Carousel / Carrousel / Caroussel / Carroussel. Giostra

Transcription

1 Carousel / Carrousel / Caroussel / Carroussel Giostra Les actuels : 03 juin 2016 Guillaume Daubard, Daniel Vincent, Yann Orain, Philippe Repain, Claire Juramy, William Ceria, Patrick Ghislain, Sony Mejias, Julien Coridian, Alain Vallerau, Alassane Samb, Pierre Antilogus, Didier Laporte Les ex : Filipe De Matos, Walter Bertoli, Christophe Evrard, Stephano Russo, les stagiaires

2 Filter Exchange System Découpage Loader Filter Control System APC LPSC CPPM Auto-Changer Carousel LPNHE Cryostat Focal Plan On-line Filter Shutter 2

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4 910 mm 453 mm AutoChanger Overview Removable part

5 Carousel Dessin général Guiding and driving systems: Rail and carriages Ring gear Geared motor Geared brakes Encoder Structure Filters' clamp mechanism Unclamping system 5

6 Spécifications Durée de vie : 15 ans (C-EXCH-001) Un filtre doit pouvoir être changer sans démonter la caméra du télescope (C-EXCH-096) Le système changeur de filtre doit accepter des filtres de masse différente (30 à 44 kgs) (C-EXCH-009) Un filtre doit être changer en moins de 89 secondes (C-EXCH-013) Température de fonctionnement : -5 C à 30 C (C-EXCH-143) Température de survie : -15 C à 40 C (C-EXCH-144) Le carrousel doit peser moins de 250 kgs (C-EXCH-046) La position du centre de gravité du carrousel est contrainte (C-EXCH-047) Le carrousel doit avoir 5 positions de filtre disponible (C-EXCH-049) Le carrousel doit pouvoir faire rotations (C-EXCH-050) Le carrousel doit pouvoir verrouiller et déverrouiller les filtres fois (C-EXCH-106) Sismique Sécurité Maintenance 6

7 Carousel Filters position 7

8 Carousel Stay clear compliance Carousel enveloppe 8

9 Le carrousel dans le temps Fin 2006 : Discussion avec Kirk Gilmore des contributions techniques IN2P3 à la caméra LSST 01/2007 : R&D carousel au LPNHE 06/2010 : Totalité du changeur de filtre à l IN2P3 12/2012 : Installation du single filter test au CPPM 02/2015 : Commandes des 2 rings 10/2015 : Revue validation design 05/2016 : Arrivée au LPNHE du dummy backflange 10/2016 : Début commande pieces finales à Paris 06/2017 : montage backflange final à Paris 04/2018 : Intégration à SLAC 12/2019 : Opérationel au Chili 9

10 Carousel Design details Filter clamps Unclamping mechanisms Z+ Vguid Guiding & Driving Structure Slip ring Cabling 10

11 Carousel Clamp X- design Filter Pin Unlocking Cable Filter Position Sensor Clamp Status Sensor Filter Pin Unlocking Cable 11

12 Carousel Clamp X+ design Ball joint Z Sliding ball joint Point Filter Pin Clamp Status Sensor Unlocking Cable Filter Position Sensor 12

13 Carousel Filter Clamp Mechanism: Proximity Sensors Several Sensors were tested with defined criteria Range Output precision Encumbrance Baumer IWFM 08U9501 Proximity sensors chosen for a deeper test Manufacturer Balluff Product BAW G06EE-UAF20B-EP03-K Technology Inductive sensors with analogue output Size 6.5 mm L 30.5 mm 2 different setups tested Spot facing Ø Balluff BAW G06EE-UAF20B-EP03-K Spot facing depth Ball height Isolated pin Offset Ball Ø Sensor Ø Sensor 13

14 Carousel X- Clamp on the test bench X- Clamp Misalignment adjustment Filter Pin Unlocking cable cycles 14

15 Carousel X+ Clamp on the SFT Misalignment adjustment Sensors Filter X+ Clamp 15

16 Ø 50 mm Carousel Unclamping mechanism Design baseline Fixe actuator on the flange Detailed design done Maintenance: entire actuator replacement (2 screws + 1 connector) Magnetic coupling transmit power on the carousel Misalignment allowed successfully tested 0.6 Nm magnetic coupling can pull 80N thru a reducer Unlocking force transmitted to clamps by cable 60 mm Distance 6 mm Misalignment 5 mm 16

17 Carousel Z+ V-guide design Filter approach bearing Mobile frame V-guide frame Fixe and mobile roll on thrust bearing 17

18 Carousel Guiding: Design baseline 2 design studied with 2 calls passed: 1 for a classical bearing (Dec 2007) which was the initial LSST design: no valid answer 1 for circular rail (Sep 2008) Technology chosen according to specifications included in call for tender Circular rail + carriages from THK (Japanese manufacturer) THK AFE-CA Grease: Clean room specific lubricant Ordered (Nov. 2008) and delivered (Feb. 2009) Basic load rating Static permissible moment Mass Radial Reverse radial Side M A M B M C M 0 Dynamic rating C Static rating C 0 Dynamic rating C L THK: HCR 35A+60/600R Static rating C 0L Dynamic rating C T Static rating C 0T 1 Double block blocks 1 Double block blocks 1 block 1 block LM block kn kn kn kn kn kn kn-m kn-m kn-m kn-m kn-m kn-m kg kg/ LM rail 18

19 Carousel Driving: Design layout Reducer: HARMONICDRIVE Ratio 1/100 x3 Reducer: Absolute Encoder HARMONICDRIVE AMO WMKA & WMRA BLDC motor: MAXON EC90 Controller: MAXON EPOS2 70/10 Control supply Power supply CAN bus Brake: Intorq BFK

20 Carousel Driving: Motor sub-assembly Assembly and setting 4 screws (M6) with Nord-Lock washers Tunable distance between pinions with spacers Tolerance > 0.15mm Easy maintenance Interchangeable single-piece assembly 20

21 Carousel Driving: Encoder Integration Amosin Encoder from AMO Gmbh Ring: AMO WMRA Grating pitches Pitch: 1mm Linearity error +/- 5µm arc length Head: WMKA Output: SSI + Sine 1Vpp Resolution: 10 bit per pitch length Encoder resolution Less than 1µm arc length pitches / turn Ring gear Baffling Encoder Head Support Need precise gap adjustment Head replacement for maintenance Guiding rail Slip Ring Encoder Head Encoder Ring 21

22 Carousel Structure Design Space frame modular structure Posts + truss Good stiffness/mass ratio and for price/tuning optimization Off the shelf Aramid reinforced Carbon fiber tube Filament wound carbon fiber tube using HS carbon fiber and epoxy resin External aramid fiber 30% for safety when failure Steel linking parts 22

23 Carousel Structure Analysis: Natural modes Natural frequencies Filters (simplified) Around 25 Hz Structure Higher than 44 Hz Ring gear Around 45 Hz Mode Frequency [Hz] Filter bending Filter bending Filter bending Filter bending Filter bending

24 Carousel Slip-ring Many suppliers contacted Only one answer for a tailor made one Discussion with Rougier-Electro Design Brushes and rails materials (silver graphite) Brushes & holder (shape and size) Tolerances Integration Back flange Ring gear Lubrication (? to replace humidity) Constraints Nb cycles & distance Direction change effect Dry nitrogen environment behavior Key parameters Encumbrance Wear rate Electrical connection quality 24V DC power supply CAN bus (bus speed limit) Baffling Unlocking mechanism Slip Ring Ring gear Slip Ring Guiding rail Brushes 24

25 Carousel Back Flange Packaging Loader CUT C (need a 30mm width) Loader 24V dirty /20A - 2x2.5 shield - Ø9 Loader 24V Clean /1A - 2x0.5 shield - Ø6 Loader CAN bus - Ø7 (or Ø12?) Loader Safety (signal: STP - Ø7 & power: 24V /1A - 2x0.5 shield - Ø6) A-Changer CUT B Auto-Changer Safety (signal: STP Ø13 & power: 24V /2A - 2x0.5 shield - Ø6) Auto-Changer 24V Clean /1.5A - 2x0.5 shield - Ø6 Auto-Changer 24V dirty /20A - 2x2.5 shield - Ø9 Driving Safety (signal: 2 STP Ø5.6) Filter Temp Telemetry (signal: 2 STP Ø5.6) Ø5.2+Ø7.5+Ø6.5+Ø6.5+Ø6.5 +Ø7+ Ø5.6+Ø5.6 = 50.4mm Car-Power CUT J (need a 30mm width) 48V /10A - 2x1.5 shield - Ø7.5 24V /3A - 2x0.5 shield - Ø6 Driving Safety EM Signal: 2 STP Ø5.6 24V /5A - 2x0.75 shield - Ø6.5 Unclamping Safety EM Signal: 2 STP Ø5.6 Car-Control CUT K 24V Clean /1A - 2x0.5 shield - Ø6 CAN bus - Ø7 (or Ø12?) Carousel Key lock Car-Safety CUT L Safety bus - Ø7 (or Ø12?) Carousel Safety Power 24V /2A - 2x0.5 shield Ø6 Carousel Key lock Signal: 2 STP Ø5.6 Brakes Telemetry (signal: 4 STP Ø6.5) Length between 2 telescope mounting holes = 86mm Max wished cable Ø = 12 mm Max Back-flange allowed Ø = 8.3mm 2x2.50 (AWG 14) shield - Ø9-20A max 2x1.50 (AWG 16) shield - Ø7.5-12A max 2x0.75 (AWG 18) shield - Ø6.5-6A max 2x0.50 (AWG 20) shield - Ø6-4A max 2x0.25 (AWG 23) shield - Ø5-2A max Signal - 4 STP 0.25 (AWG 24) - Ø6.5 Signal - 2 STP 0.25 (AWG 24) - Ø5.6 Bus - STP - Ø7 (or Ø12?) LCA-10xxx Filter Exchange System / Carousel Final Design Review / April 21,

26 Carousel Assembly & test plan Mount the driving system 1 Motor (Bay D) Using 4 screws for easy maintenance 3 Breaks (Bays I,N & X) Using 4 screws for easy maintenance Adjust functional play between teeth Using standard spacers and laminated shims Gear center tolerance > 0.15 mm Motor controller (bay F) 14 screws, maintenance on telescope Encoder system (bay J) 26

27 Carousel Back Flange Cabling 27

28 Carousel De la CAO à la réalité 28

29 Carousel Assembly & test plan Mount Z-plates on the carriers Mount gear ring Mount aluminum ring With rail baffling, rotation plates, 90 screws Tune concentricity Mount sliding contacts Using 2 captive screws for easy maintenance Check electrical connections 29

30 Carousel Assembly & test plan Dummy Back-Flange preparation Mount Slip-ring Slip-ring, 60 screws Mount THK rail on the back-flange. 6 rails, 5 carriers, 42 screws Mount Wedges on the back-flange 6 POM wedges, 6 Steel wedges, 12 blocking rings and 120 screws Check Rail roundness and concentricity with the back-flange 30

31 Carousel Assembly & test plan Rings preparation Bande codeuse : Diametre 1500 mm Précision : le micron 31

32 Carousel Assembly & test plan Mount structure posts 2 screws on carrier & 2 screws on ring Pentagon assembly Using assembly jig Preliminary geometric validation 3D measurement Mount pentagon on posts Finalize position tuning Validation 3D measurement 32

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34 Carousel Assembly & test plan 34

35 Carousel Assembly & test plan 35

36 Carousel Assembly & test plan 36

37 Salle blanche + caisson froid (-15 C à 20 ) 37

38 A suivre 38