TTCB Progress Structural Analysis

Tracker Thermal Control System

TTCB ProgressTTCB ProgressStructural Analysis Structural Analysis

April. 22, 2006, 　 Cern, Geneva

SYSU mechanical group:

Structural Analysis: XH Diao, XM Qi, GY ChenMechanical Design: SS Zheng, XM Qi work with Corrado ,

Presented by XM QI

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FEM ModelFEM Model

Start up radiator plate

Side plate

Base plate Accumulator

Heat Exchange

Pump

Valves

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TTCB FEM ModelsTTCB FEM Models

components element Connection Element connecting to related massAccunulator shell rigid bars Accu Brackets nonstructural massAccu Brackets shell coupled degree of freedom Main plate

rigid bars Accumualtor

Heat Exchanger beam with lumped mass nonstructural massHX Brackets Down solid elements coupled degree of freedom Main plateHX Brackets up shell elements coupled degree of freedom HX Brackets DownPump beam with lumped mass nonstructural massPump Brackets shell coupled degree of freedom start up radiatormain Plate shell elements coupled degree of freedom start up radiator

constrains USSSide plate shell elements coupled degree of freedom start up radiator

constrains USSstart up Radiator shell elements coupled degree of freedom Main and Side plateValves lumped masses on start up radiatorsendors lumped masses on main paltePelteir sadle solid connector elements Accumulator

Others nonstructural mass distributed uniformaly on top of the main palte

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Mass modeling In FEM Models Mass modeling In FEM Models (Based on document (Based on document TTCSMassBudget03112005.xlsTTCSMassBudget03112005.xls by Johanes) by Johanes)

Heat Exchanegr 0. 14 1. 6 1.6-0.14 lumped mass on HX beamPump 0. 029 1. 69 1.69+0.1-0.029 lumped mass on pump beamvalves 0.1*4 4 lumped masses on main platemain Plate 2. 99start up radiator 0. 94side plate 0. 78Pump Brackets 0.01*2*2Accu Brackets 0.255+0.211HX Brackets 0.0464*2pelier sadle 0.016*2

total mass in above model : 15.337ttcb budget: 36.786rest mass: 36.786-15.337=21.449 are distributed uniformly on the top of main plate as nonstructural mass

result is conservative: 36.786 is the mass including condensor(6.12kg)

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FEM Model Elements SummeryFEM Model Elements Summery

Shell(quadrilateral): 50851 Shell(quadrilateral): 50851

Solid(linear brick): 5984Solid(linear brick): 5984

Rigid bar: 120Rigid bar: 120

Connector: 6Connector: 6

Lumped mass: 15Lumped mass: 15

Constrained elements: 630 Constrained elements: 630

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For FEM Structural Analysis DetailFor FEM Structural Analysis Detail

See following reference documents:See following reference documents:

TTCB_Structure Analysis_SYSU_I-deasV11_result_Jan2006.docTTCB_Structure Analysis_SYSU_I-deasV11_result_Jan2006.doc

progress on January, 2006progress on January, 2006

TTCB_Structure modification proposal_SYSU_I-deasV11_result_Mar2006.docTTCB_Structure modification proposal_SYSU_I-deasV11_result_Mar2006.doc

Section 5.8 Main plate layout optimization, progress on March, 2006 Section 5.8 Main plate layout optimization, progress on March, 2006

TTCB_Structure Analysis_SYSU_I-deasV11_result_April2006.docTTCB_Structure Analysis_SYSU_I-deasV11_result_April2006.doc

Section 7, Main plate thickness optimization, progress on April, 2006 Section 7, Main plate thickness optimization, progress on April, 2006

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General Analysis ResultGeneral Analysis Result

See document See document

TTCB_Structure Analysis_SYSU_I-deasV11_result_Jan2006.doc TTCB_Structure Analysis_SYSU_I-deasV11_result_Jan2006.doc

Table 5.1: main/startup/side plate and Acc Brackets/HX Bracket/Pump Bracket Table 5.1: main/startup/side plate and Acc Brackets/HX Bracket/Pump Bracket

sturctural stress and margin of safetysturctural stress and margin of safety

Table 5.2: USS/TTCB connection bolts calculation;Table 5.2: USS/TTCB connection bolts calculation;

Side plate/USS connection bolts calculation;Side plate/USS connection bolts calculation;

StartUp Radiator/Side&Main Plate connection bolts calculation;StartUp Radiator/Side&Main Plate connection bolts calculation;

Acc Bracket/main Plate connection bolts calculation;Acc Bracket/main Plate connection bolts calculation;

HX Bracket/main Plate connection bolts calculation;HX Bracket/main Plate connection bolts calculation;

Pump Bracket/main plate connection bolts calculation.Pump Bracket/main plate connection bolts calculation.

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Different Ribs layouts Different Ribs layouts

38 different layout are tried38 different layout are tried

( see ( see 060316ttcb-sysu-fem-model-facies.rar 060316ttcb-sysu-fem-model-facies.rar

ttcb-sysu-reaction-thirty-eight-modification-060319.rarttcb-sysu-reaction-thirty-eight-modification-060319.rar for detail) for detail)

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Main plates reaction force with above designMain plates reaction force with above design

Load

Case

(N) (N) (N) (N) ( l bf ) ( l bf ) ( i n. l bf . )

1 316. 6 513 602.83 845. 1 188.52 134.48

2 248. 9 - 51. 9 254.25 561. 9 125.35 56.72

3 - 206. 2 366. 8 420.79 931. 4 207.78 93.87

4 - 316. 6 - 513 602.83 0 0 134.48

5 - 951. 1 465 1058.69 560. 3 124.99 236.17

Shear Bending force

MofS

Main Plate Bolt Reaction Force and MofSafety Calculation

y Z Shear Tension Tension

Maximum reaction force 1064.6N 931.4N

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Optimization on Thickness of main pate Optimization on Thickness of main pate

Model change: Accu Slide end as moving along axis Model change: Accu Slide end as moving along axis

Three thickness 3mm,4mm,5mm were calculatedThree thickness 3mm,4mm,5mm were calculated

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Result 1 on Different Thickness of main pateResult 1 on Different Thickness of main pate

Top plate

Thickness

Case x y z (mm) Von Mises Max Principal (mm) Yield Ultimate

1 22 5. 5 5. 5 5 72. 4 62. 6 0. 365 3. 266 2. 63422 5. 5 5. 5 4 80. 5 98 0. 415 2. 837 1. 32122 5. 5 5. 5 3 147 110 0. 491 1. 101 1. 068

2 5. 5 22 5. 5 5 70. 2 62. 1 0. 115 3. 4 2. 6635. 5 22 5. 5 4 72. 1 63. 4 0. 124 3. 284 2. 5885. 5 22 5. 5 3 74. 7 65 0. 14 3. 135 2. 5

3 5. 5 5. 5 22 5 60. 8 65. 5 0. 226 4. 08 2. 4735. 5 5. 5 22 4 61. 9 66. 5 0. 25 3. 99 2. 4215. 5 5. 5 22 3 91 68. 2 0. 291 2. 394 2. 336

4 - 22 - 5. 5 - 5. 5 5 72. 4 66. 6 0. 365 3. 266 2. 416- 22 - 5. 5 - 5. 5 4 80. 5 81. 8 0. 415 2. 837 1. 781- 22 - 5. 5 - 5. 5 3 132 152 0. 491 1. 34 0. 497

5 - 5. 5 - 22 - 5. 5 5 70. 2 74. 5 0. 115 3. 4 2. 054- 5. 5 - 22 - 5. 5 4 72. 1 76. 5 0. 124 3. 284 1. 974- 5. 5 - 22 - 5. 5 3 74. 7 79. 1 0. 14 3. 135 1. 876

6 - 5. 5 - 5. 5 - 22 5 60. 8 52. 8 0. 226 4. 08 3. 309- 5. 5 - 5. 5 - 22 4 61. 9 55. 2 0. 25 3. 99 3. 121- 5. 5 - 5. 5 - 22 3 91 104 0. 262 2. 394 1. 1875

Loads Cases: Base Plate

Load Acceleration (g) Limit Stress [N/mm2] Displacement Margin of Safety

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Result 2 on Different Thickness of main pateResult 2 on Different Thickness of main pate Load Top Plate y Z Shear Tension Tension Shear Bending force

CaseThickness

(mm) (N) (N) (N) (N) ( l bf ) ( l bf ) ( i n. l bf . )

1 5 0. 5 40. 6 40.6 833. 4 185.91 9.06

4 1. 2 34. 3 34.32 863. 9 192.72 7.66

3 7. 2 20. 2 21.44 909. 9 202.98 4.78

2 5 312 - 50. 6 316.08 597. 9 133.38 70.51

4 313. 3 - 57. 7 318.57 590. 8 131.8 71.07

3 315. 1 - 67. 6 322.27 588. 1 131.19 71.89

3 5 - 294. 9 485. 3 567.88 1044. 6 233.03 126.68

4 - 293 478. 7 561.25 1051. 9 234.67 125.2

3 - 283. 4 464. 5 544.13 1062. 8 237.09 121.38

4 5 19. 8 107. 3 109.11 24.34

4 20. 6 110 111.91 24.97

3 23. 6 113. 5 115.93 25.86

5 5 - 346. 3 19. 9 346.87 383. 4 85.53 77.38

4 - 333. 6 14. 9 333.93 405 90.35 74.49

3 - 320. 9 9. 5 321.04 426. 8 95.21 71.62

6 5 58. 1 - 373. 3 377.79 656. 6 146.47 84.28

4 56 - 367. 3 371.54 558. 3 124.55 82.88

3 52. 8 - 357. 3 361.18 549. 9 122.67 80.57

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Result 3 on Different Thickness of main pateResult 3 on Different Thickness of main pate

Thickness 1 2 3 4 5 6 7 8 9 10

249 272 2815mm 150 162 182 291 330 361

4mm 147 155 171 200 231

209

258 268 272 285

184 197 211 2403mm 136 149 155 258 265 273

349

First Ten Natural Frequencies

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Following TBC for Further ProgressingFollowing TBC for Further Progressing

1.1. This version can be a final document with This version can be a final document with neccesary modification on bolts calculation? neccesary modification on bolts calculation? Or should be in more detailling; Or should be in more detailling;

2.2. Mass Budget Table Updated;Mass Budget Table Updated;3.3. Pump Controller Mass listed separately with Pump Controller Mass listed separately with

pump;pump;4.4. TTCB Design close(until no big modification TTCB Design close(until no big modification

expected);expected);5.5. Components Material Frozen; Components Material Frozen; 6.6. Bolts Connection Tables frozen;Bolts Connection Tables frozen;7.7. Modified Template for Bolts calculation. Modified Template for Bolts calculation.

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Documents

TTCB Progress Structural Analysis