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PI RACK AND CWR INSTALLATION CONCEPT REVIEW

PI RACK AND CWR INSTALLATION CONCEPT REVIEW. By Murali Krishna R. Kandlagunta mkandlagunta@sofia.usra.edu Phone: 650-604-0946. AGENDA. Date: 07/15/09 Time: 1:30 to 3:30 Location: Room 205 Meet me # 1-877-952-2053 Pass code # 113850

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PI RACK AND CWR INSTALLATION CONCEPT REVIEW

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  1. PI RACK AND CWR INSTALLATION CONCEPT REVIEW By Murali Krishna R. Kandlagunta mkandlagunta@sofia.usra.edu Phone: 650-604-0946

  2. AGENDA • Date: 07/15/09 Time: 1:30 to 3:30 Location: Room 205 Meet me # 1-877-952-2053 Pass code # 113850 • 1:30 to 1:50 Presentation of PI Rack dolly concept –Murali • 1:50 to 2:10 Discussion about the PI Rack concepts and action Items, schedule • 2:10 to 2:15 Approval or Rework design concept decision • 2:15 to 2:35 CWR installation concept presentation- Murali • 2:35 to 2:55 Discussion on CWR installation cart, action items and schedule • 2:55 to 3:00 Approval or Rework of the CWR installation concept • 3:00 to 3:10 Further comments or discussion • 3:10 to 3:20 Review Action Items • 3:20 Trip to PIFF for CWR cart demo • 3:30 Adjourn

  3. PI RACK DOLLY CONCEPT Purpose • A dolly that that can be an integral part of a 664 lbs fully loaded PI Rack so that it can be easily shipped, transported and maneuvered. Requirements • PI Rack shall be easily transferable from the dolly to the PI Pallet installed in the Aircraft • Total height of the dolly must be 4.16 inches. • Dolly shall be able to carry the fully loaded PI rack (664 lbs) • Dolly would be integral part of the PI Rack except when on the Aircraft. This includes shipping of the PI Rack with the dolly Assumptions and Estimations • Dolly is not Flight Hardware, so does not have to comply with Airworthiness standards • USRA provides the concept, design, analysis and installation documentation • NASA Ames approves the documentation provided from USRA • NASA Ames fabricates and inspects the dolly parts and assembly • NASA/USRA performs the fit check with the PI Rack • 9 dollies required. • Estimated cost of each dolly excluding labor costs: $1500 • Schedule tied to the arrival of the FORCAST instrument in Palmdale

  4. DOLLY CONCEPT 1 Spacers Rollers Positioner stops Floor stop Brackets

  5. Concept 1 • Dolly has small rollers within a U-channel • Each roller rated for 260 lbs • Floor stops are provided as the low profile steel caster does not have breaks • Mount holes are provided in the dolly to strap the PI Rack to the dolly. • C-section beam holds the PI Rack in place with fasteners • Dolly can be fork lifted to and from the shipping container • Can only be loaded from one side Floor stops can be modified to mount on the side too.

  6. Mount Holes Concept 1 with PI Rack

  7. Concept 2 Concept 2 with rollers in the middle

  8. Ramp and PI Dolly Interface

  9. PI Rack Shipping Crate Concept

  10. Questions • Who fabricates the dolly? • Schedule for finish. • Crates: none available and who is tasked to design them? • Does this follow the same procedure as the MADS drawings and documentation?

  11. CWR Installation Cart Requirements and Concept Purpose • A cart that can carry the fully loaded CWR in the upright position and has the ability to lift CWR to a range of 17 to 30 inches and tilt the CWR 16 to 20 degrees to install the CWR to the CWP. Requirements • Cart that has minimum lift of 25” and a minimum tilt of 17 degree angle. • Cart shall be maneuverable in the labs, within the Aircraft and through the aircraft door • Cart shall be able designed to safely support a fully loaded CWR

  12. Constraints • Telescope needs to be moved to approximately 17 degrees for installation, it’s the lowest stopped elevation • Fully loaded cart can only be operated on the reinforced portion of the aircraft floor. • A portion of the floor needs to be reinforced as shown in the figure 3. • Temporary test hardware wire harness may interfere during installation but can be worked around • CG of the CWR shall be closely monitored. • Cart has rigid wheels on one end. Swivel wheel are ordered • Cart would need additional weights to balance the CG shift for certain load conditions Assumptions and Estimations • Cart is not a Flight Hardware, so does not have to comply with airworthiness standards • Cart will be provided by USRA • USRA designs the interface plate between the CWR and the Cart • USRA provides concept, design, analysis and installation documents • NASA Dryden responsible for installation of reinforced floor panels • NASA Ames fabricates the interface plate • Estimated cost of the installation cart for CWR excluding labor costs: $4000 • Schedule tied to the arrival of the FORCAST instrument at Palmdale

  13. CWR Installation Cart After exploring options, BCART-500-LT, Lift and tilt cart from Beacon Industries was chosen. The cart specifications are as follows: • Platform Size (WxL): 21-½" x 40“ • Raised Height: 36“ • Lowered Height: 16-½“ • Degree of Tilt: 0-30 degrees • Capacity (LBS): 500

  14. BCART-500-LT

  15. Interface Plate

  16. Cart and CWR Assembly

  17. Aircraft Floor

  18. What's done so far? • Ordered and received BCART-500-LT in June • Basic Lift and tilt function of the cart were confirmed • CWR was strapped onto the cart with clearance underneath and padding on the side. CWR + Cart were checked for stability. • Load tested the cart with CWR fitted with different weight combinations. Test was conducted along with Dave Black. Test data presented in Appendix 1 of CWR cart installation document. Noted the stability of the Cart • Test data has instilled confidence that the cart will be stable under operating conditions • Replaced original casters with brake and swivel casters that are 1” higher than the original casters.

  19. Load Test, approaches Results, Observations and Conclusions Conservative parameters implemented • During testing Cart was lifted to maximum 36 inches. During installation the cart would be lifted to approximately 25 inches for installation at 17 degree telescope position as shown in the figure A.4 • During testing the cart was tilted to full range of 30 degrees while during installation cart would only be tilted to a maximum of 23 degrees • Position of the CWR, looking aft, is not at the center of the cart table during testing which is at a disadvantageous CG position. During installation CWR is placed more towards the center of the table. Please compare figure 5 and figure A.4 • No balance weights were employed during the testing. Balance weights will be available to achieve a more advantageous CG. Results and observations • Case 1 illustrates the error in the CWR CG locations compared to the actual mentioned in the ICD SI_AS_01 and the pro/e software • Cart was stable for all 15 cases tested. • Case 3 to case 8 and cases14 and 15 represent the CG in X (V) direction being out of the CG envelope shown in the figure 3, which means we never shall see such loading conditions on the CWR in this direction. Cart was stable.

  20. After case 16 testing, load testing was terminated. In this case Bay1 was completely empty and Bay2 was loaded with 60 lbs in the Front Bay 2 and Back Bay 2 was loaded to 90 lbs (60+30) adjustable electronic interface channels. Testing was terminated because the cylinder pin was binding probably due to asymmetric loading. Cart was stable at such loading as there was no tipping experienced at full lift and tilt. CWR will never see such a loading condition from the SI teams as this will violate the ICD requirement of the ICD SI_AS_01 by a difference of 3.51 in. • Case 11 is an important observation that needs to be closely monitored. Al though the 7.66” in z(u) direction is within the CWR envelope for the CG but at this point the CWR is very close to the edge of the cart. This is because the CWR mounted onto the cart in an offset position. So balance weights shall be used in order to offset the CG. Conclusions • If the back bay loading exceeds 60 lbs (case 7) balance weights shall be added to better balancing • Within the CG envelopes for most of the cases the cart was highly stable and sturdy.

  21. Photos of CWR Load Testing

  22. Questions: • Who is tasked with floor reinforcement (permanent or temporary)? • Can platform guarantee the telescope position at 17 degrees and minor rotation of the telescope if needed? • Does the fabrication of Interface plate follow the same procedure as MADS? • Schedule? No deadline is specified yet. FORCAST arrives sometime in September. We would like time on the airplane before hand to test install a CWR at 17 degrees once everything is fabricated, including the reinforced floor and the interface plate.

  23. Thank you

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