Module 0 meeting
Design & Assembly of the Hurdle
Getting over the hurdle
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
1
Module 0 meeting
Contents
1. Module foot design
2. How the components fit together
3. Assembly of theMo
module
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Module 0 meeting
1. Module
foot
Design
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
28-9-2015
3
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Module foot Design
Hole for M6
(ø6.5 mm)
Constrain rZ
Holes for legs
Mo
Connection
with base
Freek Sanders
Nikhef
Amsterdam
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Key for
Positioning
(constraining rX)
Hole for M6
(ø6.5 mm)
Constrain in X
Holes to prevent
virtual leak
Connection with base
(Constrain rY)
28-9-2015
Hole for
Dowel pin H7
Constrain in
Z&Y
4
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Module foot dimension
Dowel pin
key
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Displacement IP due to nonflatness base & module foot
IP
dx
a
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Nikhef
Amsterdam
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dz
As can be seen in the
previous slide, a can be
±10 µm*. This results in a
maximum a of 20 µm.
Mo
(likely smaller)
This will result in a
displacement in IP of
z: 229 µm
x: 9,7 µm
Maybe a Z constraint is
desirable
*This can be optimized, but 10 µm is around the maximum you can get with milling
17-11-2015
Assembly of the module
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Module foot connected to the
base
By moving the mid section of the base inwards, there is room
for the insulator bush. This part can be machined roughly.
(orange) While the red surfaces are princely machined
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
28-9-2015
7
Module 0 meeting
Dowel pin
A dowel pin is used as the main reference for the placement of the module
foot. By making the top tapered and letting the straight section of the pin stick
3 mm stick above the connecting base, a good repeatability can be assured
while not damaging the hole in the module foot or the dowel pin itself.
Mo
3mm
Connecting base
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Dowel pin
M6 bolt, no thread in module foot.
Mo
H7/h6, 6 mm dowel pin,
this determines the main
position of the module.
Contact surface
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Nikhef
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Surface is precision machined
28-9-2015
9
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6 Degrees of Freedom
2 D.o.F
locked
rY
Mo
X
rY
rY
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MechanicalTechnology
28-9-2015
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6 Degrees of Freedom
3 D.o.F locked
Mo
Z
rZ
rZ
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Y
Rotation around Z locked by key
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6 Degrees of Freedom
1 D.o.F locked
Mo
rY
rY
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Rotation
Foot bolded in place
(foot is not threaded)
Surface precision
machined
Mo
M6 Hole in base
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Nikhef
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2x3 mm
contact
surface
Rotation is locked
Side precision
machined
28-9-2015
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Module 0 meeting
2. How all the parts fit together
The order in this presentationMo
does not represent the assembly order
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
14
IP
Substrate
CO2 Connector
Mo
Mid plate
275 mm
183 mm
Carbon fiber legs
Capillary
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Nikhef
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296,37 mm
Module 0 meeting
The parts
Module foot
206 mm
17-11-2015
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Mid plate
The mid plate
has two
extensions
that slides into
the carbon
fiber tubes.
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Module 0 meeting
Legs
Mo
Carbon fiber legs with a slit
for inserting the mid plate.
This slit is made by a circular
sawblade.
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Connection the Mid plate to
the legs
The mid plate has two extensions that slide into the carbon
fiber tubes.
Glue
Glue
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Freek Sanders
Nikhef
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MechanicalTechnology
17-11-2015
Assembly of the module
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Mid plate with two legs
•
The mid plate with its legs
can now be connected with
the module foot.
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Gluing the legs
Glue
5 mm into the foot
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
20
Module 0 meeting
Assembled hurdle
The hurdle is now ready to be
combined with the substrate sub
assembly
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Subassembly
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Nikhef
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MechanicalTechnology
Substrate, CO2 capillaries and CO2
connector come preassembled.
A
How this is transported is
unknown and may influence the
placement of this subassembly. Mo
A’
Furthermore the connection
between the Substrate and CO2
connector is a weak link and any
stresses on the Substrate need to
be prevented.
17-11-2015
Assembly of the module
22
Connection the substrate
Module 0 meeting
Section A-A’
CO2 capillary
Brazed
Solder
Mo
Mid Plate
Freek Sanders
Nikhef
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Glue
Substrate
The brazing/soldering has already been done and the gluing still needs doing.
17-11-2015
Assembly of the module
23
Module 0 meeting
The module
All parts fit together look like
this. To make sure everything fit
within certain tolerances a glue
jig will be used
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Module 0 meeting
3. Constructing the module
This is still a concept as such there are no 3D models
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
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Keeping substrate in position in
x,y & z
•
•
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•
The X,Y position is determined
by 2 cylinders that make 3
contact points and 2 small
forces (F1=2F2) that make sure
the substrate makes contact
with these surfaces. These
Mo
forces are positioned so the
force at every contact is the
same.
The Z position is determined by
3 surfaces (these positons are
subject to change)
What is the accuracy at which the substrate edge
are cut?
F2
F1
Connector side
17-11-2015
Assembly of the module
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Module 0 meeting
Installing module foot
Install the module foot onto the glue jig. By first installing the foot and
substrate the main dimensions of the module are locked.
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
27
Module 0 meeting
Installing the legs
Install the legs onto the module foot. A guiding surface
will position
the legs so that they are in the right position. A series of leaf springs
will make sure they stay in the right positon.
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Module 0 meeting
Installing the mid plate
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
Now the mid plate can be inserted by bending the legs slightly.
This mid plate will rest on the connector and 1 support
Mo
Difference in production can be equalized by the glue layers
between the legs and the mid plate.
17-11-2015
Assembly of the module
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Installing the mid plate
Put the mid
plate on
Put glue on the CO2manifold
Mo
Clamped by two
forces
Clamped by two
forces
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
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Glue jig concept
In the end the glue jig will look like this
support
Guiding surfaces
Clamp
Leaf spring
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
31
Module 0 meeting
The End!
Thanks for listening
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
32
Module 0 meeting
Module foot connected to the
base
By lowering the mid section
of the base, there is room
for the insulator bush and it
defines a less accurate
machined zone
Multiple arcs
for giving
room to VCR
Mo
Single arc
moved 2 mm
backwards
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Nikhef
Amsterdam
MechanicalTechnology
28-9-2015
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Calculation
*
Mo
*
*
*
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Nikhef
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*y must be z
17-11-2015
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Surroundings
During assembly
Air (clean room)
Temperature
T= 20 ˚C
Mo
During operation
Vacuum
Temperature
T=20 ˚C at the module foot
T=-30 ˚C to -40 ˚C at the CO2 manifold
Other parts are in between 20 ˚C and
-40 ˚C
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
35
Module 0 meeting
Precision
The chips that go onto the substrate need to be positioned precisely.
There is no actual number for how precise the substrate and other parts have
to be positioned.
The current idea is that the chips are positioned in respect to the substrate.
Hence a precisely place substrate isMo
desirable. To allow for a precise placement
a tolerance of 10 µm in x, y and z is suggested with respect to interaction
point.
Since the module foot will be connected to rest of the system, this will need to
be placed precisely as well. This is done by a dowel pin with a tolerance of
𝟎
𝑯𝟕𝟏𝟐
𝟎 /𝒉𝟔−𝟖 and a place tolerance of 10 µm.
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
The method for adding these tolerances will be done with linear summation.
This leads to a maximum displacement of 40 µm in x, y and z (worst case, low
probability, statistical summation could be better)
17-11-2015
Assembly of the module
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Module 0 meeting
Precision
The TDR of 2013 states that a tolerance of 100 µm in z is allowed. There is no
tolerance for x and y. The only statement is that the mechanical deformation
has to be less then 20 µm in x,y and 100 µm in z. But this has since been
reduced to 40 µm in x,y and 200 µm in z (conformation needed).
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
37
Module 0 meeting
Mo
1
1
Freek Sanders
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2
1
43,5 mm
17-11-2015
Assembly of the module
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Cable length
Cable to base: 171,9mm
Hybrid to base: 160,228 mm
Mid plate to base: 154,5
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
39
Module 0 meeting
Cable around the base
Mo
Freek Sanders
Nikhef
Amsterdam
MechanicalTechnology
17-11-2015
Assembly of the module
40