Main Injector Quadrupole Installer Elohi Gonzales, University of Texas of the Permian Basin – SIST Program Linda Valerio, Fermilab August 2016 Analysis/Results The rack and pinion on the Energy Doubler Magnet Mover can support 8,700 lb. The new design needs to support a load of 13,061 lb. The resulting output force of the gear is 724 lb. Considering the maximum weight of the magnet and cradle, the resistance force of each six cam roller is 10 lb. which does not exceed the output force, hence the cam rollers meets the requirements. With the maximum weight, the resistance force of the Teflon pads is 523 lb. which does not exceed the output force of the gear, therefore the Teflon is an appropriate material to use. When combining both the resistance forces of the cam roller and Teflon pad, it does not exceed the output force of the gear. To further consider the strength of the gear, a stress analysis is performed. The gear must be able to handle a moment of 540 lbin. and not exceed the yield strength of 24 ksi with an assumption of being pulled by a 3ft. socket wrench and a 15 lb force. Based on a Von Mises stress analysis, the stresses are strong enough to not exceed 24 ksi. This is confirmed by a rough hand calculation of 18 ksi. Therefore, the gear is sufficient for this design. Abstract The Main Injector (MI) accelerates protons which are used for neutrino and muon experiments as well as other R&D purposes at Fermilab. The MI is a twomile long ring that is approximately 30 feet underground and consists of 344 dipole magnets and 208 quadrupole magnets. Quadrupole magnets are typically 8,000 12,000 lb plus the additional weight of the cradles holding them. People get injured and spend too much time trying to get the positioning correct when removing or replacing a quadrupole The objective is to design and improve the methods for installing/removing quadrupole magnets in the X (in and out), Y (up and down), and Z direction (side to side). With a good understanding of the previous magnet installation equipment, design ideas can be formed to maximize safety and efficiency. Specifications/Requirements • Maximum load 13,061 lb. • Can’t exceed the height of 10.5 in. • Can’t exceed the length of 42.5 in. • Translation in X, Y, Z • Safe easy to operate • Mobile Background There is already a machine that easily installs and removes the MI Dipole magnets, MI Dipole Installer. It uses double acting hydraulics in the X and Y direction. This will not work for a quadrupole magnet because of the allowable height under it. There is another machine that was once used to install and remove the magnets from the old Main Ring, the Energy Doubler Magnet Mover. Two of them are put under the 4 ton magnet. It uses a rack and pinion system in the X and Z direction. Teflon and cam rollers are used to minimize the coefficient of friction. The current method for installing and removing the quadrupole magnets are comealongs. Comealongs are a hand operated winch with a ratchet used to pull objects. It gives an inaccurate positioning of the magnet. It can be unsafe when the cable on the comealong snap off or when it requires someone to push the magnet to position it properly. Identification of the need Define the problem Do Background Research Specify the Requirements Brainstorm, Evaluate, and Choose the Solution Analysis, Develop, and Prototype the Solution Test the Solution Document Results Design Process Design Approach The MI Dipole Installer and the Energy Doubler Magnet Mover both have great characteristics. By using the vertical hydraulic system from the MI Dipole Installer, quadrupoles can be raised and lowered. By applying the rack and pinion system from the Energy Doubler Magnet Mover, quadrupoles can be moved side to side and in and out. The design will have Teflon for easier gliding in the X direction and cam rollers for easier driving in the Z direction. References 1. Fermilab National Laboratory. Main Injector. n.d. 18 June 2016 http://www.fnal.gov/pub/science/particleaccelerators/accelerator complex.html. 2. Oshinowo, Babatunde O'Sheg, John A. Greenwood and Virgil Bocean. "Magnet Alignment For The Fermilab Main injector Project." 2016. http://www.slac.stanford.edu/econf/C971013/papers/044.PDF. Report MI Quadrupole Magnet being removed by a come-along MI Dipole Magnet being removed by the MI Dipole Installer Energy Doubler Magnet Mover Von Mises stress analysis of the react and pinion Main Injector Quadrupole Installer Design Z X Y In Progress
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Main Injector Quadrupole InstallerElohi Gonzales, University of Texas of the Permian Basin – SIST Program
Linda Valerio, Fermilab
August 2016
Analysis/ResultsThe rack and pinion on the Energy DoublerMagnet Mover can support 8,700 lb. The newdesign needs to support a load of 13,061 lb.
The resulting output force of the gear is 724 lb.Considering the maximum weight of the magnetand cradle, the resistance force of each six camroller is 10 lb. which does not exceed the outputforce, hence the cam rollers meets therequirements. With the maximum weight, theresistance force of the Teflon pads is 523 lb.which does not exceed the output force of thegear, therefore the Teflon is an appropriatematerial to use. When combining both theresistance forces of the cam roller and Teflonpad, it does not exceed the output force of thegear.
To further consider the strength of the gear, astress analysis is performed. The gear must beable to handle a moment of 540 lb-in. and notexceed the yield strength of 24 ksi with anassumption of being pulled by a 3ft. socketwrench and a 15 lb force. Based on a VonMises stress analysis, the stresses are strongenough to not exceed 24 ksi. This is confirmedby a rough hand calculation of 18 ksi.Therefore, the gear is sufficient for this design.
AbstractThe Main Injector (MI) accelerates protons which are used for neutrino and muon experiments as well as other R&D purposes at Fermilab. The MI is a two-milelong ring that is approximately 30 feet underground and consists of 344 dipole magnets and 208 quadrupole magnets. Quadrupole magnets are typically 8,000-12,000 lb plus the additional weight of the cradles holding them.People get injured and spend too much time trying to get the positioning correct when removing or replacing a quadrupole The objective is to design and improvethe methods for installing/removing quadrupole magnets in the X (in and out), Y (up and down), and Z direction (side to side). With a good understanding of theprevious magnet installation equipment, design ideas can be formed to maximize safety and efficiency.
Specifications/Requirements• Maximum load 13,061 lb.• Can’t exceed the height of 10.5 in.• Can’t exceed the length of 42.5 in.• Translation in X, Y, Z• Safe easy to operate• Mobile
Background There is already a machine that easily installsand removes the MI Dipole magnets, MI DipoleInstaller. It uses double acting hydraulics in theX and Y direction. This will not work for aquadrupole magnet because of the allowableheight under it.
There is another machine that was once usedto install and remove the magnets from the oldMain Ring, the Energy Doubler Magnet Mover.Two of them are put under the 4 ton magnet. Ituses a rack and pinion system in the X and Zdirection. Teflon and cam rollers are used tominimize the coefficient of friction.
The current method for installing and removingthe quadrupole magnets are come-alongs.Come-alongs are a hand operated winch with aratchet used to pull objects. It gives aninaccurate positioning of the magnet. It can beunsafe when the cable on the come-along snapoff or when it requires someone to push themagnet to position it properly.
Identification of the need
Define the problem
Do Background Research
Specify the Requirements
Brainstorm, Evaluate, and
Choose the Solution
Analysis, Develop, and Prototype the
Solution
Test the Solution
Document Results
Design Process
Design ApproachThe MI Dipole Installer and the Energy DoublerMagnet Mover both have great characteristics.By using the vertical hydraulic system from theMI Dipole Installer, quadrupoles can be raisedand lowered. By applying the rack and pinionsystem from the Energy Doubler MagnetMover, quadrupoles can be moved side to sideand in and out. The design will have Teflon foreasier gliding in the X direction and cam rollersfor easier driving in the Z direction.
References1. Fermilab National Laboratory. Main Injector. n.d. 18 June 2016 http://www.fnal.gov/pub/science/particle-accelerators/accelerator-complex.html.
2. Oshinowo, BabatundeO'Sheg, John A. Greenwood and Virgil Bocean. "Magnet Alignment For The Fermilab Main injector Project." 2016. http://www.slac.stanford.edu/econf/C971013/papers/044.PDF. ReportMI Quadrupole Magnet being removed by a come-along
MI Dipole Magnet being removed by the MI Dipole Installer
Energy Doubler Magnet Mover
Von Mises stress analysis of the react and pinion
Main Injector Quadrupole Installer Design
ZX
Y
In Progress
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