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SOL-GEL COATING FACILITY CONCEPTUAL DESIGN REVIEW

SOL-GEL COATING FACILITY CONCEPTUAL DESIGN REVIEW. October 19, 2005. Purpose. Develop the ability to dip coat large optics with sol-gel solution in conjunction with our vacuum coating facility. Design parameters.

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SOL-GEL COATING FACILITY CONCEPTUAL DESIGN REVIEW

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  1. SOL-GEL COATING FACILITY CONCEPTUAL DESIGN REVIEW October 19, 2005

  2. Purpose • Develop the ability to dip coat large optics with sol-gel solution in conjunction with our vacuum coating facility. • Design parameters. • Maximum size optic: 44” diameter, 4” thick, 4,600 cu. in. volume (44” dia X 3” thick) • Ability to vacuum coat than sol-gel coat in a clean environment • Initial sol solution TEOS, provide for an additional solution type • Locate facility in upper astronomy shop optics lab. • Initial Goal • Coat ADC prisms with MgF2 and Sol-gel • ADC prisms are 41” dia. wedges approx 7/8” X 2 7//8” thick

  3. DESIGN • Dip coat facility in clean room environment • Optic handling equipment for ADC optics. • Handling equipment optic specific in general • Interface with vacuum tank facility

  4. CLEAN ROOM • Erect clean room in optics lab to include vacuum & Sol-gel coating • Initial quote for a 25’ X 25’ X 8’class 1000 room including HEPA filters & fans $16,000

  5. ADC OPTIC HANDLING

  6. ADC OPTIC HANDLING • Use a frame with Teflon pads instead of band strap • A U-shaped frame with interchangeable upper cross members • One for general lifting & turning optic over • One for Sol-gel dip • One for hardening (not shown) • Optic restraint for general lifting & turning over is provided by 4 U shaped Teflon pads • Optic constraint for Sol-gel dip is provided by 3 U shaped Teflon pads • Might be able to support optic by bevels with flat part of U being for safety

  7. Transport between stations on cart with 4 swivel wheels

  8. Uprights (Item 3) slide into frame channels, bottom frame channel sets on beam • This supports optic vertically to move around and to change top bars • Bottom of cart is generic for most large optics • Uprights are specific to ADC optic • Remove frame for vacuum coating • Load into vacuum chamber with stand used for previous coating • Revise mounting in vacuum tank to work without band used last time • Sol-gel fixture is equipped with a ½ ton crane and trolley on a beam • Garment supplier can provide fabric covers for hoists • To load optic into Sol-gel fixture • Push optic into enclosure on cart • Lift optic with ½ ton crane • Roll trolley back to lift fixture • Lower optic onto lift fixture

  9. SOL-GEL FIXTURE

  10. SOL-GEL FIXTURE • Two dip tanks and a cleaning station • Dip tanks 54” X 8” X 50” high, inside • Sides supported by steel frame (not shown) • Lid opens in 2 halves with shield at ends to provide extension of vapor height to 6” • Pneumatic opener on lid to operate remotely • Stainless steel or polypropylene (poly quote $940) • Cleaning station design TBD • Include CO2 snow and N2 blow off, operated remotely

  11. Compensator to hold Sol-gel level constant in dip tank • Provides constant vapor height in dip tank • Prevents plating of tank sides • Connection to tank 1” dia. Teflon tube • Overflow to be provided on sol-gel tank in case of compensator malfunction • (volume = to compensator volume) • Tanks & compensator mounted on a carriage • Moves from position shown to Sol-gel dip position • Steel rollers • Manual drive with stops for positive location • Lift mechanism to raise & lower optic at programmed rates • Single ball screw & 2 ball slides almost identical to ADC mechanism • Ball Screw 40 mm dia. by 5 mm pitch NSK • Bayside 10:1 gearbox • Pitman motor driven by Galil controller • Encoder on motor • NSK quote for ball screw and ball slides $5,000 • (not including end bearing mounts for ball screw)

  12. Hoist & hoist beam to load optic onto lift mechanism • Structure mounted on vibration isolators TBD • Probably Barry mounts (same as profilometer) • Base vibration requirement on size of meniscus photographed • while pulling microscope slide in NC mill

  13. COMPENSATOR

  14. COMPENSATOR • Shown as stainless steel, quote on 20’ X 12” X ¾” wall dia. polypropylene tube $600 • Volume to be 21 gal. Min. • Height not above top of fluid level in tank • NSK ball slide and ball screw quote $4,600 (not including end bearings) • Ball screw 32 mm dia X 5 mm pitch • Ball nut held stationary at top of cylinder • Ball screw and motor / gearbox move up & down guided by ball slide • Additional rod to prevent piston rotation • Bayside gearbox and Pitman motor controlled by Galil controller • Bleed in piston not shown • Piston relieved at end to allow it to go to bottom of tank without restricting output

  15. STRUCTURE • Steel weldment • Start with Deimos rails • Epoxy paint

  16. ENCLOSURE • 2” X 2” X 1/8” wall steel tube welded frame • Clad with 1/8” thick plexiglass • ¼”thick plexiglass doors on front, open from center • HEPA filters & fans on side near top

  17. HARDENING / HMDS TANK • Use existing tank • Improve insulation • Load optic from cart under overhead crane

  18. SOFTWARE • Control for 2 stage axis • One on lift mechanism requires lift and constant rate • One on compensator has varying rate depending on optic geometry

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