# Presentation: 842131

## A Preliminary Design of the Rotator for the DES Simulator Stand

*February 28, 2008*
- Edward Chi
- Fermilab/PPD/MD

## The Stand of the DES Simulator

- Stand of the Simulator @ 90 degree

- Stand of the Simulator @ 0 degree

- Telescope Simulator

- Base of the Stand

- Rotator of the Stand

- Edward Chi

## Rotator, Stand and the DES Simulator

_***Main function of the Stand Rotator:***_
- Supports the Telescope and connects to the Simulator Stand Base.
- Allow two axes rotational movement of the DECam Telescope:
-             1. The Inner Race of the Rotator rotates +/_ 165 deg. about the
-                 optical axis (about the zz axis of the above layout picture).
-             2. The rotator rotates about the zenith angle 0 to 90 deg. and
-                 90 to 0 deg. (about the xx axis of the above layout picture).

- Telescope  Simulator

- Stand of the Simulator

- Rotator of the Simulator Stand

- Telescope

## The Rotator of the DES Simulator Stand

_***The main components of the Stand Rotator:***_
-   1. The connectors that connect the inner race frame w/the Outer Ring of the Telescope.
-    2. The structural frame of the inner race.
-    3. The structural frame of the outer race.
-    4. The curved linear motion (LM) guide system.
-    5. The inner race rotational mechanism with the power transmission system.
-    6. The outer race tilt mechanism with the power transmission system.

- The total weight
- of the Rotator:
- ~ 21,000 lbs.

***Connector***

***Inner Race***

***THK Curved Rail & ***
***Guide System***

***The Inner Race rotational ***
***mechanism & its power***
***transmission sys.***

***The Outer Race tilt mechanism & its***
***power transmission sys.***

- Edward Chi

## The Connector of the Stand Rotator

- The connector
-   consists of:
- Bracket
- Boss plate
- Shims
-  Wt.  ~ 245 lbs

- The existing holes from the upper ring
-  girder truss plate of the Outer Ring

- Connect the Outer Ring
- and the Inner Race together
- by using 4 Connectors

- Edward Chi

## Inner Race Frame of the Stand Rotator

- Inner Race houses for:
- Connector
- Curved LM Guide sys.
- Roller Chain guide &
-     the preload device.

-  Inner race frame Wt.:
-  ~6,500 lbs.
- Inside dia:    215.0”
- Outside dia.: 239.0”
- Overall height: 12.0”

_*3” dia. thru. hole*_
_*for cable access*_.

- Edward Chi

## Main Components of the Inner Racer Frame

_**East entry dr. of Lab A**_
- _9’ (H) x 6’ (W)_

- Inside

**Inside door**:
- 9’ (H) x 6’ (W)

**120 degree segment:**
- Dim.: ~17.4’ (L) x 5’ (H) x 1’(D), Wt.: ~1,900 lbs.

***In order to move through the ***
***Lab A entry doors, the main ***
***Inner Race frame consists of:***
***  ****Three 120 deg. Segments,*
*  **Three connect brackets, *
* **Three joint plates.*

_**Connect Bracket**_

- j

- Joint Plate

- Edward Chi

## Outer Racer Frame of the Stand Rotator

_**Outer Race frame Spec.:**_
*Net weight: ~8200 lbs.*
*Inside dia:    240.50”*
*Outside dia.: 264.00”*
*Overall height: 12.0”*

_**Outer Race frame houses for:**_
*Inner race rotates power transmi. system*
*Mtg. brkts for curved LM guider*
*Connect Box for the power trans. shaft.*

_***In order to move through the Lab A entry doors,***_
_*** ***__***the Outer Race frame will also be designed as:***_*** ***
***  ******Three 120 deg. Segments,***
***    ****with 19.1” (L) x 5.5’ (H) x 1’ (W), wt = ~2,400 lbs.*
***  ******Three connect brackets. ***
*** ******Three joint plates & other accessories.***

***Mounting***
***Bracket (10)***

**Inner Race rotation power**
**transmission system**

_**Connect Box**__** **_

- Edward Chi

## Curved Linear Motion (LM) System of the Rotator

_***LM system not only maintains the Inner Race and Outer Race in their ***_
_***designated mechanical position,  and also:***_
-   Has the equal capability to support the primary force (~40,000 lbs) in all three
-      axes (x, y &z), it also has the capability to take the different moments.
-   Creates a stable and reliable rotational system of the Simulator because of the
-      3,000 mm diameter LM RCA rail & its components.
-   Minimizes the loading torque of the power transmission sys. by lowering the
-      coefficient of the friction between the LM rail and its bearing blocks.

_**LM bearing **_
_**Connect bracket**_

- THK LM Guide-HCR Model
- (HCR 65A10RR+30/3000 R)
- 12 segments, ~1,125 lbs.

_**LM sys. Consists of:**_
- LM curved rail
- (3 m dia., 12 segments)
- Connect bracket (10)
- LM blocks (10)
- Shims & other
-    hard wares

- Edward Chi

## Inner Race Rotational Mechanism and Its Power Transmission System - I

- The chain runs along the channel from one end of the
- chain anchor, around the idler sprocket, then around the
- center drive sprocket, then around the 2nd idler sprocket,
- and then connect to the anchor of the other end of channel.

- _Chain Anchor_
-  (preload application)

- _Chain Guide_
- _C Shape Channel_

- _Drive Shaft and Sprocket_

_*Idle Sprocket*_
_*and Shaft*_

- _Roller Chain ANSI 120-2_

- _Gear (sprkt) Box_

- _Supt. Bracket (2)_

- Edward Chi

## Inner Race Rotational Mechanism and Its Power Transmission System - II

_**Gear Reducer**_

_***Motor***_

_*Motor Brake*_

_*Encoder *_

_*Mounting*_
_*Brackets*_
*(2 axes adjustments)*

_***Disc Couplings***_

- The main components of the power transmission
- for the Inner Race rotational movement:

_***Some major factors for selecting the size and type of the ***_
_***electrical motor, gear reducer and other main components:***_
-    Load torque required of the related movement.
-    Mass inertia of the physical specifications of the related
-             objects.
-    Desirable speed.
-    The efficiency of the reducer and the other mechanisms.
-    Motor speed.
-    Reduced ratio.
-    The accelerated/decelerated time.
-    Inertia ratio.
-    Cost.
-    Product quality and the services.
-    Market availability.
-    Others.

_***The Inner Race Rotational (along z axis) movement***_
***(For the Drive Shaft)***
-      Speed range of the Drive Shaft:  ~ 26.0 to 2.6 rpm.
-      Motor: 460 VAC, 3 phase, 60 hz, 1,750  rpm,  5 hp
-                   with build in brake and Encoder.
-      Gear Reducer: Input vs. output ratio: 67.3 :1,  right angle
-                                type mounting.
-      Power transmission shaft: AISI 1045 H.R Steel.

- Edward Chi

## Inner Race Rotational Mechanism and Its Power Transmission System - III

- Inner Race rotates @
- + 165 deg.

- Inner Race rotates @
- 0 deg.

- Inner Race rotates @
- - 165 deg.

- View from the opposite side

_***The Inner Race Rotational About the Optical Axis ***_
_***(zz axis) Movement:***_
-     Rotational movement range about the optical axis (zz axis):
-                                 +/- 165 degree
-     Speed range of the Inner Race rotational movement:
-                                  ~ 1.0 to 0.1 rpm.
-      See slide #14 for the motion control details.

- Edward Chi

## Outer Race Rotational Mechanism and Its Power Transmission System

_*Motor*_

_*Planetary Gear Reducer*_

_*Disc Coupling*_

_*Power Trans. Shaft*_

_*Encoder*_

_*Motor Brake*_

_*Mtg. Brkt for Motor/Reducer*_
*(2 axis adjustment)*

**Out Race @ 0 deg**

**Out Race @ 45 deg**

**Out Race @ 90 deg**

_**The Outer Race Tilt about the Zenith Angle (xx axis) Movement**_
- Speed range of the tilt movement:  1.0 to 0.1 rpm.
- Rotational Range: 0 to 90 deg. and 90 to 0  deg.
- Motor: 460 VAC, 3 phase, 60 hz, 1,805  rpm,  3 hp
-              with build in brake and Encoder.
- Planetary Gear Reducer:  input vs. output ratio:
-                           1,805:1,  right angle type mounting.
- Power transmission shaft: AISI 1045 H.R Steel,
-                             4.875” diameter w/keyway.

- Edward Chi

## The Main Feature of the Electrical Motion Control System

_***The Manual Control Motion Control System:***_
-      AC Variable Frequency Drive for the Inner Race rotational movement.
-      AC Variable Frequency Drive for the Outer Race tilt movement.
-      Inner Race jog forward pushbutton
-      Inner Race jog reverse pushbutton
-      Outer Race jog forward pushbutton.
-      Outer Race jog reverse pushbutton.
-      Travel limit switches for all the extreme positions.
-      Emergency stop pushbutton.

_***The Auto Control Motion Control System:***_
-      AC Variable Frequency Drive for the Inner Race rotational movement.
-      AC Variable Frequency Drive for the Outer Race tilt movement.
-      Inner Race operator display panel. *
-           (current position, desired position, desired speed, etc.)
-      Outer Race operator display panel. *
-           (current position, desired position, desired speed, etc.)
-      Travel limit switches for all the extreme positions.
-      Emergency stop pushbutton.
-      * Can be as one display panel for the both.

- Edward Chi

## Design Codes, References, Notes and the Others

_***Some applicable engineering codes and references related to the design:***_
-     “Telescope Simulator Requirements and Specifications”, DES Doc. 830
-               Version 1, by Andy Stefanik, Fermilab, Sep. 11, 2007.
-     “Allowable Stress Design”, AISC, 9th edition,
-     “Structural welding Code – Steel”, ANSI/AWS D1.1-90
-     “Design of Weldments” by O. Blodgett
-     “Machine Design” by A. Hall, A. Holowenko & H. Laughlin
-    “ Design of Machine Elements” 5th ed. By Spotts.

_***Some design calculations, notes and cost quotations:***_
- 1.  Motor size selections for the Inner Race rotation:
- _[http://home.fnal.gov/~edchi/Simulator-DES/note-eng/motor-size%20-cal2-race-inner-outer.xls](http://home.fnal.gov/~edchi/Simulator-DES/note-eng/motor-size%20-cal2-race-inner-outer.xls)_
- 2.  Motor size selection for the Outer Race tilt:
- _[http://home.fnal.gov/~edchi/Simulator-DES/note-eng/motor-size%20-cal2-race-inner-outer.xls](http://home.fnal.gov/~edchi/Simulator-DES/note-eng/motor-size%20-cal2-race-inner-outer.xls)_
- 4. Power transmission shaft size:
-     _[http://home.fnal.gov/~edchi/Simulator-DES/note-eng/cal1-shaft-transmission-021508.xls](http://home.fnal.gov/~edchi/Simulator-DES/note-eng/cal1-shaft-transmission-021508.xls)__ _
- 5. Preliminary cost estimation:
-     _[http://home.fnal.gov/~edchi/Simulator-DES/cost/cost2-simulator-des-0108.xls](http://home.fnal.gov/~edchi/Simulator-DES/cost/cost2-simulator-des-0108.xls)_

- Edward Chi

## More Things Have To Do...(I)

_***Structures for the Connector,  Frames of the Inner Race and Outer Race:***_
-     Design the 120 deg. segment (ref. to  slide #7 & #8), connector, and joint plate for the outer race frame.
-     Eng. Analysis, notes & details for the structural frames, connector, critical hardware and others.
-     Further modifications for an optimizing structural frame design.
-     More eng., manufacture and fabrication details, write the procedures if it is necessary.
_***Curved Linear Motion Guide System:***_
-     Develop a lower cost, practical installation and alignment kit based on the manufacture spec. of  the Rotator.
-     Write an installation and alignment procedures.
-     Engineering analysis, notes and details.
_***Power Transmission System:***_
-     More eng. details for the connecting couplings, pillow bearing box, power trans. shafts(2), keys, key ways, shaft-gear
-      box, gear box supt. Brkts., motor mounting  brackets (3) and the others.
-     More formal engineering notes for some critical components.
-     More mass inertia study of the related components and the others for a further motor size optimizing selections.
-     Write an assembly, installation and alignment specifications, procedures and the others for the system.

## More Things Have To Do... (II)

_***Two Axes Rotational Mechanisms of the Rotator:***_
-     More eng. details for the sprocket gear box, gear transmission shafts (2), chain anchor, sprocket and roller chain guide.
-     Eng. Analysis and note for some critical parts.
-     Write an assembly, installation and alignment specifications, procedures and the other details.
_***Electrical Motion Control System:***_
-      Will assist the electrical control professional to further detail and finalize the whole motion control system.
_***Others***_:
-     Shall design the Inner Race rotational movement range about the optical axis (zz axis) +/- 180 degree instead of the
-       current +/- 165 degree (See slide #12)?
-      Any new specifications on speed range, running cycle, life time and others?
-     Any design re-configurations to meet any space, operation and other safety issues in Lab A.
-     **Please have your comments, suggestions and others for the further optimizing design of the   **
**     ****DES Simulator Stand Rotator !!!**
**                                               **I can be reached at: _[edchi@fnal.gov](mailto:edchi@fnal.gov)_  or (630) 840-2879

- Edward Chi