Hi Robert
We have considered your
observations and we have modified our
proposal.
The new drawing are
summarized in the attached sletches.
Now the insert in the grid
has an external 1/2" thread . The tolerance
between the insert thread
and the threaded hole in the grid (about
10mils) will be filled with
epoxy. The epoxy will work in compression
for the orthogonal forces,
the thread will work against on axis
forces.
Inside we have a cylindrical
part 3/8" diameter, 3/8" lenght + 3/8"
theraded hole, 1/2"
lenght. The inside thread can be 3/8". This is a
small piece, it can be done
with a good alignment between cyilinder and
thread axis. In the flexure
head we think a 3/8" hole. The
tolerance
between the shoulder of the
screw and the holes can be
holes =
3/8"-0+0.0005"
screw=3/8"-0.0005"+0
With the new design:
1. The dimensions fit with the grid constrains now.
2. The joint is exentially a
glue thread joint
The concept: DECOUPLE
ALIGNMENT FROM FIXATION, AVOID ANY REQUEST OF
TIGHT TOLERANCE ON THE
FLEXURES
with a simple tool, using
the reference holes in the bottom tray, we can
refer the tower to the grid
(better than 4mils). In flight units, the
tower will be held up by
some device (lifting device). The pins and the
alignment tools keep the
tower in place without a real g force on them
After a dry test, the tower
is removed, the inserts are put in place
with the epoxy, the tower is
put back, the screws are inserted. We do
not need a strong tolerance
between flexures and inserts, because the
1/2" thread have about
10mils tolerance. If needed this tolerance can be
increased a bit
Advantages:
NO ASIMMETRY, All the 12
joints are identical
Delicate works on small
piceces only; the required tolerance to be able
to put the tower in place is
easy NO RISK TO MISS ANY SCREW ON ANY OF
THE 18 TOWERS
If there is a problem (p.e.
a hole in one flexure head is too large
or
too small) it is easy to machine
a dedicated insert and screw
If we have to dismount the
tower, the holes in the flexures remain
clean; to restore the grid
we have to machine away the insert (no
special tolernce is needed)
When we dismount the tower
from the simulation grid, the tower flexures
are clean.
Sandro and Riccardo