TMT'OPT'PRE'07'061'REL01

1
TMT M1 Segment Support Assembly (SSA) Preliminary
Design Review (PDR)Volume-6 INTEGRATION
HANDLING

• Pasadena, California
• October 24-25, 2007
• Contributors to the development effort
• from IMTEC
• RJ Ponchione, Eric Ponslet, Shahriar Setoodeh,
  Vince Stephens, Alan Tubb, Eric Williams
• from the TMT Project
• George Angeli, Curt Baffes, Doug MacMynowski,
  Terry Mast, Jerry Nelson, Ben Platt, Lennon
  Rodgers, Mark Sirota, Gary Sanders, Larry Stepp,
  Kei Szeto
• TMT Confidential
• The Information herein contains Cost Estimates
  and Business Strategies Proprietary to the TMT
  Project and may be used by the recipient only for
  the purpose of performing a confidential internal
  review of the TMT Construction Proposal.
  Disclosure outside of the TMT Project and its
  External Advisory Panel is subject to the prior
  written approval of the TMT Project Manager.
• Note HYTEC, Inc. merged with IMTEC Inc. in
  March 2007.

2
Outline

• Volume-6 Subcell Integration Segment Handling
• Subcell Integration Alignment
• Fixed Frame Installation
• Dummy Mass
• Subcell Alignment
• Segment Lifting Jack Lifting Talon
• Jack design
• Lifting Talon design

3
Integration Handling
SUBCELL INTEGRATION ALIGNMENT
4
Subcell Alignment

• Subcell Installation Alignment
• M1 Array populated with 492 Fixed Frames
• Mass Simulators installed
• Mass load mirror cell
• Surveying targets attached to fixed Frames
• Required surveying accuracy 0.100 mm

Mass Simulator (Cast Iron)
Surveying Target, 3 ea.
Also see presentation on Surveying and Alignment
5
Fixed Frame Installation

• Install AAP Posts Mount Fixed Frames in Nominal
  Position

Sectors A,C,E
Sectors B,D,F
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Mass Simulator

• Install Mass Simulators
• Cast Iron, Low cost, simple, safe
• Correct Mass and C.G.
• Low-profile shape
• Recyclable

Lifting fixture
Nut Washer typ.
All-Thread
Mass Simulator (208 kg Cast Iron)
Steel tube with welded flange
Clamp washer (or bar)
Nut
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Target Holders

• Surveying Target Holders
• Installed temporarily
• Interchangeable
• Target interface TBD
• Depends on surveying system

Target Holder
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Subcell Alignment

• Subcell Alignment
• Fixed Frame positioning near kinematic
• 3 ea. Positioners for three in-plane DOF
• Precision turnbuckles
• Removable tooling
• 3 ea AAP jacking screws for 3 out-of-plane DOF
• AAPs accommodate /-8mm adjustment in-plane
• Cell mfg. tolerances segmentation effects
• AAPs accommodate /-5mm vertical adjustment

See Vol-2 for Alignment budget
In-Plane Positioners (Removable Tooling)
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Subcell Alignment

• Subcell Alignment
• AAP joint is secured after alignment is complete
• Top AAP disc pinned to fixed frame to prevent
  creep
• Jam nuts tightened and thread-locker applied

10
Integration Handling
SEGMENT LIFTING JACK LIFTING TALON
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Lifting Jack

• Segment Lifting Jack
• Function
• Raise and lower the MSA into and out of M1 array
  in a safe controlled manner
• Prevent glass hitting glass during Installation
  Removal (IR)
• Compatible with crane and lifting talon
  operational sequences
• Compatible with registration system
• Handoff without binding or overload
• Light weight, simple, easy to operate,
  idiot-proof
• Requirements
• Stroke 300 /-2mm (increased over DRD reqt.
  (150mm) by agreement with Project)
• Lateral motion lt0.5mm, Rotational motion adq lt
  /-0.5mm at vertex (DRD)
• See Jacking Gap Budget
• Time for motion lt1.0 minutes
• Maximum force applied lt 1.5X weight of assembly
  being lifted
• Time for segment Removal and Installation 30
  minutes
• Parameters
• Full extension at 300mm
• Array insertion at 95mm jack position (45mm
  mirror thickness50mm sensor)
• Begin registration alignment at 10mm

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Lifting Jack

• Three jacking phases
• Above Array - Coarse position control
• Jack position 100 to 300 mm
• Segment is above adjacent segments nothing to
  hit
• Array Insertion - Tight position control
• Jack position 10mm to 100mm
• Segment inserting into array
• Adjacent segment 2.5mm away (nominal edge gap)
• Registration Relaxed clocking control
• Jack position 0 to 10mm
• Allow registration system to position MSA

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Segment Lifting Jack

• Segment Lifting Jack Operations
• Raised 300mm
• MSA placed on jack
• Lowered onto Subcell

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Segment Lifting Jack

• Segment fully raised from array
• segments inclined 14.5 deg at perimeter of array
  (at zenith)
• 0.25g lateral load on jack

300mm
Perimeter of array
14.5 deg
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Segment Lifting Jack

• Three-Part Jack System
• Removable Center-Shaft installs in fixed frame
  bushings
• Stiff accurate control of segment
• Shaft engages with moving frame
• 6DOF control
• Controlled clearances to permit PMA
  self-alignment on registration features
• Shaft to moving frame clearance 0.5/-.25mm on
  diameter
• Permits small radial, tip/tilt and clocking
  motion
• Removable Motorized Screw Jack
• Motor driven Trapezoidal Screw
• will not back-drive
• motor circuit be sized to stall or shutoff at max
  design load (current)
• bolts to fixed frame, self-aligns to center shaft
• Permanently installed Clocking Pin
• Attached to fixed frame
• Provides required clocking accuracy during array
  insertion (close tolerance)

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Segment Lifting Jack
Spherical Radius (R250mm) (Permit tip/tilt at
registration

• Components of Jack System
• Center-shaft 5.2kg
• Jack 7.0 kg
• Jack, motor, housing, end pad

Clocking groove Moving frame pin engages in
groove)
Clocking Pin (Engages in slot in tower)
Track Groove
Encoded Stepper Motor
Nook ActionJac Model EM1-MSJ-1 310mm stroke
Center Shaft
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Fixed Frame

• Fixed Frame (Top plate removed)

Jack Center Shaft Support and Bushings
Tower Clocking Pin
Registration Pins 3 ea.
Jack Center-Shaft Guide Retention Pin
AAP attach hole
Actuator Attachment Castings
Holes for surveying target holders 3ea.
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Center Shaft Installation

• Fixed Frame and Center-Shaft

Jack Center-Shaft Guide Retention Pin
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Segment Lifting Jack

• Segment Lifting Jack Operations
• MSA Placed on jack at 300mm
• Moving frame indexes to end of jack
• End of shaft against end of hole in moving frame
• Cylindrical fit
• Clocking pin in groove

Moving Frame clocking pin engaged in Shaft
groove Coarse clocking control for 100-300mm
positions
0.5/-.25mm clearance (on dia.) Length of fit
90 mm
Lead-in cone allows 26mm misalignment
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Segment Lifting Jack

• Segment Lifting Jack Operations
• MSA engages clocking pin slightly above array
  insertion (100mm)
• 0.125mm dia. clearance between tower pin in
  tangential direction
• Clocking pin clearance increases at 10mm to
  permit registration motion
• 1.0/-0.1mm

Array Insertion
Clocking Pin engages in Tower slot (Note lead-in
cone /- 29mm tolerance)
Registration
Clocking Pin clearance increased at 10mm (for
registration)
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Segment Lifting Jack

• Jack Performance
• Gap budget during jacking and registration
• Begin with operational gap budget, modify for
  jacking
• Include Center Shaft clearance and deflection
• 0.25g lateral at edge of array (14.5deg
  inclination)
• Inputs shown in Table
• Jack deflection analysis in backup slides

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Gap Budget during Jacking (_at_100mm)
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Gap Budget during Jacking (_at_10mm)
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Segment Lifting Jack

• Summary
• Design concept meets requirements
• Gap budget is tight
• Glass-to-glass impact will likely occur during
  earthquake
• protect segment corners with Kapton tape as a
  minimum
• Jack motor type needs to be agreed upon

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Lifting Talon

• Lifting Talon CONCEPT Design
• Requirements
• Safety FSy gt 3.0 for 2g load
• Fail-safe (segment cannot be dropped)
• Interlocked to assure mate to moving frame
• Accommodate 14.5 deg inclination range (tip/tilt
  adjustment)
• Crane Assumption
• Crane accurate to /-5mm all directions
• Crane can move Talon in direction normal to
  optical surface for segment installation
  removal

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Lifting Talon

• Lifting Talon
• Talon claws motorized
• Low torque motor for safety
• Claw pivot point in-board of contact point
• self-closing
• Interlocks
• Open/closed positions
• Moving frame capture (3)
• Vertical contact moving frame-to-claw (3)
• Talon instrumented
• Load cell with 5N resolution
• to sense segment weight during handoff
• Tip/Tilt adjustable
• Set to match segment inclination

Tip/Tilt Adjusters
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Lifting Talon

• Lifting Talon Interface to Moving Frame
• Moving Frame captured by Talon
• Fail safe, MSA cannot fall off crane -
  Interlocked
• Self-aligning, kinematic joint Cylinder in
  V-groove

Plastic Entrance Piece Protects mirror if
accidental contact occurs
Lifting Talon
Self-aligning, kinematic joint
Moving Frame
V-groove in moving frame
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Talon Concept

• Vertical Contact Switches
• Talon opened and closed when both are green

LOW
HIGH
CLEAR (OK to OPEN)
Upper
Upper
Upper
Lower
Lower
Lower
Contact - Low
Contact - High
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Talon Concept

• Capture Limit Switches
• Indicate Moving Frame tang engaged in Talon Socket

MF Captured
MF Captured
Switch Closed
Switch Open
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Lifting Talon

• Segment Removal Sequence
• Segment lifted to full stroke 300mm
• Talon lowered (Claws open)
• stop at 5-15 mm below capture height
• Talon closed
• Interlocks verified
• Check Talon closed?
• Check moving frame tang inserted in socket?
• Jack begins to lower
• Talon Load Cell monitors handoff
• Expect TBD weight on Talon after TBD Jack Motion
• TBDs Depend on Crane stiffness
• Jack stops after retracting 40mm
• With handoff verified
• Segment extracted
• Crane Departs
• Jack re-positioned to receive new MSA

Upper
Upper
Upper
MF Captured
MF Captured
MF Captured
Lower
Lower
Lower
INTERLOCKS
INTERLOCKS
INTERLOCKS
Jack Raises Segment 300mm
Talon is lowered into position
Talon Closes
Jack lowers segment onto Talon
Crane extracts Talon and Segment
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Lifting Talon

• Segment Installation Sequence
• Jack set to 260mm
• full stroke less 40mm
• Crane lowers Talon Segment toward array
• Moving frame engages onto Jack Center Shaft
• Crane stops at segment height 275-285mm
• 65-75mm engagement on jack shaft
• Jack extended until MF liftoff detected
• Indicator lights on Talon verify handoff
• Talon opens
• Crane departs
• Jack lower segment into position.

Upper
Upper
MF Captured
MF Captured
Lower
Lower
INTERLOCKS
Jack raised to 260mm
Crane lowers segment onto Jack Position
275-285mm
Jack raised until MF liftoff
Crane and Talon Depart
Jack lowers segment into array
Segment on Jack, Talon opened
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Conclusions

• Talon/Crane/Jack Integration is challenging
• Talon design requires certain crane accuracy and
  motion
• Ongoing work will integrate systems

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Acknowledgements
Acknowledgements The TMT Project gratefully
acknowledges the support of the TMT partner
institutions. They are the Association of
Canadian Universities for Research in Astronomy
(ACURA), the California Institute of Technology
and the University of California. This work was
supported as well by the Gordon and Betty Moore
Foundation, the Canada Foundation for Innovation,
the Ontario Ministry of Research and Innovation,
the National Research Council of Canada, the
Natural Sciences and Engineering Research Council
of Canada, the British Columbia Knowledge
Development Fund, the Association of Universities
for Research in Astronomy (AURA) and the U.S.
National Science Foundation.
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BACKUP SLIDES
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Integration Handling
JACK SHAFT DEFLECTION ANALYSIS
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Bushing Arrangement

• Dimensions
• ID 35mm
• OD 50mm
• Length 28.575mm
• Center to center distance d
• 28.6mm d 291.4mm
• Material properties
• E 76GPa
• ? 0.3
• (?c)All 31.03MPa

d
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Simplified Beam Model

• Elastic deflection (simply supported overhang
  beam)
• Assumption rigid fixed frame
• F 210g Sin(14.5) 515.8N
• L 281.9mm (SSA lifted 100mm)
• E 200GPa
• I 2.3310-7m4
• Kinematic deflection
• c cmax 0.0625mm
• 28.6mm d 291.4mm
• Total deflection
• Reaction forces
• Contact stress in Bronze bushings
• Allowable contact stress 31.03MPa
• Bushing length 2 28.575mm
• KD 2E4m
• CE 1.64E-11m2/N

Radial clearance c
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Optimal Bushing Distance

• Optimal bushing distance
• doptim 291.14mm
• ?(?c)max 0.26MPa?? F.S. 31.03 / 0.26
  119.3??contact stress not an issue?
• Total deflection is fairly insensitive to d for d
  150mm
• d 150mm is chosen for manufacturing reasons

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Relative Deflections

• Deflections at 14.5
• ?1 static deflection with mirror at the
  operational z
• ?2 static deflection with SSA 100mm lifted
• ?k kinematic deflection of the shaft due to
  bushing clearances

?2
?1
Installed Configuration
Lifted 100mm
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Deflection Analysis Results

• Dimensions
• Bushing distance 150mm
• Radial shaft clearance 0.0625mm

Blue is Undeformed. Scale is arbitrary.
Installed Configuration
SSA Lifted 100mm