(Corey G, Jeff G, Jim W, Mike V)
Yesterday, we focused on subassemblies and getting them installed on the system.
Horizontal Small Actuators
All three of these were installed. A couple of notes:
1) The bolt on the "Base" (i.e. Magnet Mount) which is closest to the center of the ISI is really in a tough location to get a wrech at. Yoga poses are needed to tighten this bolt down (a torque wrench will not work back there).
2) The Actuator is pre-assembled with a Tooling Bracket which holes the coil & magnet in an ideal position. The magnet & coil sides are then carefully bolted down to Stage2 & Stage1 respectively. Coil/Magnet gaps are measured and then the Tooling is removed. Repeatedly, when the Tooling is removed, it was observed that the coil would drop on the order of 0.010-0.015"! Not sure what the trick is here to prevent this. For two of the Actuators this shift kept the gaps under the NO-GO value (we didn't want to have gaps over 0.115"). But on one, we had a gap of 0.118". This one had to be removed, Tooling re-attached, and then it was re-installed. With re-installation, this one fit in like a charm. It's gaps were balanced and no major shift was observed. It should be noted on this last Actuator that it's Pin Carrier Tooling were left in the Assembly during installation. perhaps this helped keeping things together.
3) It should also be noted that even with the Tooling, the Actuator gaps weren't always balanced (saw this with the Large Actuators). I thought this was the point of the Tooling! Is there a trick to putting these guys together. Perhaps keeping the Pin Carriers in place during the whole installation process is important.
Here are notes on biggest gap observed after Tooling removed (and also "before" gap measurements):
CORNER 1 Biggest gap (on top) = 0.111 (originally 0.098)
CORNER 2 Biggest gap (on top) = 0.118 (originally 0.109)
-----Reinstalled tooling and was balanced around 0.091"
CORNER 3 Biggest gap (on top) = 0.114 (originally 0.099)
Vertical Small Actuators
Just started installing one of these toward the end of the day. The Actuator Magnet Mounts (D0902191) were installed early, and it was noticed some of the bolts had somewhat tight fits into their helicoils. Perhaps these are electro-polished bolt candidates. Able to get the standard bolts to drop in by jiggling them a bit as you screwed them in.
Large & Small Lockers
The Small Lockers were installed with no issues. The Large Lockers were installed and then it was noticed that we blocked out access for the Spring Barrel Nuts(!). So, we had to remove all (3) Large Lockers, slip all Barrel Nuts into their holes, and then re-install the Lockers.
Locker Drawing Bolt NOTE:
So on the Assembly Drawings for both the Large (D1000854) & Small Lockers D(1000855), there are some items which aren't pointed out & are also just wrong. The issue we had were with bolts---the ones which bolt the Housing Locker Sleeve to the Stage/Plate above it (for both Lockers) and for the Large Lockers, the bolts which clamp Pin Caps down.
On the Large Actuators it is not pointed out which bolt should be used for the Pin Caps. By elimination, one would think it was the 3/8-16 x 1.5" bolts, BUT holes aren't tapped deep enough to take these bolts. So on BSC ISI#1, 1-3/8" bolts were used here. Unfortunately, the bolts used for Housing Locker Sleeves are also not pointed out in the drawing. By the process of elimination, we assume the 1-3/8" bolts were used here! (for both Large & Small Lockers).
So on BSC ISI#1, the 1-3/8" bolts were used for the Large/Small Sleeves & also on the Large Pin Caps. Unfortunately, we had a limited amount of these bolts and this left us short for BSC ISI#2! This is what we did for #2:
We saw for the Large/Small Housing Sleeves, that the 1-3/8" bolt provide LOTS of thread. We also saw that the 1-1/4" long bolt also provided plenty of thread as well. So, 1-1/4" bolts were used here for both Large/Small Lockers on BSCISI#2. Since the 1.5" bolt didn't work on the Large Locker Pin Cap, we put the 1-3/8" bolt here (as we did on #1).
Drawings changed to note this issue.