1 FPA Stage 2 MC Flange Assembly Issues and Design Proposals June 20, 2006 T. Brown

2 Type-A Type-B on A Stand repositioned to receive Type-C Type-C added along with supports MCHP Assembly Sequence where flanges and spherical seats must come together…accurately.

3 Shim geometry is formed from MC developed surfaces rather from individual curves. Separate curves would be better. The flange interface involves the need to accurately mate spherical seats and inclined flange surfaces that are separated by shim material. Can shims be accurately machined and located? Can glass epoxy be used to take up misalignment? Mold release on flange surface

4 Thin layer of glass epoxy insulation. How thin, 15 – 30 mil ? Individually machined SS wedges. Can uncured glass epoxy (placed or pumped in) be used to take out the shim alignment imperfections? Will it meet the flange load capacity? Where tapped holes do not exist on flanges can spring pins be used to hold metal shim in place? Will we be cutting and machining individual SS shim pieces?

5 Sphere Flat “V” Proposed new alignment method. 1.5” Ø Switch from aligning three spheres to aligning a sphere, flat and “V”.

6 An alignment hole is need in the flat and “V” spherical seats to locate an alignment sphere, used for locating the mating sphere.

7 PROBLEM: How do you align the spherical seats when the shim surfaces are making contact at the same time?

8 Initial Alignment Position Fixed Adjustable Position for Final Shim Compression Uses spring loaded seats! Keyed interface prevents rotation. Option 1 We’ve added a pop up system to aid alignment.

9 Three or four captured precision compression springs provides an additional 3/8” extension above flange shims to aid alignment. Alternate approach for establishing a spring loaded interface Keyed interface prevents rotation. Option 2

10 How does the A-to-A interface set-up effect the flange assembly? Left side Right side The left side is rotated over the VV and placed ¾” from its final position and supported from the roller system below. The right side is rotated to within ¾” of its final position and held by the crane. The left side is then moved to its final position via rollers and the right side mates with the spherical seats via the crane system.

11 With no shims in place the MC position is verified with metrology measurements. Left side Right side

12 13”gap Left side fixed at -0.75” to alignment plane Right side backed to Step 32 Once metrology is verified the right side is backed off 13” via crane and secured from below. The flange shim system is installed and then the device is reassembled and metrology rechecked. This sounds okay, will it work? Backing off 13” involves an inclined moment with little rotation.

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