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Mechanical Design SDN-2003

NICI REVIEW. Mechanical Design SDN-2003. Topics:. A: Review of Mechanical Requirements B: Overview of Design C: Design Details. A: Review of Mechanical Requirements (Partial List). Flow Chart Instrument Envelope: 89-GP-1000-0004 Instrument Weight Budget, Balance & CG

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Mechanical Design SDN-2003

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  1. NICI REVIEW Mechanical Design SDN-2003

  2. Topics: • A: Review of Mechanical Requirements • B: Overview of Design • C: Design Details

  3. A: Review of Mechanical Requirements (Partial List) • Flow Chart • Instrument Envelope: 89-GP-1000-0004 • Instrument Weight Budget, Balance & CG • Alignment & Stability: Tilt & De-centration • Fasteners,Dimensioning,Documentation

  4. Flow Chart

  5. NICI on ISS: Blue Channel

  6. NICI on ISS: Red Channel

  7. Instrument Only-1 Vacuum Jacket Iss Interface AO-VJ Bench Vacuum Jacket Cryostat

  8. Instrument Only-2 Access Cover Closed Cycle Cooler

  9. Gemini Instrument Envelope: ICD 1.1.1/1.9 Ref.Drw 89-GP-1000-0004 Coordinate Origin [0 0 0] CG 1 CG 2.3M 4.3 M 1.9 M

  10. Instrument Weight Budget, Balance and CG Total Weight Budget: 2 Metric Tons [4408 lbs] Out-of-Balance: 400 N-m [295 Ft-lbs] locate Instrument CG within 1 inch of [0 0 39.37] Trim Weight available 03-16-02 ~ 500 lbs

  11. Instrument Weight Budget/Balance/CGGemini CG at [0 0 39.37]

  12. Alignment & Stability Sensitivity Tables Design Guidelines

  13. Table 5.13.: SDN-1007 Tilt

  14. Table 5.14.: SDN-1007 Decentration No Impact On Flat Elements

  15. Design Guidlines Tilt: +/- 50 microns De-centration: +/- 100 microns Alignment: Mechanical Design Approach to meet Guidelines: Minimize Interfaces, minimize part buildup Precision Machined Referenced Optical Surfaces Pinned in place designs Front surface referenced Optics Stability: FEA analysis performed to meet flexure requirements: 3 areas Flexure between WFS and Focal Plane Mask Flexure between Focal Pland Mask and Detectors Flexure between the two Detectors Flexure will be discussed by Mark Stabb (Quartus Engineering) 15

  16. Fasteners,Dimensioning,Documentation • Fasteners inside and including the Vacuum Jacket are American Standards • Fasteners inside and including the AO-Bench are American Standards • Fasteners external to the above are Metric • Dual Dimensioning used on all “as built” drawings, with INCH the default and MM in brackets • Final (as built) Documentation in PDF Format on CD

  17. NICI INTERNALCryostat Optics

  18. X-Section Red Channel

  19. B: Overview of Design • Vacuum Jacket • Cold Mass • Cold Shield

  20. 5 part assembly; bolted construction Assembly Weight 426 lbs; Dimensions 30x36x34 Main body supports internal and external assemblies of Cryostat Structural rigidity of main body improved by ISS Mount and AO Bench assembly Vacuum Jacket (Red Channel)

  21. Vacuum Jacket (Blue Channel Side) Mass Reduce Pockets Access To Blue Channel Thermal Straps & Coolers Blue Filter Wheel Motor Port

  22. Cold Mass-1:Red Channel Side Blue Detector 35 K Pre-charge Cold Block (Polished) V-Truss QTY=4 Apex Point Inters Close to CG Mech. Box Pupil Imager Red Detector 35K

  23. Cold Mass-2:Blue Channel Side Access To Blue Filter Wheel

  24. Cold Shield: Shear Web Qty=4 5 part -assembly;bolted-follows shape of VJ Assembly Weight 65 lbs (Mat. Aluminum) Main Shield supported by main body of VJ with 4 shear webs Function: Reduce radiation load on Cold Mass Thermal Insulation: 4 shear webs 24 Shield Around Red Detector

  25. C: Design Details: Topics include.. • 1: Mechanism Design, Function & Performance • 2: V-Truss Design • 3: Baffles • 4: Assembly • 5: Access and Troubleshooting

  26. 1: Mechanisms (Location) • Warm Mechanisms: • Fiber Optic Calibration Source (Relay) • Tip/Tilt Steering Mirror (WFS) • Neutral Density Filter Wheel (WFS) • Focal Plane Mask (VJ entrance window) • Cold Mechanisms • Spider Wheel (Mech.Box) • Pupil Wheel (Mech.Box) • Dichroic Wheel (Mech.Box) • Red Filter Wheel (Mech.Box) • Blue Filter Wheel (Cold Block) • Pupil Imager (Front of Red Detector)

  27. Warm Mechanisms on AO-Bench (WFS-Side) Neutral Density Filter Wheel Custom Bread- Board Tip/Tilt Steering Mirror Optics Beam from Telescope Enters Relay here

  28. Mechanisms on VJ FPM (Warm)

  29. Type A. Discrete angular position mechanism Pupil Wheel Dichroic Wheel Blue Filter Wheel Red Filter Wheel Pupil Imager Type B. Continuous anti-backlash angular position mechanism Focal Plane Mask (warm) Spider Wheel Custom Mechanisms: 2 Types

  30. Type A Mechanism Profile • Discrete positioning : Using Detent • Detent Type: integral flex member, carries Hall Magnet • Position Sensing: Hall Sensor • Home Position: Double Detent in Wheel • Detent Mechanism: Compliant Worm *

  31. Components: Worm & Worm Wheel Slotted Worm Hub: Provides Angular “slop” in Wheel to be detented Detent Force: Must overcome Inertia + Friction of Wheel to be indexed Worm: Custom SP-3 VESPEL (Self lubricating) Low Tolerance Requirements Must run free to function properly Compliant Worm Design

  32. Type A Mechanism Example: Dichroic-1 Hall Sensor Carrier Detent Compliant Worm Assembly

  33. Type A Mechanism Example: Dichroic-2 Double Detent In Wheel Hall Sensor Carrier

  34. Type B Mechanism Profile • Continuous: Anti-backlash mechanism • Position Sensing: Hall Sensor, 1 magnet on Wheel • Home Position: Done with Magnet on Wheel • Worm: Material VESPEL SP-3 (Self-lubricating) • Anti-backlash Wheel: Off the Shelf

  35. Type B Mechanism Example:Spider Wheel Bearing Inner Races Preloaded Preload Disk Bearing Outer Races Clamped Preload Spring Fixed Housing Anti- Backlash Wheel Hall Sensor Spider Mask Rotating Shaft Hall Magnet

  36. Spider Rotator: Clipped Angular Contact Bearings Hall Sensor Worm Hall Magnet Rotating Spider Mask Anti-backlash Worm-wheel

  37. Type B Mechanism Example: Focal Plane Mask

  38. Animatics Series 34 Blue Access Cover To connect/disconnect From Drive Train Warm Motor: 7 Places Flex Coup- ling Ferro- Fluidic Feed- Through

  39. All of Cold Mass in NICI supported by 4 V-Trusses High Stiffness in-Plane-of Truss, compliance in out-of-plane direction Apex and shoe Material: Stainless 303 Apex to shoe connection: G-10 Insulator Vertical Height 14.5 inches, Base to Apex Epoxied assembly 2:V-Truss Design

  40. 3: Baffling for NICI Cold Block • Minimize off axis light scattered from components outside field-of-view to reach detector • Baffles oversized by 15% to reduce scattered light • Fore optics: 10 baffles (green) • Red Science Channel: 10 Baffles (red) • Blue Science Channel 10 Baffles (light blue) • 3 Baffles in front of detector are at detector temperature (30-35K), limits solid angle seen by detector (yellow) • White Beam from Dichroic

  41. 4: Assembly • A brief outline………

  42. Main body of VJ on 3’ x 6’ table top

  43. Main Shield (Subassembly of Cold Shield) is readied Getters are shown between CCC clearance holes

  44. Main shield installed in VJ • Main body of VJ shown transparent • Bolts to secure main shield to main body accessible from this side

  45. Cold Structure: Blue Channel Side Blue Filter Wheel is installed Optics installed: blue flat and blue Camera OAP Cavity For Pre-charge Motor For Blue Wheel(later)

  46. Precharge Can is installed prior to insertion

  47. Cold Structure ready for insertion into main body Ropes not shown: Weight 140 lbs

  48. Cold Structure shown inserted Bolts on V-Trusses accessed from this side

  49. Plan view shows access to bolts on V-Truss shoes 24 captivated bolts V-Truss Bolts

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