1. IBL Wire Handling Concepts for Beampipe Support and Adjustment
Neal Hartman
June 21, 2011

2. Wire “Handling” Beampipe Extraction Requirements
Must either extend wire with zero radius increase
OR remove adjuster
Preferably, we can handle both
Beampipe mounting requirements
Must be able to “mount” wires to IST far inside the package
This should be achievable with only wire action (not an absolute requirement, but preferable)

3. Extraction – Extend Wire with no Radius Increase
Installed Wire
Extension Wire
Wire Collet
Trim back wire braid
Wire Collet
Epoxy or solder
Wire Collet
Inject or flow
Into new collet
Now Wire
MAY pass
Through collet

4. Extraction – Remove Adjuster 1/2
Adjustor
Longeron
Wire
Install Temporary Jig
Temporary Fixation Jig
Adjustor
Longeron
Cut

5. Extraction – Remove Adjuster 2/2
Temporary Fixation Jig
Adjustor
Longeron
Remove Adjustor, install Extension
Temporary Fixation Jig
Small Wire Crimp
Longeron
Extension Wire
Now wire can pass into longeron

6. Beampipe Mounting Mechanism
OPEN for Insertion
Closed for Support
This is shown for
Beampipe Diameter of ~50mm

7. IST Mounting Mechanism
OPEN for Insertion
Clear bore
Dia. 130
Closed for Support
This is shown for
IST Diameter of ~86mm

8. Issues – Wire Mounting Cruciform Hole is about 200mm
This shouldn’t pose problem for inserting wire mounting system
However, mounts exceed this diameter when actuated
Could be problematic on one side of the ID for beampipe bakeout (large axial motion)
Wire also runs quite close to the cruciform
Limits the size of the “leaf springs” and could be problematic
May need positive engagement to ensure load carrying capacity for vertical wire (see next slide)

9. Wire Mechanism w/ Positive Engagement
Receiving fixtures
On horizontal springs
(perhaps unnecessary)
Pins on vertical springs
Actuation of horizontal wires performed first, then vertical wires, to engage pins and provide
Positive engagement for movement/support in both dimensions.

10. Potential Solution to Size of Wire Mounting Mechanism
Thinner
Thicker
Fits within 200mm
Diameter, but only barely…

11. Next Steps Clearly, all of this needs prototyping
Wire extension
Adjustor removal
Wire mounting
For wire mounting, before prototype…
Must analyse flexible structure (composite material)
Define thicknesses, laminate, etc.
Reduce size?
Define necessary clear bore for IST insertion…
One other note – baseline IBL weight will most likely exceed the wire tensions used in the original adjustors. This will most likely require some kind of re-design in order to handle higher load.