Extruded Control Rod Guide Frame for Nuclear Reactor Alignment
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Solution Overview
Problem
The manufacturing process of control rod guide frames using spaced-apart guide plates is labor-intensive and susceptible to welding-induced distortions, requiring a significant number of welds and increasing the risk of control rod buckling and wear during insertion or shutdown in nuclear reactors.
Innovation Solution
The use of extruded radial guide frame sections made of stainless steel, assembled to form a guide frame with a central passage of constant cross-section, which provides continuous guidance for control rods, minimizing torsion through torque application during extrusion and machining control rod guidance channels for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If spaced-apart guide plates are used to construct the guide frame, then manufacturing complexity and welding requirements are reduced, but control rod alignment precision and structural stability deteriorate
Solution Approach 1:
The guide frame is divided into multiple modular guide frame sections that can be manufactured separately and then assembled. Each section contains guide surfaces for controlling rod alignment, allowing precision machining of individual components while simplifying overall manufacturing through modular construction and reducing welding requirements.
Solution Approach 2:
Multiple guide frame sections are combined to form the complete guide frame structure. The sections are designed with mating features that ensure precise alignment when assembled, merging the advantages of modular manufacturing with the precision of integrated structures.
2Strength
If extensive welding is used to assemble guide frame sections, then structural integrity is improved, but welding-induced distortions and control rod buckling risk increase
Solution Approach 1:
Guide surfaces and alignment features are pre-machined on individual guide frame sections before assembly. This preliminary precision machining ensures that when sections are assembled, the control rods are properly aligned without requiring extensive welding that could cause distortions and buckling.
Solution Approach 2:
Mating features and alignment interfaces act as intermediaries between guide frame sections, ensuring precise positioning and reducing the need for welding. These intermediary elements facilitate accurate assembly while minimizing thermal distortion risks.
3Manufacturing precision
If a continuous extruded structure is used for the guide frame, then control rod guidance precision is improved, but manufacturing flexibility and assembly ease deteriorate
Solution Approach 1:
The continuous extruded guide frame structure is segmented into multiple guide frame sections, each manufactured separately with precise guide surfaces. This segmentation maintains the guidance precision of continuous structures while improving manufacturing flexibility and reducing the complexity of producing a single large extrusion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the risk of control rod buckling, minimizes wear, and decreases manufacturing complexity and costs by eliminating the need for extensive welding, while ensuring precise alignment and efficient coolant flow in nuclear reactors.
Implementation Method 1
at least two radial guide frame sections made of extruded steel
Data Source
AI summary
A control rod guide frame has a central passage of constant cross-section as a function of position along a central axis that passes through the central passage. The central passage is sized and shaped to guide a traveling assembly including at least one control rod as it moves along the central axis. The control rod guide frame comprises at least two radial guide frame sections secured around and defining the central passage. Each radial guide frame section may comprise an extruded radial guide frame section, which may be made of extruded steel. The central passage may include control rod guidance channels parallel the central axis and machined into the extruded radial guide frame sections. The at least two radial guide frame sections may be interchangeable. In some embodiments the at least two radial guide frame sections consist of between four and eight radial guide frame sections.