1. Takashi Matsushita t.matsushita@imperial.ac.uk Imperial College T. Matsushita 1 Station five – assembly/QA

2. T. Matsushita 2 Assembly/QA sequence Station five assembly/QA sequence 1. Visual inspection of doublet-layers - check any damage caused during transit 2. Trim fibres 3. Bundling/QA 4. Connectorisation/QA 5. Vacuum-chuck alignment 6. Glue doublet-layer to carbon-fibre station 7. Attach connectors to carbon-fibre station 8. Cut fibres 9. Pot fibres 10. Polish fibres 11. CMM of station five

3. T. Matsushita 3 Trim fibres Fibres are trimmed on rubber sheet with cutter knife 1. Align centre fibre on horizontal white line 2. Hold down about 10 fibres with finger 3. Cut fibres along vertical white line NB: Fibres are cut again before potting/polishing of fibres. We will probably use hot-knife (knife- shaped soldering tip). Cut surfacePolished surface

4. T. Matsushita 4 Station assembly - tools Station holder Bundling Comb Connectorisation bridge (old design) Vacuum chuck Alignment jig

5. T. Matsushita 5 Bundling - tool Comb – for bundling and QA [version 3] bundles of four columns (6-5-6-5) for one connector (22 way) Comb in use

6. T. Matsushita 6 Bundling – map view V Start bundling from channel 108 to right, then channel 109 to left View from end of chuck looking at the connector end of the fibre ribbon

7. T. Matsushita 7 Bundling – map view W Start bundling from channel 106 to right, then channel 109 to left View from end of chuck looking at the connector end of the fibre ribbon

8. T. Matsushita 8 Bundling – map view X Start bundling from channel 106 to right, then channel 109 to left View from end of chuck looking at the connector end of the fibre ribbon

9. T. Matsushita 9 Connectorisation - tools Bridge – holds ten connectors Bridge in use Fibre radius guide

10. T. Matsushita 10 Connectorisation - map View V View W View X Thread numbered bundle to corresponding connector hole Start connectorisation from C1 to C5, then C10 to C6

11. T. Matsushita 11 QA – light source/optics LED: EG-5UV405-15 from ETG Inc. - Peak 405 nm, range 400-410 nm - 12 mW output Spot size ~ 0.5 mm x 5 mm on white paper on doublet-layer Needs mount for stage LED Spherical lens Cylinder lens Slit 40-40mm matched lens

12. T. Matsushita 12 QA - setup Stage for LED scanning arrived on 3rd Aug. Need to set it up Table for bundling/connectorisation/QA is being manufactured stage Vacuum chuck CCD mount Details of table for vacuum chuck/ CCD mount

13. T. Matsushita 13 QA - counting CCD image of four columns of comb and corresponding connector will be recorded with help of GUI 7 fibres in each bundle7 fibres in each hole

14. T. Matsushita 14 QA - scanning Need to develop stage controller programme Need to illuminate single fibre with smaller spot size Bundle sequence map [view V]

15. T. Matsushita 15 QA – check sheet for view V

16. T. Matsushita 16 Vacuum chuck alignment Set the cross hair to a reference fibre at one end 1. Scan across to the other end, check the offset, reduce the offset to half by adjusting cam. Then reset the cross hair to the reference fibre 2. Scan back and check the offset, reduce the offset to half Repeat step 1 and 2 Hole for cam

17. T. Matsushita 17 The rest Glue doublet-layer to carbon-fibre station Attach connectors to carbon-fibre station Cut fibres Pot fibres Polish fibres - two diamond fly cutters will be available; need to book CMM of station - how many points? need to book Do we need mirroring check at Imperial? It is very difficult to check/record during QA procedure.

18. T. Matsushita 18 Summary Preparation for station five assembly/QA is underway Fibre degradation test is underway at Brunel TODO 1. Set up stage for scanning 2. LED optics mount for stage 3. Smaller slit for single fibre scanning