Engineering : design calculations and project management

The process of designing an ILL instrument can be broken down into several key stages:

Objective Definition

• Understand the specific goals and operational needs of the instrument.
• Collaborative work between scientists and engineers to identify the mechanical requirements necessary to achieve the scientific objectives.

Conceptual Design

• Develop initial design concepts using CAD (computer-aided design) software to create 2D and 3D models of the mechanical systems.
• Propose innovative solutions to overcome challenges such as limited space, precision requirements, and environmental constraints (e.g., temperature, pressure, radiation).

Detailed Design

• Perform engineering calculations (stress, thermal, vibration analysis) to ensure the system meets functional and safety standards.
• Create detailed specifications for sourcing materials and components, ensuring they meet durability, cost, and environmental compatibility.
• Produce comprehensive drawings for fabrication and procurement of the necessary assemblies.

Prototyping and Fabrication

• Design prototypes to test and validate the concepts
• Collaborate with manufacturing teams or suppliers to fabricate parts, ensuring they meet the required tolerances and specifications.

Testing and Validation

• Conduct tests to validate the mechanical performance under various conditions.
• If necessary, adjust the design to address any identified inefficiencies or performance gaps.

Integration and Maintenance

• Ensure the design integrates smoothly with existing systems and infrastructure.
• Verify that the design complies with internal and external regulations.
• Develop user manuals, maintenance protocols, and training materials for operational teams.

The design of individual components contributes to the overall functionality of a scientific instrument. Each component is designed taking into account factors such as material properties, load distribution, tolerances, and manufacturing processes to ensure functionality and reliability.

Examples of Applications

• Designing neutron guide systems, housings and support infrastructure.
• Design of detector mechanics.
• Development of focussing monochromator mechanics with tailored crystal properties.
• Developing solutions for rotating machines such as choppers.
• Custom laboratory fixtures such as test systems or experimental setups.
• Designing sample environment chambers for temperature or pressure-controlled experiments.
• Integrating robotic arms and automated systems for sample handling.

To optimise and validate the design of components and modifications to systems, we integrate our design process with simulations of mechanical properties, thermohydraulic, magnetism, neutron transport, and radiation physics where necessary. Simulations allow us to verify how innovative ideas will perform and bridge the gap between design and reality, ensuring that models accurately reflect real-world conditions.

Core Activities

Numerical Simulations

• Use computational tools to simulate mechanical, structural, magnetic, thermal, or fluid behaviours under various conditions.
• Model interactions between materials, forces, and environmental factors.

Structural Analysis

• Assess structural integrity, stress, strain, fatigue, and deformation in designs.
• Ensure that equipment, components, and prototypes meet safety standards and operational requirements.

Thermal and Fluid Dynamics Analysis

• Analyse heat transfer, fluid flow, and thermodynamic properties in neutron production equipment and experimental systems.

Support for Experimental Research

• Provide calculations to guide experimental setup, particularly in magnetism and neutron polarisation
• Assist researchers in translating theoretical models into practical implementations.

Documentation and Reporting

• Produce detailed technical reports, including calculations, assumptions, and results.
• Communicate results clearly to engineers and scientists