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Rail_test_system.pptxAug 12, 2010 version

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TPC – Time Projection Chamber (main detector in STAR)

HFT – Heavy Flavor Tracker SSD – Silicon Strip Detector IST – Inner Silicon Tracker PXL – Pixel Detector (PIXEL)

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rail test system

rail_test_system.SLDASMhttp://www-rnc.lbl.gov/~wieman/container_UTA_7_8_10.zip

8/12/2010this document: http://www-rnc.lbl.gov/~wieman/Rail_test_system.pptx

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part/file cnfg material source total#

p. ref

grf

1 PIT_glue_plate_to_rail_hanger_free.SLDPRT 6061 UTA 16 3

2 PIT_end_fixture.SLDPRT PIT east end,PIT west end

MIC6, 2in LBL & UTA 1 each 10,11

3 PST_end_fixture.SLDPRT east, west MIC6, 2in LBL & UTA 1 each 11,12

4 IDS_flange_alignment_pin.SLDPRT steel UTA 4 13

5 Tooling ball CL_1_SCB steel CL 8 3

6 Tooling ball MC 8481A34 steel MC 36 3,15,16

7 tee_nut_custom_half_in_slot.SLDPRT 1018 cold rollsteel

UTA 20 14

8 PIT_base_fixture.SLDPRT PIT, PIT mid, PST

MIC6, 2in LBNL 1 each 14

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10 PIT_fixture_flex_lever.SLDPRT 6061 UTA 4 3

11 PIT_hole_fixture_end_addapter.SLDPRT 6061 UTA 1 3

12 PIT_hole_fixture_end_addapter_mirrored.SLDPRT 6061 UTA 1 3

13 dowel pin 0.125 X .375 in, MC 98381A470 steel MC 4

14 PIT_hole_fixture_beam.SLDPRT 6061 UTA 1

parts list for assembly: rail_test_system.SLDASM

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part/file cnfg material source total#

p. ref

grph

15 kin_cross_support.SLDPRT 6061 UTA 3 15,37

16 grand_master.SLDPRT 6061 LBL 1 15,16,17

17 ¼ in steel ball, precision steel 18

18 shoulder screw, MC 90298A535 steel MC 6

19 spring 6 lb, MC 9435K78 steel MC 6

20 shoulder screw, 10-24, 5/8 in, MC 90298A39 steel MC 3

21 spring 9 lb, MC9432K79 steel MC 3

22 butch_plate_single.SLDPRT 6061? UTA 18

23 grand_master_support_plate.SLDPRT MIC6 UTA 1 19

24 dowel_pin_MC98381A471.SLDPRT steel MC 2

parts list for assembly: rail_test_system.SLDASM

6PIT_rail_20mm_assembly.SLDASM (on test)

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part/file cnfg material source total#

p. ref

grph

25 PIT_rail_20mm.SLDPRT east v2 CF LBNL 4 21,22

26 PIT_rail_20mm.SLDPRT main v2 CF LBNL 12 21,22

27 PIT_rail_coupler_20mm_v2.SLDPRT 6061 UTA 8 23,24,28

28 PIT_rail_arm_20mm_v2.SLDPRT 6061 UTA 8 23,24,27

29 PIT_rail_arm_achor_post_v2.SLDPRT 6061 UTA 8 21,24,26

30 PIT_rail_hanger_ext_v3.SLDPRT 6061 UTA 4 24,25

31 PIT_rail_hnaager_ext_mirror_v3.SLDPRT 6061 UTA 4 24,25

32 socket head cap screw 8-32 x 1 in aluminum FE 32 19

33 rail_mount_dowel_pin.SLDPRT long 6061 UTA 16 24

34 cylinder_nut.SLDPRT 6061 UTA 32 24

35 cam_rail_TR_1.SLDPRT 6061 UTA 2 21,29,30

36 cam_rail_TR_2.SLDPRT 6061 UTA 2 21,29,30

37 cam_rail_TR_3.SLDPRT 6061 UTA 2 21,29,30

parts list for subassembly: PIT_rail_20mm_assembly.SLDASM (on test)

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part/file cnfg material source tot#

p. ref

grph

38 socket head cap screw 8-32 x .375 in aluminum FE 48

39 shoulder screw 8-32 MC 95446A220 brass MC 24

40 rail_holder_sq_bar.SLDPRT CF LBNL 2 6

41 rail_holder.SLDPRT ring on bearing 6061 UTA 4 35,36

42 rail_holder.SLDPRT ring on insert plus west end connection

6061 UTA 2 32,34

43 linear bearing liner Pacific Bearing FMN20 PB 24 35

44 Retain_ext_modified_MC98541A139.SLDPRT steel MC/LBNL 40 35

45 set screw dog MC 92505A191 steel MC 20 35

46 bullet nose diamond pin MC 31335A31 steel MC 6

47 bullet nose aligning pin MC 31335A11 steel MC 6

48 bullet nose liner MC 31335A51 steel MC 8

49 liner_MC_31445A116.SLDPRT steel MC 4

50 rail_holder_west_strap.SLDPRT MIC6 UA 2 33

parts list for subassembly: PIT_rail_20mm_assembly.SLDASM (on test)

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details for rail_test_system.SLDASM

pages 8-14

tolerances: ±0.25 mm unless specified

10PIT_end_fixture.SLDPRT (PIT east end) PIT_end_fixture.SLDPRT (PIT west end)

westside

westside

eastside

eastside

LBNL water jet from2 in MIC6

leave ¼ in on outer edges and round hole to be machined off

cut lightning holes on model line

after water jetting these parts will be sent to UTA for final machining

11PIT_end_fixture.SLDPRT (PIT west end)

ref surfaces

tooling ball location tolerance on front and back side: ±0.025 mm

diameter tolerance:+.013 mmslip fit for Brunson adapter

surface location tolerance:±.050 mmsets SSD location and probably sets glue bond thickness 1 of 6

location tolerance:0.050 mmsets SSD location

width tolerance:+.025 mm - .00 mmslip fit 1/8 in pin

hole position tolerance:.05 mm

hole diameter tolerance:0.05 mm

sideways hole position tolerance:±.05 mm

press fit for 1/8 in dowel pin.hole diameter tolerance:-0.013 mm

hole position tolerance:±0.05 mm

hole diameter tolerance:-0.013 mmpress fit for bullet/diamond pin liners

hole position tolerance:±.025 mm

hole diameter tolerance:+0.013 mm for slip fit on¼ in pin

tolerances on (PIT east end) configuration the same where applicable

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PST_end_fixture.SLDPRT (east) west configuration similar, but fewer holes

tolerances for both configurations the same as PIT_end_fixture.SLDPRT where applicable , see previous page

ref surfaces

water jet at LBNLmachining at UTA

LBNL water jet from2 in MIC6

leave ¼ in on edges and round hole to be machined away

cut lightning holes on model line

http://www-rnc.lbl.gov/~wieman/container_UTA_7_8_10.zip

these parts are in PST_trans_v2.SLDASM which is now included in

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IDS_flange_alignment_pin.SLDPRT

both diameter tolerances: -0.013mmfor slip fits

14PIT_base_fixture.SLDPRT (PIT, PIT mid, PST)

plane and parallel to ±0.05 mmlength tolerance: ±0.05 mm

sideways position tolerance ±0.05 mm

slip fit for 1/8 dowel pinwidth tolerance: +0.013 mm

water jet OK for lightning holes and all non specified edges

water jet and machine at LBNL

tolerances the same for all three configurations

15grand_master_kin_assembly.SLDASM

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this plane perpendicularto a ref cylinder axis

line betweenholes centered onref cylinder axis to ±0.05 mm

separation tolerance±0.05 mm or match drilledwith butch_plate_single.SLDPRT

diameter tolerance:+0.000 mm-0.013 mmfor bullet insert press fit

this and other 2 similar planestolerances to chord and axisof ref cylinder: ±0.05 mm

±0.05 mm tolerances are to preserve glue bond thicknesses

these and other similar holesdiameter tolerance:-0.013 mmfor press fit with tooling balls,glue in OK if ends up sloppy

grand_master.SLDPRT

17grand_master.SLDPRT

separation tolerance:±.25 mm or match drill with grand_master_support_plate.SLDPRT

diameter tolerance:±0.125 mm for slip fit

18butch_plate_single.SLDPRT

surfaces parallel to 0.05 mm

hole position tolerance with respect to each other: ±0.05 mm

can be match drilled to appropriate parts

diameter tolerance: +.000 - .013 mm for press fit with bullet liners

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position tolerance:±.25 mm or match drill with grand_master.SLDPRTdiameter tolerance:+0 -.013 mm forpress fit with 1/8 inch dowel pin per McMaster Carr recommendation for their pin

grand_master_support_plate.SLDPRT

mill top face onlyfrom ½” stockslightly less than 1/2” thick plate no problem

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details for sub assembly PIT_rail_20mm_assembly.SLDASM (on test)

pages 21-36

tolerances: ±0.25 mm unless specified

21PIT_rail_20mm_single_v2.SLDASM

file config material quant. imagePIT_rail_20mm_single_v2.SLDASM PIT test TN 2PIT_rail_20mm_single_v2.SLDASM PIT test TS 2

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file config material quantity image

PIT_rail_20mm.SLDPRT east v2 CF 4

PIT_rail_20mm.SLDPRT main v2 CF 12

toleranceOD +0-50mID +50-0m

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file config material quant. imagePIT_rail_mount_20mm_v2.SLDASM tester normal 8PIT_rail_mount_20mm_v2.SLDASM tester mirror 8

24PIT_rail_mount_20mm_v2.SLDASM ( tester normal)

8-32 x 1 in aluminum cap screwsvender: Fastner-express.com

PIT_rail_arm_anchor_post_v2.SLDPRTPIT_rail_hanger_ext_v3.SLDPRT

rail_mount_dowel_pin.SLDPRT (long)

PIT_rail_arm_20mm_v2.SLDPRT cylinder_nut.SLDPRT

PIT_rail_coupler_20mm_v2.SLDPRT

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file config material quant. imagePIT_rail_hanger_ext_v3.SLDPRT MCC 88805K64 8PIT_rail_hanger_ext_mirror_v3.SLDPRT MCC 88805K64 8

fillet not important, remove sharp edges

diam +.05mm - 0

#8-32 tap all small holes

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diam +0mm – 0.013mm press fit with 1/8 in dowel pin

file config material quant. imagePIT_rail_arm_anchor_post_v2.SLDPRT 6061 16

#8-32 tap one hole

diam +0-0.05 mm

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#8-32 tap 4 holes

diameter tolerance +.025-0 mmslip fit 1/8 in pin

surface to cyl. surface tolerance .05 mm (controls glue bond thickness)

PIT_rail_arm_20mm_v2.SLDPRT

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file config material quant. imagePIT_rail_coupler_20mm.SLDPRT 6061 16

diameter tolerance:+0-.2 mmaffects rail position

diameter tolerance:±.05mmaffects glue bond

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file config material quant. imagecam_rail_TR_1.SLDPRT v2 6061 1cam_rail_TR_2.SLDPRT v2 6061 1cam_rail_TR_3.SLDPRT v2 6061 1

thickness tolerance ± 0.13 mmfor the 3 pieces

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file config material quant. imagecam_rail_TL_1_v2.SLDPRT v2 6061 1cam_rail_TL_2_v2.SLDPRT v2 6061 1cam_rail_TL_3_v2.SLDPRT v2 6061 1

thickness tolerance ± 0.13 mmfor the 3 pieces

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each guide rail has one end fixed and one end sliding lengthwise

detail from PIT_rail_20mm_single_v2.SLDASM

part config material quant. image8-32 x .375 in aluminum socket headvender: Fastner-express.com aluminum 32 total

8-32 shoulder head MC 95446A220 brass 32 total

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file config material quant. imagerail_holder_termination_assembly.SLDASM 2

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file config material quant. imagerail_holder_strap_assembly.SLDASM 2rail_holder_west_strap.SLDPRT 6061 2

tolerance of relative position of inner holes to each other ± .025 mm (controls glue bond thickness, and must match bullet pins on other parts)inner hole diameter tolerance +0-.013 mm (press fit for bullet nose liners)

make from .5” x 2” barback side and long edgesnot machined, will change modelto be 2 in wide

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file config material

quant. image

rail_holder.SLDPRT ring on insert plus west end connection

6061 2

bullet nose (McMaster 31335A11) 1 perdiamond nose (McMaster 31335A31) 1 per

tolerance 4 outer edges ± 0.025 mm ( controls glue bond thickness and limits slider binding)

tolerance inner hole position ± 0.025 mmtolerance inner hole diameter +0-.013mm (press fit nose bushings)

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file config material

quant. image

rail_holder.SLDASM 4Retain_ext_modified_MC98541A139.SLDPRT 8 perrail_holder.SLDPRT ring on bearing 6061 1 perlinear bearing liner, Pacific bearing FMN20 4 perset screw dog 8-32 McMaster 92505A191 steel 4 per

MC master-Carr part number98541A139with one ear ground off and hot glued to prevent rotation. Two retainers on each bearing liner

tolerances on this part, see next page

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file config material

quant. image

rail_holder.SLDPRT ring on bearing 6061 4

tolerance on 4 outer edges and centers of 4 open circles ± .050 mm ( controls rail positions, must avoid slider binding)

diameter tolerance of 4 open circles +0.025 mm-0(fit bearing liners without forcing)

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kin_cross_support.SLDPRT

All fillets and chamfers shown in the model can be eliminated, deburring is sufficient

Fillet from endmill radius OK

These 6 holes will have balls glued in. The holes are slightly oversize for a glue bond and a vent hole has been added so that the balls will not piston out due to a trapped air bubbles.These devices are designed for reproducibility of placement. Precision is not so important as long as the location of the three parts in the grandmaster_kin_assembly.SLDASM are not interchanged. These 3 parts and their positions will be labled.

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References:

MC http://www.mcmaster.com/FE http://www.fastener-express.com/PB http://www.pacific-bearing.com/CL http://www.carrlane.com/