Review

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 Spectrums
  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 TBRLAT
  is not bagged TBR (cant 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 specd 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