1. Support and alignment of PXL box with MSC, operation steps
During this operation the PXL box rests on two 6 inch aluminum box beams. These beams are supported independent of walking platform
Each half of the PXL detector is supported on two round slide rails both in the PXL storage box and in the MSC.
In this procedure the box most be accurately moved into position to align the slide rails of the box with the rails in the MSC
Up dated, includes measurement tool for checking alignment of two rail systems and instructions
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mechanics/Cave/HFT_wide_angle_hall_top v2.SLDASM

2. Outline Insertion box support Insertion steps Alignment tool
Requirements
Design
Operation
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3. This model is incomplete, replace
View of East Pole Tip With West Box Support
This model is incomplete, replace
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4. Install the west box beam (assembly weighs 83 lbs)
mechanics/west pole tip/WEST_POLETIP_ASM-1_2008.SLDASM
remove the BBC
Install the west box beam (assembly weighs 83 lbs)
The end supports stay permanently bolted to the end cap.
Note, there is a support lip for the box beam to ease installation when the beam is bolted into place.
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mechanics/cave/HFT_wide_angle_hall_top v2.SLDASM display: view for BxS

5. Slide the box into roughly the correct position
The box must be maneuvered as shown to clear various obstructions.
The box has a base of polyethylene to allow it to slide more easily over the channel beams.
Guides on the channel help in this positioning (see next slide)
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6. The x motion is limited by a stop that contacts the polyethylene base of the PXL box as the box is slid in z toward the interaction region
note this part now a box beam
The button also provides a limit on the final z motion and the box can then be slid in x to the end of the guide groove for the final rough positioning.
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7. Fine adjustment system
Z adjustment
West rail
Full 6 degrees of adjustment
Adjustment range > ± ½ inch Ys Z Yn Xw
Y adjustments
X adjustments
West rail
East rail
East rail Xe Y X Z Yn Ys Xw Xe y z x
STAR coor. + rotations
Jack Screw identifications
East
North
West
South Ye
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8. Fine positioning of the box to align the 20 mm round PXL rails
Adjust the x and z position screw assemblies on the west channel beam so that the coupling pin can be inserted
Use the two y adjustment screws on either end of jack assembly to raise the box to start the alignment of the PXL rails. This raises the box above the guide buttons so that there is full freedom for the fine adjustment
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9. Fine positioning of the box to align the 20 mm round PXL rails
On the east rail seat the linear bearing pad into the channel. This will require adjusting the x screw and holding the pad in the right orientation and raising the y screw
Once properly engaged use the y screw to raise the box off the guide buttons
The x and y adjustments can now be used to fine tune the box position
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10. Alignment Requirements
Collinearity
The rails in the box must be collinear with the rails in the MSC to allow the carriage to transfer from one set of rails to the other with out binding.
Slider bearing  L 
Carriage support rails
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11. Alignment Requirements
End to end alignment
The rails must but close enough end to end to allow the slider to pass over the intersection
In our case with  = 100 m we have a 200 m tolerance assuming that the separation of the two rails are the same in the two systems.
This alignment gets forced by using tapered butt joints
The initial alignment has to be good to ~ 3 mm to engage the tapers. Bending the rails by 3 mm will not violate the collinearity condition.
Carriage support rails
Slider bearing 2
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12. Alignment measurement system
Laser Auto Collimator East
(LACE)
Laser Auto Collimator West
(LACW) Y X Z Yn Ys Xw Xe y z x
STAR coor. + rotations
Jack Screw identifications
East
North
West
South
STAR
coordinates
The above alignment monitor is used to determine the alignment of the two rail systems with respect to each other as the box support screws are adjusted. The system allows sequential independent setting of the 5 degrees freedom, i.e. the two angles of collinearity (x, y), x position, y position and z the angle about the z axis. This is accomplished with an auto collimation laser system plus two video cameras viewing survey targets. These parts are identified in the following slide. The two elements slide on the rails with spring loaded v blocks. The right element, LACW is located on the MSC support rails and the left element, LACE is located on the rails in the PXL transfer/storage box. The v blocks are tapered such that when the rails are aligned roughly by eye the right element can be slid across from the box rails to the MSC rails.
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Laser auto collimation figures from align_figure_instrument.SLDASM

13. Alignment measurement system, identification of parts
cross hair rotation adjuster
camera targets
video cameras
cross hair diode laser
laser auto collimator mirror
mirror angle adjuster
laser pointing angle adjuster
The above figure shows the two elements (LACW and LACE) mounted on a single set of rails. This the configuration for aligning the system prior to use.
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14. Alignment Instructions
Outline of steps
Zero the laser auto collimator
Establish camera target match
Adjust box into rough alignment by eye
Adjust box into collinear alignment (x, y) with laser auto collimator
Adjust box into x,y and z alignment using the laser cross hairs
Adjust box into x, y and z alignment using cameras/survey targets
Recheck collinearity
Engage rails Y X Z Yn Ys Xw Xe y z x
STAR coor. + rotations
Jack Screw identifications
East
North
West
South
from align_box_support_fig.SLDASM
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15. 1. Zero the laser auto collimator
Install the LACE and LACW on a set of calibration rails – could be the rails in the PXL storage box
Separate the two elements by 1 to 1.5 meters
To install
engage v block on lower rail
open spring loaded v block and engage on the upper rail and release
rotate safety latch into protect location – this still relies on spring load to engage the rail, but it prevents accidental derailment
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16. 1. Zero the laser auto collimator
Adjust laser pointing to center on mirror
Adjust laser cross hair rotation and secure with set screw
Adjust laser focus
center laser image
on mirror center cross hairs
laser vertical and horizontal angle adjust
rotate to focus laser cross hairs
set screw to secure cross hair rotation
laser cross hair rotation
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17. 1. Zero the laser auto collimator
Adjust mirror angle to center reflected laser cross hairs back on the out going laser beam image
reflected laser cross hairs
defocused image of out going laser on a frosted glass with a hole in the center
mirror with adjustable mirror mount
adjust mirror to center these two images
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18. 2. Establish Camera target match
slide LACE and LACW together and back off to not quite touching
connect target illuminators (USB powered LEDs in LACE)
Bring up the two videocam views of the two survey targets and manual focus with the viewing software
Mark screen with cross hairs centered on the target views
The measuring system is now calibrated and aligned ready for use.
survey targets
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19. 3. Adjust box into rough alignment by eye
Using the jack screws bring the rails of the box into alignment with the MSC rails by sighting down the rails. A level can facilitate this process. Keep the rails separated such that the rail ends do not make contact, but are close enough such that the LACW can slide over the gap.
4. Adjust box into collinear alignment (x, y) with laser auto collimator
Slide the LACW from the box rails onto the MSC rails.
Move the LACE back 1 to 1.5 meters to where it is convenient view the reflected laser cross hairs and the outgoing laser image on the front of the LACE module.
using the jack screws, buck in the y alignment by first moving the box such that the laser is more or less centered on the mirror. Adjust the Ys and Yn jacks so that the laser cross hairs are rotated in z to be vertical/horizontal as viewed with respect to the mirror cross hairs. Then adjust Xe and Xw jack screws to center the vertical elements of the laser cross hair images on each other on the face of LACE as was done during the zeroing step. At this point the centering of the laser on the mirror is not important as long as a reflected image is maintained back at the LACE module.
Repeat using Y and (Ys = Yn) to achieve x alignment by overlapping the horizontal elements of the laser cross hair images. Ys and Yn are moved together during this operation to maintain the z alignment. Y X Z Yn Ys Xw Xe y z x
STAR coor. + rotations
Jack Screw identifications
East
North
West
South
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20. 5. Adjust box into x,y and z alignment using the laser cross hairs
Tweak z alignment by adjusting Yn and Ys in equal and opposite directions to zero the angle between the laser cross and the mirror center cross hairs on LACW.
Align x using the Xe and Xw jack screws together to overlay the vertical laser line with the vertical mark
Align y using the Y, Ys and Yn together
center laser image
on mirror center cross hairs
It might turn out that aligning in this manner is good enough to get smooth carriage transfer from one set of rails to the other. But, the next step will improve the alignment accuracy of x,y and z Y X Z Yn Ys Xw Xe y z x
STAR coor. + rotations
Jack Screw identifications
East
North
West
South
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21. 6. Adjust box into x,y and z alignment using cameras/survey targets
Move LACE to almost touching LACW and turn on LEDs and cameras
Use jack screws as in the previous step to align the camera reference marks to the survey targets without disturbing the collinearity.
7. Recheck collinearity
Move LACE back 1 to 1.5 m and recheck collinearity with the laser auto collimator
8. Engage rails
Using the Z jack screw butt the rails so that the cone and sockets engage. Use care to avoid excessive force on the MSC rails. Y X Z Yn Ys Xw Xe y z x
STAR coor. + rotations
Jack Screw identifications
East
North
West
South
Withdraw the LACW and remove and remove the LACE. The PXL can now be inserted.
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