THE REPLACEMENT OF THE ISOLDE ROBOTS

1. THE REPLACEMENT OF THE ISOLDE ROBOTS Remote manipulations / diagnostics in radioactive areas and handling of radioactive material Workshop, Geneva, Switzerland 6th May 2013 JL.GRENARD (CERN) Engineering Department / Transport Group

2. The ISOLDE facility ISOLDE: Isotope Separator On Line JL GRENARD EN-HE

3. What do the robots do? • Exchange the targets for the ISOLDE facility • The robots are part of the process of the facility Weight ~26Kg JL GRENARD EN-HE

4. The target area High Resolution Separator (HRS) 2 1 General Purpose Separator (GPS) Key target positions and movements JL GRENARD EN-HE

5. Interfaces of the facility Storage shielded shelves Front end JL GRENARD EN-HE

6. A need for a ‘’robot’’ why? • Dose rate when exchanging the targets -> several Sv/h in contact • Repetitive task -> ~30 targets per year • Well defined environment -> target area designed for this dedicated task JL GRENARD EN-HE

7. The existing robots JL GRENARD EN-HE

8. The environment • Several Gray/year • Obstacles on the GPS line Ventilation duct, pipes on the celling Vacuum chamber JL GRENARD EN-HE

9. Reason of the replacement • Many breakdowns during the last years • The robots are 20 years old -> will not be supported by the robot manufacturer in the coming years • The facility will evolve : new storage, new targets types, improvement of target life cycle • No flexibility in the programing of the trajectories of the present robots JL GRENARD EN-HE

10. Different options were evaluated • Dedicated manipulator • Robot mounted on an Automatically Guided Vehicle • Industrial robot mounted on a linear axis And some variant of the previous options… JL GRENARD EN-HE

11. Dedicated manipulator • Custom built manipulator mounted on a track system • Possibility to integrate a force feedback • Could be used for other tasks • (ie: repair of the front end) Not retained Custom built equipment much more complex than needed JL GRENARD EN-HE

12. Robot mounted on an AGV • Completely autonomous vehicle • Battery powered • Onboard controller • Navigation system integrated for the positioning Not retained In case of failure all the electronic is onboard JL GRENARD EN-HE

13. Industrial robot mounted on a linear axis Two options • Copy of the existing system -> trench not covered • Robot mounted on a linear axis installed on the celling -> floor cleared JL GRENARD EN-HE

14. How to decide in between those options? JL GRENARD EN-HE

15. How to decide in between these options? Risk analysis as a guideline • Experience of the current process • List of failures during operation with the existing system • Machinery directive • Standards (human aspect) • Facility aspect (protection of equipment installed in the area) • Upgrade of the facility • New risks caused by the robots • New risks caused by the change of the process JL GRENARD EN-HE

16. Solution adopted 1/2 Two industrial robots mounted on a linear axis JL GRENARD EN-HE

17. Solution adopted 2/2 • Robot positioning based on resolver technology • Foundry arm (already include Viton seals) which makes it partially radiation hard • Safe robot technology which integrate safety volumes -> no need to add extra sensors for protecting the infrastructure JL GRENARD EN-HE

18. The gripper • Include recovery method • Sensor feedback for each movement • Collision detection module (with a release function) JL GRENARD EN-HE

19. Some modifications • Relocation of an electronic board outside of the radioactive area • Replacement of all the cables • Replacement of all cables supports JL GRENARD EN-HE

20. A full scale mock up Testing of the system including recovery methods JL GRENARD EN-HE

21. Interfaces with the infrastructure • Sensor feedback of the position for each movement / interface In the presently installed robots there is no sensor feedback JL GRENARD EN-HE

22. Recovery in case of failure • Integrated in the design • All sensors feedback could be overwritten in an expert mode JL GRENARD EN-HE

23. Installation • Point to be considered during the design phase as high dose rates -> ALARA Level 3 Collective dose expected : ~10mSv • Shielding of the area • Use of special tooling for installation JL GRENARD EN-HE

24. Modification of the infrastructure • Rerouting of ventilation duct, pipes and cables trails • Modification of one portion of the robot rail JL GRENARD EN-HE

25. Programming of the trajectories • Dedicated simulation software which automatically generates the code Limitation: depending on the installation some points would have to be adjusted JL GRENARD EN-HE

26. Some points to note • A robot could be use for a dedicated task with a well prepared and known environment. • The installation process must be integrated in the design phase • The design of the interfaces (mechanical, sensor feedback) is as critical as the design of the robot itself • Testing of the failures in a mock up installation is the only way to demonstrate the recovery procedures • Keeping the ‘’human’’ in the loop is important JL GRENARD EN-HE

27. Summary • A robot for a dedicated and repetitive task : the ISODLE target exchange • Several solution studied before a final choice • Testing all the failure scenarios • The installation and the commissioning of the robot JL GRENARD EN-HE