Robotic Crab Gimbal Assembly for UKAEA 

Hutchinson was commissioned by UKAEA to manufacture precision fabrications and mechanical assemblies for a high integrity robotic handling system, engineered for remote operation in radioactive environments at the European Spallation Source, a major scientific research facility in Sweden. The complex steel fabrication features 268 individual components, each engineered to extremely precise tolerances.
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Client

UKAEA is a UK government research organisation developing fusion energy as a clean, sustainable power source. As part of the UK’s contribution to the European Spallation Source (ESS) in Sweden, UKAEA was tasked with delivering key components for the ESS Active Cells Facility.

Project Overview

This precision-engineered component forms part of a robotic handling system used to remotely manage radioactive materials in hazardous environments. Working from a customer-issued design, the project demanded tight tolerances, advanced welding and machining, and full traceability throughout. While select machining operations were carried out offsite, all other fabrication, assembly, inspection, and quality control processes were completed in-house to ensure compliance and meet critical delivery timelines.

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The Crab Gimbal Assembly consists of 268 precision-engineered components, manufactured to extremely tight tolerances.

Manufactured to exacting standards

This was a highly complex project requiring a wide range of specialist in-house capabilities, including:

  • High-tolerance machining

  • Precision cutting and welding

  • Assembly and painting

  • Non-destructive testing

  • Factory acceptance testing (including point load testing)

  • Coating inspection and application

To meet the ESS project’s stringent quality and traceability requirements, Hutchinson followed its standard operating procedures, including:

  • Hutchinson’s BS EN 1090-1 Execution Class 4 certification supported the manufacture of components to the highest classification.

  • Material procurement followed strict country of origin requirements and CFSI compliance as per Hutchinson’s Quality Procedures.

  • Welding quality was assured by Hutchinson’s in-house International Welding Engineer and Responsible Welding Coordinator, in line with BS EN ISO 3834-2.

  • Dimensional accuracy was verified using a FARO Quantum-e 3D measurement and inspection system.

  • Coating processes were controlled and inspected by an Icorr Level 3 qualified inspector, with application completed via airless spray in Hutchinson’s internal coating facility.

Meeting the demands of high-spec nuclear projects

“Delivering a project of this complexity requires more than just technical expertise, it demands proven processes, tight quality control, and dependable collaboration. Our team’s experience ensured this high-integrity assembly met every requirement.”

 

Susan Wiseman,
Business Development