ELogs/MechanicalEngineering

Electronic Log for Mechanical Engineering

To Do

Modifications to Peli 1510 case after Prague/UCLH

Wheels & Mobility (Zarges)

   ===== Redesign Wheel Fitting Mechanism =====
   * The current bolt/axle slot is poorly suited for removal (too big/shallow).
   * Explore improved methods for wheel installation, removal, and securement.

   ===== Wheel Holders =====
   * Wheel holders from the Zarges case are currently located on my desk.
   * Redesign and reprint parts to fit beneath the Peli case and support the Zarges mechanism.

Peli Case Modifications

   ===== Alignment Plates =====
   * Alignment plates appear to sit at different heights, possibly due to misaligned bolt holes.
   * The issue may be caused by new wheel holder prints making one side sit higher.
   * Investigate options:
     ** Redrill bolt holes  
     ** Create wider plates to match the Peli case lip  
     ** Design improved alignment plates

   ===== Box Markings =====
   * Add markings on the case to align with cover plate positions.
   * Intended to ease module removal and reinstallation.
   * Note: This is challenging with the Peli case design.

Thermal & Mechanical Concerns

   ===== Raspberry Pi Heat =====
   * The case exhibits poor airflow.
   * Consider adding ventilation while maintaining:
     ** Light-tightness  
     ** Structural integrity  
   * (Note: "Light-tight" and "ventilation" are typically at odds.)

   ===== Module Height & Pi Proximity =====
   * Module 4 is too close to the Raspberry Pi and was warm after the beam test.
   * Redesign crossbars to:
     ** Lower the overall stack height  
     ** Improve thermal spacing

1. New scintillator stack holders:
   • Stack holders 3D printed: remake by hand if time allows.
   • Mounting plate to screw to Thorlabs optical breadboards in Peli cases:
     • Rough version already 3D printed.
     • Needs modifying to fix stack holder in place with M14(?) nuts.
     • Must be able to mount upside down.
   • New frame needed for patch panel with 50mm stand off to allow deeper connectors not to interfere with scintillator stacks.
2. Holder for NPL Transmission Calorimeter:
   • TC needs to mount into Peli Case in front of stack holders.
   • CAD STEP-files already received from Sam Flynn (NPL) for existing holder.
   • If making new holder, exit pipe for electronics cabling needs to be shortened to fit in small Peli case.
   • If making holder for holder, must mount to Thorlabs optical breadboard (M6 holes on 25mm pitch?).
   • Centre of holder must be 71 mm from baseplate (scintillator stacks are 50mm radius, plus 21mm offset from base).
3. Holder for Birmingham Pixel Sensor:
   • Tony Price (Birmingham) has provided dimensions to HB.
   • Holder needed to support pixel sensor between TC and scintillators.
   • Peli case needs 100x10mm slot cut to left of side handle to allow sensor ribbon cable to pass through.
4. Nozzle mount for detector enclosure:
   • Small Peli case needs to be nozzle-mounted for beam tests.
   • Dimensions already obtained from UCLH measurements:
     • SJ has contacted UCLH to check whether we can bypass light curtain.
     • Assume we can't and design to bypass mechanically...
   • 3 parts needed:
     • Nozzle mounting plate that sits inside nozzle using range modulator plate mounting slots.
     • U-bracket that slots in to this mounting plate — bypassing the light curtain — with a 40 x 30 cm hole for the beam to pass through.
     • Peli Case support that fixes to the U-bracket and holds the Peli Case whilst gantry is rotating.

Scintillator Machining

1. Bari scintillating fibre holder:
   • Bari are designing the scintillating fibre assembly for the QuADProBe.
   • Prototype fibre array holder machined from aluminium.
   • Clinical prototype ideally needs a version in plastic.
   • Review Bari CAD drawings and recommend suitable materials.
2. Scintillator machining:
   • Promising results from Datron: chase up potential workshops who could machine scintillator for us.
   • Liaise with Martin Blackman in main workshop to assess quality of his scintillator machining.
   • Write case and obtain quote for us to purchase Datron Neo.

Completed

2023

January-May

Enclosure design for small-scale Clatterbridge detector prototype (with Simon).

• Includes feedthroughs, mounts for NUC PC, Raspberry Pi and USB104 FPGA.
• Nozzle mounted

2022

November-December

Design and 3D print external frame with alignment marks and alignment plates for small Peli case.

Duplicate alignment bar from Zarges case with circular studs to allow alignment with treatment couch.

October

Modified medium-sized Peli case ready for beam tests:

• Install Thorlabs optical breadboard in base of case.
• Cut out window at each end of case for mylar window installation.
• Cut out 2 windows for 2-gang patch panels, 1 per side.
• Cut out 2 windows for 1-gang patch panels, 1 per end.
• 3D print internal frames for mylar windows with bolt holes in each corner. Drill bolt holes in Peli case.
• 3D print external frame with alignment marks matching centre line of optical breadboard (vertical) and 71mm above optical breadboard (horizontal). Match bolt holes to mylar window frames.
• 3D print alignment plates that are strong enough to double as external cover plates when shipping enclosure.

September

Machine a patch panel complete with 10 smaller panels that can be swapped between on the main patch panel to allow for various electrical feedthroughs

August

Created CAD cross hair for Peli Case to be printed. Also created small printed windows to clamp Mylar smooth over the beam entry point.

July

Created CAD models for internal components including:

• Scintillator holder.
• 2x Side Vice faces.
• 1x Front Vice face.
• Cover for beam entry point.

These were printed soon after.

Beam entry point was cut out of the case, piece was sent for testing with Adam Gibson.

Machined two special 1/4-20 UNC screws for camera mount.

Tapped all holes on Scintillator holder to take m5 nylon screws to allow vice faces to travel.

June

Initiated design of large Peli Case. Received Lab scissor jack used to mount camera.

May

CAD Prototype a sliding system to mount multiple scintillator holders into a case

February

Create CAD model for small Peli Case so ideas on how to install the holder into the case can be prototyped

2021

November

Design initial prototype of a new holder that will clamp scintillator sheets together. Will supersede previous adhesive idea

June

Prepare scintillator sheets to be adhered together using standard primer