TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 1 TMT M1...

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TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 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.

Transcript of TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 1 TMT M1...

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 1

TMT M1 Segment Support Assembly (SSA) Preliminary Design Review (PDR)

Volume-6: INTEGRATION & HANDLING

Pasadena, CaliforniaOctober 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 ProjectGeorge Angeli, Curt Baffes, Doug MacMynowski, Terry Mast, Jerry Nelson, Ben

Platt, Lennon Rodgers, Mark Sirota, Gary Sanders, Larry Stepp, Kei Szeto

TMT ConfidentialThe 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.

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 2

OutlineVolume-6: Subcell Integration & Segment Handling– Subcell Integration & Alignment

Fixed Frame Installation

Dummy Mass

Subcell Alignment

– Segment Lifting Jack & Lifting TalonJack design

Lifting Talon design

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 3

SUBCELL INTEGRATION& ALIGNMENT

Integration & Handling

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 4

Subcell AlignmentSubcell Installation & Alignment:– M1 Array populated with 492 Fixed Frames

– Mass Simulators installedMass load mirror cell

– Surveying targets attached to fixed Frames:Required surveying accuracy 0.100 mm

Also see presentation on Surveying and Alignment

Mass Simulator(Cast Iron)

SurveyingTarget, 3 ea.

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 5

Fixed Frame InstallationInstall AAP Posts & Mount Fixed Frames in Nominal Position

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

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 6

Mass SimulatorInstall Mass Simulators:– Cast Iron, Low cost, simple, safe

– Correct Mass and C.G.

– Low-profile shape

– Recyclable

Mass Simulator(208 kg Cast Iron)

NutClamp washer (or bar)

Steel tube with welded flange

Nut & Washertyp.

All-Thread

Lifting fixture

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 7

Target HoldersSurveying Target Holders– Installed temporarily– Interchangeable– Target interface TBD

Depends on surveying system

Target Holder

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 8

Subcell AlignmentSubcell 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– AAP’s accommodate +/-8mm adjustment in-

planeCell mfg. tolerances & segmentation effects

– AAPs accommodate +/-5mm vertical adjustment

In-Plane Positioners (Removable Tooling)

See Vol-2: forAlignment budget

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 9

Subcell AlignmentSubcell 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

Post: bolted to truss

Spherical Nut 2ea.

SphericalWasher 2ea.

Lock Nut 2ea.

Dowel Pins2 ea.

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 10

SEGMENT LIFTING JACK &LIFTING TALON

Integration & Handling

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 11

Lifting JackSegment Lifting Jack:– Function:

Raise and lower the MSA into and out of M1 array in a safe controlled mannerPrevent glass hitting glass during Installation & Removal (I&R)Compatible with crane and lifting talon operational sequencesCompatible 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 <0.5mm, Rotational motion: d < +/-0.5mm at vertex (DRD)

– See Jacking Gap Budget

Time for motion <1.0 minutesMaximum force applied < 1.5X weight of assembly being liftedTime for segment Removal and Installation 30 minutes

– ParametersFull extension at +300mmArray insertion at +95mm jack position (45mm mirror thickness+50mm sensor)Begin registration alignment at +10mm

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 12

Lifting JackThree 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 controlJack position: +10mm to +100mm

Segment inserting into array

Adjacent segment 2.5mm away (nominal edge gap)

– Registration – Relaxed clocking controlJack position: 0 to +10mm

Allow registration system to position MSA

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 13

Segment Lifting JackSegment Lifting Jack Operations:– Raised 300mm– MSA placed on jack– Lowered onto Subcell

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 14

Segment Lifting JackSegment fully raised from array:– segments inclined 14.5 deg at perimeter of array (at zenith):

0.25g lateral load on jack

14.5 deg

300mm

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TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 15

Segment Lifting JackThree-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 JackMotor 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 PinAttached to fixed frame

Provides required clocking accuracy during array insertion (close tolerance)

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 16

Segment Lifting JackComponents of Jack System– Center-shaft: 5.2kg– Jack: 7.0 kg

Jack, motor, housing, end pad

Center Shaft

Spherical Radius (R250mm)(Permit tip/tilt at registration

Clocking grooveMoving frame pin engages in groove)

Nook ActionJacModel EM1-MSJ-1310mm stroke

TrackGroove

Clocking Pin(Engages in slot in tower)

Encoded StepperMotor

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 17

Fixed FrameFixed Frame (Top plate removed)

Actuator AttachmentCastings

Jack Center Shaft Support and Bushings

Registration Pins3 ea.

Tower Clocking Pin

AAP attach hole

Holes for surveying target holders 3ea.

Jack Center-Shaft Guide & Retention Pin

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 18

Center Shaft InstallationFixed Frame and Center-Shaft

Jack Center-Shaft Guide & Retention Pin

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 19

Segment Lifting JackSegment 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

0.5+/-.25mm clearance (on dia.)Length of fit: ~90 mm

Lead-in coneallows 26mm misalignment

Moving Frame clocking pin engaged in Shaft groove:Coarse clocking control for 100-300mm positions

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 20

Segment Lifting JackSegment 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 motion1.0+/-0.1mm

Clocking Pin engages in Tower slot(Note lead-in cone +/- 29mm tolerance)

Clocking Pin clearance increased at 10mm (for registration)

ArrayInsertion

Registration

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 21

Segment Lifting JackJack Performance– Gap budget during jacking

and registrationBegin 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

QUANTITY PARAMETER NAME VALUE

OPERATIONAL PARAMETERS mmZPSA Location of tip/tilt center of roattion (guide flexure C.L.) COR -55.739

ZPSA distance from optical origin to vertex on optical surface Z_Vertex 4.32Actuator Max Operational Range Actuator_Range 5.0

JACKING PARAMETERSAdjacent Segment Actuator Range Error During Jacking ERR_ACT_JACKING 0.5

Jack Position at Registration Z_1 0Jack Position at Array Insertion Z_2 100ZPSA Distance from Opt Surf Vertex to Top Land (Shaft to MF fit) Z_TOP_LAND -69.600Segment-to-Jack Fit Length (Distance between lands) SEG_JK_LGTH 91.200ZPSA Location of Registration Features at Base of Tower Z_REG -334.125

Segment-to-Jack Shaft Fit, UPPER Land, Clearance (on Dia) CLR_SEG_JK_UPR 0.500Segment-to-Jack Shaft Fit, LOWER Land, Clearance (on Dia) CLR_SEG_JK_LWR 0.500Segment-to-Jack Fit Tolerance (on Dia) TOL_SEG_JK_FIT 0.250

Segment-to-Clocking Pin Tangential Clearance (on Dia) RAISED CLR_SEG_PIN_Z2 0.125Segment-to-Clocking Pin Fit Tolerance (on Dia) RAISED TOL_SEG_PIN_Z2 0.100Segment-to-Clocking Pin Tangential Position Error - RAISED ERR_SEG_PIN_Z2 0.500Clocking Pin Radius R_CLK_PIN 379.58

Segment-to-Clocking Pin Clearance (on Dia) LOWERED CLR_SEG_PIN_Z1 1.000Segment-to-Clocking Pin Tolerance (on Dia) LOWERED TOL_SEG_PIN_Z1 0.100Segment-to-Clocking Pin In-Plane Position Error - LOWERED ERR_SEG_PIN_Z1 0.200

Jack-to-Fixed Frame In-plane Clearance (on Dia) CLR_JK_FF 0.075Jack-to-Fixed Frame In-plane Fit Tolerance (on Dia) TOL_JK_FF 0.050

Used in jack delection calcs only, not in spreadsheets

Jack Shaft In-Plane Position Error (on Dia) RAISED ERR_JK_Z2 0.300Jack Shaft Position (on Dia) LOWERED ERR_JK_Z1 0.200

Includes bushing position, shaft straightness (on Dia)

Jack Deflection Analysis ResultsJack System Deflection at RAISED (Relative to Adjacent Seg) DEFL_JK_Z2_REL 0.571Jack System Deflection at LOWERED (Relative to Adjacent Seg) DEFL_JK_Z1_REL 0.351Jack System Deflection at RAISED (Absolute) DEFL_JK_Z2_ABS 0.621Jack System Deflection at LOWERED (Absolute) DEFL_JK_Z1_ABS 0.401

Includes shaft-FF clearance, Shaft bending, FF distortionfrom HPS-280001-104

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 22

Gap Budget during Jacking (@+100mm)GAP CLOSURE EFFECT MAGNI TUDE MULTI PLI ER* GAP LOSS, mmSegment edge & PMA assembly tolerance 0.300 1.00 0.300

Per Polished Mirror Assembly Drawing: 280-TMT-01-11000. Edge profile tolerance +/-.300mm WRT Tower [APPLIES TO ADJACENT SEGMENT]Segment edge to Moving Frame Bore Tolerance 0.150 1.00 0.150

Estimate, (APPLIES TO SEGMENT BEING JACKED)Subcell manufacturing/ assembly error (Target to Tower) 0.043 1.00 0.043

Accuracy from registration features to alignment targets. RSS of In-plane, Decenter and Clocking** (1/2 of P-P)) [APPLIES TO INSTALLED SEGMENT]

Subcell initial alignment error 0.115 1.41 0.163RSS of In-Plane, Decenter, & Clocking** (1/2 of P-P) [APPLIES TO BOTH SEGMENTS]

Surveying error 0.087 1.41 0.123RSS of In-Plane, Decenter, & Clocking** (1/2 of P-P) [APPLIES TO BOTH SEGMENTS]

SSA registration repeatability 0.083 1.00 0.083RSS of In-Plane, Decenter, & Clocking** (1/2 of P-P) [APPLIES TO INSTALLED SEGMENT]

Gravity-induced PSA deformations 0.010 1.00 0.010Assume max 5% difference in effective stiffness of neighboring PSA’s; 1g deflection=0.20mm based on fmin>35 hz.

Siesmic-induced PSA deformations 0.000 1.00 0.000Assume 0.1g reposne of PSAs. Adjacent PSAs out-of-phase. Basis: 1g deflection=0.203mm based on fmin>35 hz.

Temperature-Induced PSA translations 0.010 1.00 0.010Temperature gradients, CTE non-uniformity, PSA-PSA variations… ???

Temperature-Induced PSA rotations 0.046 1.00 0.046Cell/Subcell CTE mismatch: Adjacent segment clocking is out of phase at sector boundary. 6.4 u-rad/C * DT=10Cmax = 64u-rad each

Thermal expansion of cell 0.073 1.00 0.073Assume nominal gap is set for 0°C; steel cell (CTE~11.7 ppm/°C), max neg. ΔT=-5°C, 1.247m between segment centers)

Gravity-induced cell deflection 0.000 1.00 0.000Work done at zenith

Maximum gap closure before tip/ tilt (RSS of above contributions) 0.413

TYPE Actuation Adjacent Segment decenter due to tip/ tilt (est.) 0.038 1.00 0.038

2 Assumes 0.5 mm tilt of installed segment

Segment to J ack Shaft: I n-Plane plus Tip/ Tilt and Tol. 0.983 1.00 0.983Effect of Moving Frame-to-J ack Shaft Clearances (upper and lower lands) and Tolerances causing in-plane and Tip/Tilt decenter AT OPTICAL SURF.

Segment to Clocking Pin - Clocking 0.344 1.00 0.344Clearance, tolerance, and tangential error at clocking pin, reduced by 0.5 factor ** AT INSERTION

J ack Shaft position - I n Plane 0.150 1.00 0.150Shaft Straightness & Perp at shaft tip

J ack Shaft static deflection at edge of array (.25g) 0.571 1.00 0.571Shaft to Fixed Frame Tolerance and Clearance (0.025-.125mm dia max) included in the shaft deflection (kinematic + elastic) AT INSERTION

J ack I nduced Motion - LI NEAR SUM of above 2.048

Linear Sum of RSS'd Types 1-3 Errors 2.498

Nominal Gap Width 2.500

Gap Margin 0.002ZSEG Location of tip/tilt center of rotation, mm = Actuator radius, mm = 531.0

* Multiplier relates single segment effect to total change in gap. Random effects on adjacent segments are RSS'd, giving the 1.41 factor.

** Clocking at vertex results in gap closure: DGap = D * sin(30) = 0.5*symbol

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TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 23

Gap Budget during Jacking (@+10mm)GAP CLOSURE EFFECT MAGNI TUDE MULTI PLI ER* GAP LOSS, mmSegment edge & PMA assembly tolerance 0.300 1.00 0.300

Per Polished Mirror Assembly Drawing: 280-TMT-01-11000. Edge profile tolerance +/-.300mm WRT Tower [APPLIES TO ADJACENT SEGMENT]Segment edge to Moving Frame Bore Tolerance 0.150 1.00 0.150

Estimate, (APPLIES TO SEGMENT BEING JACKED)Subcell manufacturing/ assembly error (Target to Tower) 0.043 1.00 0.043

Accuracy from registration features to alignment targets. RSS of In-plane, Decenter and Clocking** (1/2 of P-P)) [APPLIES TO INSTALLED SEGMENT]

Subcell initial alignment error 0.115 1.41 0.163RSS of In-Plane, Decenter, & Clocking** (1/2 of P-P) [APPLIES TO BOTH SEGMENTS]

Surveying error 0.087 1.41 0.123RSS of In-Plane, Decenter, & Clocking** (1/2 of P-P) [APPLIES TO BOTH SEGMENTS]

SSA registration repeatability 0.083 1.00 0.083RSS of In-Plane, Decenter, & Clocking** (1/2 of P-P) [APPLIES TO INSTALLED SEGMENT]

Gravity-induced PSA deformations 0.010 1.00 0.010Assume max 5% difference in effective stiffness of neighboring PSA’s; 1g deflection=0.20mm based on fmin>35 hz.

Siesmic-induced PSA deformations 0.000 1.00 0.000Assume 0.1g reposne of PSAs. Adjacent PSAs out-of-phase. Basis: 1g deflection=0.203mm based on fmin>35 hz.

Temperature-Induced PSA translations 0.010 1.00 0.010Temperature gradients, CTE non-uniformity, PSA-PSA variations… ???

Temperature-Induced PSA rotations 0.046 1.00 0.046Cell/Subcell CTE mismatch: Adjacent segment clocking is out of phase at sector boundary. 6.4 u-rad/C * DT=10Cmax = 64u-rad each

Thermal expansion of cell 0.073 1.00 0.073Assume nominal gap is set for 0°C; steel cell (CTE~11.7 ppm/°C), max neg. ΔT=-5°C, 1.247m between segment centers)

Gravity-induced cell deflection 0.000 1.00 0.000Work done at zenith

Maximum gap closure before tip/ tilt (RSS of above contributions) 0.413

TYPE Actuation Adjacent Segment decenter due to tip/ tilt (est.) 0.038 1.00 0.038

2 Assumes 0.5 mm tilt of installed segment

Segment to J ack Shaft: I n-Plane plus Tip/ Tilt and Tol. 0.983 1.00 0.983Effect of Moving Frame-to-J ack Shaft Clearances (upper and lower lands) and Tolerances causing in-plane and Tip/Tilt decenter AT OPTICAL SURF.

Segment to Clocking Pin - Clocking 0.616 1.00 0.616Clearance, tolerance, and tangential error at clocking pin, reduced by 0.5 factor ** AT REGISTRATION

J ack Shaft position - I n Plane 0.100 1.00 0.100Shaft Straightness & Perp at shaft tip

J ack Shaft static deflection at edge of array (.25g) 0.351 1.00 0.351Shaft to Fixed Frame Tolerance and Clearance (0.025-.125mm dia max) included in the shaft deflection (kinematic + elastic) AT REGISTRATION

J ack I nduced Motion - LI NEAR SUM of above 2.050

Linear Sum of RSS'd Types 1-3 Errors 2.501

Nominal Gap Width 2.500

Gap Margin -0.001ZSEG Location of tip/tilt center of rotation, mm = Actuator radius, mm = 531.0

* Multiplier relates single segment effect to total change in gap. Random effects on adjacent segments are RSS'd, giving the 1.41 factor.

** Clocking at vertex results in gap closure: DGap = D * sin(30) = 0.5*symbol

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TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 24

Segment Lifting JackSummary– 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

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 25

Lifting TalonLifting Talon CONCEPT Design– Requirements:

Safety: FSy > 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

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 26

Lifting TalonLifting 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 instrumentedLoad cell with 5N resolution

– to sense segment weight during handoff

– Tip/Tilt adjustableSet to match segment inclination

Tip/Tilt Adjusters

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 27

Lifting TalonLifting 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 PieceProtects mirror if accidental

contact occurs

Moving Frame

Lifting Talon

Self-aligning, kinematic joint

V-groove in moving frame

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 28

Talon ConceptVertical Contact Switches– Talon opened and closed when both are “green”

Upper

Lower

Upper

Lower

Upper

Lower

Contact - Low Contact - High

LOW HIGH CLEAR (OK to OPEN)

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 29

Talon ConceptCapture Limit Switches– Indicate Moving Frame tang engaged in Talon Socket

Switch Closed

MF Captured MF Captured

Switch Open

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 30

Lifting TalonSegment Removal Sequence– Segment lifted to full stroke: 300mm

– Talon lowered (Claws open)stop at 5-15 mm below capture height

– Talon closedInterlocks verified

– Check Talon closed?– Check moving frame tang inserted in socket?

– Jack begins to lowerTalon 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 verifiedSegment extracted

Crane Departs

– Jack re-positioned to receive new MSA

Jack Raises Segment +300mmTalon is lowered into positionTalon ClosesJack lowers segment onto TalonCrane extracts Talon and Segment

Upper

Lower

MF Captured

INTERLOCKS

Upper

Lower

MF Captured

INTERLOCKS

Upper

Lower

MF Captured

INTERLOCKS

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 31

Lifting TalonSegment 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 detectedIndicator lights on Talon verify handoff

– Talon opens

– Crane departs

– Jack lower segment into position.

Jack raised to +260mmCrane lowers segment onto JackPosition: +275-285mm

Jack raised until MF liftoffCrane and Talon DepartJack lowers segment into arraySegment on Jack, Talon opened

Upper

Lower

Upper

Lower

MF CapturedMF Captured

INTERLOCKS

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 32

ConclusionsTalon/Crane/Jack Integration is challenging– Talon design requires certain crane accuracy and motion

– Ongoing work will integrate systems

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 33

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.

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 34

BACKUP SLIDES

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 35

JACK SHAFT DEFLECTION ANALYSIS

Integration & Handling

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 36

Bushing Arrangement

d

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

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 37

d

L

F

R1 R2

Simplified Beam Model

EI

LdFLwe

3

)(2

)/1(2 dLcwk

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 = 2.33×10-7m4

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

– p = R / 0.028575

)/1(

/

2

1

dLFR

dFLR

EDc CK

pmax)(

Radial clearance c

ket www

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 38

Optimal Bushing Distance

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

0 50 100 150 200 250 300 350

Bushing Distance (mm)

De

fle

cti

on

(m

m)

Kinematic Deflection Elastic Deflection

Total Deflection 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

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 39

Relative Deflections

2

1

Installed Configuration Lifted 100mm

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

TMT.OPT.PRE.07.061.REL01 HPS-280001-0105 – Volume-6 – October 24-25 2007 – Slide 40

Deflection Analysis Results

2

1

Configuration

Lift (mm)

1

(mm)

2

(mm)

kin

(mm)

D21k

(mm)

D’2k

(mm)

1 0.00 0.04959 0.12439 0.27656 0.35136 0.40095

2 100.00 0.04959 0.26097 0.35990 0.57127 0.62087

3 300.00 0.04959 0.82726 0.52656 1.30423 1.35382

Dimensions:– Bushing distance: 150mm

– Radial shaft clearance: 0.0625mmBlue is Undeformed.Scale is arbitrary.

Installed Configuration SSA Lifted 100mm