TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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.

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 3 SUBCELL INTEGRATION & ALIGNMENT Integration & Handling

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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 mm Also see presentation on Surveying and Alignment Mass Simulator (Cast Iron) Surveying Target, 3 ea.

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 5 Fixed Frame Installation Install AAP Posts & Mount Fixed Frames in Nominal Position Sectors A,C,ESectors B,D,F

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 6 Mass Simulator Install Mass Simulators: –Cast Iron, Low cost, simple, safe –Correct Mass and C.G. –Low-profile shape –Recyclable Mass Simulator (208 kg Cast Iron) Nut Clamp washer (or bar) Steel tube with welded flange Nut & Washer typ. All-Thread Lifting fixture

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 7 Target Holders Surveying Target Holders –Installed temporarily –Interchangeable –Target interface TBD Depends on surveying system Target Holder

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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 In-Plane Positioners (Removable Tooling) See Vol-2: for Alignment budget

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 9 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 Post: bolted to truss Spherical Nut 2ea. Spherical Washer 2ea. Lock Nut 2ea. Dowel Pins 2 ea.

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 10 SEGMENT LIFTING JACK & LIFTING TALON Integration & Handling

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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:  d  < +/-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

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 13 Segment Lifting Jack Segment Lifting Jack Operations: –Raised 300mm –MSA placed on jack –Lowered onto Subcell

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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 14.5 deg 300mm Perimeter of array

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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)

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 16 Segment Lifting Jack Components of Jack System –Center-shaft: 5.2kg –Jack: 7.0 kg Jack, motor, housing, end pad Center Shaft Spherical Radius (R250mm) (Permit tip/tilt at registration Clocking groove Moving frame pin engages in groove) Nook ActionJac Model EM1-MSJ-1 310mm stroke Track Groove Clocking Pin (Engages in slot in tower) Encoded Stepper Motor

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 17 Fixed Frame Fixed Frame (Top plate removed) Actuator Attachment Castings Jack Center Shaft Support and Bushings Registration Pins 3 ea. Tower Clocking Pin AAP attach hole Holes for surveying target holders 3ea. Jack Center-Shaft Guide & Retention Pin

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 18 Center Shaft Installation Fixed Frame and Center-Shaft Jack Center-Shaft Guide & Retention Pin

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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 0.5+/-.25mm clearance (on dia.) Length of fit: ~90 mm Lead-in cone allows 26mm misalignment Moving Frame clocking pin engaged in Shaft groove: Coarse clocking control for mm positions

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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 Clocking Pin engages in Tower slot (Note lead-in cone +/- 29mm tolerance) Clocking Pin clearance increased at 10mm (for registration) Array Insertion Registration

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 22 Gap Budget during Jacking

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 23 Gap Budget during Jacking

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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 Moving Frame Lifting Talon Self-aligning, kinematic joint V-groove in moving frame

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 28 Talon Concept Vertical Contact Switches –Talon opened and closed when both are “green” Upper Lower Upper Lower Upper Lower Contact - Low Contact - High LOWHIGHCLEAR (OK to OPEN)

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 29 Talon Concept Capture Limit Switches –Indicate Moving Frame tang engaged in Talon Socket Switch Closed MF Captured Switch Open

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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 Jack Raises Segment +300mm Talon is lowered into positionTalon ClosesJack lowers segment onto TalonCrane extracts Talon and Segment Upper Lower MF Captured INTERLOCKS Upper Lower MF Captured INTERLOCKS Upper Lower MF Captured INTERLOCKS

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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 mm 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. Jack raised to +260mm Crane lowers segment onto Jack Position: mm Jack raised until MF liftoffCrane and Talon DepartJack lowers segment into arraySegment on Jack, Talon opened Upper Lower Upper Lower MF Captured INTERLOCKS

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 32 Conclusions Talon/Crane/Jack Integration is challenging –Talon design requires certain crane accuracy and motion –Ongoing work will integrate systems

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 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.

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 34 BACKUP SLIDES

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 35 JACK SHAFT DEFLECTION ANALYSIS Integration & Handling

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 36 Bushing Arrangement d Dimensions: –ID = 35mm –OD = 50mm –Length = mm –Center to center distance: d –28.6mm ≤ d ≤ 291.4mm Material properties: –E = 76GPa – ≈ 0.3 –(  c ) All ≈ 31.03MPa

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 37 d L F R1R1 R2R2 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 -7 m 4 Kinematic deflection –c = c max = mm –28.6mm ≤ d ≤ 291.4mm Total deflection Reaction forces Contact stress in Bronze bushings –Allowable contact stress ≈ 31.03MPa –Bushing length = 2 × mm –K D = 2E4m –C E = 1.64E-11m 2 /N –p = R / Radial clearance c

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 38 Optimal Bushing Distance Optimal bushing distance: –d optim = mm –  (  c ) max = 0.26MPa  F.S. = / 0.26 =  contact stress not an issue  –Total deflection is fairly insensitive to d for d ≥ 150 mm –d = 150mm is chosen for manufacturing reasons

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 39 Relative Deflections 22 11 Installed ConfigurationLifted 100mm 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

TMT.OPT.PRE REL01 HPS – Volume-6 – October – Slide 40 Deflection Analysis Results 22 11 Configurati on Lift (mm)  1 (mm)  2 (mm)  kin (mm)  2  1  k (mm)  ’  2  k (mm) Dimensions: –Bushing distance: 150mm –Radial shaft clearance: mm Blue is Undeformed. Scale is arbitrary. Installed ConfigurationSSA Lifted 100mm