80693e35 - 1.0 - Biosheild Optical Labrynth Technical Design Description.pdf

ITER UPPER WIDE ANGLE VIEWING SYSTEM PROJECT

55.GA UWAVS Technical Design Description for Bioshield Optical Labyrinth

Sponsored by Oak Ridge National Laboratory c/o Princeton Plasma Physics Laboratory

Under Subcontract No: S013437

Prepared by General Atomics

304243-R00027 Revision A

GA Project 30424

PPPL APPROVAL

VERSION Date Signatory QA Engineer SE External

ITER

Reviewer

Approver

1.0 6/4/2024

Mark Smith Patrick Temple Pete Dugan N/A Ravinder Bhatia

SEE EDRM

Notification

N/A

304243-R00027 Revision A

ITER UPPER WIDE ANGLE VIEWING SYSTEM

PROJECT

55.GA UWAVS TECHNICAL DESIGN

DESCRIPTION FOR BIOSHIELD OPTICAL

LABYRINTH

Sponsored by Oak Ridge National Laboratory c/o Princeton Plasma Physics Laboratory

Under Subcontract No: S013437

Prepared by General Atomics PO Box 85608

San Diego, CA 92186-5608

GA PROJECT 30424

R el ea se d

4/

/0

R eleased 2024/06/03

55.GA UWAVS TDD for Bioshield Optical Labyrinth 304243-R00027/A ii

REVISION HISTORY

Revision Date Description of Changes

A See

Watermark Initial Release

POINT OF CONTACT INFORMATION

PREPARED BY:

Name Position Email Phone

Ryan Finden Mechanical Engineer Ryan.Finden@ga.com 858-455-3865

APPROVED BY:

Name Position Email Phone

David Chan Quality Engineer David.Chan@ga.com 858-455-3532

Sean McCartney Lead Engineer Sean.McCartney@ga.com 858-248-6652

Anthony Gattuso Program Manager Anthony.Gattuso@ga.com 858-455-2910 ea se d

4/

/0

R iii

TABLE OF CONTENTS

REVISION HISTORY .................................................................................................................. II

POINT OF CONTACT INFORMATION ....................................................................................... II

ACRONYMS .............................................................................................................................. V

1 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Definitions

1.3.1 Units

1.3.2 Coordinate Systems

1.3.3 Geometry

2 BOL SUBSYSTEM OVERVIEW

2.1 Key Functions

2.2 Primary Components

2.3 Functional Flow Block Diagram

2.4 BOL Size, Weight, and Power (SWaP)

3 SUBSYSTEM DETAILED DESIGN DESCRIPTION

3.1 Opto-mechanical Design

3.1.1 Mirror

3.1.2 Mirror Housing and Flexures

3.1.3 Elevation Axis

3.1.4 Azimuth Axis

3.1.5 Limit Switches

3.1.6 Mirror Mount Base

3.2 Structures Design

3.2.1 Breadboard and Standoffs

3.2.2 Enclosure

3.2.3 Legs

3.2.4 ISS-PCSS Shroud

3.2.5 Washers

4 INTERFACES AND SERVICES

4.1 Electrical Services

4.2 ISS Interface and Alignment

5 INSTRUMENTATION AND CONTROL SCHEME

6 REFERENCES

APPENDIX A COTS PARTS SPECIFICATIONS .................................................................... A-1

APPENDIX B MATERIAL SPECIFICATION........................................................................... B-1

LIST OF FIGURES

Figure 1. Coverage of divertor from a) one UWAVS diagnostic and b) five Upper Port UWAVS diagnostics

Figure 2: 55.GA UWAVS diagnostic system

Figure 3. (a) BOL dogleg with light beam visible (b) top-down view of dogleg layout

Figure 4. Key components and assemblies of the BOL

Figure 5. Bioshield Optical Labyrinth (BOL) between the IOT (left) and the BEOC (right)

R el ea se d

4/

/0

R iv

Figure 6. BOL functional Flow Block Diagram

Figure 7. BOL size envelope

Figure 8. A60 mirror mount assembly

Figure 9. A60 Mirror and beam footprint

Figure 10. (a) A60 mirror housing and flexures; (b) and flexure assembly

Figure 11. Mirror side plungers

Figure 12. (a) A60 mirror mount with the mirror unit removed; (b) and top-down view

Figure 13. A60 elevation axis exploded view

Figure 14. Newmark® RM-8 azimuth actuation stage

Figure 15. Allectra® 363-SWITCH-RAD-1 and its specs

Figure 16. A60 mirror base

Figure 17. BOL structural summary

Figure 18. BOL structures with mirror mounts hidden

Figure 19. A60 Breadboard and Position

Figure 20. Isolated BOL Enclosure

Figure 21. BOL Leg

Figure 22. (a) BOL in the Bioshield, (b) BOL shroud

Figure 23. BOL-BEOC shroud in the aft of ISS (a) extension, (b) retraction of the shroud

Figure 24. Nord-Lock joint configurations seen on the BOL (a) through-bolt joint configuration,

(b) threaded plate joint configuration

Figure 25. BOL cable routing from the ISS up to the enclosure

Figure 26. BOL cable interface with ISS connector and internal routing

Figure 27. BOL Fischer Cable Connectors

Figure 28. Location of BOL on ISS and within the Bioshield

Figure 29. BOL on the Two ISS Interface Plates

Figure 30. BOL Alignment Puck and Bottom Plate

Figure 31. BOL Local Coordinate System and Laser Targets

Figure 32. ISS Alignment Strategy

Figure 33. Clamp force vs cycle count for Nord-Lock® washers against other locking methods A-

LIST OF TABLES

Table 1. Applicable CAD models

Table 2. Mass Breakdown of Subsystem

Table 3. BOL Components and Power

Table 4. Rad-Hard Motor Specifications .................................................................................. A-1

Table 5. Rad-Hard Brake Specifications.................................................................................. A-1

Table 6. NEWMARK Rotary Stage Specifications ................................................................... A-2

Table 7. Material Specification Table ...................................................................................... B-1 ea se d

4/

/0

R v

ACRONYMS

Acronym Description

BEOC Back End Optics & Cameras

BOL Bio-Shield Optical Labyrinth

CP Closure Plate

EPDM Ethylene Propylene Diene Monomer

FDR Final Design Review

IO ITER Organization

IOT Interspace Optics Tube

ISS Interspace Support Structure

PC Port Cell

PCSS Port Cell Support Structure

PDR Preliminary Design Review

PI Port Integrator

SL-1

Seismic Level 1 – Defined by ITER for investment protection

SL-2

Seismic Level 2 – Equivalent to Safe Shutdown

Earthquake

SL-3

Seismic Level 3 – Extremely Unlikely Earthquake defined for HCC

UWAVS Upper Wide Angle Viewing System

VIS Visible (light) ea se d

4/

/0

R

1 INTRODUCTION

The 55.GA Upper Port Wide Angle Viewing System (UWAVS) views the divertor in sections and provides machine protection (monitoring for overheating of surfaces), plasma control (basic and advanced), and physics measurement roles. UWAVS is located in UP 2/8 (RFDA), UP 11/14

(USDA) and UP 17 (EUDA). The UWAVS coverage of the divertor is shown in Figure 1.

Figure 1. Coverage of divertor from a) one UWAVS diagnostic and b) five Upper Port UWAVS diagnostics

1.1 Purpose

The purpose of this document is the technical design description (TDD) of the Bioshield Optical

Labyrinth (BOL) subsystem, as part of the ITER diagnostic 55.GA Upper Visible and Infrared Wide

Angle Viewing System (UWAVS). The BOL subsystem resides in the ITER Ex-Vessel Interspace, and is baselined as a common, identical design between all five installed instances of UWAVS

(Upper Ports 2, 8, 11, 14, and 17).

In subsequent sections, the BOL subsystem design will be described as follows:

Subsystem overview

Subsystem and subassembly detailed design summary

Summary of interfaces and services

Instrumentation and control scheme summary

R el ea se d

4/

/0

R

1.2 Scope

This document provides detailed component design architecture, function, and methodology for the UWAVS (55.GA) BOL subsystem at the preliminary design phase. The BOL subsystem design is common for all five Upper Ports (2, 8, 11, 14, and 17).

High-level definitions of the UWAVS system architecture, decomposition, and functions are described in the UWAVS System Design Description Document [1].

1.3 Definitions

1.3.1 Units

The units of the international system (SI) are used unless otherwise stated.

1.3.2 Coordinate Systems

Coordinate system references are consistent with the ITER Tokamak Global Coordinate System

[2] unless otherwise stated.

1.3.3 Geometry

The CAD geometry referenced throughout this report is listed below in Table 1.

Table 1. Applicable CAD models.

Model CAD File

Native CATIA File UWAVS_BOL_SUBYSYSTEM_ASSY.CATProduct, A.26 ea se d

4/

/0

R

2 BOL SUBSYSTEM OVERVIEW

The UWAVS architecture is based on a modular approach that includes key functional subsystems in and outside of the vacuum vessel as shown in Figure 2.

Figure 2: 55.GA UWAVS diagnostic system

2.1 Key Functions

The BOL has five key functions and driving requirements:

1. Relay the light beam through the Bioshield with a labyrinth/dogleg to minimize the radiation exposure to workers in the Port Cells [3].

2. Allow for steering of the 55.GA light beam to maintain alignment between the IOT on the

ISS and the BEOC on the PCSS after removal and reinstallation of either support structure with a minimum angular step size of 0.25 mrad.

3. Enshroud the light beam from external light and contaminate dust.

4. Survival of the subsystem through SL-2 seismic [3].

5. Maintain functionality for the 20-year ITER lifetime without failure [3].

The BOL has a dogleg to reduce neutron streaming. The aperture is 220mm and the offset is

186mm (Figure 3). This dogleg allows light to pass through the subsystem while reducing the harmful radiation passing through the system.

R el ea se d

4/

/0

R

Figure 3. (a) BOL dogleg with light beam visible (b) top-down view of dogleg layout

2.2 Primary Components

The major components and subassemblies of the BOL are shown in Figure 4. The BOL sits within the Bioshield and maintains alignment between the IOT and BEOC after maintenance periods when the ISS or PCSS are reinstalled. This is done using two actuated mirror mount assemblies.

The two assemblies also create an optical dogleg within the Bioshield to reduce neutron streaming through the 55.GA diagnostic beam path. The A60 mirror assemblies are secured to a breadboard in an enclosure that prevents the ingress of dust and stray light. The enclosure is secured to a subsystem bottom plate through four legs. The bottom plate features alignment pucks that allow the subsystem to be aligned to the ISS or PPAD virtual datum at installation. Figure 5 shows a render of the BOL between IOT and BEOC with a visible light beam.

Figure 4. Key components and assemblies of the BOL

(a) (b) el ea se d

4/

/0

R

Figure 5. Bioshield Optical Labyrinth (BOL) between the IOT (left) and the BEOC (right)

2.3 Functional Flow Block Diagram

Figure 6 shows the BOL subsystem block diagram that highlights function, decomposition, and interfaces. Color codes and line types are noted in the legend.

Figure 6. BOL functional Flow Block Diagram

BOL

IOT

BEOC

R el ea se d

4/

/0

R

2.4 BOL Size, Weight, and Power (SWaP)

The overall dimensions for the BOL are shown in Figure 7. Table 2 lists the individual and total weights of the BOL (508 kg). A list of materials is given in Table 7 in APPENDIX B

Figure 7. BOL size envelope

Table 2. Mass Breakdown of Subsystem

Subassembly Component Qty Mass (kg) Total Mass (kg)

BOL_CABINET_ASSY BOL_CABINET_BOTTOM_PLATE 1 85.6 85.6

BOL_CABINET_ASSY ENCLOSURE_WELDMENT 1 49.1 39.6

BOL_CABINET_ASSY STARBOARD DOOR 1 14.1 14.1

BOL_CABINET_ASSY PORTSIDE DOOR 1 6.0 16.0

BOL_CABINET_ASSY SHEET METAL RFWD 1 8.9 8.9

BOL_CABINET_ASSY SHEET METAL LFWD 1 9.0 19.0

BOL_CABINET_ASSY SHEET METAL TOP A 1 1.0 1.0

BOL_CABINET_ASSY SHEET METAL TOP B 1 14.8 14.8

BOL_CABINET_ASSY SHEET METAL TOP C 1 5.5 5.5

A60M1 ASSY Full Assembly 2 65.8 131.6

Breadboard Assy Breadboard 1 33.6 33.6

Breadboard Assy Standoff 6 0.8 5.0

Bottom Leg C-Channel leg 4 8.2 32.6

Bottom Leg Fasteners 1 0.3 0.3

Bottom Plate Botto Plate 1 108.8 108.8

Bottom Plate Puck assy 4 0.4 1.6

Total 507.56 kg

R el ea se d

4/

/0

R

Table 3 lists the voltages, currents, and power for components in the system. The total power load is 172W. These values are the maximum seen, only occurring during alignment tasks after initial installation or Long Term Maintenance (LTM) periods. Very little power is required outside of alignment tasks.

Table 3. BOL Components and Power

Component Quantity Voltage Amperage Total

Wattage Cable

AWG

RH-U17-2 Motor 2 24V 1.08A 52W 26

B017A U17 Brake 2 24V 0.13A 6W 26

RH-U21 Motor 2 24V 1.60A 77W 22

B11 U23 Brake 2 24V 0.73A 35W 26

363-SWITCH-RAD Limit Switch 8 24V 0.01A 2W 28

Total 3.55A 172W ea se d

4/

/0

R

3 SUBSYSTEM DETAILED DESIGN DESCRIPTION

The BOL achieves the key functions by incorporating two flat mirror mounts with tip/tilt (elevation and azimuth) controllability in a dogleg configuration within an enclosure. This is achieved with a combination of rad-hard motors and 316L stainless steel worm-gear based rotary stages.

This configuration is the baseline design.

3.1 Opto-mechanical Design

Two actuated mirror mounts maintain alignment of the light beam between the IOT on the ISS and BEOC on the PCSS. Two degrees of freedom are available: ±20° in elevation and ±5° in azimuth for both mounts. The azimuth actuation amount is limited due to space constraints, but adequately keeps the system aligned for the expected ISS and PCSS installation tolerances [4].

The mounts are composed of stainless steel off-the-shelf parts connected with a stainless steel machined structure.

Figure 8. A60 mirror mount assembly

3.1.1 Mirror

The A60 mirrors are flat and are made of N-BK7 glass with a silver coating. They are wider than tall to accommodate the wide beam footprint (Figure 9). The mirrors are oversized to account for misalignment between and ISS and PCSS. They have a width-to-thickness ratio of 10:1. Each mirror weighs 8.9 kg.

R el ea se d

4/

/0

R

Figure 9. A60 Mirror and beam footprint

3.1.2 Mirror Housing and Flexures

The mirror is housed in a 316L stainless steel case and constrained with plungers and flexures to form the “mirror unit”. Three elastic flexures, shown in Figure 10, retain the mirror in the housing with sufficient preload to survive SL-2 events (<-3.8,17,17> m/s2), in addition to standard gravity.

They are composed of a 17-7 steel plate with a rounded aluminum tab (R=32mm) that makes contact with the mirror surface. The rounded aluminum tab is bonded to the flexure plate with the radiation-resistant, low-outgassing epoxy MasterBond® EP33. The rounded aluminum reduces contact stresses by distributing the spring load across the mirror surface. Three precision-milled bosses support the rear of the mirror and are positioned opposite of the flexures to avoid inducing any bending stresses within the mirror.

The remaining two degrees of translation of the mirror are secured with side plungers (Figure 11).

The plungers are preloaded to values higher than the mirror mass multiplied by SL-2 accelerations to prevent the mirror from shifting during an SL-2 event.

Figure 10. (a) A60 mirror housing and flexures; (b) and flexure assembly el ea se d

4/

/0

R

Figure 11. Mirror side plungers

3.1.3 Elevation Axis

The elevation axis is controlled by a 25mm shaft that is supported on the mirror base free to spin in two precision ball bearings inside the pink flanges shown in Figure 12. The mirror housing is fixed to the shaft via the green flanges and collar clamps. This forces the mirror housing to rigidly rotate with the shaft. The green collar clamp is secured to the right side of the shaft and is bolted to an adapter plate. The adapter plate is bolted to a stainless Newmark® RM-3 worm-gear driven rotary stage. With the weight of the elevation axis supported by the mirror base, the stage can precisely control the mirror’s elevation. An exploded view of this is shown in Figure 13.

The RM-3’s gearbox gear ratio allows for a 1.55 μrad step resolution for the elevation axis. The worm gear inside the stage multiplies the motor’s torque, allowing it to counter the torque exerted by the mirror unit’s weight. Outside of alignment activities, a rad-hard motor brake is used to keep the assembly stable. Currently the torque generated from the mirror unit during SL-2 loading exceeds the maximum torque of the brake. This can be resolved in final design by reducing the weight of the mirror unit and by stiffening the BOL structure to raise its first natural frequency out of floor response frequencies with high accelerations.

Figure 12. (a) A60 mirror mount with the mirror unit removed; (b) and top-down view el ea se d

4/

/0

R

Figure 13. A60 elevation axis exploded view

3.1.4 Azimuth Axis

The base of the A60 mirror mount is an all-stainless Newmark® RM-8 rotary stage driven by an

Empire Magnetics RH-U21 NEMA 23 radiation-hardened (rad-hard) stepper motor and rad-hard brake, resulting in a step size of 1.55 μrad. The axis of rotation is coincident with the front face of the mirror to reduce beam path length changes between A60M1 and A60M2 when the azimuth angle is changed.

The rotary stage is the bottom-most part in the mirror mount assembly and is bolted to the BOL breadboard with four M8 bolts (Figure 14).

Figure 14. Newmark® RM-8 azimuth actuation stage

3.1.5 Limit Switches

The mirror mounts use rad-hard limit switches to maintain an indexed “home” and “away” position for both azimuth and elevation axis. The switches are Allectra® 363-SWITCH-RAD-1. An image

R el ea se d

4/

/0

R of this switch and its specifications are shown in Figure 15. The switches are positioned to prevent the mounts from colliding with the enclosure. The switches are rated for 107 Gy (the expected maximum dose in the Interspace is 107 Gy).

Figure 15. Allectra® 363-SWITCH-RAD-1 and its specs

3.1.6 Mirror Mount Base

The majority of components used in the mirror mount assembly are held together by a machined central base (Figure 16). The base is 316L stainless and weighs 18.7 kg. Two gussets stiffen the base to reduce oscillations and deflections from the 33 kg of offset mass it supports. The bottom and backside have weight-reducing pockets to help move the center of gravity towards the center of the stage.

Figure 16. A60 mirror base

3.2 Structures Design

The mirror mounts sit on a series of structures securing them down to the ISS. A cross-section overview is shown in Figure 17. An enclosure attached to the structure prevents the ingress of light and dust into the subsystem. The structure has been analyzed using the SL-2 load cases during both operational and bakeout conditions and satisfies the structural integrity requirements.

[5]. This structure is shown in Figure 18.

R el ea se d

4/

/0

R

Shoulder bolts are used throughout the structure to align components at assembly. M12 bolts are used through the structure and M24 bolts are used to secure the subsystem to the ISS.

Figure 17. BOL structural summary

Figure 18. BOL structures with mirror mounts hidden

3.2.1 Breadboard and Standoffs

Both A60 mirror mount assemblies are bolted into a 25mm thick 316L stainless steel breadboard

(Figure 19). The breadboard is supported by six standoffs. The standoffs are standard 38mm diameter, 95mm tall optical posts made of nonmagnetic 303 stainless steel. The breadboard has four M8 threaded holes for each mirror mount assembly, and six 14mm through holes for the standoffs’ 12mm shoulder bolts. While shoulder bolts are used to locate the breadboard, the location isn’t critical as the mirror mounts will be positioned with respect to the BOL coordinate system.

R el ea se d

4/

/0

R

Figure 19. A60 Breadboard and Position

3.2.2 Enclosure

The mirror mounts sit within an enclosure that prevents the entrance of dust and light into the subsystem (Figure 20). The enclosure is a weldment of stainless steel rectangular tubing and sheet metal. The enclosure has removable panels and a removable structure to be detailed in final design for assembly or maintenance access.

The square tubing is 304 stainless with a 50mmx50mm profile and 2.5mm wall thickness.

The sheet metal is American gauge 16 (1.6mm thick). The weldment and breadboard standoffs are secured to a 19.1mm thick 304L bottom plate.

Figure 20. Isolated BOL Enclosure

3.2.3 Legs

Four legs secure the enclosure to the bottom plate (Figure 21). The legs are made from blocks of

304L stainless steel. The bottom and top bolts are concentric to prevent moments being generated from preloads. The pocket provides adequate clearance for tooling to torque the bolts.

R el ea se d

4/

/0

R

Figure 21. BOL Leg

3.2.4 ISS-PCSS Shroud

Between the ISS and PCSS, dust and external light are blocked by a telescoping shroud that connects the BOL to BEOC (Figure 22). During maintenance periods the shroud can be unbolted from the BEOC and slid within the Bioshield, as shown in Figure 23.

The shroud is made of two stainless steel tubes, and a bellow to account for misalignments between the ISS and PCSS. The larger tube is US Size 8 Schedule 10 (219.1mm OD, 211.6mm

ID), and the smaller tube is US Size 8 Schedule 40 with a trimmed OD (211.2mm OD, 202.717mm ID). The smaller tube has two EPDM O-rings to keep it sealed and centered within the larger tube. A stainless steel bellow provides flexibility to accommodate misalignments between the ISS and PCSS. Both the larger tube and bellow are welded to stainless steel plates to allow them to be bolted to the structures.

Figure 22. (a) BOL in the Bioshield, (b) BOL shroud

(a) (b) R ea se d

4/

/0

R

Figure 23. BOL-BEOC shroud in the aft of ISS (a) extension, (b) retraction of the shroud

3.2.5 Washers

All washers on the BOL are Nord-Lock® washers to keep the system secured and joints preloaded over its 20 years of service. Performance data is shown in Figure 33 in Appendix A.

Joint configurations are shown in Figure 24 below.

Figure 24. Nord-Lock joint configurations seen on the BOL (a) through-bolt joint configuration,

(b) threaded plate joint configuration

R el ea se d

4/

/0

R

4 INTERFACES AND SERVICES

This section provides a brief, high-level summary of the BOL subsystem external interfaces and service requirements. Detailed interface descriptions and associated data can be found in the following interface sheets (IS):

55.GA IS for UPP-02 [6]

55.GA IS for UPP-08 [7]

55.GA IS for UPP-11 [8]

55.GA IS for UPP-14 [9]

4.1 Electrical Services

The BOL requires electrical and sensor cable routing from the ISS. The cables will be routed from the ISS bulkhead underneath the ISS up to the center of the BOL. A notional cable run is shown in Figure 25 in purple and is for reference only. The BOL cables share a common connection at the ISS and leverage a Y-bundle to separate the IOT and BOL connectors at two locations on the interface plates. The terminations for the BOL cables are Fischer® 316L stainless steel rad-hard quick connectors (Figure 25). Quick-connects will reduce the amount of time to disconnect the subsystem for ALARA consideration. The connectors are rated to 107 Gy, which is the maximum expected dose in the Interspace.

Figure 25. BOL cable routing from the ISS up to the enclosure el ea se d

4/

/0

R

The ISS cables terminate at a bulkhead on the bottom center of the BOL. Jumper cables connect the bulkhead to the bottom of the BOL enclosure (Figure 26). Cables are internally routed within the enclosure to the motors and brakes. Each of these connections use the Fischer® quick-connectors. Disconnection of the BOL will only be necessary when removing the subsystem from the ISS.

Figure 26. BOL cable interface with ISS connector and internal routing

Three cables will be necessary externally for the BOL. Figure 27 shows the connector layouts and estimated cable diameters.

Figure 27. BOL Fischer Cable Connectors

4.2 ISS Interface and Alignment

The BOL subsystem sits within the Bioshield centered on the ISS (Figure 28) and requires one mechanical interface with the ISS. This interface is facilitated by the IOT interface plates and the

BOL bottom plate. The interface plate falls under the design ownership of the respective Port

Integrator, with 55.GA design features implemented, and is common to all instances of UWAVS.

55.GA owns the BOL bottom plate design and is responsible for its fabrication.

R el ea se d

4/

/0

R

Figure 28. Location of BOL on ISS and within the Bioshield

The BOL bottom plate interfaces between the two interface plates on the ISS and the BOL support legs, as shown in Figure 29. Alignment pucks (Figure 30) allows for 12mm of lateral movement and 1.03° of rotation of the subsystem on the ISS interface plate. At assembly, the subsystem is placed on to the ISS interface plates and slid into place to where the holes are roughly aligned.

The subsystem is then aligned to laser retroreflector fiducials (see section 4.2). Once in place, alignment pucks are placed into the bottom plate counterbored holes and the subsystem is bolted to the ISS.

Figure 29. BOL on the Two ISS Interface Plates el ea se d

4/

/0

R

Figure 30. BOL Alignment Puck and Bottom Plate

The BOL is shipped with three laser alignment nests. Laser retroflector spheres are placed in the nests to establish a local coordinate system (Figure 31) of the BOL subassembly. The BOL is aligned to the ISS fiducials. Once installed, the BOL positioning is finely adjusted to improve the nominal position using the installed and measured Closure Plate and Building fiducial data as shown in Figure 32 [10].

Self-centering welded nut interfaces are required to mount the BOL bottom plate to the ISS.

Through holes in the interface plate allow the penetration of fasteners.

Figure 31. BOL Local Coordinate System and Laser Targets

Figure 32. ISS Alignment Strategy el ea se d

4/

/0

R

5 INSTRUMENTATION AND CONTROL SCHEME

This section provides a brief overview of the BOL subsystem Instrumentation and Controls (I&C) scheme. For more detailed information, see the following documents:

I&C System Design Specification (I&C SDS) [11]

55.GA PID for UPP-02 [12]

55.GA PID for UPP-08 [13]

55.GA PID for UPP-11 [14]

The BOL contains motors, motor brakes, and thermocouples each needing power and/or signals.

Motor drivers, controllers, and data acquisition for the BOL equipment resides in the Diagnostics

Hall due to the harsh environment of the Interspace and Port Cell. Thermocouples exist both within the enclosure and on the mirrors to monitor temperature as the optical performance may be sensitive to the large temperature changes in the Interspace. Specific I&C hardware controlling schemes have not been selected at this level of design and will be defined during the final design phase.

R el ea se d

4/

/0

R

6 REFERENCES

[1] System Design Description for 55.GA for Installation in UP2, 8, 11, and 14 (UWAVS-35), 304243-R00017, Rev A, ITER_D_WL5RAE, v1.0.

[2] ITER Coordinate Systems, ITER_D_2A9PXZ, v3.7.

[3] Sub-System Requirement Document sSRD-55.GA: IR Cameras: Vis/IR TV (Upper), ITER_D_WYWS36, v1.2.

[4] System Design Description for Interspace Support Structure (ISS), Port Cell Support Structure (PCSS) for Lower, Equatorial and Upper Ports, ITER_D_7M5RVG, v1.2.

[5] 55.GA UWAVS Engineering Calculation Note for Bioshield Optical Labyrinth, 304243- R00012, Rev A, ITER_D_ATYJVY, v1.0.

[6] IS-55.GA-55.U2-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port UPP#2, ITER_D_X5W4BE, v1.2.

[7] IS-55.GA-55.U8-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port UPP#8, ITER_D_X838G5, v1.2.

[8] IS-55.GA-55.UE-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port UPP#11, ITER_D_XBXM65.

[9] IS-55.GA-55.UH-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port UPP#14, ITER_D_UDQG3P, v0.0.

[10] 55.U2 - On site Assembly Plan(s), ITER_D_VQ9Q2Z, v1.2.

[11] 55.GA UWAVS I&C System Design Specification, 304243-S00025, Rev A, ITER_D_ARS734, v1.0.

[12] 55-GA-A0 IR Cameras: VIS/IR TV (Upper) UPP02 PID, ITER_D_PJ4JFG, v2.0.

[13] 55-GA-B0 IR Cameras: VIS/IR TV (Upper) UPP08 PID, ITER_D_PJAC7P, v1.0.

[14] 55-GA-C0 IR Cameras: VIS/IR TV (Upper) UPP11 PID, ITER_D_PJCAT5, v1.0.

ea se d

4/

/0

R

A-1

APPENDIX A

COTS PARTS SPECIFICATIONS

Table 4. Rad-Hard Motor Specifications

Table 5. Rad-Hard Brake Specifications ea se d

4/

/0

R

A-2

Table 6. NEWMARK Rotary Stage Specifications ea se d

4/

/0

R

A-3

Figure 33. Clamp force vs cycle count for Nord-Lock® washers against other locking methods ea se d

4/

/0

R

B-1

APPENDIX B

MATERIAL SPECIFICATION

Table 7. Material Specification Table

Component Material

A60 adapter plates and flanges SS304L

A60 collar clamps SS18-8

A60 flexure pad Al-6061

A60 flexure plate SS17-7

A60 mirror N-BK7

A60 mirror base SS304L

A60 mirror housing SS304L

A60 rotary shaft SS303

A60 rotary stages SS304L

A60 side plunger assembly SS316L

Alignment pucks Inconel 718

Bellow tubing SS304L

Bottom plate SS304L

Breadboard SS304L

Breadboard standoffs SS304L

Enclosure (sheet metal, support plate, tubing) SS304L

Enclosure feet SS304L

Enclosure, support plates and legs, breadboard SS304L

Limit switch SS316L, silver, ceramic, Vespel

M24 bolts Inconel 718

M8, M12 bolts and washers SS316L

NEMA 17 rad-hard motor SS316L, SmCo, copper

NEMA 23 rad-hard motor SS316L, AlNiCo3, copper

Shroud bellow SS321

Shroud O-ring seal EPDM ea se d

4/

/0

R ea se d

4/

/0

R