum tension is : -9,9 -20,4 -3,5 = -33,8 N/mm2 (compressive stress) On the bottom side the maximum tension is : +9,9 +20,4 -3,5 = +26,8 N/mm2 (tension stress)

In accordance with other lifting parts (chains, lifting belts, fittings etc., which have safety factors from 4 till 7 it would be desirable to have for the lifting frame a safety factor in this range. This means that the profile mentioned above is not satisfying ! We will now make a similar calculation for a hollow section tube 80.80.5 Material: Fe37-2-DIN59411 ; Ix=Iy= 141 x 104 mm4 ; Area= 15 x 102 mm2 ; Mass= 11,3 kg/m Wbending= 35,3 x 103 mm3 ; E= 21x104 mm4 ; Lbuckling= L1*2= 4315 mm ; a=90mm

Maximum buckling stress allowed:

_

bu

max

58,2Safety factor 1,72

33,8ss

= = =

.66,3010.1510.141

2

4

yx mmii ===BU 4315 141 Euler elastic range.

30,66L

il = = =

22

42

2

_

2,104141

1021..mmN

xEbu ===

2 pl

ps

3 221

1 3

1.6,76.9,81.10 .43159,9

8.15,68.10b

b

b

MN mm

Ws

-

= = =

222 3

3549.9020,4

15,68.10b

b

b

MN mm

Ws = = =

21

1 1 1 1 1. . . . .

2 2 2 4 8bM q l l q l l q l= - =

212

31263,5

8,96.10H

cF

N mmA

s = = =





Caused by the compression force FH1

On top of the beam the maximum tension is : -7,3 -9,1 -2,1 = -18,5 N/mm2 (compressive stress) On the bottom side the maximum tension is : +7,3 +9,1-2,1 = +14,3 N/mm2 (tension stress)

Note: This safety factor is a worst case scenario, because in real this tension is divided along the cross-section of the tube. Another calculation using secans-formula gives a higher safety factor. In spite of this we use a hollow section tube 80.80.5 for the lifting frame.. This is mainly given by beam geometry imperfections (f.i. straightness) , currency aspects, etc. The tubes (part 02-drwg. AMP-AQ-01) are identical as those calculated above. However, they are shorter and subject to lower forces, thus safer concerning (Euler)buckling. A buckling calculation is not relevant in this case.

3 221

1 3

1.11,3.9,81.10 .43157,3

8.35,3.10b

b

b

MN mm

Ws

-

= = =

222 3

3549.909,1

35,3.10b

b

b

MN mm

Ws = = =

21

1 1 1 1 1. . . . .

2 2 2 4 8bM q l l q l l q l= - =

212

31262,1

15.10H

cF

N mmA

s = = =

_

bu

max

104,2Safety factor 5,63

18,5ss

= = =



TENSION STRESS AND MOMENT IN WELDING JOINTS NOTE ! FOR PRACTICAL AND SAFETY REASONS IS CHOSEN FOR :

Welding height = 3 mm. All weldings parallel w.r.t. the ocurring load (Fh) will take up this load. (Figure 2) All weldings perpendicular to the occurring load (Fh) will take up the occuring moment.

(Figure 3) Max. allowable tension stress (proportional limit) = 240 N/mm2)

SEE FIGURE 3 and 4 (VIEW P (drwg.: AMP-AQ-01 PART 01 TO PART 02)

Figure 3 Total welding length (LTOT) = 2(40+40+30)= 220 mm. ; a= 3 mm ; FH= 3549 N.

SEE FIGURE 4 Distance b= 170 mm

.H2

TOT

F 3549 N 2405,4 ; SAFETY FACTOR 44,4L .a 220.3 mm 5,4

props

s

st

t= = = = = =

.H2

TOT

F .90 3549.90 N 2403,91 ; SAFETY FACTOR 61,3170.A 170.2.80.3 mm 3,91

props

s

st

t= = = = = =



Figure 4 Now we make a similar calculation for the short sections. SEE FIGURE 5 and 6 (VIEW P drwg.: AMP-AQ-01 PART 01 TO PART 02)

Figure 5 Total welding length (LTOT) = 2.91= 182 mm. ; a= 3 mm ; FH= 3549 N.

.H2

TOT

F 3549 N 2406,5 ; SAFETY FACTOR 36,9L .a 182.3 mm 6,5

props

s

st

t= = = = = =


22 June 2005 Page 10 of 12

SEE FIGURE 6 Distance b= 90,8 mm

Figure 6

.H2

TOT

F .90 3549.90 N 2407,4 ; SAFETY FACTOR 32,490,8.A 90,8.2.80.3 mm 7 , 4

props

s

st

t= = = = = =


22 June 2005 Page 11 of 12

SURFACE PRESSURE IN LOCKING CLAMP PINS and HOLE PLATE 1 (PART 02 DWG. AMP-AQ-01 SEE FIGURE 5 R1=7 mm ; R2=-9mm ; t=18 mm.

Figure 5 Assuming Hertz-formula (with Poisson-ratio= 0,3) is valid : Note: For other Poisson-ratios see: Tymochenko

1 2

1 1 1 1 10,0317 31,5mm.

7 9R

R R R= - = - = =

ACCORDING NEN 3320-A.3 A MAXIMUM SURFACE PRESSURE OF 2d IS ALLOWED FOR STATIC LOADS. THE OCCURING PRESSURE IS 479,6 N//mm2 SAFETY FACTOR = 2*360/479,6= 1,5

423549.21 100,175. 479,6N

18.31,5SURFACEx

mms = =chainF .E0,175.

.SURFACE t Rs =


22 June 2005 Page 12 of 12

VON MISES STRESS IN LOCKING CLAMP PINS and HOLE PLATE 1 (PART 02 DWG. AMP-AQ-01

Figure 6 Figure 7 (below) Fchain=3549N. a1=22,9mm a2=24,9mm a3=23,5mm t=18mm. Proportional limit = 240N/mm2

Maximum occuring stress (stress resultant0 = 28 N/mm2

Safety factor = Proportional limit / stress resultant = 240 / 28 = 8,57

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