PXL Mechanical Hinge rework in aluminum and carriage redesign Kinematic rework and analysis Insertion test - detailing and fabrication instructions Spatial Calibration

New carriage design Low mass, reduced space usage

Test of cable load support Analysis in seconds

Hinge structure in aluminum, improved stability. Low mass, 2 mm thick - stable. Expanded air duct passage.

Cam guide FEE check 20 lb load, 20 micron deflection, yield – no problem

Kinematic mounts, cock and lock spring loaded contacts to define detector location when inserted

Kinematic Mounts Insertion and Retraction Forces May 11, Joseph Silber

Behavior to model 10

Offset, Radii Horizontal offset makes manual analysis of design difficult. R1 ≠ R2 contributes further to this. 11

Further considerations Constraint surfaces are not C1 continuous, so contact conditions require some additional searching logic, and discontinuities in calculated forces are expected. The combined assembly consists of two “top” mounts and one “bottom”. These effects must be calculated in phase with each other for summing up the forces. Total insertion and retraction force differ in magnitude, due to non-conservative friction forces. Friction forces differ depending on static versus dynamic. 12

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Status We now have a general code for analyzing kinematic constraints of arbitrary piecewise complexity. Now use code to optimize the design. Analysis of current design shows potential gains in: – smoothing the insertion and retraction force curves – eliminating the negative force condition (“suck-in”) – simplifying the offset and radius conditions of contacts 16

rail test system rail_test_system.SLDASM 17 5/3/2010 this document: models:

18 part/filecnfgmaterialsourcetotal # p. ref grf 1PIT_glue_plate_to_rail_hanger_free.SLDPRT6061UTA16 2PIT_end_fixture.SLDPRTPIT east endMIC6LBNL/UTA?1 3PIT_end_fixture.SLDPRTPIT west endMIC6LBNL/UTA?1 4PIT_end_fixture.SLDPRTPST east endMIC6LBNL/UTA?1 later 5PIT_end_fixture.SLDPRTPST west end MIC6LBNL/UTA?1 later 6Tooling ball MC 8481A34steelMC36 7tee_nut_custom_half_in_slot.SLDPRT6061UTA6 8PIT_base_fixture.SLDPRTPITMIC6LBNL/UTA?1 9PIT_base_fixture.SLDPRTPSTMIC6LBNL/UTA?1 later 10PIT_fixture_flex_lever.SLDPRT6061UTA4 11PIT_hole_fixture_end_addapter.SLDPRT6061UTA1 later 12PIT_hole_fixture_end_addapter_mirrored.SLDPRT6061UTA1 later 13dowel pin X.375 in, MC 98381A470steelMC4 later 14PIT_hole_fixture_beam.SLDPRT6061UTA1 later parts list for assembly: rail_test_system.SLDASM example

19 this plane perpendicular to a ref cylinder axis line between holes centered on ref cylinder axis to ±0.05 mm separation tolerance ±0.05 mm or match drilled with butch_plate_single.SLDPRT diameter tolerance: mm mm for bullet insert press fit this and other 2 similar planes tolerances to chord and axis of ref cylinder: ±0.05 mm ±0.05 mm tolerances are to preserve glue bond thicknesses these and other similar holes diameter tolerance: ±0.005 mm for press fit with tooling balls, glue in OK if ends up sloppy grand_master.SLDPRT Example tolerance spec

development of spatial map Bob Connors Spiros Margetis Yifei Zhang touch probe 2-3  m (xyz) and visual 2-3  m (xy) 50  m (z) active volume: huge 10 gm touch probe force visual sub micron (xyz) repeatability 5  m accuracy over active volume no touch probe active volume: 30 in X 30 in X 12 in MEMOSTAR3, 30  m pitch

Visualization of touch probe data in solid works Coordinate Measuring Machine gives touch probe ball location plus a unit vector in the direction of the touch force. This figure shows ball location plus ball radius times unit vector. Michal and Xiangming have developed code for putting coordinate machine data into more convenient form