Introduction

Leading a team of six, I undertook a significant research and development project focused on designing an efficient and reliable transportation and handling system for pulsers. The pulser is used in enhancing the performance of laser targets at Lawrence and Livermore’s National Ignition Facility (NIF). Our objective was to create a seamless process for removing and installing these 1375-pound pulsers, transitioning them from a test bed to the vertical enclosure known as the EMI cabinet. To accomplish this, we devised two subsystems: the lift system and the transport system. The lift subsystem involved intricate rigging operations utilizing in-house cranes, a custom spreader bar, slings, hoists, and a specialized flange. This subsystem effectively facilitated the safe removal and rotation of the pulser into a vertical position for subsequent transportation. The transport subsystem, on the other hand, featured a custom base, a pallet jack, and secure straps, enabling the smooth movement of the pulser from the test bed to the EMI cabinet., these cabinets are located at various locations within NIF. By combining our technical expertise, meticulous planning, and precise execution, we successfully developed a robust and dependable system that optimizes the transportation and handling of pulsers, contributing to LLNL’s overall operational efficiency and effectiveness

Project Requirements

• The system must lift and transport the pulser, weighing 1375 lbs, from the test bed to the EMI Cabinet located at the NIF Facility.

• Has to be able to move through tight corners and transport or varying distances and load into a truck.

• Be able to maneuver the pulser from a horizontal position at the test bed to a vertical position at the cabinet.

• Equipment must be able to install the pulser in the EMI Cabinet which is 8 ft x 7.7 ft x 7.7 ft (height x length x width) space.

• All operations such as setup, transportation, and installation into the cabinet must be completed within an 8 hour work day.

• The budget for fabrication is $10k.

• The Image above shows the starting position and the final position of the pulser.

Solution

Lifting system

• The Lifting system consisted of a crane, spreader bar, chain hoist, and a custom flange made in SolidWorks.

• These were used to pick up the pulser from the test bed and rotate it vertically and place it on the custom base which was used to transport the pulser.

• We had to calculate the weight distribution through force equilibrium in the X and Y directions which helped solve for a moment about the pulser arm allowing for a controlled rotation.

Transportation System

• The Transportation System consisted of a custom based, designed in SolidWorks allowing it to be used universally by any pallet jack or forklift.

• I ran the Finite Element Analysis on the custom base ensuring it would be able to hold the weight of the pulser.

• We created a concept of operations that showed how the pulser would get to its final destination.

• Created a DFMEA to ensure safety of the components and workers