LAT Environmental Test Planning and Design Review 3-4 May 2005 MGSE Design

1. LAT Environmental Test Planning and Design Review 3-4 May 2005 MGSE Design Martin Nordby Mike Foss Marc Campell John Ku

2. Environmental Test MGSE Design Concept • Test Interface Plate • LAT is mounted to the TIP at SLAC, and stays mounted to it until integration on the SC • This eliminates the need for complex load transfers and additional MGSE • Test Stand • For all tests but the sine vibe test, the LAT is mounted to the Test Stand • This serves as a support, transport cart, and frame off of which ancillary MGSE and STE is mounted • Transport Container • This is comprised of a pallet with a base-isolated mount plate and a cover • The LAT is bolted to the mount plate by way of the TIP • The pallet also serves as a storage base for the LAT at NRL and Spectrum • All other MGSE is secondary to these 3 LAT Test Interface Plate Test Stand SC Flexures LAT on Test StandSupported by the Test Interface Plate

3. TIP / Test Stand Preliminary Design and Operations • This is “home base” for the LAT • Used for all tests • Easy to add to or adapt for test-specific needs • The Test Stand provides all functions needed for handling the LAT • Moving, hoisting, and turn-overare all done using the Test Stand • Casters, jacks, and extension beams are all removable to accommodate any test configuration • All load transfers are straightforward, with simple bolted joints and standard hoisting and rigging Cross-Bars for load-sharing during turn-over SC Top Deck Acoustic Sim Extension Beams for: -above cg lifting -turning over -horiz lifting -horiz support in T-Vac Test Interface Plate Empty TIP on Test Stand LAT Uprighting Operation After T-Vac

4. Transport and Storage Container • Transport Container provides isolated environment for the LAT during transport • Wire rope coils isolate LAT from shock and medium/high frequency vibrations • Air-tight container allows for purging to maintain low humidity in the box • Insulated cover isolates LAT from ambient temperature extremes • Pallet doubles as a work platform • With the cover removed, the pallet provides clear access to the LAT for pre- and post-ship testing • We may use this as a storage location for the LAT between operations at NRL Vibration isolating wire rope coils Mount plate Transport Container Pallet Cover mounts around perimeter of pallet Test Interface Plate LAT on Transport Container Pallet

5. Environmental Test Flow and MGSE/STE Use Mount on Test Stand X-axis Sine VibeLPTY-axis Sine VibeLPT Receive LATfrom SLAC Unpack, Prep, CPT Z-axis Sine VibeLPT EMI/EMC TestLPT Mount RadiatorsLAT LPTRadiator CPT Turn Over Prep for T-Vac Acoustic TestLPT Measure Mass, X/Y C.G. CPT, SVACThermal-Vac TestCPT, SVAC Pack, Prep, and Ship to SASS PackRadiators Rotate Upright Remove RadiatorsDe-Mount off Test Stand

6. MGSE List • The table shows a complete list of all known MGSE needed for environmental testing at NRL and transporting the LAT MGSE/STE Needed for Environmental Testing

7. Test Interface Plate (TIP) Design • The TIP is permanently mounted to the LAT after LAT integration • This is done at SLAC • Mounting procedure for SC flexures • All 4 flexures are positioned using Spectrum’s master gauge tool (the slave was used for machining our Grid holes) • Mount brackets are positioned and bolted • Flexure-Bracket holes are match-reamed and hardware installed • (Still needs Spectrum review) • The Grid Perimeter Ring is used for hoisting the LAT • This means that the TIP hangs from under the LAT • The TIP needs to be light enough to not cause any loading issues • Design status • Detailed drawings complete and in check • Preliminary analysis in process • Final structural analysis not started • Plan for completion early enough to use in Grid Qual testing Aluminum interface plate carries no loads, but only locates Flexures SC Flexure Mounting hardware and method is identical to Spectrum plans Mounting hardware passes through plate SC Flexure mounted to plate by way of Mount Bracket

8. TIP Design Requirements Summary from Test Plans • Loads and Capabilities • Capable of handling inertial loads of LAT during sine vibe test and transport • Carries LAT when horizontal or vertical, plus thermal stresses due to temp variations in T-Vac • Total TIP mass not to exceed 200 kg (current estimate: 129.5 kg), so LAT + TIP can be lifted using the Grid Perimeter Ring • Interfaces • Provides alignment of flexures that matches Spectrum alignment • Compatible with vibe table expander head and slip table bolt patterns • Mounts to: Test Stand, Transport Container pallet, Mass properties mount plate • Accommodations • Accommodates a top deck acoustic simulator • Accommodates installation of a SC top deck sink plate between TIP and X-LAT Plate

9. TIP Structural Analysis

10. Test Stand Design • Test Stand is designed to be simple to fabricate and test • Welded box beam construction is welded clean then painted • Sub-assemblies are machined to provide accurate mounting hole patterns • Assembly is proof- and operationally tested independent of the LAT, using Spectrum test weights (TBR) • Design status • Detailed drawings complete and in check • Preliminary analysis in process • Final structural analysis not started • Completion tied to Pathfinder schedule TIP interface bolt plates Extender Beam bolt plates Test Stand Assembly Removable casters for moving LAT Test Stand Weldment

11. Test Stand Design Requirements Summary from Test Plans • Loads and Capabilities • Supports LAT in horizontal configuration during hoisting, transport, and on T-Vac trolley • Capable of leveling the LAT to an accuracy of 0.1 degrees in both principal axes • Functions over temp range of –TBD to +TBD degC while maintaining angular stability of LAT to within +/- 0.1 degrees • Includes active heating to stabilize average temps • Interfaces • Extension Beams compatible with T-Vac trolley mounting and floor loading capabilities • Accommodations • Accommodates SC simulator sink plates during T-Vac • Provides clear access around LAT perimeter and underside for EMI test antennae

12. Test Stand Structural Analysis

13. Transport Container Design • Some preliminary features • LAT is ship weight is ~ 7500 lbs • Construction • 2-piece Aluminum with Base Pallet and Lid Box • Lid is hoisted on and off • 6” min (TBR) clearance from instrument • Design status • Proof-of-concept design complete • Re-working design to spec as a turn-key design/build contract • In the process of specifying LAT design and performance constraints, then the spec and statement of work will be bid for design, fab, and testing Mount plate provides rigid mount for LAT Base-isolation coil springs Base Pallet(LAT + TIP removed) Cover Box provides clearance for LAT dynamic motion LAT on Base Pallet(Cover Box removed) TIP mounts directly to Pallet mount plate LAT in Transport Container

14. Transport Container Design Requirements Summary • Loads and Capabilities • Capable of handling transportation loads of LAT + TIP by air or truck • Capable of storing LAT for 24 hours (TBR) outside • Capable of being lifted by forklift or moved by air bearings • Provides base isolation to protect LAT from accelerations exceeding fight design levels, given an input of ground- or air-transport acceleration spectra • Interfaces • Compatible with Test Interface Plate • Standard skids, lifting features, and tie-downs for transportation equipment • Accommodations • Provides clearance around LAT to allow for relative motion due to base-isolation system • Cover includes: port for mounting purge line, two-way pressure relief valve and filter for incoming air, feedthroughs for environmental monitors (TBR) • Internal cleanliness level Class 10,000 TBR—LAT is not bagged TBR (can’t contact ACD MLI) • Environmental monitors to track temperature, humidity, and 3-axis accelerations during transport (on container and LAT mount plate)

15. NRL Environmental Test Facilities • Facilities drawings are being developed for all areas where LAT will be located or tested • Intended to capture all facility-specific information needed for LAT testing • This includes power and network tie-in points for testing LAT • All drawings are in work now, with either advanced check prints or released versions (in NRL configuration management system) NRL Facility Drawings

16. MGSE Development Timeline

17. MGSE and Facilities Issues List • Summary • The three key pieces of MGSE have been designed and are in the process of being analyzed and finalized • Concepts exist for most of the remaining MGSE • Issues • Our pathfinder program is keyed to receiving the TIP and Test Stand by mid-September. These are big parts which will take time to fab, inspect, and test  Marc Campell is developing a detailed design and fab schedule for these • STE sink plates for T-Vac are still poorly designe, thermally. These need to be spec’d out to confirm that we have preserved enough space for them, and that the Test Stand works as-designed  Martin Nordby actively working with thermal people to lock in the thermal design and spec out the design of these