Pasadena, California October 24-25, 2007 Contributors to the development effort: from IMTEC

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

6. 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

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

8. 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 • AAP’s 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)

9. Dowel Pins 2 ea. Post: bolted to truss Spherical Washer 2ea. Spherical Nut 2ea. Lock Nut 2ea. 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

11. 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 (I&R) • 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 <0.5mm, Rotational motion: adq < +/-0.5mm at vertex (DRD) • See Jacking Gap Budget • Time for motion <1.0 minutes • Maximum force applied < 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 thickness+50mm sensor) • Begin registration alignment at +10mm

12. 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

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

14. 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

15. 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)

16. 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

17. Fixed Frame (Top plate removed) Fixed Frame 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.

18. Fixed Frame and Center-Shaft Center Shaft Installation Jack Center-Shaft Guide & Retention Pin

19. 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

20. 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)

21. 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

22. Gap Budget during Jacking (@+100mm)

23. Gap Budget during Jacking (@+10mm)

24. 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

25. Lifting Talon • Lifting 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

26. 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

27. 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

28. 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

29. Talon Concept • Capture Limit Switches • Indicate Moving Frame tang engaged in Talon Socket MF Captured MF Captured Switch Open Switch Closed

30. 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 Jack lowers segment onto Talon Talon Closes Talon is lowered into position Crane extracts Talon and Segment

31. 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 Crane lowers segment onto Jack Position: +275-285mm Segment on Jack, Talon opened Jack lowers segment into array Jack raised until MF liftoff Crane and Talon Depart Jack raised to +260mm

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

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.

34. BACKUP SLIDES

35. Integration & Handling JACK SHAFT DEFLECTION ANALYSIS

36. 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

37. F L d R1 R2 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 = 2.33×10-7m4 • 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 Radial clearance c

38. 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

39. 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

40. 2 1 Deflection Analysis Results • Dimensions: • Bushing distance: 150mm • Radial shaft clearance: 0.0625mm Blue is Undeformed. Scale is arbitrary. Installed Configuration SSA Lifted 100mm