Mechanical Analysis of The R.P.C./M.D.T. Lifting Frame For Transport in Atlas

ATLAS-MDT/RPC-ASSEMBLY LIFTING FRAME (CERN) AMP-A Q-02
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.
22 June 2005
Page 1 of 12
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
22 June 2005
Page 2 of 12
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: Amsterdam@mennens.nl
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:
22 June 2005
Page 3 of 12
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
MDT
RPC
LIFTING FRAME (all parts incl.)
3000 N.
3750 N.
3750 N.
approx. 2000 N.
tan = 2158 2450 ; = 41,37
tan = 21581160 ; = 61,74
tan = 1160 2158 ; = 28, 26
FV1 =
FCHAIN = FV1 SIN = 3125
SIN 41,37
1
(2000 + 3750 + 3750 + 3000 ) = 3125 N .
4
= 4729 N
FH = FCHAIN . COS . = 3549 N
FH1 = FH . COS = 3126 N
FH 2 = FH . SIN = 1680 N
22 June 2005
Page 4 of 12
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
47,07.10 4
ix = i y =
= 22,92mm.
8,96.102
4315
= L BU =
= 188,5 Euler elastic range.
i
22,92
Maximum buckling stress allowed:

_
bu =
2 .E 2 .21x10 4
=
= 58,2 N mm2
2
2
188,5
22 June 2005
Page 5 of 12
Caused by moment fig. 2-02:
M b1 =
b1 =
1
1
1
1
1
q.l . l q.l . l = q.l 2
2
2
2
4
8
M b1 1.6,76.9,81.10 3.43152
=
= 9,9 N mm 2
3
Wb
8.15,68.10
b2 =
M b2
3549.90
=
= 20,4 N mm 2
3
Wb 15,68.10
Caused by the compression force FH1
c =
FH 1
3126
=
= 3,5 N mm2
A 8,96.10 2
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)
_
Safety factor =
bu
max
58,2
= 1,72
33,8
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
141.10 4
ix = iy =
= 30,66mm.
15.10 2
4315
= L BU =
= 141 Euler elastic range.
i
30,66
Maximum buckling stress allowed:

_
bu =
2 .E 2 .21x10 4
=
= 104,2 N mm 2
2
2
141
22 June 2005
Page 6 of 12
M b1 =
b1 =
1
1
1
1
1
q.l . l q.l . l = q.l 2
2
2
2
4
8
M b1 1.11,3.9,81.103.43152
=
= 7,3 N mm2
3
Wb
8.35,3.10
b2 =
M b2 3549.90
=
= 9,1 N mm 2
3
Wb
35,3.10
Caused by the compression force FH1
c =
FH 1 3126
=
= 2,1 N mm 2
2
A 15.10
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)
Safety factor =
bu
max
104,2
= 5,63
18,5
Note: This safety factor is a worst case scenario, because in real this tension is divided along the crosssection 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.
22 June 2005
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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.
s =
FH
LTOT . a
prop . 240
3549
N
= 5,4
;
SAFETY
FACTOR
=
=
= 44,4
220.3
mm 2
s
5,4
SEE FIGURE 4 Distance b= 170 mm
s =
FH .90
3549.90
N
240
=
= 3,91
; SAFETY FACTOR = prop. =
= 61,3
2
170.A TOT 170.2.80.3
mm
s
3,91
22 June 2005
Page 8 of 12
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.
s =
FH
LTOT . a
3549
N
240
= 6,5
; SAFETY FACTOR = prop . =
= 36,9
2
182.3
mm
s
6,5
22 June 2005
Page 9 of 12
SEE FIGURE 6 Distance b= 90,8 mm
Figure 6
s =
FH .90
3549.90
N
240
=
= 7,4
; SAFETY FACTOR = prop . =
= 32,4
2
90,8.A TOT 90,8.2.80.3
mm
s
7,4
22 June 2005
Page 10 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 1 1 1 1
=
= = 0,0317 R = 31,5mm.
R R1 R2 7 9
SURFACE = 0,175.
Fchain .E
t .R
SURFACE = 0,175.
3549.21x104
= 479,6N mm2
18.31,5
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
22 June 2005
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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
22 June 2005
Page 12 of 12

Mechanical Analysis of The R.P.C./M.D.T. Lifting Frame For Transport in Atlas

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

NIKHEF Reference no.: