tmt.opt.pre.07.062.rel01 hps-280001-0105 – volume-7 – october 24-25 2007 – slide 1 tmt m1...

TMT.OPT.PRE.07.062.REL01 HPS-280001-0105 – Volume-7 – October 24-25 2007 – Slide 1

TMT M1 Segment Support Assembly (SSA) Preliminary Design Review (PDR)

Volume-7: SUMMARY AND FUTURE PLANS

Pasadena, CaliforniaOctober 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 ProjectGeorge Angeli, Curt Baffes, Doug MacMynowski, Terry Mast, Jerry Nelson, Ben

Platt, Lennon Rodgers, Mark Sirota, Gary Sanders, Larry Stepp, Kei Szeto

TMT ConfidentialThe 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.


OutlineVolume-7: Summary and Future Plans– Prototype Testing

Test Plans– Component

– Full Prototypes

– Schedule

– SummaryWhere we are and where we’re going

Technical Risks

– Conclusions


PROTOTYPE TESTING

Summary & Future Plans


Prototype TestingTest Plan Outline– Component tests

Warping harness actuator & leaf springs

Adhesive bonding tests

GCMS testing of Stepper Motors

– Full Segment Prototypes:P1-SSA Prototype

– 1.44m Aluminum Spherical Segment

Regular Hexagon, Meniscus Shaped

– Learn about assembly process and tolerance stack-ups

– Mechanical & Electro-Mechanical Form, Fit and Function Testing

P2-SSA Prototype– 1.44m Glass-Ceramic Spherical Segment

– Polishing Prototype

– Optical performance verification

Print-thru vs. zenith angle and temperature

Warping Harness optical performance

SSA Components for P1-SSA & P2-SSA nearly identical– P2 can include minor modifications to P1design (schedule limited)


P1-SSA Prototype TestingP1 Test Facility and Equipment and Instrumentation Requirements

(Note: All work to be performed at IMTEC except vibe & adhesive testing)

– Dummy mirror cellWith tip/tilt capability 0-180 degrees, two axes, manual adjustment.

– Overhead crane or hoistGeneral handling operations

Segment Installation/Removal verification

– Laser tracker system (or other method/equipment)Determine segment position during various test operations

– Jacking (zenith pointing and inclined)

– Registration repeatability (zenith pointing and inclined)

Need to subtract deformations of the test stand from the global motions

– Instrumented Static Test FixtureApply load and measure load & deflection

Apply piston and lateral loads to segment to characterize stiffness and strength

– Main actuator simulatorsStepper driven screw actuators for cyclic testing of PTT flexures

– Warping Harness Controller and DAQ (as discussed above)


P1-SSA Prototype TestingWarping Harness – Component-level testing to include:

– 3 ea. Type-1 leaf springs (single 190mm long beams)

– 3 ea. Type-2 leaf springs (both arms of each assembly used)

– 9 Axes total

Motion control and data acquisition:– National Instruments DAQ card

Analog inputs for strain gages

Digital outputs for stepper motor and relay control

– 1.6 kHz low-pass Strain Gauge module (10V excitation, Gain of 100)

– Hardware and software suitable for both Component and P1-SSA testing

Component test hardware can be re-used on P1-SSA Prototype

– P1-SSA Prototype-level testingMechanical & Electro-mechanical Form, Fit and Function of WH on an Aluminum Segment


P1-SSA Prototype TestingWarping Harness test objectives – Assess assembly and installation aspects [Component and P1]

Initial alignment of screw-drive to leaf spring– How does it feel? Easy to align to run free? Sequence of assembly?

Motor removal and replacement

– Verify actuator range of travel [Component and P1]– Determine optimum stepper-motor driver parameters [Component and P1]– Verify moment output [Component]

Linearity vs. step count– screw pitch lead error effect– screw straightness

Resolution– Stick-slip and torsional wind-up in leaf-spring and drive (shaft coupling)

Cross-coupling error– Axial load in beam due to misalignment, screw run-out and large-deflections

– Hard-stop survival and recovery [Component] Snap-ring end-stop strengthCan we reverse off hard stop using motor?Manual intervention (feel of turning the knob – obvious which way to turn?)Idiot proof check: Could someone damage anything by turning knob violently?


P1-SSA Prototype TestingWarping Harness test objectives – Life cycle testing [Component]

Lifetime, wear, friction vs. cycles

Assess strain gauge creep

– Stall torque margin [Component]measure torque vs. stroke using torque gauge (motor removed)

– Dead-band [Component and P1]Verify that we can find dead band

Measure residual moment when in dead band

– Warm-up and heat dissipation [Component]Develop operational timeline

– Gauge power-on time constant determination

– Gauge and motor multiplexing delay and performance assessment

– Settling times

– Determine heat dissipation [Component]– Stepper motor and strain gauges combined considering operational timelines

– P1 Hard-stop test sequence [P1]Run actuators to hard stops in specified sequence to test flexures and pivots


P1-SSA Prototype TestingSubcell Integration and Alignment Testing– Verify Fixed Frame and AAP installation process (handling and fit)

Fully test Sector-A,-C,-E hardware

Build and fit-check Sector-B, -D, -F (requires BDF mirror cell mockup - simple)

– Verify Fit & function of 3 ea. turnbuckle positioners

– Verify installation of Dummy Mass and Surveying Targets

– Perform simulated alignmentsCharacterize resolution, accuracy and repeatability of the alignment process

Verify range-of-motion

Verify design of AAPs, tools, and procedures


P1-SSA Prototype TestingRegistration System– Verify repeatability of segment installation and removal

Perform in parallel with Jack Testing

Multiple install/removals

Use tip/tilt of mock-up Mirror Cell to assess effects of part clearance– Zenith pointing & inclined

Jack System– Jack installation and removal form, fit, function

– Verify segment position control at critical jack heightsSegment zenith pointing

Segment inclined to 14.5 deg (2 cases: gx & gy) [0.25g lateral]

– Strength verification2x Factor of safety: inclined to 30 degrees (2 cases: gx & gy) [0.5g lateral]

– Requires mirror cell mock-up with tip/tilt capabilitylaser tracker to measure relative motion (subtract fixture compliance)

– Shaft hard stop verification

– Stall torque/force verification (Max force <1.5 x payload)


P1-SSA Prototype TestingLifting Talon – Form fit & function

– Interlocks and handoff to Jack (Scope TBD – Vertical or inclined?)

SSA Lock Test– Verify lock strength and function

Perform repeated lock/unlock operations with varying loads applied to the system– 1g dead weight

– add mass to system to simulate force required to over-power actuator off-loader

Inspect components for wear or damage

Fatigue Test– Life-cycle testing of lateral guide flexure and actuator rod flexures

Test setup inclined to 45 degrees to induce lateral load

Main Actuator Simulators cycled through range of PTT motions (+/-2.5mm)

Axis of inclination varied periodically to simulate segment interchange between sectors

10 Cycles/night x 365 x 50 years = 182,500 cycles [TBC]

Test 2X the expected life: 365,000 cycles

at 1200 test cycles per hour (3 sec/cycle) requires ~13 days


P1-SSA Prototype TestingAdhesive bond testing– Required if published data not available:

Strength, CTE & Modulus measured over TMT temperature range

Static stiffness– Perform load-deflection test to verify 12N/micron piston stiffness requirement

System Dynamics and Strength (Highest-risk testing performed last) – 3 axis Shock & Vibe testing (at outside vendor: e.g. Ball Aerospace or JPL)

Operational configuration– P1 Prototype attached to adapter that simulates Mirror Cell interface

– Dummy actuators: K = 10N/micron

Determine base-input transfer functions and mode frequencies with low-level inputs– Correlate with FEA, verify minimum frequency requirements

– Measure optical surface motion and amplification factors

Qualify design to survival/handling shock inputs– repeat low-level tests to screen for failure

– Shipping configuration qualificationSegment supported in container with partial SSA supported by segment

– This test could be delayed until later date when more is known about shipping


SCHEDULE



SSA Project ScheduleSUCCESS BASED: Assumes no major changes to design

October 24-25 2007 SSA PDR - TodayDecember 15 2007 Design-lock for P1-SSA prototype (PDR + 6 weeks)January 15 2007 Order WH Component-test Hardware & InstrumentationJanuary 31 2008 Begin procurement of early release prototype parts

- Long lead and low risk parts

February 15 2008 SSA Prototype Drawing Releases Complete (Design lock + 2 months)- Nominal 1.44m segment

February 16 2008 Begin design of test equipment (Cell, vibe fixture, etc.)April 1, 2008 Begin procurement of test equipment (3 month lead time)May 15, 2008 Begin final assembly of P1-SSA Prototype (3 months after dwg release)

- 45 day duration

July 1, 2008 Begin P1-SSA Mechanical testing (90 days) - Form, fit & function mechanical testing

August 1, 2008 Revise design and drawings based on initial testing (30 days)September 1, 2008 Begin procurement of P2-SSA prototype parts (2 month lead time)November 1, 2008 P2-SSA Prototype ships to polisherApril 2009 Propagate SSA design to 82 types – 5 months

- Final drawing package

June 2009 SSA Final Design Review


SUMMARY



Where We AreWe have a mature Preliminary Design

We do not have a finished Preliminary Design

Several details to complete– Balance of whiffletrees & correcting moment implementation

– Resolve optical performance issue or decide performance acceptable as is

– Fine tune sheet flexures

– Resolve 35 Hz and Mass Budget deficiencies or work to new requirementsCould proceed with MSA portion of prototypes and let Fixed Frame design catch-up

– Adhesive selection needs review

– Final material selection review

– Produce detailed drawings

– Crane/Talon/Segment/Jack integration needs refinement


Where We’re GoingFuture Tasks:– Finalize Preliminary Design

– Update dimensions affected by segmentationNominal AAP location (hole in fixed frame)

a few mm change from current CAD model

– Release P1-SSA Prototype Drawings

– Begin P1-SSA Procurement

– Begin component test procurement

– Prepare Test Plans

– Design and Fabricate Test fixtures

– Procure Data acquisition and Motion Control system for WH testing

– Define metrology equipment for P1-SSA testingDetermine cost and lead time

Rent equipment, or contract with consultant

– If required, the addition of passive damping will be a major undertakingCould be phased in to maintain Polishing Development schedule


Technical Risks

Technical Risk Risk Reduction

Verifying optical performance predictions. Applies to Gravity, Thermal, and Warping Harness performance.

Optical testing of P2-SSA prototype.

Optical effect of manufacturing tolerances and assembly errors.

Perform analysis to determine sensitivities. Include in the PSS analysis/budget.

Difficult to reach the 35 Hz requirements. Costly in terms of mass, material, and Engineering.

Relax the 35 Hz frequency requirement.

Mass estimates exceed the budget. Adjust mass budget and/or 35 Hz requirement.

Adhesive selection and bond performance characterization are a concern. The baseline (EA2216) has a high CTE and a high Modulus at low temperature. Causes excess distortion and stress. May be fine, but deserves review.

Find a low modulus, low CTE adhesive with heritage and test data relevant to our application.

Verifying performance of Alignment and Registration systems.

Prototype testing will help resolve.

Manufacturing tolerances as related to the Alignment, Gap and Jacking budgets

Complete the P1-SSA drawings and build hardware.

Manufacture of many thin and slender parts. Distortion and dimensional control important.

Prototype production will clarify issues.


CONCLUSIONS



ConclusionsThe SSA Preliminary Design is nearing completion

We must decide on:– Optical performance at system level – Acceptable?

– Dynamic performance – Acceptable?

– Passive damping – Required?

– Crane/Talon/Jack system strategy – Change Talon concept?

Schedule dependent on above decisions

Build Hardware ASAP– Proceed with Warping Harness prototyping

– We need hardware & testing to evolve to a SSA Final Design

Schedule is aggressive– Success based

– Design changes may impact P1-SSA & P2-SSA delivery


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.07.062.rel01 hps-280001-0105 – volume-7 – october 24-25 2007 – slide 1 tmt m1...

Documents

rel01 hps

p1ssa p2ssa

outline volume

segment prototypes

segment position

tmt project manager

test stand

tmt project george angeli