1 FPA Stage 2 Peer Review May 12, 2006 T. Brown

2 FPA Stage 2 Status Summary of Stage 2 activities Review current design status Review schedule details Look at D-site layout

3 FPA Stage 2 Activities Assemble a MCHP Bolt flanges together with shear capacity at some locations. –Possibility for reamed holes, matched tooling or epoxy filled holes. Install a half dozen magnetic loops on MCHP Set up a magnetic alignment system and validate it’s operation with a C-to-C connection (one time operation). Complete a full period assembly using magnetic alignment, with the success of C-to-C test. Perform alignment and electrical checks along the way.

4 An adjustable support stand is used to construct the MCHP Back stiffening structured added. Original configuration The stand has been revised to increase lateral stiffness. The center support is removed to accept Type-C MC

5 Type-A Type-B on A Stand repositioned to receive Type-C Type-C added along with supports MCHP Assembly Sequence

6 C-to-C coils are joined for interface check and to validate the magnetic alignment system Support brackets are added to support the MC when used with the magnetic alignment system.

7 The adjustable support stand drawings are finished and the analysis is “almost” complete and ready for a final design review.

8 An overlooked requirement has surfaced. Approximately 20 MC saddle loops need to be added to the MC’s over the full machine, not equally distributed. Question – can they be placed on a MCHP?

9 Magnetic alignment system The C-to-C set-up is used to validate the alignment method. Fiberglass tube with 20 wire loops on each side of the parting plane. A single hanger can be attached to reduce deflection. Shim stock is needed at the base of the aligned MC

10 Magnetic alignment system for FPA Used to validate mechanical alignment of a full period assembly and identify adjustments as needed Shim stock is needed at the base of the aligned MC

11 Flange activities….. This is not well defined at this time.  Three spherical are set to establish MC alignment  (machined?) shims are added to match orientation  Insulated bushings are installed. Some are reamed to provide shear capacity. Every MC has some studs. Type- A has a lot. A-to-A shear connection with 0.75” Ø holes

Ø hole Ø stud.125” radial clearance (excluding insulation) Just starting to play with this but; With an 040” axial movement dx, dy, dz) and a.05° rotation (rx, ry, rz) the stud and hole clearance is.059” and there is a 0.36” wing clearance. As-built conditions need to be considered.

13 Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 MC Fab Ron’s Current FPA Schedule Stage 2 schedule revised to current assembly arrangement. Stage 3 Stage 2 No change in Stage 3 schedule One set of Stage 2 fixtures Reqd

14 Plan View – Field Period Assembly Stages Stage 1 Stage 3 Stage 1 Stage 5 Stage 2 Stage 4 Completed prior to Stages 3 and 5 Move out. C site operation