dynamic characterization of the transportation tooling for ...shock absorber performances model...
TRANSCRIPT
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Dynamic Characterization of the
Transportation Tooling for
Cryomodule SSR1
Paolo Neri, Francesco Bucchi
University of Pisa
Department of Civil and Industrial Engineering
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Aim
Design of the shock absorbing system for the transportation of cryomodule SSR1:
- Length: 5.5 m
- Diameter: 1.4 m
- Weight: 8-10 t
- Number of cavities: 8
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Design plan
Design approach:
- Dynamic characterization of the main sub-assembly
- Assessment of shock absorber capabilities
- Transportation tooling design
- Transportation tooling performance verification
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Cryomodule dynamic characterization
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FEM modeling
Thin surfaces: shell elements to reduce model size
Material properties and shell thickness derived from CAD
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Cryomodule structure
Main parts:
1. Vessel
2. Thermal shield
3. Strong back
4. Cavities
5. Support posts
6. Solenoid
1
2
3
4
6
3
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Model structure
Each main part represents a sub-assembly, which is modelled separately.
Sub-assembly are then imported (and copied) to produce the full model
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Vessel
3900 kg43489 nodes35521 elements
All connections guaranteed exploiting node merging and fixed joint connections (no contact elements)
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Thermal shield
220 kg29386 nodes30977 elements
All connections guaranteed exploiting node merging and fixed joint connections (no contact elements)
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Strong back
300 kg31759 nodes39377 elements
All connections guaranteed exploiting node merging and fixed joint connections (no contact elements)
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Cavities
Two different geometries, each repeated 4 times:170 kg118882 nodes126509 elements
All connections guaranteed exploiting node merging and fixed joint connections (no contact elements)
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320 kg14565 nodes14534 elements
All connections guaranteed exploiting node merging and fixed joint connections (no contact elements)
Support posts
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One geometry, repeated 4 times:40 kg14519 nodes14257 elements
All connections guaranteed exploiting node merging and fixed joint connections (no contact elements)
Solenoid support
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Assembly
6200 kg1127769 nodes1190605 elements
All connections guaranteed exploiting node merging and fixed joint connections (no contact elements)
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Results
Natural frequencies and detailed mode shapes
e.g. antennaout-of-phase mode, 130 Hz
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What is missing?
In order to reduce the number of elements, the bellows connecting the cavities and the two-phase pipe were removed.They were replaced with lamped stiffness (6x6 matrix)
Fixed
Unit displacement
𝐹𝑥𝐹𝑦𝐹𝑧𝑀𝑥
𝑀𝑦
𝑀𝑧
=⋯
⋮ 𝐾 ⋮⋯
𝑈𝑥𝑈𝑦𝑈𝑧ϑ𝑥ϑ𝑦ϑ𝑧
K can be estimated by applying unit displacement/rotation along each direction and computing the corresponding reaction force/moment.
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Assessment of shock absorber capabilities
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Shock absorber performances
Mechanical filter, cut frequency depending on modal analisys
Springs element for filtering
Mixed approach fem-Adams→ evaluation of springs , model simplification (field vs bellows)
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Shock absorber performances
CM vessel imported from FEM using Modal Neutral File (.mnf)
Cavities imported from CAD as rigid bodies
Two-phase pipe modeled in MB environment using beam theory
Bellows modeled as lumped stiffness matrices whose characteristics were derived from FEM
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Shock absorber performances
Cryomodule
Inner frame
4 Spherical joints in total
Cryomodule
Cavities
4 Spherical joints per cavity
Model details - Constraints
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Shock absorber performancesModel details – Bellows modeling
Cavity ith Cavity jth
Field Element
Solenoid Field Element
𝐹𝑥𝐹𝑦𝐹𝑧𝑀𝑥
𝑀𝑦
𝑀𝑧
=
𝑘11𝑘21𝑘31𝑘41𝑘51𝑘61
𝑘12𝑘22𝑘32𝑘42𝑘52𝑘62
𝑘13𝑘23𝑘33𝑘43𝑘53𝑘63
𝑘14𝑘24𝑘34𝑘44𝑘54𝑘64
𝑘15𝑘25𝑘35𝑘45𝑘55𝑘65
𝑘16𝑘26𝑘36𝑘46𝑘56𝑘66
𝑢𝑥𝑢𝑦𝑢𝑧𝜗𝑥𝜗𝑦𝜗𝑧
Cavity
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Shock absorber performancesModel details – Two-phase pipe
𝐹𝑥𝐹𝑦𝐹𝑧𝑀𝑥
𝑀𝑦
𝑀𝑧
=
𝑘11𝑘21𝑘31𝑘41𝑘51𝑘61
𝑘12𝑘22𝑘32𝑘42𝑘52𝑘62
𝑘13𝑘23𝑘33𝑘43𝑘53𝑘63
𝑘14𝑘24𝑘34𝑘44𝑘54𝑘64
𝑘15𝑘25𝑘35𝑘45𝑘55𝑘65
𝑘16𝑘26𝑘36𝑘46𝑘56𝑘66
𝑢𝑥𝑢𝑦𝑢𝑧𝜗𝑥𝜗𝑦𝜗𝑧
Timoshenko beam elements
Field Elements
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Shock absorber performancesModel details – Modal Neutral File (mnf)
• FE model has ~800000 dofs
• 50 natural modes were extracted from Ansys (r = 50)
• 46 interface nodes were selected (𝑖 = 276)
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Mode Number MB Frequency (Hz) MB no Pipe/Bellows (Hz) Difference (%)
7 9,6 9,5 2%
8 15,2 15,3 1%
9 17,9 17,1 4%
10 21,6 18,8 15%
11 23,1 20,8 11%
12 23,3 22,4 4%
13 26,4 22,8 16%
14 27,1 24,1 13%
15 27,3 24,4 12%
16 27,8 24,8 12%
17 27,9 24,8 12%
18 28,2 25,4 11%
19 28,4 25,7 10%
20 28,4 26,1 9%
21 28,9 26,3 10%
22 30,1 26,5 14%
23 30,9 26,6 16%
24 31,1 26,8 16%
25 31,6 27,4 15%
26 32,9 30,1 9%
27 34,0 30,9 10%
28 34,5 32,3 7%
29 38,0 33,8 13%
30 38,5 34,3 12%
31 40,8 37,9 8%
32 42,2 40,6 4%
33 43,1 42,3 2%
34 43,7 43,0 2%
35 45,2 43,7 3%
36 45,6 43,9 4%
37 46,1 44,3 4%
38 46,8 44,7 5%
39 46,9 45,5 3%
40 47,2 46,3 2%
41 47,7 46,8 2%
42 48,3 49,5 2%
43 49,5 49,5 0%
44 49,5 50,7 2%
45 50,7 52,5 3%
46 52,5 54,9 4%
47 54,9 55,4 1%
48 55,3 57,4 4%
49 56,7 59,2 4%
50 59,5 59,2 0%
Shock absorber performances
Adding pipes and bellows, natural
frequencies are generallydifferent from the onesfound in the previousanalysis. However no low-frequency new
natural modes arise.
STEP 1 - Verification of .mnf import + rigid cavities
Maximum difference5%, ascrivable to the different (FEM-MB)
connection technique between Cavities and their bases, belongingto the rigid cylinder.
The difference isconsiderd negligible
for our purposes.
Mode Number MB Frequency (Hz) FEM Frequency (Hz) Difference (%)
7 9.5 9.5 0%
8 15.3 15.4 1%
9 17.1 17.2 1%
10 18.8 19.1 1%
11 20.8 21.2 2%
12 22.4 22.7 1%
13 22.8 23.1 1%
14 24.1 24.8 3%
15 24.4 25.1 3%
16 24.8 25.4 3%
17 24.8 25.6 3%
18 25.4 25.7 1%
19 25.7 26.9 5%
20 26.1 27.2 4%
21 26.3 27.3 4%
22 26.5 27.4 3%
23 26.6 27.5 3%
24 26.8 27.7 3%
25 27.4 27.7 1%
26 30.1 30.4 1%
27 30.9 31.2 1%
28 32.3 32.4 0%
29 33.8 33.8 0%
30 34.3 34.5 0%
31 37.9 37.8 0%
32 40.6 40.9 1%
33 42.3 42.5 1%
34 43.0 43.1 0%
35 43.7 43.8 0%
36 43.9 44.1 0%
37 44.3 44.5 0%
38 44.7 44.9 0%
39 45.5 45.5 0%
40 46.3 46.3 0%
41 46.8 46.8 0%
42 49.5 49.7 0%
43 49.5 50.0 1%
44 50.7 51.2 1%
45 52.5 52.3 0%
46 54.9 55.3 1%
47 55.4 55.5 0%
48 57.4 57.3 0%
49 59.2 59.1 0%
50 59.2 59.4 0%
STEP 2 – Implementation of piping and bellows
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Shock absorber performances
1st natural mode – 9.6 Hz 2nd natural mode – 15.2 Hz
Mode displacements are magnified
Some examples of natural modes
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Shock absorber performances
4 vertical springs under the flexible cylinder Rigid body model with same mass/intertia
VerticalFictitious
Springs
𝛿𝑠𝑡~ 25 mm𝑓𝐻𝑒𝑎𝑣𝑒 ~ 3.1Hz
𝑓𝐻𝑒𝑎𝑣𝑒 =1
2𝜋
𝑘𝑡𝑜𝑡𝑚
𝑚~ 9500 kg
Assessment of CM mass + TT
𝑘𝑡𝑜𝑡 ~ 3600 N/mm
First Assessment!
4 springsFirst attempt
𝑘𝑣 ~ 900 N/mm
𝑓𝐻𝑒𝑎𝑣𝑒 =1
2𝜋
𝑔
𝛿𝑠𝑡
First assessment of natural frequency
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Transportation tooling design
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Transportation frame design
Square tubular beam: 4x4x0.375 inch
Helical isolator
Positions of springs can be adjusted to hold different cryomodules
Inner frame
Outer frame
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Commercial components
M32-850-08
Up to 110 mm travel
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Commercial components
One spring along each direction
VS
45° angled springs
!!Travel reduction in case of combined vertical/lateral loading!!
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Frame dimensions
276 inch
87
inch
(<
90
inch
)
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Transportation frame static analysis
Fixed constraint
Cryomodule weight: 8 t
Bushing spring to represent helical isolator
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Transportation frame static analysis
Equivalent Von Mises Stress, MPa
Structural SteelYield stress 250 MPa
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Transportation frame static analysis
Vertical displacement (magnified plot)
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Transportation tooling performance verification
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Shock absorber performances
Actual springs configuration
Longitudinal spring
Verticalspring
LateralspringFL Corner
Longitudinal bushing
Verticalbushing
Lateralbushing
𝐹𝑥𝐹𝑦𝐹𝑧
=𝑘𝑥 0 00 𝑘𝑦 00 0 𝑘𝑧
𝑢𝑥𝑢𝑦𝑢𝑧
Charge 2.2
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Shock absorber performancesFrequency response
Heave unitary input Roll unitary input
Pitch unitary input
Natural frequencies
𝑓 (Hz)1,903,013,274,064,465,31
Computed considering total CM + inner TT mass of 9500 kg
Charge 2.2
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Shock absorber performances
1st NM 2nd NM
Frequency Response – Central Cavity CM – Heave excitation
Absolute magnitude is not realistic. The ratio between static and
considered frequency magnitude has to be considered.𝑦-disp 𝑥-disp
Solid line: with springsDashed line: without springs
Charge 2.2
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Shock absorber performancesFrequency Response – Central Cavity CM – Roll excitation
1st NM 2nd NM
𝑥-disp
Absolute magnitude is not realistic. The ratio between static and
considered frequency magnitude has to be considered.
Solid line: with springsDashed line: without springs
Charge 2.2
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Shock absorber performancesFrequency Response – Central Cavity CM – Pitch excitation
1st NM 2nd NM
𝑧-disp
Absolute magnitude is not realistic. The ratio between static and
considered frequency magnitude has to be considered.
Solid line: with springsDashed line: without springs
Charge 2.2
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Shock absorber performancesSome doubts
• Pitch, Roll and Heave NM haveresonances in the range 2-5 Hz.
• The amplitude of the resonancepeak is determined consideringsprings datasheet
May the TT resonances match the truck loading bed resonances, causing large springs travel?
Stiffer springs would move the TT resonances at higher frequency,
avoiding matching with truck resonances, but should reduce the
filtering effect Charge 2.2
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Shock absorber performancesAlternative springs set
Stiff spring set
Soft spring set
49 110
Charge 2.2
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Shock absorber performancesFrequency Response – Central Cavity CM – Heave excitation
Which is better?Reference actual road loading bed displacement profile is needed!
1st NM 2nd NM
Soft Springs
Stiff Springs
Charge 2.2
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Shock absorber performancesActual loading bed displacement implementation
Outer TT
Inner TT
x, y and z time histories are imposed to three points of the lower TT (corresponding to the vertical spring position for 3 corners).
Highly stiff complaint constraints were used to avoid over-constraing.
Recorded TT displacement during LCLS-II CM transportation
Charge 2.2/2.3
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Shock absorber performancesActual loading bed displacement implementation
Charge 2.2/2.3
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Shock absorber performancesDisplacement of vertical springs – Gravity + Actual vertical profile
Vertical displacement of a vertical spring
Lat Dis Long Dis
Charge 2.2/2.3
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Shock absorber performancesReference bellow forces - Gravity + Actual vertical profile
Charge 2.2/2.3
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Shock absorber performancesDisplacement of soft vertical spingsGravity + Actual vertical profile + Severe turning + Emergency braking
Charge 2.2/2.3
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Shock absorber performancesDisplacement of soft spings (all springs in every direction)Gravity + Actual vertical profile + Extreme bending and braking
Max Available Travel~ 110 mm
Charge 2.2/2.3
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Critical components structural assessment
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Plot Vs time/frequency
Bellows Forces/Moments
Kext1
K1K2K3 K1K2 K3K3 K1K2Kext1
K1K2Kv
KpKv Kv Kv
6 different bellows types are identified:
• Kext1, between end cavities and external vessel;• K1, between cavity and solenoid (solenoid rightside in Fig.);• K1, between cavity and solenoid (solenoid leftside in Fig.);• Kv, between solenoid and two phase pipe;• Kp, between different parts of the two phase pipe.
Charge 2.3
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Bellows forces and moments
Forces Moments
Soft
Rigid
2 bellows
Forces/moments related to the most critical bellow of each type are plotted Charge 2.2
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Bellows forces and moments
Forces Moments
Soft
Rigid
4 bellows
Forces/moments related to the most critical bellow of each type are plotted Charge 2.2
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Bellows forces and moments
Forces Moments
Soft
Rigid
4 bellows
Forces/moments related to the most critical bellow of each type are plotted Charge 2.2
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Bellows forces and moments
Forces Moments
Soft
Rigid
3 bellows
Forces/moments related to the most critical bellow of each type are plotted Charge 2.2
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Bellows forces and moments
Forces Moments
Soft
Rigid
14 bellows
Forces/moments related to the most critical bellow of each type are plotted Charge 2.2
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Bellows forces and moments
Forces Moments
Soft
Rigid
4 bellows
Forces/moments related to the most critical bellow of each type are plotted Charge 2.2
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Bellows forces and moments
Exemplification plots refer to the bellow subject to higher forces/moments (bellow 11, type Kp)
Soft
Rigid
Frequency contribution for 𝑓 > 10 Hz are cut by mechanical filter due to
TT springs
The ratio between forces amplitude (soft vs. rigud) is about 5.
Time Domain Frequency Domain
Charge 2.2
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Thermal shield – bellows clearence
Time Domain Frequency Domain
1st natural mode contribution, involving
thermal shield, is filtered
Displacement amplitude is reduced by about 5
Maximum displacement for soft config. ~0.3 mm
y
x
c~70 mm
c
Charge 2.2
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Bellows assessment
BextB1B2B3 B1B2 B3B3 B1B2Bext B1B2
BvBv Bv Bv
2 × Bext4 × B14 × B23 × B34 × Bv14 × Bp: 2-phase pipe
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Bellows assessment
Modal analysis of each bellow: natural frequencies higher then excitation frequencies
B1, 𝑓1 = 835 Hz B2, 𝑓1 = 835 Hz B3, 𝑓1 = 40 Hz
Bp, 𝑓1 = 283 Hz Bv, 𝑓1 = 330 Hz Bext, 𝑓1 = 66 Hz
Charge 2.2
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From Ansys model, constant in time
Linear analysis: sum of single analysis, already performed to assess lamped stiffnesses
Bellows assessment
Fixed
Unit displacement𝐹𝑥𝐹𝑦𝐹𝑧𝑀𝑥
𝑀𝑦
𝑀𝑧
=⋯
⋮ 𝐾 ⋮⋯
𝑈𝑥𝑈𝑦𝑈𝑧ϑ𝑥ϑ𝑦ϑ𝑧
σ𝑥𝑥σ𝑦𝑦σ𝑧𝑧τ𝑥𝑦τ𝑦𝑧τ𝑥𝑧
=⋯
⋮ ෩𝐾 ⋮⋯
𝑈𝑥𝑈𝑦𝑈𝑧ϑ𝑥ϑ𝑦ϑ𝑧
෩𝐾 = 6 × 6𝑛 (n is the number of nodes)
σ𝑒𝑞(𝑡)
From Adams model, time dependent
Determining the worst combination is not trivial, analysis along time history
Charge 2.2
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Bellows assessment
Example: edge bellow, Bext
Charge 2.2
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Bellows assessment
Bext, σeq,max = 22 MPa B1, σeq,max = 60 MPa B2, σeq,max = 62 MPa B3, σeq,max = 2 MPa
Bv, σeq,max = 84 MPa Bp, σeq,max = 35 MPa
Charge 2.2
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Bellows assessment
Comparison between helical isolator and rigid connection
Bellow With Isolators:𝝈𝐞𝐪,𝒎𝒂𝒙 MPa
Without Isolators:𝝈𝐞𝐪,𝒎𝒂𝒙 MPa
Ratio
Bext 22 118 5.4
B1 60 296 4.9
B2 62 282 4.5
B3 2 10 5.0
Bv 29 150 4.9
Bp 35 137 3.9
Charge 2.2
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Antenna assessment
Antenna stem(two concentric flexible beams)
Antenna tip(lumped mass)
Charge 2.2
Displacement magnitude (<0.01 mm for soft configuration) of the antenna tip is measured on the plane normal to the antenna stem. Without inner beam, the displacement is reduced due to the less
weight.
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Antenna assessmentAntenna tip
(lumped mass)
In & Out
Rigid
High frequency natural modes are filtered by TT
Charge 2.2
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Sensors positioning
BextB1B2B3 B1B2 B3B3 B1B2Bext B1B2
BvBv Bv Bv
2 × Bext4 × B14 × B23 × B34 × Bv14 × Bp: 2-phase pipe
Sensor positioning: tri-axial piezoelectric accelerometers
3 on the inner frame3 on the outer framen End-coupler flangesn Bextn Bv
Charge 4
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Frame details
Possibility to shift main parts for adjustments or for other cryomodules
Outer frame Inner frame
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Frame details
HelicalIsolator
Mounting plates
Different helical isolator can be mounted on the frame through different mounting plates
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Frame details
Without the end-couplersWith the end-couplers: vertical and lateral isolators must be switched
!
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Conclusions
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Conclusions
Finite element model for dynamic characterization
Combined FEM – MB for shock absorber system design
Transportation tooling mechanical design
Performance verification through recorded data
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Conclusions
What to check before transportation:
Assembled Cryomodule weight
Inner and outer frame weight
Displacement along vertical direction (due to gravity)
Transportation trial from vendor to Fermilab with simulated loading (concrete beams)
FRF measurement between outer frame and inner frame (filtering assessment)
Charge 4
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THANK YOU
Paolo Neri, Francesco Bucchi
University of Pisa
Department of Civil and Industrial Engineering
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THANK YOU
Paolo Neri, Francesco Bucchi
University of Pisa
Department of Civil and Industrial Engineering