Assembly of two complete bender stands was completed on Friday June 2nd as well as installation of new hardware on the dipole magnets for support, adjustment, and seismic restraint.  All parts were installed according to drawing TBP1804.

One of the frames was assembled with the caster wheel configuration.  This frame was pushed from the proton hall B2 level to its final installation location in the ARIEL tunnel.  The frame was a tight fit around the first corner around BPM 26 but it could still pass by without having to remove any items including the electrical boxes on the right side of the tunnel (when facing towards ARIEL).  Part of the grouting for the BPM 26 support stand and the next three stands after that was ground away to allow more clearance for the frame.  The nut/bolt on the frame casters on one side were swapped which also provides an additional ~1/8" clearance.  After these modifications the stand was pushed out past this area and then back to its installation spot confirming that there is now ample clearance.

The other frame was assembled in the configuration with stand legs.  This frame has been moved to the proton hall extension loading bay to be used for magnet field testing.

Both dipole magnets have been assembled with the new adjuster blocks and support legs.  For the magnet labeled “No.01” the original support legs were removed, cleaned in the ultrasonic cleaner, and then reassembled with way oil  The support leg support pads (TBP1822) were replaced with new parts, but all other parts were reused.  For the other magnet, labeled “No.03”, new support legs were fabricated because it was supported differently in its previous location and did not have these parts.  The fasteners attaching the adjuster blocks and support legs to the magnets were torqued to the recommended torque for each fastener based on the fastener grade and size.

Various minor changes to the design were made since the release of drawings, primarily to improve ease of manufacture.  As-built drawings will be released after the magnets have been installed on the stands in case additional changes arise.

Adjustment blocks were installed on the second dipole bender today (labeled "No. 03" "C15-III-57/15").  The mounting holes on the magnet were not aligned properly, so modification was required for two of the blocks.  The counterbored holes on TBP1809 were slotted 0.10" vertically, and on TBP1808, 0.06" horizontal slotting was required.  A stress analysis was performed to confirm that the blocks are still strong enough to withstand the seismic loads (PDF attached).

 BL4N 35-deg bender magnet "No. 1" has been installed onto the magnet stand with "stand leg" configuration in the Proton Hall Extension loading bay area.  The magnet fit as expected, and with the support legs resting on the ball transfers the magnet position could be easily adjusted by turning one of the adjuster leg fasteners (with the others loose).  After experimenting with position adjustment, the fasteners were torqued to 70ft*lbs.

The engineering analysis (Document #138415) as well as drawings TBP1804, 1805, 1806, 1811, and 1820 are in the process of being updated to reflect all as-built changes.

 The beam dump and upper lead shield flexible hose assemblies have been replaced with smaller diameter versions to allow for easier remote handling.  The new beam dump hoses are TEL5501 (Rev A) & TEL5502 (Rev A).  The new upper lead hoses are TEL5503 (Rev B) and TEL5504 (Rev B).  All Swagelok joints were installed 1-1/4 turns past finger tight as per Swagelok instructions.  The new Swagelok connections have not been leak tested yet.  This will be done after the remote handling test of the vacuum seal and water block which is scheduled to begin on May 27th.

A leak test was performed on the beam dump water system on June 9 in the afternoon.

- Pipe segments tested: The entire HAW system except for the expansion tank, air separator and HAW pump
- Test medium: air
- Test pressure and duration: 60 minutes at 50psi with no loss in pressure
- Swagelok joints and VCR joints around the beam dump which had been opened since last test were sprayed with Snoop: no bubbles

On Dec 2 the cables from the BD service stand area to the junction box were traced to establish which sensors correspond to which cable number in the junction box.

The beam dump thermocouple probe cable numbers are as follows (as labeled on the beam dump and the TC block upper half):
TC#1: T44,  TC#2: T55,  TC#3: T11,  TC#4:  T22,  TC#5: T66,  TC#6: T77
 

The service stand water sensor cable numbers are as follows:
Inside Tray, East Side: 44
Inside Tray, West Side: 22
Under Tray, East Side: 33
Under Tray, West Side: 11

On March 29, 2017, a 9 tonne steel shield block was transferred from the ARIEL Target Pit and placed into a 
wood container on the Target Hall B1 level with the overhead crane main hoist in Local Mode without incident. 
Afterwards, the overhead crane was switched into Test Mode (which is the same as Remote Mode but without the 
Target Hall interlocked) and an attempt was made to transfer the shield block from the wood container on the B1 
level to a wood container in the Target Pit remotely with the main hoist. At 11:51:09, after lifting the shield 
block ~1 m above the B1 level, a "136. Main Hoist West Drum South Motor Drive Fault (900 VFD)" alarm pop-up was 
shown on the overhead crane HMI in the crane control room which disabled the controls on the remote console. 
The reset button on the remote console was pressed and the remote lifting operation was resumed briefly until 
the same fault occurred at 11:51:42 and the reset button was pushed once again. While attempting to lower the 
shield block back down to the ground this fault-reset sequence reoccurred at 11:57:25, 11:58:16, 11:58:28, 
11:58:43, 11:59:27, and 12:00:27, at which point the remote crane operation was aborted and the shield block 
was lowered down to the Target Pit floor with the main hoist in Local Mode, without incident. The Test Mode 
faults did not appear to depend upon the speed/acceleration of the lift, nor did they appear to be spaced apart 
by a fixed time interval. Upon closer inspection of the alarm history screen in the HMI (shown below) and the 
exported alarm log (attached below), almost every time the fault #136 occurred, the following three additional 
faults were logged simultaneously in the alarm history (but were not displayed as a pop-up on the main HMI 
screen):
"103. Main Hoist East Drum North Motor Drive Fault (700 VFD)" 
"104. Main Hoist East Drum South Motor Drive Fault (800 VFD)" 
"135. Main Hoist West Drum North Motor Drive Fault (1000 VFD)" 

On March 31, 2017, the overhead crane main hoist was operated once again in Test Mode; however, no load was 
connected to the hook block to determine if the faults that occurred two days earlier could depend on the load. 
The main hoist hook block was remotely lowered ~3 m below the upper 'home' position, and then remotely raised 
as high as possible to function test the upper limit switch in remote mode; at 14:21:05 immediately after 
initiating the 'hoist up' motion, the same four faults occurred simultaneously. This incident shows that these 
specific faults do not depend on what load is connected to the hook block. Note: the crane position data from 
March 31 is attached below, however the times shown are 1 hour fast due a DST adjustment error.

Follow up with the crane supplier, COH, is required to obtain a index and troubleshooting guide for these (and 
all other) fault codes.

2017-04-06 update: Sylvain Raymond of COH has been assigned to resolve these crane faults by Maxime Dubé-Blanchet 
of COH.

A spare pendant for the overhead crane was procured from COH. The pendant's functionality is the same as the original one's. The pendant was tested today by Adam Newsome - all functions behave as expected.

Important - to change to the spare pendant in the case of failure of the original one, insert a battery into it, and transfer over the small black transmitter card shown in the attached picture. The pendant will not pair with the receiver without this card. There is nothing else that needs to be set up for it to work.

The spare pendant is kept in a labeled box on top of the electrical cabinets located in the crane control room (L1 floor).

Today while operating the crane with load, the crane stopped moving. Upon investigating, all safety signals appeared to be OK. Fault messages regarding drive faults for various VFDs were present, which seemed to stem from an ethernet adapter card fault (see attached photo). It is unknown how this occurred, but suspected that it was due to a brief blip in network communications or the external drive power supply control signal. It is worth noting that the diesel generator tests took place today, and there could have been some affect from a power surge because of this.

The crane was power-cycled using the main disconnect, and safety system reset. The faults disappeared. The crane was operational again.

If this issue occurs again, it should be investigated more thoroughly. It would be worth checking if there were any generator tests or other things which could cause some sort of power surge.

Dec 10, 2024

Testing completed:
 - Used hydraulic scissor jack cart to test raising/lowering service tray onto front-end, with only manipulators, placement of jack table done by hand because it isn't freely moving on the plane of the lift table.
 - Removal and insertion of the center post pin with indirect view to FE.
 - Application and removal of VCR gaskets on HVFT water connection array with 3D printed tool, only for 1/2" size (service tray side of VCR joints).
 - Checking whether the VCR joints can be done up with the service tray 'lifted' (not fully connected but the screws on the HVFT bracket are slid onto their slots)


Observation/notes:
 - Lift table slope creates some difficulty bringing the service tray up.
 - Effective misalignment of service tray changes with the degree in which it is 'brought up' because the ribbon connectors start to compress and exert load, tipping the service tray. There isn't a 'CG' that we can place the table under which will balance the service tray throughout the attachment operation.
 - Service tray is large and will not be fully supported by the base jig without custom jig on top.
 - Using a clamped piece of 2x4 wood on the jack cart worked to increase the supported region during testing, something similar with the base jig may work.
 - The service tray needs to be brought up such that the HVFT is ~1" from being fully engaged before the screws on the bracket can be upturned and start to engage. Likely the bus bar connectors will have started engaging before this is achieved (bus bar connectors roughly 2" in depth), this can create complications because the loading on the base jig will be really uneven at that point.
 - The pin for the center post can be easier to handle if we added a handle or an extender. A makeshift handle was made using tape and scrap U-channel nearby.
 - We managed to remove and attach the pin with the HTV table facing East using a remote camera view, but in practice it would be ideal if we could rotate the front end with service tray supported by some jig between orientations where the HVFT and center post are more easily accessed. This will require the ribbons and the alignment cylinders on the HVFT to transmit some force onto the lift table to overcome any friction the base jig may have on the lift table during rotation.
 - With the brackets on the HVFT on, we were able to start and even tighten the VCR joint closest to the corner bracket (using low clearance wrench, no photo).
 - Difficult to get at all brackets on HVFT and do up, will need cameras irrespective of the orientation, did not do up the bracket yet so we don't know how careful we need to be when inching each up and establishing the HVFT connection.
 - Difficult to get at and rotate screws on HVFT bracket, with torque tool due to proximity with HVFT structure, a longer bit on the torque tool will be beneficial. Note, using an Allen key with the manipulator gripper is difficult because of the same issue.
 - VCR wrenches slippery without catching features, will add pin for better grip
 - If 'fence' on HVFT for water lines is taken off it is quite easy to loose track of where the lines are supposed to return to, should have markings/labels for where the water lines need to return.
 - HTV side ribbons bend inward instead of outward.

Recommendations/follow up items/questions + answers as appropriate:
 - Consider adding grabbing features and an extender attachment for the center post pin: (Dec 16, 2024) Michael agreed to cut the tab and cross-pin the center post pin to match the HTV water connector pins.
 - Can we change the screws used on the HVFT bracket to be longer so it can engaging before the bus bars? (Dec 16, 2024) Michael will look into.
 - Can we add a lip to the HVFT top brackets to keep the screws in place and not fall out during tightening? (Dec 16, 2024) Michael will look into.
 - Consider more items that may help simplify the brackets on the HVFT
 - Is it possible to re-orient the center post holes to be toward the HVFT instead of aligned with the HTV platform axis, this may avoid the need for re-orienting the FE when raising/lowering the service tray. (Dec 16, 2024) Michael will look into.
 - Need to capture effect of bus bars connection in future testing. (Dec 16, 2024) Albert will design and send something to the shop to work with Phoenix's mock up.
 - Need to repeat service tray testing with base jig.
 - Check if ribbons are bending in the right direction. (Dec 16, 2024) Yes.
 - Perform full service tray coupling with actual machined brackets to inform coupling operation (3D printed brackets currently not strong enough and deflect unrealistically).(Dec 16, 2024) received spares from Michael.
 - Need modification to wrench to prevent slippage. (Dec 16, 2024) Albert and Aaron working on this (will simply add cross-pin)
 - VCR gasket tool for smaller size VCR's to be made.(Dec 16, 2024) Chad to do.
 - Real deal VCR gasket tools to be made out of soft metal to prevent scratching sealing surfaces in operation
 - If not possible to do with base jig, possibly a suspended plate with turnbuckles instead will be sufficient to support the service tray during attachment/removal operations. (Dec 16, 2024) Discussed with Michael the possibility of changing the HVFT 'cables' to threaded rod to also facilitate ejection of the service tray on the HVFT side (necessary to disconnect bus bar connections).

 

The APTW front end was moved into the hot cell, on the lift table, following procedures outlined in Document-244862.

The mock-up frame was transferred from the east turntable to the west turntable above the front end. The east turntable is covered with the aluminum plate. During covering we accidentally broke the o-ring for the turntable plate flange. The new o-ring seal should be made ~1" longer in circumference to avoid difficulties with seating in the o-ring groove.

When we attempted to move the front-end with the manipulator, we noticed that the front end tended to carry on sliding down the slope of the hot cell (see TRI-DN-23-20 / Document-238536). The manipulators were subsequently unable to arrest the front end, likely because they cannot apply a load towards the CG of the front end. Therefore, for heavy-duty jigs in the hot cell it is advisable to avoid using wheels/rollers that allow the heavy assemblies to move freely on the lift table.

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UPDATE Nov 21, 2024

• FE attachment related tests completed:
  • replacement of shim plates
  • mock-up alignment of FE with shield plug (adjustment made in person, hot cell operator instruct and give direction with remote camera views
• Difficulties encountered:
  • keeping track of which hole/screws are seen by the cameras during alignment was difficult for the operator
  • shim plate awkward to handle if not familiar
  • incompatible coupling screw and nut threads (M24 course vs fine threads) prevent completion of coupling and uncoupling tests
  • 'loose' service tray requires separate alignment check when raising the FE with the lift table
• Lessons learned:
  • shim plate replacement easier if FE is semi-attached (screw lifts FE, leaving small gap for shim plate to be inserted)
  • need a cover plate to prevent dropping shim plate and associated screws
  • rotation clearance of FE checked, will clear
  • need to also check service tray alignment when raising
  • magnetic cameras would be beneficial for this operation
• Follow up items:
  • crane-based positioning of FE for replacement to be tested after concrete pours/hand-testing/when APTW is exchanged for AETE.
  • future design of protective covering when performing shim plate removal
  • optionally implement magnetic camera array to check hole alignment by looking directly at the holes

At end of shift, mock up and FE was separated, markings made on floor to specify where FE needs to be to couple.

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UPDATE Nov 25, 2024

Replacement nuts arrived (M24x3) for the coupling screws. Tests were completed to try and couple/uncouple the front end to the cart/mock up.

• For taking the FE on/off the cart the cart should be able to rotate with the FE so that we can secure the coupling screws.
• For dropping the FE off from the shield plug, we should make use of the alignment features (cup and cones), once screws are undone and the FE rests on the cones on the cart, it should be secured.
• If markings on floor is made to assist with alignment, we need to do two sets; one for unloaded cart, one for loaded cart, this is because the lift table will tilt differently when there is a load.
• The threads on the coupling screws are fine threaded in the real case, there is a slight concern with cross-threading when turning them onto the nuts remotely (from above).
• Existing camera views sufficient to check for clearance between coupling plates and FE structures.
• To allow the FE to guide freely into the alignment features (cup/cone), it may be a good idea to still use the air skates, but supplement it with structural 'stopping' features to keep it from rolling off the table.

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UPDATE Nov 26, 2024

We returned the front-end to the cart to allow the shield-plug mock up to be rotated by the target hall crane (turntable still not functioning as of this date).

During this operation we noticed that the front end did not fully return to the alignment cones on the cart (see images), somehow the contact pad screws made contact first, and so the two-faced alignment cone did not come into contact.

For the real support frame we should use a minimal number of contact points. Also,more clearance at the coupling screws between the cart to the front end should be added.

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UPDATE Nov 27, 2024

We rotated the mock-up frame manually to have the HTV side face the hot cell window. During which the o-ring fell and we decided to cut it for convenience, this should be replaced with an equivalent o-ring but made ~1" longer in circumference.

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UPDATE Nov 28, 2024

Today we attempted to re-couple the front end to the mock up frame in the orientation where the HTV faces the hot cell window. The misalignment between the FE on the cart to the mock-up frame is worse in this orientation than in the previous (90 CCW facing down). There was approximately a 1" gap difference between the opposite ended screws. Factors contributing to the misalignment include uneven seating of the FE onto the bosch frame and uneven 'brake' engagement on the bosch frame wheels. During the attachment process the the screws had to be tightened very unevenly, with the HTV side being tightened far more than the extraction electrode side.

Additionally, the service tray shifted significantly from handling in the previous days and it was difficult to align the locating pins/cylinders. This further complicated the coupling process, in the future the service tray attachment should be made a separate operation to the process of coupling the  FE to the shield plug.

Under these conditions, during tightening, the inner screw at the HTV-side somehow jammed against the nut and the nut conversely jammed into the bracket. Subsequently, that screw could not be tightened further and required great difficulty to be removed, even after removing the bracket. In the aftermath, the nut bracket became forced apart (see picture) and the threads on the screw deformed beyond use. This is a critical failure mode for this coupling system. Note that the screw was hand started onto the nuts on the brackets prior to fully tightening the screws.

We believe the factors contributing to this failure include:

1. bracket gap being too large and allows the nut to wedge itself during tightening,
2. screw threads not being hardened/of proper grade,
3. tightening the screws too unevenly and sharply (too large turns per-screw when bringing the FE up, 1/2-1 turn) / allowing some screws being slack,
4. high misalignment (pitch and roll) between the FE plate and the mock-up frame,
5. the brackets not being able to accommodate the observed misalignment,
6. hole for screw is ~short and creates possibility for jamming when there is misalignment (pitch and roll),
7. aligning the service tray locating features while aligning the screw holes for the FE coupling was difficult,
8. possibly the extra lead in (chamfer) on the coupling screws is excessive and a non-standard design, which may cause problems starting the nut, likely a standard chamfer on the end of a standard screw would be sufficient for this operation

In the real operation, the long length of the screw will help prevent this failure from happening but some things to keep in mind/improve on would be:

1. bracket re-design to use standard wrench/nut gaps to avoid nut jamming
2. use hardened threads
3. try to see if no-lead in/chamfer/using standard screw profiles is sufficient
4. re-design the coupling system to not require a nut at the bottom and avoid cross-threading/thread jamming in the hot cell (move threads and nuts all above the FE assembly)
5. extra: the screw should not be fine threaded in the real case to avoid cross threading
6. minimize misalignment when trying to couple in the future (rotate turntable to minimum misalignment orientation)
7. tighten the screws more incrementally to have them go together evenly, don't allow screws to be fully slack if possible to prevent jamming
8. fully remove the service tray and attach only after the FE is attached

Of the above recommendations we strongly recommend re-designing the nut bracket - even when coupling was smooth (without misalignment) the nuts made a visible dent onto the bracket at the highest point (see image). A smaller gap (standard wrench gap) would prevent such a mark from forming.

We replaced the deformed screw with a standard (off the shelf) one to keep the FE secure to the mock-up.

We also noted after completing coupling that the extraction electrode, farthest out screw had damaged threads (see image).

It is recommended to perform repeated coupling/decoupling operations in the hot cell after some process/design changes are made/implemented to work out any possible failure modes with this operation.

The four water connections on the front end plate of the APTW that will connect to the HTV were tested for replacement with the manipulators:

• The pin on these connectors were fairly easy to remove and replace with the old pin detent tool.
• The horizontal VCR joint on the DRIVE BEAM CONE (ATA3674) could be undone with the manipulator and standard wrenches, it is advisable to use 'semi-closed' wrenches on the nut to prevent it from dropping when torquing or undoing the joint.
• Of the four water lines, only the top line could be taken out and returned by hand, testing with manipulator still to be done.
  • It would be nice for this top most line to have a clamp or something to keep the VCR nut on the bottom U-bend from falling.
• The second line from the top interferes with the bus bar when trying to be removed by hand.
• The second line from the bottom has a VCR connection obstructed by the same bus bar when trying to remove by hand.
• The bottom line catches on the other lines when trying to remove by hand, the other lines likely need to be removed first to allow this line to be exchanged.
• is the intent for the bus bar need to be removed to exchange these lines?

 Testing will resume in the following week for these water lines.

The four water connections on the front end plate of the APTW that will connect to the HTV were tested for replacement with the manipulators:

• The pin on these connectors were fairly easy to remove and replace with the old pin detent tool.
• The horizontal VCR joint on the DRIVE BEAM CONE (ATA3674) could be undone with the manipulator and standard wrenches, it is advisable to use 'semi-closed' wrenches on the nut to prevent it from dropping when torquing or undoing the joint.
• Of the four water lines, only the top line could be taken out and returned by hand, testing with manipulator still to be done.
  • It would be nice for this top most line to have a clamp or something to keep the VCR nut on the bottom U-bend from falling.
• The second line from the top interferes with the bus bar when trying to be removed by hand.
• The second line from the bottom has a VCR connection obstructed by the same bus bar when trying to remove by hand.
• The bottom line catches on the other lines when trying to remove by hand, the other lines likely need to be removed first to allow this line to be exchanged.
• is the intent for the bus bar need to be removed to exchange these lines?

 Testing will resume in the following week for these water lines.

November 27, 2024

Testing completed:

• Removal and re-insertion of 2x multi-pin coupling cable for HTV (see pictures, left most and right most, middle had no wire at the time).
• Tested using 'wire' method to pull cable once removed back through the original path.
• Test without rotating table, on cart, some obstruction that does not reflect reality in operation, rotated cart by hand, will require rotation during operation.

Observations/notes:

• Right connector has wires come across and may interfere with the middle connector, will require removal of multiple connectors to exchange one depending on configuration.
• Locating pins on high voltage multi-pin connector needs to be short for voltage bias reasons.
• Right-most black multi-pin cylindrical connector has higher risk of machined block end catching when fishing from the HTV side.

Recommendations:

• May be a good idea to add a holder connector to go into the multi-pins and give the manipulators a better grip for handling. Directly grabbing on the cylinder of the multi-pin connector is ok though.
• Some strain relief at the machined connector blocs (service tray side) will help prevent damage during wire replacement/routing.
• Possibly re-route some of the electrical connectors to the back side of the HTV column for easier access and shorter length.
• Will need chart mapping where the cables go and indexing different connections for future hot cell work (will be updated on SW model).
• Locking pins on multi-pin connectors can be removed and replaced manually with the manipulator.
• Adding a 'slippy' sheath onto the replacement cable for routing and to prevent catching would be a good idea in the future.

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Dec 02, 2024

Testing completed:

• Removal and re-insertion of 1x ceramic-ended wires specifically the one obstructed by the gas line on the right side of the HTV connection array as viewed from the hot cell window.
• Removal and re-insertion of main multi-pin connector cable bundle from the HVFT connector array on the service tray.
• Removal and re-insertion of the gas line obstructing the right-side ceramic electrical connectors << very difficult/impossible to do (recommend modifications + tooling).

Observations/notes:

• Electrical wires/connectors generally straightforward to exchange.
• Plastic/ceramic components on connectors are easy to damage during exchange operation.
• Most connectors require the metal/cylindrical bits to be 'grabbed' by the manipulators if no custom tool is used
• Rectangular multi-pin connector bracket if single is difficult to return to slot since not supported on both sides
• Need documentation/reference material to make sure connectors get returned to where they need to be
• Screws on connector are deep into the FE assembly, creates viewing difficulty
• Cameras hard to use for these screws because of beam dump being highly active when FE is in operation
• Ceramic (mass marker) connectors fine to grab on the conductor part
• When trying to re-align the ceramic bodies to line up the screw holes, found that it was really easy to damage/break the ceramics, avoid using hard tooling/manipulators on the ceramic parts
• Plastic components on multi-pin rectangular brackets got damaged after handling with manipulators
• Full sized pin detent tool not compatible with smaller pins, should make smaller sized pin detent tool, smallest clearance found on HVFT side of multi-pin connector bundle
• Routing HVFT side of multi-pin bundle through wires poses risk of damaging exposed pins

Recommendations:

• Should buy longer bits/ends for torque control tool to get better view angles on screws.
• Maybe captive screw for the gas is a good idea to prevent the screw from dropping.
• Torque tool should be set properly (torque and rotation rate) before performing screw exchanges involving the HTV connectors on the front end
• Return of the gas line (on bracket) to its location on the FE is difficult, suggested modifications include:
  • Changing orientation of cutout on bracket to let stainless bent/welded tube to be returned separate from the bracket.
  • Changing screws for the stainless part on the gas line to be standard size (M6) for hot cell exchange operations.
  • Changing the unused screw hole on the FE to be pinned and allow for better alignment of the bracket onto the FE
  • Removing burr on sheet metal part on hose/wire opening at the bottom to prevent the braided hose from catching.
• Should make a rotator tool (3D printed) to help adjust the ceramic end of the mass marker connector and have the screw hole and thread aligned
• Maybe plastic covers for water/gas connectors to prevent scratching of outer surface
• Make smaller pin detent tool or settle for old tool already made
• Possibly design cover to protect exposed pins on multi-pin bundle during replacement

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Dec 12, 2024:

Testing completed:

• Tested removal and return of the gas line obstructing some ceramic electrical cables on the right side of the HTV connector array on the front end, now with 6mm pin (McMaster 97493A162) threaded into the previously unused hole to help guide the previously  unused hole to help guide the bracket.

Observations/notes:

• Chad Fisher commented that even without the pin it should be possible to complete the removal and return operation if a 3D printed (soft )tool is made to grab onto the tubes and guide it with the bracket into the alignment hole/slot.
• Old recommendations still stand though + maybe make the pin longer/custom with more lead in.

Recommendations:

• Remove the retaining tab at the bottom to allow the hose to be positioned more freely.
• De-burr the sheet metal part to prevent catching on the braided hose.

After a recent power cycle, the y-axis referencing was lost for the 1000 kg crane. The position readout was also incorrect, somewhere on the order of > 30,000 mm. On 2024-11-29, A. Newsome re-referenced the y-axis. The position readout correctly reset to zero, and both +y and -y motion is functioning correctly, but the y-axis position readout on the HMI constantly displays 0 and does not change. To be investigated.

Update 2024-12-02:

After going online with the PLC, it was determined that the reason for the display of 0 as the position is that the two values used for calibration of the +y and -y limits were actually the same, meaning the scaling factor (the difference between these two values) was 0, which resulted in the displayed value being 0. The root cause of this is that the encoder was not functioning correctly so its value was not changing when the crane moved and it was stuck at one value. Upon investigation of the encoder input card, the red "ERR" light was on. This indicates the encoder signals are not properly reaching the input card. Once this was discovered, it was remembered that this happened in July 2024 as well (no e-log was written). In July, the root cause was identified as being a loose encoder signal wire in a junction box. Junction box CJB1-BC, located on the bridge crane near its disconnects, was opened and investigated. Upon checking each wire, it was determined that the red wire seemed not to be making full contact. The wire was removed and re-inserted, and the "ERR" indicator on the encoder card turned off. The crane's +y and -y limits were re-referenced. The crane is functioning normally after re-referencing. (Note: if something like this happens again, during the re-referencing process, the displayed value on the HMI will be incorrect.. this is because the PLC's scaling factor is not fully adjusted until both +y and -y limits are reached. The actual encoder measurement taken at those limits is used for the scaling factor. This is not an ideal way to program the system, but this is how it works with all ARIEL hot cell subsystems. So incorrectly displayed values can be ignored, in general, until full referencing is completed).