LBNF LongBaseline Neutrino Facility LBNF Neutrino Beamline Horn
LBNF Long-Baseline Neutrino Facility LBNF Neutrino Beamline Horn and Baffle Modules Preliminary Design Review Module Drive Systems Design Mike Campbell August 3, 2020
Outline 1. Horizontal Positioning Axis a) Drive System & Analysis b) Sliding Contact c) Sensors 2. Vertical Positioning Axis (A, B, C) a) Drive System & Analysis b) Water-Cooled Drawbar c) Thermal Analysis 3. Vertical Positioning Axis (Baffle) a) Drive System b) Baffle Interface 4. Summary 2 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Outline 1. Horizontal Positioning Axis a) Drive System & Analysis b) Sliding Contact c) Sensors 2. Vertical Positioning Axis (A, B, C) • Keith Gollwitzer • Mike Campbell • Cory Crowley a) Drive System & Analysis • Nnamdi Agbo b) Water-Cooled Drawbar • Matt Sawtell c) Thermal Analysis • Joe Angelo 3. Vertical Positioning Axis (Baffle) a) Drive System b) Baffle Interface 4. Summary 3 The Team: 8. 13. 20 • Kris Anderson • Vladimir Sidorov • Meredith Lee M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis Stepper motor / gbox w/ acme screw push / pull Travel: +/- 1/2” req +/- 5/8” act 4 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis Round locator pin / bushing Round pin w/ Y-axis compliance floating 5 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Drive System Pin engagement is vertical Compliance for pin center distance Wedge plates welded to tops of carriage beams Inclined surface at 5. 789⁰ 6 8. 13. 20 Drive assembly is level M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Drive System Goals: no small moving parts that can seize up over time no hardened steel Rc > 30 corrosion resistance 7 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Drive System Goals: no small moving parts that can seize up over time no hardened steel Rc > 30 corrosion resistance Thus: anodized AL and SS construction no ball bearings 8 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sensors AL body, mil spec, washdown proof limit switches LVDT: no ball bearings, rad tolerant 9 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact Sliding contact w/ low coefficient of friction 10 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact Sliding contact w/ low coefficient of friction Gbox & stepper motor still have hardened gears & ball bearings ● no choice ● replaceable 11 8. 03. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact 12 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact 13 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact 14 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact 15 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact 16 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact 17 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis – Sliding Contact 18 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Horizontal Positioning Axis - Analysis 1. 2. 1/2” dia x 4 threads/inch acme threads a) b) c) 316 SS screw w/ tungsten disulfide coating µ=0. 10 for all 7075 alum nut w/ tungsten disulfide coating calculations axial load = 9830 lbs, torque = 786 inlbs, SF = 4. 6 2. Thrust bearing: same materials & coating as above a) b) bearing stress = 1483 psi, torque = 1687 inlb total torque to turn screw = 786 + 1687 = 2473 inlb 3. Wittenstein 100: 1 planetary gearbox a) b) Φ 40 mm output shaft w/ torque rating SF = 1. 4 rigid SS coupling w/ 12 mm keyways, SF = 1. 4 4. Two possible stepper motors (nema 34) a) b) 19 low cost: industrial grade w/ max torque SF = 1. 5 rad-hard: Empire Magnetics w/ max torque SF = 1. 1 (∆$ = $10 k / motor) 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Horns A, B, & C Stepper motor / gbox w/ acme screw 20 8. 13. 20 Travel: +/- 1/4” req +/- 1/2” act M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Horns A, B, & C - Drive System 21 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Horns A, B, & C - Drive System Same stepper motor as horiz drives but smaller gbox LVDT and lim switches Double drawbars Linear motion guides: Graphalloy cam followers (or equiv) Sliding contact thrust bearing 22 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Horns A, B, & C - Drive System Water-cooled drawbar supply / return water lines Linear motion guides: Graphalloy cam followers (or equiv) 23 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Horns A, B, & C - Drive System 13. 1/2 feet long Stepped dia for labyrinth joint Horn attachment from top of module via 1. 5”-6 threaded rod & nut (same as numi) Round & Diamond pins 24 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Analysis 1. 1. 1/2” dia x 4 threads/inch acme threads a) b) c) 316 SS screw w/ tungsten disulfide coating µ=0. 10 for all 7075 alum nut w/ tungsten disulfide coating calculations axial load = 9558 lbs, torque = 602 inlbs, SF = 2. 2 2. Thrust bearing: same materials & coating as above a) b) bearing stress = 1352 psi, torque = 1014 inlb total torque to turn screw = 602 + 1014 = 1616 inlb 3. Wittenstein 70: 1 planetary gearbox a) b) Φ 32 mm output shaft w/ torque rating SF = 1. 4 rigid SS coupling w/ 10 mm keyways, SF = 1. 8 4. Two possible stepper motors (nema 34) a) b) 25 low cost: industrial grade w/ max torque SF = 1. 6 rad-hard: Empire Magnetics w/ max torque SF = 1. 2 (∆$ = $10 k / motor) 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Water-Cooled Drawbar 26 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Water-Cooled Drawbar – Analysis 1. Current Plan: water-cooled drawbars are required for 1. 2 MW 2. Calculations for each drawbar at 2. 4 MW operation: RAW water: 70 psi supply, 20 psi return, 7. 2 gpm / drawbar Q = 0. 5 k. W / drawbar (based on e-dep data) RAW water: Tin = 70 ⁰F = 21. 1 ⁰C, ∆T = 0. 3 ⁰C, Tout = 21. 4 ⁰C Max Temp in S. Steel drawbar = 21. 53 ⁰C = 70. 75 ⁰F (∆T = 0. 43 ⁰C) 3. Thermal expansion =. 001” (negligible) 4. FEA separate presentation 27 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Baffle 28 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Baffle – Drive System Travel (bottom of stroke): +/- 1/4” req +/- 1/2” act Plus: 12” lift out of beam Top plate U-shaped to accommodate 12” more guided motion Whole drive assembly recessed down into endwall to fit under ceiling at upstream end of battlement 29 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Vertical Positioning Axis – Baffle – Lower Interface Drawbar extensions added at the bottom to facilitate 12” more travel Baffle interface: same round & diamond pins 30 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
Summary 1. Reviewed module drive designs for Horns A, B, C, and Baffle 2. Horiz positioning requirement = +/- 1/2” 3. Vert positioning requirement = +/- 1/4” 4. Step motor / gbox / acme screw driven 5. Vert. motion: graphalloy cam follower guides 6. Other moving parts: sliding contact w/ tungsten disulfide coating 7. Sensors: LVDT plus home & limit switches 8. Double drawbars at each end of module, water-cooled 9. Baffle module has 12” extra vertical stroke & recessed mount 10. Analysis complete (thermal FEA separate presentation) 31 8. 13. 20 M. Campbell | LBNF Horn & Baffle Modules Drive System Design LBNF
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