Master-Slave Manipulators (MSMs) are the most widely used general-purpose remote handling tools in nuclear industry. An MSM consist of two arms: the master arm and the slave arm. The slave arm is usually placed in the hostile area (hotcell) and the master arm in a safe area (operating area). The arms, which are placed on either side of a thick concrete wall, are connected at the top through a through-tube. From the operating area, when the operator moves the handgrip of the master arm, the motion gets reproduced on the tong of the slave arm in the remote area. For the operator to view the hotcell from outside, lead glass shielding window is used.
BARC has developed many models of MSMs with different payloads and ranges. They are used in various hot cells in BARC and other DAE units. Extended Reach Master Slave Manipulator and Sealed Type Three-Piece Master Slave Manipulator are the recent addition to this list.
Extended Reach Master Slave Manipulator (ERM) has six independently controlled joints for arbitrary positioning and orienting an object. Power is transmitted from the master arm to the slave arm through a set of stainless steel wire ropes, tapes and a parallelogram mechanism. To reduce the operator's effort, the manipulator joints are mechanically balanced. The first three axes of the manipulator are provided with electrical indexing motions. Indexing increases slave arm range, improves operator ergonomics, improves viewing and helps in keeping the slave arm horizontal, before inserting it into the hotcell or withdrawing it from the hotcell. Extended reach, which is indexing in the telescopic joint, is provided to increase the slave arm reach, so that the manipulator can be used in larger cells. The 9 kg capacity ERM has a reach of 3.4 m.
Know-how covers detailed engineering drawings and technical documentation for manufacturing Extended Reach Master Slave Manipulator
Parties with sound financial background and relevant engineering experience along with precision manufacturing and assembly capabilities would be preferred.
Master-Slave Manipulators (MSMs) are the most widely used remote handling tools in nuclear industry. Bhabha Atomic Research Centre (BARC) has developed various models of master-slave manipulators with different payloads and ranges. They are used in various hot cells in BARC and other DAE units. Extended Reach Master Slave Manipulator (ERM) is a recent addition to this list. ERM has low friction compared to other manipulators.
Master-slave manipulators (MSMs) are the most widely used general purpose remote handling tools used in nuclear industry. In master-slave manipulation, human being is within the process, and his abilities are extended to the remote place. An MSM has two arms: the slave arm, which is usually located in the hot cell and the master arm in the control station. When the operator grasps and manipulates the master arm, the motion of his hand is reproduced at the slave arm, performing the necessary task. In most of the cases, the master arm and the slave arm are made geometrically similar to each other. MSMs are usually employed in pairs and the operator manipulates the master arms using both his hands. A through tube which passes through a thick concrete wall shielding separating hot cell and the operating area connects the master and slave arms. Lead glass shielding window is used for viewing the hot cell from outside. From the operating area, operator moves the handgrip of the master and the motion is reproduced on the tong of the slave in the remote area.
Extended Reach Master Slave Manipulator has 6 independently controlled joints (6 DOF) for arbitrary positioning and orientating the object. Power is transmitted from the master to the slave through stainless steel wire ropes, stainless steel tapes and a parallelogram mechanism. To reduce the operator's effort, the manipulator joints are mechanically balanced in all configurations. The first 3 axes of the manipulator are provided with electrical indexing motions. It increases the range of slave arm, improves operator ergonomics, provides better viewing, and helps to orient the slave for insertion of the manipulator into the hot cell.
Extended Reach Master Slave Manipulator is sophisticated equipment, consisting of assembly of a large number of parts. A very high degree of reliability has been built into the equipment to avoid costly breakdowns. Selection of raw materials has been done for high strength to weight ratio of parts and corrosion resistance.
Manufacturing Processes Involved
Most of the parts used in the manipulators are of Stainless Steels (SS-304, SS-410) and Aluminium Alloys (Al-6061-T6, Al-7075-T6 and Al-LM-11). The job is assembly intensive. It involves assembly of large number of fabricated parts, ball bearings, gears, metallic wire ropes, metal tapes, clutch wire, fasteners etc. The following are the manufacturing processes involved in making the manipulator :
Machine Tools/ Equipments needed for Manufacture :
Three-Piece Master Slave Manipulator (TPM) is an advanced version of Master Slave Manipulator developed by BARC. The 25 kg capacity manipulator has three electrically controlled joints, in addition to the six manually controlled joints. All the manipulator joints are mechanically balanced to reduce operator's effort. Unlike other MSMs, power is transmitted across the cell wall through a set of parallel shafts. Modular design of TPM enables the operator to remotely assemble and disassemble the slave arm inside the hotcell. Another unique feature of the manipulator is its sealed construction, which provides isolation of the hot cell from the outside atmosphere. The sealing integrity is maintained, even during the remote replacement of the slave arm.
Know-how covers detailed engineering drawings and technical documentation for manufacturing Sealed Type Three-Piece Manipulator.
Parties with sound financial background and relevant engineering experience along with precision manufacturing and assembly capabilities would be preferred.
Sealed Type Three-Piece Manipulator is an advanced version of MSM. It is modular in design such that its slave arm can be remotely assembled and disassembled in the hot cell. Unique feature of the manipulator is its sealed construction, which provides total isolation of the cell atmosphere from the outside atmosphere. The master arm and the slave arm can be removed or installed on the through tube without breaking integrity of the cell and prevents the leakage of contamination from hot cell to outside. The sealing integrity is maintained even after the removal of the master arm or the slave arm. Three electrically powered motions are provided on the major joints of the manipulator to enhance the range of the equipment.
Within the master and slave arms, cables are used for motion transmission. Any motion on the master is converted to rotary motion with the help of cables, pulleys and rope drums. The motions are then transmitted from the master to the slave side with the help of rotary shafts in the Through Tube.
A three-piece master-slave manipulator (TPM) consists of three distinct and easily separable assemblies: the master arm, the through-tube and the slave arm. The unique feature of 3-piece construction is that, its slave arm can be remotely replaced in the hot cell. This modularity reduces installation and maintenance time. Unlike other Master Slave Manipulators (MSMs), TPM uses parallel rotating shafts for power transmission, along the through-tube. This feature is effectively used in indigenous TPM to provide sealing and shielding across the cell wall.
A through tube passes through a thick concrete wall shielding, separating hot cell and the operating area. It connects the master and slave arms. Lead glass shielding window is used for viewing the hot cell from outside. From the operating area, operator moves the handgrip of the master and the motion is reproduced on the tong of the slave in the remote area. Sealed Type Three-Piece Manipulator is an advanced version of MSM.
TPM is modular in design such that its slave arm can be remotely assembled and disassembled in the hot cell. Because of its sealed construction, it provides total isolation of the cell atmosphere from the outside atmosphere. The master arm and the slave arm can be removed or installed on the through tube without breaking integrity of the cell. Three electrically powered motions are provided on the major joints of the manipulator to enhance the range of the equipment. Another unique feature of TPM is extended balancing, which will balance its joints in their extended positions also.
The manipulator can perform seven manual motions namely X, Y, Z, Azimuth Rotation, Twist Rotation, Elevation Rotation, Squeeze and three electrically driven motions. X motion is the left-right swing motion of the arms about the axis of the through tube in a plane parallel to the cell wall. Y motion is the rotation of arm about the shoulder joint of the manipulator. Z motion is the up and down motion of the telescopic boom tubes. Wrist joint of the manipulator gives the Twist rotation and Elevation rotation to the end effector. The wrists on both master and slave sides are identical and detachable. Azimuth motion is achieved by rotating the master boom and transmitting the same rotary motion to the slave boom. Squeeze motion is affected by the pistol grip on the master side which remotely operates Tong on the slave side.
Within the master and slave arms, cables are used for motion transmission. Any motion on the master is converted to rotary motion with the help of cables, pulleys and rope drums. The motions are then transmitted from the master to the slave side with the help of rotary shafts in the Through Tube.
Manufacturing Processes Involved
Most of the parts used in the manipulators are of Stainless Steels (SS-304, SS-410 and 17-4 PH) and Aluminium Alloys (Al-6061-T6, Al-7075-T6, and Al-LM-11). The job is assembly intensive. It involves assembly of large number of fabricated parts, ball bearings, gears, metallic wire ropes, metal tapes, clutch wire, fasteners etc. The following are the manufacturing processes involved in making the manipulator :
Machine Tools/ Equipments needed for Manufacture
