Ring Flavors and Loading & Integration Boundary Conditions UPDATE

1. Ring Flavors and Loading & Integration Boundary ConditionsUPDATE Neal Hartman 22 July 2019

2. Basic Assumptions • Structurally, all rings of a given type are identical • All rings are essentially phi-symmetric, except for the pipe • The pipe must be positioned at a given phi (this is non-negotiable for welding and manifold)

3. Two Possible Paradigms • Paradigm 1 - Ring Flex and Pigtail are integrated • Option 1 • There is only 1 variety of ring flex (or board) per ring type • Modules and buttons must rotate around the ring with change in phi-position for the services • Consequences of Option 1 • Modules must be loaded at any phi relative to the pipe (including under the pipe) • Rings must be assembled into the QS radially (complication of tooling) • Benefits of Option 1 • Only 1-2 flextype(s) per ring type • No connectors on Ring Flex

4. Phi vs. Z Position Services Modules Buttons All rotate With phi As a function Of Z Footer

5. Phi Clocking on Ring Ring 1 Ring 3 Ring 2 Phi steps are non-uniform and depend on both Z and R, i.e. There are many flavors, not sure yet how many. This will require multiple positions on the loading tool. Footer

6. Module loading orientations Every degree of Module Overlap with pipe is possible Footer

7. Quarter Shell Assembly Ring in this tray installs In this radial direction Ring in this tray installsIn this radial direction Footer

8. Supporting Rings During Assembly QS must also be independently Supported from the assembly fixture (not shown here) Install Orientations Rings must remain Supported by some external Fixture (shown as ”table” here) That constrains them during The assembly process Footer

9. Two Possible Paradigms • Paradigm 1 - Ring Flex and Pigtail are integrated • Option 2 • There are multiple varieties of ring flex (or board) per ring type • Modules and buttons do NOT rotate around the ring with change in phi-position for the services • Ring flex rotates around ring in 1-module (36 degree) increments • Consequences of Option 2 • Enough flexes must be made to take into account the distinct tray vs. module clocking orientations • Rings must still be assembled into the QS radially (complication of tooling) • Benefits of Option 2 • No connectors on Ring Flex • No loading modules under the pipe

10. Quarter Shell Channels Original goal was evenly spaced channels, like this… which would maybe mesh with few ring flex flavors Footer

11. Complication – Bundles are not all same width…so ring clockings not regular spacings not at all regular… Ring Pipes 2x Coupled Barrel 1/4 2x Coupled Barrel 2/4 2x L0.5 But Direct Data means that all trays are filled to same height while width changes – There is no extra space, other Than going taller and closer to the 14mm Envelope limit Barrel 3/4 2x L1 Barrel 4/4 Barrel Pipes Footer

12. Two Possible Paradigms • Paradigm 2 - Ring Flex and Pigtail are separate • Option 1 • Pigtail is connected by solder (or similar) to the ring flex (or board) • Pigtail connects to PP0 by connector • Modules and buttons do NOT rotate around the ring with change in phi-position for the services • Ring flex rotates around ring in 1-module (36 degree) increments • Pigtail takes up mismatch between tray and ring clocking • Consequences of Option 1 • Several types of pigtail will be necessary • Attachment method to ring flex must be developed • Rings must still be loaded radially in a variety of angles into QS • Benefits of Option 1 • No connector on Ring Flex • No fabricating many different styles of ring flex (large and expensive) • No loading modules under the pipe

13. Two Possible Paradigms • Paradigm 2 - Ring Flex and Pigtail are separate • Option 2 • Pigtail is connected by connector to both ring and PP0 • Modules and buttons do NOT rotate around the ring with change in phi-position for the services • Ring flex rotates around ring in 1-module (36 degree) increments • Pigtail takes up mismatch between tray and ring clocking • Consequences of Option 2 • Several types of pigtail will be necessary • Connector on ring flex may have reliability issues (TBD) • Benefits of Option 2 • No fabricating many different styles of ring flex (large and expensive) • No loading modules under the pipe • No loading rings at multiple phi orientations (simple sideways slot-in integration)

14. Decision/Risk Matrix • We can argue about these relative values, but at least the senses are correct • Definitely seems to point to some form of paradigm 2 • But of course this is only a suggestion…. Footer

15. Rings that follow in the same orders can use the same flexes, à priori Even spacing Most regular order Footer

16. Rings that follow in the same orders can use the same flexes, à priori 4 red flavors (x4) 1 green flavor (x4) 1 yellow (x2) 1 cyan (x2) 1 dark blue (x2) 4 independents (x1) 12 flavors for 30 rings Footer

17. BUT!!! This causes some issues for welding…. Footer

18. Welding Requires space in adjacent shell Welding access detail Welding access along edge of Quarter Shell Manifold detail Footer

19. Welding Requires space in adjacent shell Weld head needs to stay away from ring Footer

20. Cascade of Rings allows Weld Space in Adjacent Shell Already Potentially Two problems… Footer

21. Conclusions • Total of 12 Flex Flavors if we can rearrange rings • But, not entirely obvious we can do this • Welding space is somewhat compromised • Maybe can handle (high Z locations = more space) but not sure • Martin working on 3D routing now, can put this to test soon in CAD Footer