A Machine for Tribological Experimentation on Indexing Continuous
Media with Specific Application to Semiconductor Testing
by
Alexander D. Sprunt
S.B. Mechanical Engineering
Massachusetts Institute of Technology, 2000
SUBMITTED TO THE DEPARTMENT OF MECHANICAL ENGINEERING
IN PARTIAL FULFILLMENT OF THE DEGREE OF
MASTER OF SCIENCE
at the
BARKER
MASSACHUSETTS INSTITUTE OF TECHNOLOGY
MASSACHUSETTS
June 2001
lINSTITUTE
OF TECHNOLOGY
0 2001 Massachusetts Institute of Technology
All rights reserved
JUL 1 6 001
LIBRARIES
A
Signature of Author ..............
. . .. . . . . . . . ..
Depart
. .V
..... .
'tof Mechanical Engineering
May 11, 2001
Certified by ..........
Professor Alexander H. Slocum
Thesis Supervisor
Accepted by ...............
Professor Ain A. Sonin
Chairman, Department Graduate Committee
I
A Machine for Tribological Experimentation on Indexing Continuous
Media with Specific Application to Semiconductor Testing
by
Alexander D. Sprunt
Submitted to the Department of Mechanical Engineering
on May 23, 2001 in Partial Fulfillment of the
Requirements for the Degree of Masters of Science
at the Massachusetts Institute of Technology
ABSTRACT
Technology was developed to facilitate electrical contact tribology experiments on continuous media, dramatically reducing the difficulty of employing virgin material for each
test. Specifically, a tester was designed to accurately reproduce semiconductor contactor
operating environments while measuring contact resistance in-situ, thereby effecting the
study of operating temperature, test current, cleaning method, and cleaning interval on
contactor life. To manipulate the continuous media while preserving exact constraint,
novel web handling machine elements were devised. Universal joints and beam type flexible couplings were employed for gimballing and castering axes, both at standard caster
radii and at roller center. A kinematic edge constraint was designed. The torque transmission properties of clamped connections were alloyed to the favorable kinematics of typical
pinned type connections by compliantly mounting a spherical roller bearing as a pinch
roller.
Thesis Supervisor:
Professor Alexander H. Slocum
Department of Mechanical Engineering
4
ABSTRACT
ACKNOWLEDGMENTS
Funding for this research was provided by Teradyne Corporation of Boston, Massachusetts. A large portion of the design work and all the assembly of the "Gummer," as the
testing machine was affectionately known, took place at the Integra Test Division in Bedford, Massachusetts.
I would like to thank the future readers of this thesis. It is by no means certain there will be
any, but I would like to thank these hypothetical (do I dare write it?) people just the same.
On several occasions, I have been the first person to borrow a thesis from the library. Each
time, I have thought with a smile about the shiver of excitement and pleasure that would
pass through the author if they knew their thesis had just been checked out from the
library. And on the off chance this thesis is widely read, I thank all those who follow the
first reader as well. Do not feel compelled to read the whole. Chapter 1 and Chapter 4 are
the most interesting.
5
6
ACKNOWLEDGMENTS
7
3
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledgments
Nomenclature
Cho
telr 1
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dolistic
rn
a Prbenh
T
fein
17
and DesIts
Me*thni
19
1.1 Abstract:
20
)f......................................
1.2 Introductio n
................................
20
1.3 Tester Des cription . . . . . . . . . . . . . . . . . . . . . . . .
21
1.4 Prediction s and Preliminary Results
1.4.1 Sou rce Current . . . . . . .
1.4.2 Op erating Temperature . . .
1.4.3 Cle aning Interval . . . . . .
1.4.4 Cle aning Method . . . . . .
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23
24
25
25
1.5 Conclusio rn s . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
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27
2.1 What is a Contactor?
. . . . . . . . . . . . . . .
27
2.2 What's the Problem?
. . . . . . . . . . . . . . .
29
2.3 A Solution . . . . . . . . . . . . . . . . . . . . .
31
Chapter 2.
Chapter 3.
Introduction
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Concept selection - Choosing a test medium
33
3.1 Why not use a handler, a tester, and real devices?
33
3.2 Gravity Feed . . . . . . . . . . . . . . . . . . . . .
34
3.3 Big Disk . . . . . . . . . . . . . . . . . . . . . . .
35
3.4 Foil Feed . . . . . . . . . . . . . . . . . . . . . . .
38
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38
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41
3.5 Foil Location
3.6 Summary
Chapter 4.
Applied Exact Constraint Web Handling
43
. . . . . . . . . . . . . . . . . . . . . . .
43
. . . . . . . . . . . . . . . . . . . . .
44
4.3 Kinematic Web Handling Background . . . . . . .
4.3.1 Exactly Constraining Webs . . . . . . . . .
4.3.2 Zero Constraint Rollers . . . . . . . . . . .
45
45
47
4.1 Abstract
4.2 Introduction
8
4.3.3 Gimballed Rollers
. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Concepts . . . . . . . . . .
4.4.1 First Concept . . . .
4.4.2 Second Concept . .
4.4.3 The Edge Constraint
4.4.4 Web Plane Diagram
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55
4.5 First Bench Level Prototype . . .
4.5.1 Universal Joints . . . . .
4.5.2 Making it Work . . . . .
4.5.3 Pseudo-Stability . . . . .
4.5.4 Edge Constraint . . . . .
4.5.5 Limitations of the Concept
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57
57
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59
60
62
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64
4.7 Third Bench Level Prototype: Internal Flexible Couplings . . . . . . . . . .
65
4.8 Final System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
4.9 Conclusions
74
4.6 Second Bench Level Prototype: Internal Universal Joints
Chapter 5.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plunging Module
. . . . . . . . . . . . . . . . . . . . . . . . . . .
75
5.1 Module Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
5.2 Spring Pin Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
5.3 Bearings and Actuation
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
5.4 Preventing Foil Motion
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
Current Sourcing and in-situ resistance testing . . . . . . . . . . .
83
Chapter 6.
6.1 Current Sourcing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
6.2 In-Situ Resistance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Worst Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 BLP Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
84
85
Chapter 7.
Controller Specification . . . . . . . . . . . . . . . . . . . . . . . .
87
7.1 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
7.2 System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
7.3 Pneumatic Schematic
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
7.4 Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1 Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
89
90
9
7.5 Sequences .
7.5.1 Startup
7.5.2 Test Sequence
7.6
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
Data Logging and Operator Alert
90
90
91
91
Chapter 8.
Test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
Chapter 9.
Conclusions
99
. . . . . . .
9.1 Future Improvements
. . . . . .
99
9.2 Additional Applications . . . . .
101
. . . . . . . . . . .
101
9.3 Conclusions
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3
Appendix A.
Thermal Model Results
Appendix B.
Web Handling details
. . . . . . . . . . . . . . . . . . . . . . 10 5
107
9.4 Index Roller Wrap Angle.....
107
9.5 Minimum Roller Size
. . . . . . .
107
. . . . . . . . .
108
9.7 Slip Clutch . . . . . . . . . . . . .
108
. . . . . . . .
109
9.6 Index Roller Size
9.8 Idler Rotation Disk
Appendix C.
Part and assembly drawings
. . . . . . . . . . . . . . . . . . . . ill
10
11
Figure 1.1
Isometric view of test machine
Figure 1.2
Resistance test schematic. Note that conduction path includes the frame and
the GraphalloyTM bearings. . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 2.1
A picture of a QA Technologies spring probe and a cross section view of a
typical spring probe. (from QA Technologies Catalog) . . . . . . . . . 28
Figure 3.1
A Handler-Tester System (Delta Design Company)
. . . . . . . . . .
33
Figure 3.2
A gravity feed handler (Delta Design Company) . . . . . . . . . . . .
34
Figure 3.3
CIRRIS Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
Figure 3.4
Sketch of Big Disk testing system, side and top views
. . . . . . . . .
36
Figure 3.5
Various Probe tip types (reproduced from QA Technologies' catalog) .
37
Figure 4.1
Two methods of exactly constraining a web.
Figure 4.2
Decay of cross track error as the instant center moves closer to infinity
Figure 4.3
Adding an additional roller can cause over constraint if the new roller is not
carefully chosen. Overconstraint manifests itself as multiple instant centers
of rotation, which can destroy a web. The appropriate web plane diagram
symbols have been overlaid on this figure. . . . . . . . . . . . . . . . 48
Figure 4.4
A fanciful axially compliant roller that is unworkable because it has only one
roller surface, and can therefore never leave contact with the web, preventing it from resetting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 4.5
"B" is a gimballed roller (figure reproduced from Blanding) . . . . . .
Figure 4.6
By taking advantage of the three dimensional twist compliance of section AB, the gimballed roller (B) creates a joint in the web plane. The section A-B
is exactly constrained by the edge constraint at A and the angular constraint
at B. The section B-C is exactly constrained by the implied axial constraint
at B and the angular constraint at C. The overlaid web plane symbology is
explained below. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 4.7
"Movie Projector" style arrangement . . . . . . . . . . . . . . . . . .
53
Figure 4.8
Second, and more space efficient arrangement
54
Figure 4.9
Web Plane diagram for both arrangements, mis-alignment is deliberately
exaggerated to emphasize any overconstraint. . . . . . . . . . . . . . 56
Figure 4.10
A universal joint mounted to provide gimballing and castering. Note the
length of the caster radius, i.e. the distance between the universal joint and
the axis of rotation of the spool. . . . . . . . . . . . . . . . . . . . . . 57
Figure 4.11
The plan for implementing arrangement two in hardware. Note the gravity
defying positions of the supply and take-up spools. The frame is not shown.
58
. . . . . . . . . . . . . . . . . . . . .
21
. . . . . . . . . . . . . . 46
. . . . . . . . . . . . .
47
51
12
Figure 4.12 Slightly modified "movie projector" arrangement. Note the counterweights
and that gravity and foil tension are loading the universal joints in tension.
59
Figure 4.13 The foil finding its own edge constraint . . . . . . . . . . . . . . . . .
60
Figure 4.14 The kinematic edge constraint. A cam follower on a spring arm nests the
web against the fixed cam follower to create an edge constraint. The third
cam follower turned out to be superfluous. . . . . . . . . . . . . . . . 62
Figure 4.15 Spool assembly, note the size of the counterweight.
. . . . . . . . . . 63
Figure 4.16 A cross track position of zero indicates alignment is complete. Reducing the
caster radius to zero resulted in instantaneous alignment of the roller. Determining if this was a problem was one goal of the second bench level prototype. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 4.17 Spool core with internal universal joint providing gimballing and castering
axes. . ...
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 4.18 Spool mount based on a flexible coupling. Functionally equivalent to the
hardware in Figure 4.10. . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 4.19 Section of a spool core based on flexible coupling
. . . . . . . . . . .
Figure 4.20 The flexible coupling bench level prototype without foil loaded.
Figure 4.21
. . .
69
69
Web Plane Diagram of BLPs two and three that does not include castering at
the flexible couplings. Note the "tears" in the web where it is overconstrained. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 4.22 The spring mounted spherical roller bearing and the index roller
Figure 4.23 A picture of the pinch roller assembly
. . .
72
. . . . . . . . . . . . . . . . .
73
Figure 4.24 The final machine. The ribbon cables are used to test the contactors.
.
73
Figure 5.1
Spring Pin arrangement to optimize foil utilization while maintaining index
system simplicity . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 5.2
Flexure designed for linear motion for 1/2 inch stroke over a broad temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 5.3
Contactor sub-assembly with flexures and piston attached . . . . . . .
77
Figure 5.4
The plunge sub-system attached to the machine frame . . . . . . . . .
78
Figure 5.5
A picture of the contactor assembly showing the stops and the spring pins
79
Figure 5.6
Top view of plunging module (with the actuating piston removed) showing
the two dimensional kinematic coupling used to align the contactor plate
with the plunging module . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 5.7
Front View of plunge sub-system - note the feet
. . . . . . . . . . . .
81
13
Figure 6.1
Resistance test schematic. Note that conduction path includes the frame and
bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 6.2
Picture of Graphalloy resistance test bench level prototype. Note the heavy
gage wire for current sourcing and the smaller gage wire for four wire resistance measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 6.3
Cross-section of bench level prototype for testing Graphalloy resistance. The
BLP was connected to a power supply to simulate the effects of the current
source array driving current through the contactor. The digital multimeter
tested the resistance of the assembly using the four-wire method.
. . .
86
Figure 7.1
System Schematic, the contractor was responsible for the components inside
88
.............................
the dashed box. ......
Figure 7.2
System Pneumatic Schematic. Valve assembly, regulator, etc. supplied by
contractor. Actuators already installed on machine . . . . . . . . . . . 89
Figure 8.1
Wide field view of the witness marks left by the array of spring pins on the
90/10 Sn/Pb clad Alloy 42 foil (37.5 X magnification) . . . . . . . . . 93
Figure 8.2
Tight field view of the witness marks (203 X magnification)
Figure 8.3
A plot of contact resistance vs. number of hits for several different current
settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 8.4
The mean of each pin's resistance measurements is plotted against the
amount of current sourced through the pin. The squares represent the average of those averages for each current group. . . . . . . . . . . . . . . 96
Figure 8.5
Plots of the resistance data for all ten pins in the 100 mA group. For
unknown reasons, the contact resistance of pin 19 is consistently higher than
that of the other pins. . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 9.1
A cross section of the slip clutch
Figure 9.2
The idler rotation disk mounted to the shaft of the idler roller. The fiber optic
sensor is mounted in the small hole in the bracket to the right of the disk.
110
. . . . .
94
. . . . . . . . . . . . . . . . . . . . 109
14
15
TABLE 1.1
Paper Authors ...............
TABLE 1.2
Properties of some contact materials
.
..
24
TABLE 2.1
Properties of some contact materials
. . .
29
TABLE 3.1
Air Properties . . . . . . . . . . . . . . .
39
TABLE 4.1
Paper Authors . . . . . . . . . . . . . . .
43
TABLE 4.2
The three types of zero constraint rollers .
49
19
TABLE 4.3
61
TABLE 4.4
Modes of Helical Coupling Misalignment.
68
TABLE 7.1
Inputs . . . . . . . . . . . . . . . . . . .
90
16
NOMENCLATURE
d
contact resistance [Q]
beta, reciprocal temperature [1/K]
temperature [K]
ambient temperature (outside environmental chamber) [K]
environmental chamber temperature [K]
thermal conductivity [W/mK]
kinematic viscosity [m 2 /s]
temperature change [K]
Grasshof Number with respect to length [-]
Prandtl Number [-]
Rayleigh Number with respect to length [-]
Nusselt Number with respect to length [-]
distance between an edge constraint and a fixed roller [m]
y
cross track displacement of a web [m]
Yo
x
cross track displacement boundary condition [m]
Cres
fl
T
Tambient
Tchamber
k
V
AT
GrL
Pr
RaL
NUL
rc
in-track displacement of web [m]
caster radius [m]
17
18
NOMENCLATURE
Chapter 1
REALISTIC SPRING PROBE TESTING
METHODS AND RESULTS
This chapter is a summary of the entire thesis and was submitted to the International Test
Conference as a 2001 conference paper.
TABLE 1.1 Paper Authors
Walter DiVito
Teradyne, Inc.
26 Crosby Drive
Bedford, MA 01730
vox: (781) 999-8464
fax: (781) 999-8289
WalterDivito@teradyne.com
Alexander H. Slocum
Massachusetts Institute of Technology
Room 3-455
77 Massachusetts Avenue
Cambridge, MA 02139
vox: (617) 253-0012
fax: (617) 258-6427
slocum@mit.edu
David Gessel
Teradyne, Inc.
26 Crosby Drive
Bedford, MA 01730
vox: (781) 999-8366
fax: (781) 999-8289
gessel@dis.org
Alexander D. Sprunt
Massachusetts Institute of Technology
Room 3-470
77 Massachusetts Avenue
Cambridge, MA 02139
vox: (617) 253-1953
fax: (617) 258-6427
asprunt@mit.edu
Scott Ziegenhagen
Teradyne, Inc.
44 Simon Street
Nashua, New Hampshire 03060
vox: (603) 879-5449
fax: (603) 879-4449
ScottZiegenhagen@teradyne.com
19
20
REALISTIC SPRING PROBE TESTING METHODS AND RESULTS
Presenter: Alexander D. Sprunt
Topics:
Tools for Understanding Contactor Systems
1.1 Abstract:
A tester was developed to accurately emulate spring probe operating environments. The
effects of operating temperature, test current, cleaning method, and cleaning interval on
spring probe life were systematically studied.
1.2 Introduction
Despite the widespread dependence on such systems for back-end testing, the lifetime and
the variables that materially influence the lifetime of contactor systems have not been systematically studied. Spring probe manufacturers test mechanical life, but such data is of
little use to the system designer. Mechanical lifetimes in excess of one million cycles are
commonly seen during such tests, but similar performance is unheard of in the field. Foreshortening of probe life due to plunge errors and cleaning mishaps can be prevented, or at
least minimized, by a robust interface design, but the specifics of probe contamination and
cleaning necessary for coherent systems design remain unknown. To remedy this omission, a probe tester has been developed. The tester reproduces actual contactor working
conditions with high fidelity while measuring contactor resistance (Cres), the industry
standard metric for probe health.
The tester has been used to evaluate spring probe life against the following variables over
the accompanying ranges:
- Source Current (0-200mA per probe)
* Operating Temperature (20'C-150'C)
* Cleaning Interval (cleaning every 10k hits - no cleaning)
- Cleaning Method (various brush types, Electro-Hydro-Dynamic (EHD))
Tester Description
21
Future experiment variables and their current values:
- Spring Probe Base Material (BeCu)
-
Spring Probe Plating Material (plated gold over nickel)
" Device Under Test Base Material (Alloy 42)
* Device Under Test Plating (90/10 SnPb)
Spring Probe
Work Area
supply
oSpool
0
supply
Spool
Figure 1.1 Isometric view of test machine
1.3 Tester Description
The tester was designed around the experiments it was intended to perform. The quantity
of testing requires the tester to operate autonomously for extended periods of time. A single run of 20k hits, a typical cleaning interval, at one and a half seconds per hit will take
over eight hours. The "lead frames" being tested also must be presented to the contactor
head at operating temperature. To do otherwise invalidates the test. The solution is to store
all the "lead frames" to be consumed during a test period inside the environmental chamber maintaining the tester at operating temperature.
22
REALISTIC SPRING PROBE TESTING METHODS AND RESULTS
Both cost and the necessity of fitting inside the environmental chamber make actual lead
frames a poor choice for the test medium. Instead, a continuous foil with the same thickness and composition as a standard lead frame was adopted. The foil need only be wound
off the supply reel, presented to the spring probe array, and wound onto the take-up reel
(Figure 1.1).
The spring probes are presented with virgin material for each contact in order to mimic
actual operating contamination in a handler. In a compromise between packing constraints
and statistics, the tester was designed to hold fifty spring probes, that have been mounted
and aligned to optimize foil use while simplifying the indexing motion.
Realistically reproducing spring probe operating conditions serves no purpose if the condition of the probes cannot be monitored. To that end, the tester does in-situ four-wire
resistance measurement of each of the fifty spring probes. The two connections to each
probe's receptacle are accomplished quite readily by mounting the receptacles in a circuit
board, but the other two connections are somewhat more circuitous. The return path for
the current used in the four-wire test and the second voltage probe connection are both
made via the tester frame (Figure 1.2). Naturally, the resistance of this path was a concern.
The worst case resistance scenario for making these connections through the tester frame
is if the current all travels through only one of the bearing sets supporting the foil advance
sub-system. Bench level testing revealed (and later use of the tester confirmed) that this
line contact inside the GraphalloyTM bearing has a negligibly small resistance of only a
few milliohms.
The tester was designed with the assumption that Cres could be greatly influenced by the
amount of current sourced through each probe. Because of this predicted coupling, the
current through each of the fifty spring probes is independently sourced. If the voltage
across the whole probe array had been regulated instead, more current would have flowed
through the lower resistance probes. Since current affects Cres, sourcing current in this
Predictions and Preliminary Results
Individual
Current
Regulator
Four Wire
Resistance
Tester
Voltage
Probes
Probe &
Receptacle
Fnil
23
Test
Current
Source
and
Return
,,
Graphalloy TM
Bushings
U1
Figure 1.2 Resistance test schematic. Note that conduction path includes the frame and the
GraphalloyTM bearings.
manner would have created a feedback loop, that would work to make the resistance of
each probe equal to that of every other probe
1.4 Predictions and Preliminary Results
1.4.1 Source Current
It was anticipated higher source currents would decrease spring probe life. The contact
regions between spring probes and devices under test are very small. The small size of
these regions is not an artifact. Designers favor smaller contact regions because they are
more effective at piercing any oxidation or contaminant layers that form atop the devices
under test. Imagine driving a sharp stick (the probe) through a thin layer of ice (the oxidation layer) to get to the mud underneath (the base material). Oxidation films form
extremely quickly. Even gold forms a 0.3 Angstrom film within 2 minutes of exposure to
air. But though quite hard (Table 1.2), oxides are also brittle and quite resistive.
24
REALISTIC SPRING PROBE TESTING METHODS AND RESULTS
TABLE 1.2 Properties of some contact materials
Resistivity (ohm-cm)
Element
Tensile Strength (MPa)
Aluminum
Pure
2.65 10-6 a
Oxidized
>10 -1014 a
Pure
45 b
Oxidized
2944 a
Beryllium
4 -10-6 c
>1017 a
300 b
1462 a
a. [Shackelford, 2000]
b. [Buch, 1999]
c. [Bauccio, 1993]
Test currents are almost always small, but the ohmic heating these currents induce is
intense because the regions themselves are so petit. This heating creates microscopic solder joints between solder balls or solder coated leads and probe tips. Each time a spring
probe lifts off a device under test, this solder joint breaks, and some of the solder cladding
from the lead frame is carried away with the probe tip. As the principal source of contamination in the testing process, this is the contaminant the various cleaning processes strive
to remove. The contaminant is harmful because it degrades the probe's ability to make
contact with the device under test. A stick with a big glob of mud at the tip does not punch
through ice nearly so well as a clean stick.
It is anticipated that because higher source currents create more ohmic heating at the interface, contamination will be accelerated by higher currents. Testing has begun, and the
tester is accurately reproducing operating conditions, but data is not available at this time
1.4.2 Operating Temperature
It was anticipated that higher temperatures would decrease spring probe life. Both anecdotal evidence from customers and our understanding of the process gave rise to this
belief. Higher temperatures make the solder cladding on the lead frames softer, and softer
cladding is more likely to rip away from the base material when the source current solders
the probe tip to the lead frame.
Conclusions
25
1.4.3 Cleaning Interval
This experiment sequence features fewer unknowns than the others. The effectiveness of
cleaning at extending spring probe life is an extremely widely held belief, especially
among spring probe manufacturers. Company A recommends cleaning their contactors
every shift. Not doing so voids their warranty. Company B reports that effective contact
life varies by two orders of magnitude depending on installation and cleaning methods.
Company C reports that contamination and a lack of reliable cleaning method is the typical cause of death for their spring probe board test products. A more quantitative understanding of the process is desired. How much cleaning is necessary to substantially
improve contactor life? How should cleaning cycle interval be adjusted to accommodate
particular environmental conditions? How can cleaning methods and frequencies be optimized from a systems standpoint.
1.4.4 Cleaning Method
The most widespread back-end cleaning method is brushing. We wanted to know if any
type of brush is more equal than the others, and also whether there exists some other
acceptable cleaning method more suitable to automation. We therefore experimented with
various different kinds of brushes (fiberglass, stiff horse hair, brass, stainless steel, and
low carbon steel) and different cleaning methods such as electro-hydro-dynamic (EHD).
1.5 Conclusions
The tester holds the promise of for the first time enabling systematic testing of spring
probes and other contacting technologies performance under actual operating conditions.
26
REALISTIC SPRING PROBE TESTING METHODS AND RESULTS
Chapter 2
INTRODUCTION
2.1 What is a Contactor?
Semiconductors are tested throughout the manufacturing process. A tester transmits test
signals to the Device Under Test (DUT), monitors the output, and determines if the device
is good. DUTs are electronic devices, and the signals they receive and transmit are electrical in nature. A contactor provides the electrical connections between the tester and the
DUTs. A contactor may connect a tester to one device at a time or it may have multiple
regions of contact elements (each element makes one connection), and facilitate the testing of many devices in parallel. As machines on an automated manufacturing line, a tester
and its contactor test thousands of devices each shift, making and breaking electrical contact each time.
There are many different types of contactors. While the principles outlined here are applicable to all contactors, this thesis will focus on contactors employing spring probes as
their contact elements. With some application specific modifications, the test machine in
this thesis could generate data for most any kind of contactor, but from the outset, spring
probe data was seen as being of the most immediate use. For simplicity, all explanations
will use the nomenclature of spring pins rather than that of generic contactors. Extension
to other particular types of contactors will be left as an exercise for the reader.
27
28
INTRODUCTION
Spring probes are popular for back-end testing. The back-end is defined as all processes
that occur after fabrication of the transistors is complete, e.g. metallization, dicing, and
packaging. Spring probes' telescoping design accommodates the variations in surface
height common to the back-end. A typical spring probe has three parts: a probe, a tube,
and a spring (Figure 2.1). The probe makes contact with the DUT. The tube guides the
telescoping motion of the probe, and the spring applies a restoring force opposing that
telescoping action.
I0
e pmwirq
Probe Tube
fid
5 ce
Ind
to rD bleT
contact
jAxal
korc
for probw tip
to UVT conrac
Figure 2.1 A picture of a QA Technologies spring probe and a cross section view of a typical
spring probe. (from QA Technologies Catalog)
Handlers present DUTs to testers. Customers, especially the military, often require devices
be tested at extreme temperatures. A typical range is -50 to 150'C. If a device is to be
tested at temperature, the handler may also be responsible for slewing the device from
ambient. Because good electrical connections are also good thermal connections, heat will
flow between the DUT and the contactor in the presence of a temperature gradient. As the
What's the Problem?
29
thermal mass of a DUT is often much smaller than that of the contactor touching it, fast
changes in device temperature are possible. Great care is therefore taken to maintain the
contactor at the temperature of the DUTs, because to do otherwise would defeat the purpose of testing at temperature.
2.2 What's the Problem?
Even "noble" metals oxidize. Gold forms a 0.03 nm thick oxidation layer after 2 minutes
of exposure to air. Aluminum oxide grows at approximately 2 nm per minute. This oxidation layer is insulative (Properties of some contact materialsTable 2.1) and must be pierced
before the currents associated with the signal voltages can be passed. This is what a contactors does.
Oxidation layers are ceramics and tend to be quite hard but brittle. (Table 2.1); sapphire is
impure aluminum oxide. Fortunately, these oxide layers sit atop (unoxidized) base material that is much softer and conductive (Table 2.1). The tips of spring probes are often
TABLE 2.1 Properties of some contact materials
Resistivity (ohm-cm)
Tensile Strength (MPa)
Element
Pure
Oxidized
Pure
Oxidized
Aluminum
2.65 .10-6 a
>10 .1014 a
45 b
2944 a
Beryllium
4 .10-6 c
>1017 a
b
1462 a
30 0
a. [Shackelford, 2000]
b. [Buch, 1999]
c. [Bauccio, 1993]
macroscopically sharp, but when piercing oxidation layers, the microscopic peaks and valleys present on even a polished probe are what matter. The probes are made of hard metals
such as beryllium copper (BeCu) or steel, and when the probe is plunged, the microscopic
peaks on its surface pierce the oxidation layer just as a stick may be used to punch through
30
INTRODUCTION
the ice atop a mud puddle. The bulk resistance of the underlying base material is low
(Table 2.1), so good, i.e. low resistance, contact is achieved once the probe reaches this
material.
Because of the nature the oxidation layer penetration, many small peaks punching through
a hard but brittle medium, the area where one conductor makes intimate contact with the
other tends to be quite small. The currents passed also tend to be small, but because the
areas are also petit, the current flux is quite high. This high current flux results in enough
ohmic heating to spot weld the probe tips to the DUT. When the contactor is withdrawn,
these spot welds do not break cleanly. Some of the soft underlying base material is ripped
off the DUT and adheres to the probe tip. The phenomenon is aggravated by increased
temperature, for the base material softens, making it more susceptible to traumatic
removal.
As base material accumulates on the probe tip, the probe becomes less effective at making
contact with the DUT. Imagine trying to punch through a sheet of ice with a stick whose
pointy end is covered with mud. The industry standard metric for contact effectiveness
and health is contact resistance, Cres, a measurement of the resistance from the probe
through to the DUT. As mentioned before, the bulk resistances of the materials on either
side of the contact region are low, so the bulk of the contact resistance comes from the
contact region. Contact resistance must be low for effective testing because when combined with the system's inherent capacitance it forms a low pass filter. This low pass filter
interferes with testing, so after a spring probe has been made sufficiently dirty, it must
either be replaced or cleaned.
In the back-end, this cleaning is done manually with a fiberglass brushes. During operation, the contactor is sandwiched between the tester and the handler. The system must
therefore often be partially disassembled for contactor cleaning or replacement. During
this maintenance, expensive hardware sits idle.
A Solution
31
Worse, a whole contactor does not fail at once. Individual probes may fail long before others, and since multiple DUTs are often tested by a single contactor (parallel testing), the
manufacturer is faced with a difficult choice. If operation is continued, devices at the bad
sites will have to be discarded or re-tested. If operation is suspended, valuable machine
time will be wasted and throughput will suffer. It is also impossible for the manufacturer
to know whether replacing the single bad element will have any lasting benefit. After
cleaning or replacement, testing may resume only to have another site may fail. There is
no systematic predictive data, operator experience governs these decisions.
To make matters still worse, there is no bright line for contact failure. Failure is often
intermittent and must be detected by tracking the yield for each region of the contactor. If
the manufacturing process is under control, the operator knows some percentage of
devices are expected to fail. If a contactor region detects more than its share of failures, it
may come under suspicion, but until it is tested off-line, little can be known for sure.
Manufacturers of testing equipment face these same questions, but without the benefit of
employing experienced line operators. The answers impinge on many important design
decisions. What is the optimum level of contactor parallelism? What is the optimal contactor for a particular application? Of what material should the contactor be made? Should
contactor maintenance be scheduled rather than being conducted on an ad-hoc basis, and if
so, what should the interval be? How much effort should be dedicated to making the
tester-contactor-handler system rapidly serviceable? How can contactor problems be better managed at a systems level
2.3 A Solution
The testing machine described in this thesis was designed to provide the data to answer
these and other questions. In light of the theories about the mechanisms of contactor contamination, the machine was required to test at temperature, to provide a virgin "DUT" for
each hit (more on the quotations marks later), and to source current to replicate test cur-
32
INTRODUCTION
rent. The following machine parameters are reconfigurable (typical values and ranges are
in parenthesis):
-
Source Current (0-200mA per probe)
Source Current Duration (0-arbitrary)
Spring Probe Plunge Distance (full range)
Spring Probe Geometry (arbitrary with 90 degree cone baseline)
Operating Temperature (20'C-l 50'C)
Cleaning Interval (cleaning every 10k hits - no cleaning)
Cleaning Method (various brush types, Electro-Hydro-Dynamic (EHD))
Spring Probe Base Material (BeCu)
Spring Probe Plating Material (plated gold over nickel)
Device Under Test Base Material (Alloy 42)
Device Under Test Plating (90/10 SnPb)
While reproducing contactor operating conditions along the lines of the parameters above,
the test machine measures and records the contact resistance of each spring pin at an operator specified interval. Tests such as auger spectroscopy of the probe tips, examination of
the "DUTs," and post-mortems on the spring probes are performed offline.
Naturally, this is not the first machine designed to test contactors. Contactor vendors do
test their products. Unfortunately, their principal concern is mechanical life. And while
they do test at temperature, a hard contact target is used instead of anything more akin to a
DUT. Manufacturer's testing is also done without sourcing current. The mechanical lifetimes measured are on the sunny side of 1 million hits, while semiconductor manufacturers would be astounded by lifetimes a tenth as long. It is hoped that improved testing
fidelity will mend the relation between testing and practice, resulting in enhanced practice.
Chapter 3
CONCEPT SELECTION - CHOOSING
A TEST MEDIUM
3.1 Why not use a handler, a tester, and real devices?
Using existing equipment conduct the testing is an obvious option. All the engineering has
already been done. It might seem that after some software was written and some off-theshelf equipment purchased, testing could begin immediately. This is likely the case, but
there are some serious caveats. First, while much is made of incessant drop in the prices of
semiconductor devices, such devices are still not free. With potential hit counts measured
in the millions, the cost of using real devices (even at the improbable cost of $0.01 each) is
prohibitive. Finally, testers and handlers (Figure 3.1) are major pieces of capital equipment, and while obtaining the data is important, it could not justify tying up $0.50 million
of equipment indefinitely.
Figure 3.1 A Handler-Tester System (Delta Design Company)
33
34
CONCEPT SELECTION - CHOOSING A TEST MEDIUM
3.2 Gravity Feed
A close substitute for using a full fledged handler/tester system would be to employ a
gravity feed machine, a limited kind of tester like a cable tester from CIRRIS, and test
devices. Each cycle, the gravity feed machine would present a test device to the contactor.
The contactor would be plunged into the test device. Custom electronics would source
current to approximate testing conditions. At some user specified interval, the contactor
would be plunged against a "gold brick" or some other low resistance electronically inert
medium while the CIRRIS tester measured contact resistance.
Gravity feed machines hold devices in a magazine, and use gravity to place devices into a
work area. In addition to being readily available, they are already designed to run at temperature, so housing the whole setup in an environmental chamber would satisfy the
requirement for at temperature testing. Prima facie, finding such a machine with sufficient
capacity small enough to fit inside the available environmental chamber should not be
extremely difficult.
Figure 3.2 A gravity feed handler (Delta Design Company)
Unlike full fledged testers, cable testers measure only resistance. They cannot perform the
more advanced input-output highly time dependant tests full-fledged testers do. Not coincidentally, they are much less expensive. Also, a Signature Touch One cable tester from
Big Disk
35
CIRRIS Systems Corporation was already available. Because of the CIRRIS' limited
capabilities, custom electronics would have to be designed and built to source current
through the contactor, but such circuits are well understood, so this was not considered a
challenge.
Figure 3.3 CIRRIS Tester
When testing against DUT like material has been done in the past, test devices have been
used. Test devices are equivalent to real devices from a contactor's perspective. They have
the same form factor and the leads are the same as those on a real device, but they are electronically inert. Alas, they are also relatively expensive ($0.10 to $2.00). And fresh
devices must be provided every hit, for in a previous experiment using test devices, when
no attempt was made to provide virgin devices for each hit, the contactor being tested
eventually wore through the test device.
3.3 Big Disk
Having found the use of real devices and test devices, despite the advantages of being able
to use off the shelf equipment, to be unacceptable, alternatives were sought. One such
alternative to using devices is combining a big disk (or rectangle) coated with typical leadframe cladding and a servo axis to position the contactor anywhere over the disk.
Each cycle, the contactor would be advanced to a new location above a virgin area on the
test disk. The contactor would then be plunged into the disk. As before, current would be
36
CONCEPT SELECTION - CHOOSING A TEST MEDIUM
Figure 3.4 Sketch of Big Disk testing system, side and top views
sourced though the contactor by custom electronics. For resistance measurement, a cable
tester could be wired into both the disk and the contactor. Measurement could be programmed to occur at the discretion of the operator.
The disk is made of the same material as typical device contacts, and has been clad similarly, so the physics of the contact mechanics and contamination process should be essentially the same. Most of the packaging congruity provided by using real or test devices is
Big Disk
37
not needed. This type of setup cannot fully reproduce the probe-DUT interaction for
devices having non-planar contact regions. A typical example of this is the Ball Grid
Array (BGA) type device. A BGA consists of a grid of small spheres. Each sphere is contacted by its own spring probe. Spring probes for BGA applications do not have a single
point, but rather a series of them surrounding a common center (see Figure 3.5). This combination self centers and creates three point contacts between the probe and the sphere.
While this is not identical to single point contact against a plane, it was felt that results of
a relative nature would be sufficient.
Figure 3.5 Various Probe tip types (reproduced from QA Technologies' catalog)
The problem with this solution is entirely practical. The available environmental chamber
has an internal volume of only 22 by 20 by 19 inches. Being optimistic, a disk of 396
square inches (22 x 20 x 0.9 - for overhead) could be fit inside the chamber. Experts
advised that maintaining virgin material conditions would require each probe to touch
down in its own 0.025" by 0.025" square of pristine material. Fifty spring probes could be
tested at one time by the CIRRIS tester and was large enough to make for statistically
meaningful results. But the industry standard cleaning interval is every 20k hits, and it was
desired that the testing machine be able to run unattended for at least that long, so the minimum area was 625 square inches (20,000 hits x 50 pins x 0.025 in 2 per pin hit). A disk
big enough to meet the requirements would not fit in the available environmental chamber.
38
CONCEPT SELECTION - CHOOSING A TEST MEDIUM
3.4 Foil Feed
Using continuous foil instead of a disk solves the area problem. The disk system made all
of its area available at all times, which was not necessary. Foil can be wound off a supply
spool, presented to the contactor, and wound back onto a take-up spool. Otherwise, the
cycle is identical to disk cycle.
3.5 Foil Location
Indeed, switching from a disk to a foil based system could have obviated the area problem
entirely. Unlike the disk, the foil was small enough to move in and out of the environmental chamber. A hole already existed in the chamber's side, and it was possible to enlarge
hole without damaging the chamber's performance. Three different possibilities existed:
mount both the supply and take-up reels outside the chamber, mount the supply reel inside
the chamber and the take-up reel outside, and mount both reels inside the chamber.
Mount Both Spools Outside the Chamber
The key to mounting both spools outside the chamber was heat transfer. Could the incoming foil be brought to the environmental chamber's temperature before it reached the contactor working area? To answer this question, a simple thermal model was constructed.
Linear and quadratic relations are used to interpolate between the data points in Table 3.1.
The temperature of the environmental chamber may be set anywhere from -50C to 150C,
and as it is not obvious a priori which is the limiting case, the calculation is done a 25 C
increments between the two. Beta is calculated:
P
=
1
(3.1)
Because it varies as the foil is brought to temperature, AT is approximated as the mean of
the difference between the outside ambient temperature (293K), and the chamber temperature:
Foil Location
TABLE 3.1
39
Air Properties
Kinematic
Viscosity, v
(m2 /s)
Temperature
(K)
200
250
300
350
400
450
7.590-10-6
1.144-10- 5
1.589-10-5
2.092-10-5
2.641-10-5
3.239-10-5
Conductivity, k
(W/mK)
Prandtl
Number, Pr
1.81-10-2
2.23-10-2
0.737
0.720
2.63-10-2
3.00-10-2
3.38-10-2
3.73-10-2
0.707
0.700
0.690
0.686
- Tchamber
AT = Tambient 2chme
(3.2)
The Grasshof and Rayleigh Numbers are then calculated:
GrL
RaL
=
PgL (A T)
(3.3)
GrL x Pr.
(3.4)
With those calculations complete, the specific Nusselt Number relations can be used for
each of the different modes the foil may be in:
Vertical Wall (RaL < 109 ) [Mills, Table 4.10]:
9j
-16-
Nu
=
0.68 + 0.670 RaL x 1 + (0.492)
Pr J
Top surface when working above ambient (105 < RaL
(3.5)
10
NUL = 0.82(RaL) 5
Bottom surface when working above ambient (105 < RaL <2x17 ) [Ibid]:
(3.6)
40
CONCEPT SELECTION - CHOOSING A TEST MEDIUM
NUL = 0.54(RaL) 4
(3.7)
As can be seen from Appendix A, which includes the numerical results, a foil with a reasonable width (1.5" in this case), can be brought to temperature within a reasonable distance after entering the environmental chamber.
Alas, after the analysis, it was decided that mounting the supply reel outside the chamber
would create the appearance of a source of error, reducing confidence in the data. Measuring the temperature of the foil during testing would resolve the issue, but was considered
difficult because the foil was in motion. Because the associated problems were not considered insurmountable, it was decided to mount the supply spool inside the chamber rather
than incur unnecessary risk.
Mount the Take-Up Spool Outside the Chamber
Mounting the take-up spool outside the environmental chamber could have fewer adverse
thermal consequences. Once the foil had been used, its temperature was of no consequence to the experiment. The only concern was that the foil outside the oven would
exchange enough heat to alter the temperature of the foil still being tested, but thermal
modelling indicated the effect would be negligible. Sending the used foil outside the
chamber also preserved the option to unceremoniously dump it into a box rather than
going to the trouble of winding it back onto a spool. Nonetheless, once it was verified by
Bench Level Prototype (BLP) that winding the used foil onto a spool would not present
substantial difficulty, it was decided not to pursue this option.
Mount Both Spools Inside the Chamber
Mounting both spools inside the chamber presented a small packing challenge, but it was
the preferred option nonetheless. With both spools inside the chamber, the neatness of the
packaging would be maintained. Furthermore, the passage out of the chamber was small,
and electrical and pneumatic umbilicals were already passing through it. Pushing the foil
Summary
41
through such a confined space might cause unpleasantness. Also, the machine was as
likely to be used outside the chamber as inside it, and provision would have to be made to
mount the take-up spool in both cases.
3.6 Summary
Using foil to approximate the DUTs was found to have the right mix of fidelity and practicality. The cost of using real or proxy devices was prohibitive, and simply servoing over a
sheet of material could not provide sufficient surface area. Storing all the foil inside the
environmental chamber alleviated concerns about experimental integrity. Programming a
soak period inside the chamber was considered more reliable than relying on heat transfer
processes that were not verifiable in real-time. Nonetheless, the thermal model's predictions predicted fail safe operation. Even if the thermal soak interval was insufficient, adequate time could be provided to warm up cold foil coming off the spool.
42
CONCEPT SELECTION - CHOOSING A TEST MEDIUM
Chapter 4
APPLIED EXACT CONSTRAINT WEB
HANDLING
Based on a paper to be submitted for publication in the American Society of Mechanical
Engineers' Journal of Mechanical Design
TABLE 4.1 Paper Authors
Alexander H. Slocum
Massachusetts Institute of Technology
Room 3-455
77 Massachusetts Avenue
Cambridge, MA 02139
Alexander D. Sprunt
Massachusetts Institute of Technology
Room 3-470
77 Massachusetts Avenue
Cambridge, MA 02139
vox: (617) 253-0012
fax: (617) 258-6427
slocum@mit.edu
vox: (617) 253-1953
fax: (617) 258-6427
asprunt@mit.edu
4.1 Abstract
Novel web handling machine elements were devised to manipulate exactly constrained
continuous media for use in a machine to test electrical contactors. Universal joints and
beam type flexible couplings were employed for gimballing and castering axes, both at
standard caster radii and the roller center. A kinematic edge constraint was designed. The
torque transmission properties of clamped connections were combined with the favorable
kinematics of typical pinned type connections by compliantly mounting a spherical roller
bearing as a pinch roller.
43
44
APPLIED EXACT CONSTRAINT WEB HANDLING
4.2 Introduction
During manufacture, contactors electrically connect semiconductor devices to test equipment. Despite their widespread use, the lifetime and the variables that materially influence
the lifetime of contactor systems have not been systematically studied. Contactor manufacturers do test their products, but under idealized circumstances. As part of a program to
better characterize semiconductor contactors by testing them against virgin material for
each hit, a web handling system with the following functional requirements was developed:
* Index a 1.5" wide strip of 0.005" thick foil (0.0046" of Alloy 42 with
0.0004" 90/10 Sn/Pb cladding) in 0.025" increments (the foil is a proxy for
the leads of the semiconductor devices)
* Expose a 6" section of foil for testing
* Operate for extended (> 12 hr.) periods unattended (a typical run is 20k hits)
* Operate at temperatures ranging from -50' to 1500 C (-580 to 3020 F)
* Fit (along with additional test equipment) inside a 22" x 20" x 19" environmental chamber
A web' is "a strip of flexible material whose width is much greater than its thickness and
whose length is much greater than its width" [Blanding]. The principal challenges are getting the web headed in the proper direction and stabilizing its motion in that direction. By
analogy, think of a car on an perfectly straight and empty desert highway. Theoretically, if
the car is placed on the road parallel with the edges, it could travel forward indefinitely
and remain on the road, but because the alignment of the car's wheels can never be perfect
(for that matter, neither can the edges of the road), some feedback mechanism must be
provided to steer the car back to the center of the road when it begins to wander [Blanding]. Compliant webs, e.g. rubber and leather belts, can be guided by crowned rollers, but
stiff webs like metal foils, photographic film, and paper, must be guided by other means.
1. Searching for literature was considerably complicated by the concurrent use of the term as slang for the
World Wide Web (WWW)
Kinematic Web Handling Background
45
Such means typically consist of some stable arrangement of fixed rollers, castered rollers,
gimballed rollers, and edge constraints. Those familiar with the operation of still and
motion cameras and movie projectors will know that stiff webs can also be guided by
sprocket holes and similar devices. Manufacturing metal foil with analogous features for
such a low volume application was dismissed as impractical, and an effort was begun to
design a kinematic web handling system.
4.3 Kinematic Web Handling Background
4.3.1 Exactly Constraining Websi
In three dimensions, rigid bodies have six degrees of freedom, three translations and three
rotations. In two dimensions, rigid bodies have three degrees of freedom, two of translation and one of rotation. A body is exactly constrained if the number of its constraints and
the number of its desired degrees of freedom sum to the number of degrees of freedom
inherent to the space in which it exists. Though they move in three dimensions, webs are
two dimensional objects, and two constraints will exactly constrain them to move along a
particular path. A web's path in three space is determined by the spatial arrangement of
rollers, but a web's stability in its own two dimensional space is determined by the type of
rollers. Practical web handling equipment leaves the web with one degree of freedom, for
static webs are of limited use.
There are two kinds of web constraints: rollers and edge constraints. A pair of rollers or a
roller and an edge constraint exactly constrain a web. The intersection of the axes of the
roller pair or the intersection of the axis of the roller and the normal to the edge of a web at
the edge constraint (Figure 4.1) is the web's instant center of rotation. Because it is unstable, the two roller arrangement is seldom used. For unless the rollers can be perfectly
aligned to each other and the web perfectly aligned on them, either of which is an impossisource on kinematic web handling, Blanding's book "Exact Constraint:
Machine Design Using Kinematic Principles," is the primary source for the theory in
this summary.
1. As the principal
46
APPLIED EXACT CONSTRAINT WEB HANDLING
Instant Centers of motion abo ut which the web will rotate
I/i
I'
/ I
/
I
/
I
\/\\
x
KdH
Rc ller
Edge Constraint
Figure 4.1 Two methods of exactly constraining a web.
bility, the web will eventually run off the rollers. Because the instant center of the rollerroller arrangement is fixed by geometry, any initial imperfection is amplified over time.
The roller and edge constraint arrangement is preferred because it is stable and because
many web manipulations require a reference edge. The arrangement is stable because its
instant center is not fixed (Figure 4.2), but varies as the cross track position of the foil
changes. If the web is conveyed in the direction indicated, the normal to the edge of the
web at the edge constraint will rotate until the intersection with the roller's axis line has
moved out to infinity. With the instant center at infinity, only pure translational motion
can occur. The cross track position of the web, (y), decays exponentially as the web moves
downrange (x):
x
y = yee
.
(4.1)
Kinematic Web Handling Background
47
I'
// I
y=0
I~
I'
/ I
/ I
I
/I
I
I
/
|
I
I
I
z|
YIF
L-H
Figure 4.2 Decay of cross track error as the instant center moves closer to infinity
Adding constraints, e.g. additional rollers, creates multiple instant centers, and forcing a
web to rotate about multiple instant centers can cause tearing, wrinkling, and other undesiredconditions. But because practical web handling systems have more than one roller,
some way must be found, which is the role of zero constraint rollers.
4.3.2 Zero Constraint Rollers
Zero constraint rollers can be added to an already exactly constrained web handling system without creating a redundant constraint. If the zero constraint roller in Figure 4.3 were
a regular roller, the web would have two conflicting instant centers, with all the attendant
consequences. There are three kinds of zero constraints: nonrotating shoes, axially compliant rollers, and castered rollers (Table 4.2).
48
APPLIED EXACT CONSTRAINT WEB HANDLING
Instant Center 1
(at infinity)
Fixed Roller
(Angular Constraint)
Edge Constraint
Instant
Center 2
Zero Constraint
(nonrotating shoe,
axially compliant
roller, or castered
roller)
Foil
Figure 4.3 Adding an additional roller can cause over constraint if the new roller is not carefully
chosen. Overconstraint manifests itself as multiple instant centers of rotation, which can destroy a
web. The appropriate web plane diagram symbols have been overlaid on this figure.
Nonrotating Shoes
Nonrotating shoes are rollers that cannot rotate. The web must slide over them, breaking
the friction lock normally present between a rotating roller and the web. The absence of
this connection makes the web freer to slide in the cross-track direction, preventing axial
constraint. Nonrotating shoes were a poor fit for the contactor testing machine, because
the sliding contact between the shoe and the web would be a source of harmful lead particles. Implementing an air bearing nonrotating shoe was also unattractive, due to the inconvenience of conditioning the air prior to exhausting it inside the environmental chamber.
No experimentation was done with nonrotating shoes, and they are mentioned here only
for completeness.
Kinematic Web Handling Background
TABLE 4.2 The three types of zero constraint rollers
Web
Non-Rotating
Shoes, the flat
grounded edge
indicates
Shoe
Axially Compliant Rollers, US
Patents
#4,221,480 (left)
and #5,244,138
(right), (images
from B landing)
Caster Axis
Roller
Caster Axis
Castered Rollers
Roller
- The caster axis
%~
"C
%
r
%
is normal to the
roller axis and
parallel to the
angular bisector
of the angle
formed by the
foil enter and
leaving the roller.
49
50
APPLIED EXACT CONSTRAINT WEB HANDLING
Axially Compliant Rollers
Axially compliant rollers (Table 4.2) are stiff in the radial direction, but compliant axially,
thereby facilitating rolling contact without overconstraint. The axial compliance must be
of a particular kind, however. "The roller surface will freely move in the crosstrack direction as demanded by the web and will then restore itself to its initial position after the web
has left contact." The fanciful mechanism in Figure 4.4, will not work. It cannot return to
Springs
00000
00000h
000
000000
Housing
Roller
Figure 4.4 A fanciful axially compliant roller that is unworkable because it has only one roller
surface, and can therefore never leave contact with the web, preventing it from resetting.
its initial position because its single surface will never loose contact with the web. A pair
of rollers featuring the appropriate kind of axial compliance is shown in Table 4.2. The
rubber disks of the roller on the left bend axially (while maintaining their radial stiffness)
to accommodate misalignment of the web. The roller on the right is composed of sheet
flexures serving the same purpose. These rollers could have been used, but neither kind
was readily available. Several vendors were contacted without success. Even if a vendor
had been found, the lead time for rollers of appropriate diameter and width and capable of
Kinematic Web Handling Background
51
withstanding temperatures of up to 150C would likely have been unacceptable. And if
availability had not been a problem, the rollers would have only been useful for the idler
roller. Some other solution would have had to be found for the spools.
Castered Rollers
Like axially compliant rollers, castered rollers avoid overconstraining the web by providing an additional degree of freedom between the roller and the machine frame. As with
casters on shopping carts and dollies, an axis of rotation is added upstream of the roller
with respect to the web motion (Table 4.2). Optimally, the caster axis is also parallel to the
bisector of the angle formed by the web when it enters and leaves the roller (Table 4.2).
This second requirement and gravity greatly restrict the possible configurations of real
web handling mechanisms.
4.3.3 Gimballed Rollers
By twisting the two-dimensional plane the web inhabits, gimballed rollers create joints
that allow for the re-direction of the web in three dimensions (Figure 4.5). A gimbal axis is
A
B r
C
Figure 4.5 "B" is a gimballed roller (figure reproduced from Blanding)
52
APPLIED EXACT CONSTRAINT WEB HANDLING
similar to a caster axis, but instead of being parallel to the angle bisector, it is parallel to
the incoming web span. By allowing the A-B section to twist, the roller at C no longer
"sees" the constraint at A. From roller C's perspective, gimballed roller B becomes an
implied axial (or edge) constraint for which roller C provides the attendant angular constraint (Figure 4.6). This is the equivalent of creating a "joint" in the two dimensional
space the web inhabits. The optimal wrap angle of the web around a gimballed roller is
900, but between 450 and 135* is acceptable. Wrap angles of 1800 and 00 will not work.
Pin Joint In Web Plane
Implied Axial Constraint
Figure 4.6 By taking advantage of the three dimensional twist compliance of section A-B, the
gimballed roller (B) creates a joint in the web plane. The section A-B is exactly constrained by the
edge constraint at A and the angular constraint at B. The section B-C is exactly constrained by the
implied axial constraint at B and the angular constraint at C. The overlaid web plane symbology is
explained below.
4.4 Concepts
After preloading on kinematic web handling theory, brainstorming produced the two
arrangements shown in Figures 4.7 and 4.8. Contactors are typically plunged down into
the Device Under Test (DUT). Doing so ensures that any particles or other debris gener-
Concepts
53
ated during testing are carried away with the devices. The two arrangements sought to
continue this practice, preserving experimental fidelity.
4.4.1 First Concept
The first concept bears some resemblance to a movie projector (Figure 4.7). Both spools
and the idler roller are gimballed and castered. The indexing roller is fixed. When combined with the edge constraint, the web is exactly constrained. Special care was taken to
create a large wrap angle around the index roller. Torque is transmitted to the foil by the
capstan effect, so a greater wrap angle increases the torque that can be transmitted to the
foil. Foil tension is maintained by a torque source attached to the take-up spool and a slip
clutch coupled to the supply spool. A stepper motor drives the index roller to break the
equilibrium between the torque source and the slip clutch and advance the foil.
r-----------Edge
Test Apparatus
Constraint
Index
Rollerd
Supply
Spool
Idler
Take-Up
Spool
Environmental
Chamber
Figure 4.7 "Movie Projector" style arrangement
The requirement that the web be indexed in fixed steps could also have been met by driving the take-up spool with a servo motor and hanging an encoder on the fixed "index"
roller, but it was felt that this solution did not increase mechanical simplicity and would
54
APPLIED EXACT CONSTRAINT WEB HANDLING
have considerably complicated the control system. The index roller was sized such that
driving the stepper discretely in half step mode produced the desired interval of foil
advance.
4.4.2 Second Concept
The second concept is very similar to the first from the perspective of the foil (Figure 4.8).
As said before, webs are two dimensional structures, and despite the changes in the three
dimensional positions of the various spools and rollers, the order the web passes through
them is the same, and the web distances between them are roughly equal. The spools and
the idler roller are once again gimballed and castered, while the fixed index roller and the
edge constraint combine to exactly constrain the foil. Also as in the first concept, a torque
Edge
Constraint
-1
r-----------
Test Apparatus
|
Oven
Idler
Index
Roller
Spool
0
Sppoly
Figure 4.8 Second, and more space efficient arrangement
source is attached to the take-up spool, a slip clutch is coupled to the supply spool, and a
stepper motor driving the index roller breaks the equilibrium.
Concepts
55
4.4.3 The Edge Constraint
The edge constraint was not a part of either concept from the beginning. Both arrangements proved to be stable, though not in the way originally believed. It was thought,
despite Blanding's warning, that the flanges on the sides of the spools would serve as edge
constraints. Fortunately, such was not the case. If it had been, both arrangements would
have been unstable. As will be seen, when a Bench Level Prototype (BLP) was constructed, the web found its own edge constraint.
4.4.4 Web Plane Diagram
Web plane diagrams are constructed to check web handling systems for overconstraint
and stability. In Blanding's system, edge constraints are symbolized as arrows from
ground, indicating that they fix the distance from the web edge to the machine frame (but
not the angle). Fixed rollers are indicated by a solid line from the machine frame to the
web, and are linked to the web edge with a right angle symbol, for when used in conjunction with an edge constraint, the web's edge will be orthogonal to the roller's axis. Zero
constraints are represented by dashed lines and can intersect the web at any angle. The
dashed line indicates that they can intersect the web at an arbitrary angle and at an arbitrary distance from the machine frame. Gimballed rollers are represented like a fixed
roller, but with the addition of a pin joint, which allows the web to change direction with
respect to the frame (Figure 4.6). To emphasize that they will not be perfectly aligned in
the hardware, the lines representing constraining rollers are deliberately drawn nonsquarely, and the foil is represented at an arbitrary angle with respect to ground. Different
elements can be combined in the diagram by combining their symbols. A castered and
gimballed connection is represented as a dashed line (without a right angle symbol) and
pin joint, and would not apply an angular constraint to the web. The constraints in
Figure 4.3 have been overlaid with the appropriate web plane symbology.
As mentioned before, the two configurations are essentially the same from the web's perspective, so a single web plane diagram (Figure 4.9) will suffice for both. Initially, the
56
APPLIED EXACT CONSTRAINT WEB HANDLING
Idler Roller
(gimballed and castered)
Supply Spool
(gimballed and castered)
Index Roller
(fixed)
Edge Constraint
Take-up Spool
(gimballed and castered)
Figure 4.9 Web Plane diagram for both arrangements, mis-alignment is deliberately exaggerated
to emphasize any overconstraint.
edge constraint was omitted. The literature did not describe the proper treatment of
flanged spools, and it was incorrectly assumed the spools' flanges would provide the necessary crosstrack constraint. The correct treatment of spools is to assume the web emanating from them is fully constrained "upstream" of them. Immediately after being wound off
the spool, the web can neither slide in the cross track direction or change its angle with
respect to the spool. Because the spools are gimballed and castered, the edge constraint is
necessary to properly constrain the web between them. The diagram reflects these
changes. Note that the gimballing of the idler roller appears to be unnecessary. It is not
necessary for the foil to change direction there. Blanding says little about underconstraint
of webs, which this appears to be, but a possible explanation will be put forth later.
First Bench Level Prototype
57
4.5 First Bench Level Prototype
4.5.1 Universal Joints
Despite the deliberate skewness of web plane diagrams, the gimballing and castering
motions necessary to facilitate self-alignment are quite small. Flexures are a natural choice
to accomplish such motion. But manufacturing is greatly complicated by the necessity of
making the gimballing and castering axes perpendicular. The best rapid prototyping tool
available for making flexures, abrasive waterjet cutting, works in two dimensions. A minimum of two parts would therefore have to be made for each joint. While not a problem in
itself, this cascading of joints consumes precious space inside the environmental chamber.
Brainstorming about machine elements that might already include a pair of cascaded
orthogonal axes of rotation, turned up the universal joint. Mounted as in Figure 4.10, the
Spool
Motor
Universal
Joint
Figure 4.10 A universal joint mounted to provide gimballing and castering. Note the length of the
caster radius, i.e. the distance between the universal joint and the axis of rotation of the spool.
58
APPLIED EXACT CONSTRAINT WEB HANDLING
universal joint creates gimbal and caster axes. Gimballed and castered mounts were
designed for the spools and the idler, and a fixed mount was designed for the index roller.
These elements were assembled into the second arrangement concept (Figure 4.11), but in
this initial configuration, the BLP did not function. The arrangement relied on the tension
in the foil to hold the spools (weighing 10 lbs. each) upright. It may be feasible to apply
enough tension to support the spools in that manner, but it proved to be impossible with
this BLP.
Stepper
Idler
Roller
Index
Roller
Supply
Spool
Take-up
Spool
0
0
Figure 4.11 The plan for implementing arrangement two in hardware. Note the gravity defying
positions of the supply and take-up spools. The frame is not shown.
4.5.2 Making it Work
The situation was salvaged by the modular design of the BLP. By re-configuring the BLP
into the movie projector arrangement, the effect of gravity was effectively reversed. The
BLP was re-configured rather than being turned upside down because contactors must be
First Bench Level Prototype
59
plunged down to prevent debris contamination. Counterweights were also added to move
the center of gravity of the gimballing and castering assemblies to the center of the universal joint. Balancing the motors attached to the spools required a considerable amount of
weight, but the results can be seen in Figure 4.12. Though careful balancing was required,
Supply
Universal
Joints
Spool
Index
Roller
Idler
Take-up
Spool
Foil
Counterweight
Figure 4.12 Slightly modified "movie projector" arrangement. Note the counterweights and thai gravity and foil tension are loading the universal joints in tension.
the system worked. Tension was created between the powered DC motor on the take-up
spool and the shorted DC motor fixed to the supply spool. The stepper motor coupled to
the index roller broke the equilibrium between the two motors and advanced the foil.
4.5.3 Pseudo-Stability
There was a problem: over a number of indexes, the take-up spool was slowly pulled out
of position, and the foil would climb the flange. The solution was to limit the range of the
spool's self-alignment mechanism. After the spool hit the stop, the intermittent motion of
-
60
---
,~--~
--- ~.~ -----
--
-
APPLIED EXACT CONSTRAINT WEB HANDLING
the foil advance would work the foil back down between the flanges for the cycle to start
again. The system worked, but these behaviors did not inspire confidence.
At the idler roller, the cause of the problem was revealed. While it rolled well and changed
the course of the foil as intended, the idler did not self-align. Rather, it had a tendency to
fall off to one side just as the take-up spool did, but less dramatically. When it moved to
one side, the edge of the foil would come into contact with structure of the mount
(Figure 4.13). The foil was finding its own edge constraint! Returning to an earlier anal-
Foil 04
m
Idler Roller
0
Foil
Rubbing
Mount
Counterweight
Universal
Joint
Figure 4.13 The foil finding its own edge constraint
ogy, the road had been made perfectly straight, but because it did not know where the
shoulder was, the car had a tendency to depart the road anyway. The web was doing the
equivalent of riding along against the guardrail, for it was only neutrally stable. This revelation prompted the design and installation of an edge constraint.
4.5.4 Edge Constraint
The edge constraint was designed with kinematic principles. The evolution of the design is
illustrated in Table 4.3. The constraint holds the foil between a pair of cam followers, one
-~
~1
First Bench Level Prototype
TABLE 4.3
1
11
O
1'
Fixed Roller
Blanding's Idealized Edge Constraint: Web may pivot about
the fixed roller. Edge constraint is shaped such that force
may only be applied normal to
the edge of the web (e.g. a circle). Nesting force (arrow) is
provide by unspecified means.
2
-
-
Nesting force cannot be supplied by a rigid structure. The
web will either be underconstrained (as shown here) or
overconstrained (pinched)
3
Nesting force is correctly
applied using a spring loaded
arm. The edge constraint and
the fixed roller now exactly
constrain the web. The spring
force must be chosen with care
or the web will buckle
4
The rigid circular sections have
been replaced with rotating cam
followers. In addition to greatly
reducing friction, the addition
of the cam followers prevents
particle generation
61
62
APPLIED EXACT CONSTRAINT WEB HANDLING
fixed, and one on a spring actuated arm (Figure 4.14). A third cam follower kept the foil in
Spring
opThird Cam
Follower
Compliant
Cam Follower
Fixed
Roller
Fixed Cam
Follower
Figure 4.14 The kinematic edge constraint. A cam follower on a spring arm nests the web against
the fixed cam follower to create an edge constraint. The third cam follower turned out to be superfluous.
the plane of the first two.
Some experimentation was required to find a spring that did not buckle the foil, but with
that done, the edge constraint was a complete success. The idler roller now self-aligned
properly, and more importantly, the foil no longer tended to climb the flange of the takeup spool. The hard stop restricting the take-up spool's range of motion was no longer necessary. The third cam follower mounted in the middle of the foil was not necessary either.
It seldom contacted the foil, and was eliminated from the final design. Given there was no
need to alter the path of the web as it passed through the constraint, the fixed roller was a
much more effective means of guiding the foil between the other two cam followers.
Figure 4.3 includes a schematic representation of the final version.
4.5.5 Limitations of the Concept
Despite the success of the BLP, the web handling problem had not been solved satisfactorally. The counterweights worked, but were unwieldy. And because the motors would
First Bench Level Prototype
63
have to be thermally insulated, the counterweights would only become heavier
(Figure 4.15). The weights also made the spools that much heftier and harder to load. And
Motor
Universal Joint
I
9
Counterweight
Figure 4.15 Spool assembly, note the size of the counterweight.
though the concept could likely be made to work, the space consumed and the constraints
imposed by the universal joint mounting system made fitting everything inside the environmental chamber quite challenging. Finally, although it was not a technical shortcoming, the whole machine tended to tilt and sag when foil was not loaded. Desire for a more
elegant solution prompted the second and third bench level prototypes.
64
APPLIED EXACT CONSTRAINT WEB HANDLING
4.6 Second Bench Level Prototype: Internal Universal Joints
The problems with the first bench level prototype would be solved if the universal joints
were moved to the center of the spools and the roller. The motors would no longer gimbal
and caster with the spools and the roller, thus greatly reducing the size of any counterweights. Shrinking the counterweights would greatly ease foil loading, and because the
self-alignment mechanism would be balanced when unloaded, the machine would no
longer sag. Finally, the space consumed by the long gimballing and castering axes could
be reclaimed.
Blanding did not recommend reducing the caster radius to zero, however: "The exact
value of the caster radius is not critical," but "the caster radius (the distance between the
caster axis and the roller axis) should be about the same order of magnitude as the length
of the roller (or the width of the web)." Furthermore, the roller would come into alignment
as a "decaying exponential function of the caster radius:"
x
y = y0 e r
(4.2)
As the caster radius, (re, Table 4.2), approaches zero, the distance the foil has traveled (x,
Figure 4.2) before alignment is complete (the equivalent of five time constants)
approaches zero (Figure 4.16). Though this result may mean that the roller could statically
self-align itself with the web, it was not clear. However, since the advantages of a system
thus constructed were so great, a second (and later a third) bench level prototype was
tested.
The cascaded axes of the universal joints were placed at the center of the idler roller and
spool cores (Figure 4.17). There is no equivalent to the caster radius for the gimballing
axis, so the second BLP was not different from the first in that regard. Material was
removed from the outside ends of the rollers and cores to make their centers of mass coincide with the axes of the universal joints. To accommodate inevitable imbalances, a
threaded rod was fixed to the outside end to position counterweights.
Third Bench Level Prototype: Internal Flexible Couplings
65
Distance Travelled (x) vs. Cross-track Position (y)
1-
rc =1
----515
0.9 -
45
0.8--
135
0.7
20.6 0.5
0.4
0.3 0.20.1
0
------ - - - -0
20
--
60
40
x (arbitrary consistent units)
80
100
Figure 4.16 A cross track position of zero indicates alignment is complete. Reducing the caster
radius to zero resulted in instantaneous alignment of the roller. Determining if this was a problem
was one goal of the second bench level prototype.
The BLP functioned, but required a disappointingly large amount of fine-tuning. Less misalignment could be accommodated than in the previous prototype, and care had to be
taken to assemble all the rollers in the same plane. Reducing the caster radius to zero did
not appear to cause any problems, for the rollers did self-align, but misalignments that
would have been accommodated by the first BLP were enough to ground the universal
joint on the inside of the roller. The small clearance between the universal joint and the
inside of the roller was likely at fault, but any disappointments with the second BLP were
swept away by the success of the third.
4.7 Third Bench Level Prototype: Internal Flexible Couplings
During the experimentation with the first BLP, it was realized that the universal joints
could be replaced with beam type flexible couplings. And the restoring force inherent to
66
APPLIED EXACT CONSTRAINT WEB HANDLING
Input Shaft
Universal Joint
Center
Counterweight Shaft
\\\\\71
Material removed for
roller balance
Figure 4.17 Spool core with internal universal joint providing gimballing and castering axes.
the flexible coupling held out the intriguing possibility of further simplifying the design
by the eliminating the counterweights. Compare the flexible coupling based mount in
Figure 4.18 with the original gimballing and castering mount in Figure 4.10. The concern
was the flexible coupling's two additional degrees of freedom.
As illustrated in Table 4.4, flexible couplings deform in three relevant ways. The gimbal
and caster axes are created by the coupling's accommodation of angular misalignment.
Depending on the reference frame, this represents rotation about one or two axes. The
other misalignments accommodated are shaft parallelism and axial misalignment. It was
unknown what effect the coupling's ability to accommodate shaft parallelism misalignments would be. Such a deformation could be thought of as a motion orthogonal to the two
dimensional plane inhabited by the web, i.e. the equivalent of simply translating the roller,
which is known to have no effect for small motions, but it was not certain. That the
amount of parallel misalignment accommodated by couplings is typically on the order of a
quarter millimeter was also a source of confidence. Nonetheless, determining the impact
on system performance of parallel misalignment would be a major goal of the BLP.
Third Bench Level Prototype: Internal Flexible Couplings
67
Foil Spool
Bearings
Motor
Flexible Coupling
(conventional use)
Flexible Coupling
(gimbal and caster)
Figure 4.18 Spool mount based on a flexible coupling. Functionally equivalent to the hardware in
Figure 4.10.
More was known about the impact of the coupling's accommodation of axial misalignment. Initially, it was tempting to think of the coupling's axial motion as a new way to
facilitate axial compliance, but some reflection revealed this to be incorrect. The coupling's axial motion is exactly like that of the fanciful mechanism in Figure 4.4. A zero
constraint roller can not be created in this fashion. Knowing that a motion will not perform
a service, is not the same as knowing it will not perform a disservice, but like parallel misalignment, it was thought that the displacement would be small. According to catalog data,
typical couplings can accommodate only a few tens of thousandths of an inch of axial misalignment without damage. It was believed that such small displacements would not
present a problem.
'~1
68
APPLIED EXACT CONSTRAINT WEB HANDLING
TABLE 4.4 Modes of Helical Coupling Misalignment.
Angular Misalignment: two orthogonal
angular misalignments
create gimballing and
castering axes (photograph reproduced from
the catalog of the Helical Products Company)
Parallel Misalignment:
equivalent to slightly
changing the position
of a roller on the frame.
Has no alignment effect
(photograph reproduced from the catalog
of the Helical Products
Company)
Axial Misalignment:
thought to be a form of
axial compliance, but
actually equivalent to
the mechanism in
Figure 4.4, and therefore does not create a
zero constraint roller
As shown in Figure 4.19, the center of stiffness of each flexible coupling was aligned with
the center of its roller. Material was removed from the outside end of each roller to make
the roller's center of mass coincident with the coupling's center of stiffness.
Third Bench Level Prototype: Internal Flexible Couplings
69
Flexible
Coupling
//Zz/
Weight
Removed
for Balance
ZZZZI
Drive Shaft
Figure 4.19 Section of a spool core based on flexible coupling
The flexible coupling BLP worked flawlessly (Figure 4.20). Practical concerns dictated
Figure 4.20 The flexible coupling bench level prototype without foil loaded.
the implementation of the film projector arrangement, but by this time, experience suggested arrangement two would also work, so because of its packing advantages over the
film projector arrangement, it was chosen for the final version.
70
APPLIED EXACT CONSTRAINT WEB HANDLING
Constructing a web plane diagram (Figure 4.21) of the second and third BLP's that doesn't
including a castered joint at the flexible couplings makes it clear that castering is taking
place. The diagram contains multiple incidences of the web changing course between roll-
Edge Constraint
0
Supply Spool
Idler Roller
Index Roller
Take-up Spool
Figure 4.21 Web Plane Diagram of BLPs two and three that does not include castering at the flexible couplings. Note the "tears" in the web where it is overconstrained.
ers, something that it cannot do. If castering were not occurring at the flexible couplings,
the web would be overconstrained, and the system would not work. Castering with a
caster axis of zero suggests that gimballing and castering may really be a mechanism to
make the axes of all the rollers parallel.
4.8 Final System
Due to the extensive prototyping that preceded it, the final system worked almost perfectly
from the beginning. The only significant problem encountered was not related to the web
handling kinematics and had not been tested for by any of the prototypes, but it did have a
web handling solution, so is included here.
It was not critical that the mechanism advance the web by precisely 0.025" each index, but
it was essential the foil move enough that the probes contact virgin material each index. To
Final System
71
detect'foil motion, a sensor was hung on the idler roller's shaft. During the initial system
shakedown, this failure mode was a significant problem. The cause was slippage between
the web and the index roller. The wrap angle around the index roller had mistakenly been
validated with quasi-static assumptions. The friction lock between the web and the index
roller could not transmit enough force to rapidly accelerate the large inertia of a full supply
spool. Increasing web tension was a solution, but was not attractive from a robustness
standpoint.
Instead, a pinch roller was designed to clamp the web to the index roller. Like reducing the
caster radius to zero, this was something explicitly discouraged by Blanding: "Such a
clamped connection completely constrains the web in two dimensions. Any additional
constraints would be an overconstraint." The testing machine's web was already fully constrained, so a clamped connection must be avoided, but Blanding offered some encouragement as well: "If the pressure roller were relatively short in length and centrally located
relative to the platen roller, the "pinned" model might be appropriate." The machine had
been designed using the pinned model. In Blanding's words: "a good conceptual model of
the connection between the web and roller is to imagine that a single thumbtack has been
used to secure the web to the roller surface at the approximate center of the contact area
between the web and roller." Naturally, "the thumbtack would have to be repeatedly
moved as the web advances." This is not as difficult as might be thought.
The torque transmission properties of a clamped connection were combined with the kinematic properties of a pinned connection by pinching the middle of the foil between a
spherical roller bearing on a spring arm and the fixed index roller (Figure 4.22). A spherical ball bearing could have sufficed, but thermal concerns about cage material dictated
that a spherical roller bearing be used instead. The self aligning properties of the bearing
facilitate alignment with the index roller's axis of rotation and pivoting with the web prior
to equilibrium (Figure 4.2), thereby preventing web overconstraint. A picture of the final
machine can be seen in Figure 4.24.
72
APPLIED EXACT CONSTRAINT WEB HANDLING
Force Adjustment
Screw
Sp herical
Rc ller Bearing
0
0
o0
eb
n
Compression
Spring
Fi xed Index
Ro Hler
Figure 4.22 The spring mounted spherical roller bearing and the index roller
After debugging was completed and the pinch roller had been installed, a speed run was
conducted to confirm that the machine's various novel elements could be used for continuously (in addition to discretely) moving webs. The web was run at speeds up to 19 cm/
sec. Testing was not done at higher speeds because the DC motor on the take-up spool
could not keep up with the web's rate of advance. The only anomaly encountered was a
slow precession of the spring loaded pinch roller. As the web ran between it and the index
roller, the pinch roller would periodically ride up on its edges. The rate of precession was
proportional to web speed, so though it has never been observed, the behavior may be
occurring during indexed operation. More likely, precession is prevented at low speeds by
small scale sideslip between the web and pinch roller. Crowning the outer surface of the
pinch roller might prevent precession, but could also result in underconstraint, i.e. what
fixes the axis of rotation of a spherical bearing with a crowned outer race?
ik
Final System
Tension .
Adjust Screw
Foot
Spherical Roller
Bearing
Spring
Edge Constraint
Web
Index Roller
Figure 4.23 A picture of the pinch roller assembly
Pinch
Roller
Idler
Roller
Index
Roller
Edge
Constraint
Take-Up
Spool
0
SSupply
Spool
Figure 4.24 The final machine. The ribbon cables are used to test the contactors.
73
74
APPLIED EXACT CONSTRAINT WEB HANDLING
To test the system's sensitivity to the coupling's accommodation of parallel and axial misalignment, the machine was designed to fit two different kinds of couplings. Helical Products' HCR 100-12-12 could be used as well as a custom coupling designed for increased
axial and parallel stiffness. The lower stiffness of the standard HCR coupling made for
more shaking of the spools, but the machine functioned with both kinds of coupling
installed, leading to the conclusion that the parasitic axial and parallel deflections are of
little consequence.
4.9 Conclusions
Although the idler is underconstrained, the system works very well, so web tension may
have some ability to contain underconstraint by favoring the shortest path between the
sources of tension. If the first and second BLPs had not also functioned, it would be tempting to attribute some importance to the restoring force of the flexible couplings, but taking
all the data into account, this seems unlikely.
The use of beam type flexible couplings and universal joints at zero caster radius to create
gimballing and castering axes is believed to be a major innovation. The fabrication and
mounting of spools whose diameter is on the order of the width of the web being supported has been greatly simplified. Specialized axially compliant rollers are no longer necessary. The necessary properties can be created using readily available machine elements
and parts simple enough to be machined from whole cloth. The use of a spherical bearing
as a pinch roller is likely just as important. Because the web can be pinched without overconstraint, systems that would otherwise need to be highly tensioned may now be run
more forgivingly. Finally, it has been demonstrated that the principals of kinematic web
handling can be used to design a working machine.
Chapter 5
PLUNGING MODULE
5.1 Module Requirements
The design of the plunging module was driven by the number of pins it was required to
hold, fifty, and the minimum pitch of those pins, 0.010". The machine tests fifty pins at a
time as that was a large enough number to produce meaningful data quickly, and not so
large as to require a prohibitively large amount of space inside the environmental chamber. Coincidentally, it is within the range of the number of pins that a typical contactor
might contain. A pitch of 0.010" was chosen because it is the largest pitch for which pins
are commonly available. Smaller pins can always be mounted at a pitch larger than their
minimum.
The stroke of the plunge module is approximately equal to the longest stroke available for
the largest size spring pin, 0.5 in. The data produced on the machine will be used to design
contactor systems for handlers, so the machine was designed to equal or better the planarity provided by such systems, 0.001 inch per inch. As spring probes are specifically
designed for poor planarity applications, it was not expected that poor tester planarity
would substantially affect the outcome. Finally, it was also necessary that the plunging
module fit inside the environmental chamber along with the web handling module and that
it operate over a temperature range of -50' to 150* C.
75
76
PLUNGING MODULE
5.2 Spring Pin Arrangement
To optimize foil use while preserving the simplicity of the indexing system, the pins were
mounted 0.025" apart in the direction normal to the motion of the foil (the crosstrack
direction). Since the foil is advanced in 0.025" increments, doing so allots each spring pin
its own 0.025" by 0.025" square of virgin material for each plunge. To reconcile the crosstrack spacing of 0.025" with the minimum pitch requirement of 0.10," the pins were
mounted on a diagonal (Figure 5.1). This diagonal determines the width of the foil, 1.5"
(0.025" x 50 + 2 x 0.125" margins).
50X 0.097
NON -CUMULATIVE
50X 0.025
NON-CUMULATIVE
DETAIL
Crosstrack
Direction
Foil Index
Direction
A
(0.100)
Figure 5.1
simplicity
Spring Pin arrangement to optimize foil utilization while maintaining index system
5.3 Bearings and Actuation
The stroke length of 0.5 inch and the requirement that the system operate over a wide temperature range made flexures an obvious bearing option. Linear rails like those from
STAR Linear or Thompson are rated to only 100' C, and provide more travel than necessary. A linear bearing could have been built from components such as the Graphalloy
bearings used elsewhere in the machine, but there was no need. As part of a recently can-
Bearings and Actuation
77
celled project, a set of flexures optimized for linear travel over a 0.5 inch stroke had been
designed and fabricated (Figure 5.2). The flexures had even been designed for the same
temperature range. As seen in Figure 5.3, with one end of the flexure attached to the contactor assembly and one end fixed to the machine frame, the contactor is plunged by a
pneumatic piston.
Frame Mounting
Holes
Contactor
Mounting Holes
Direction of
Flexure Motion
9.000
Fixed End
Figure 5.2 Flexure designed for linear motion for 1/2 inch stroke over a broad temperature range
Figure 5.3 Contactor sub-assembly with flexures and piston attached
78
PLUNGING MODULE
A pneumatic piston was selected for actuation. A single kind of piston could not serve for
the full temperature range, but the modular nature of the actuator allows for rapid changeout between high and low temperature models. A system based on an electric actuator
could have been designed and would have had certain advantages, i.e. explicit control of
plunge rate and software configured plunge depth, but no off the shelf alternatives were
available. As a compromise between the two, it was decided to allocate space inside the
environmental chamber and controller resources for a future upgrade to electric actuation.
The mounts for the pneumatic piston were fabricated as attachments to the frame and the
contactor assembly to facilitate the same upgrade.
The stop inside a pneumatic piston is not a reference surface, so hard stops were mounted
on the contactor to halt the plunge at the appropriate distance from the plate supporting the
foil (Figure 5.4). Because each kind of spring pin has a different stroke and uncompressed
0
Foil Support
Plate
o
0
Stop
0
Figure 5.4 The plunge sub-system attached to the machine frame
Preventing Foil Motion
79
Spring Pins
Stop
Plunge Plate
Figure 5.5 A picture of the contactor assembly showing the stops and the spring pins
height, different stops are required for each type of pin to be tested. A set of stops sized to
the un-plunged height of the contactor was used to align the flexure displacement axis to
the plunge plate supporting the foil. To do an alignment, the plunge module is assembled
and loosely attached to the machine with screws. While holding the contactor hard against
the plunge plate supporting the foil, the screws fixing the plunge module to the frame are
tightened, aligning the plunge module to the frame. After an alignment has been performed, a two dimensional pin and groove kinematic coupling is employed to repeatibly
fixture the contactor plate to the plunge module.
5.4 Preventing Foil Motion
During real testing, the DUT does not move. It is unknown, what effect dragging a probe
across a contact pad would have on both the pad and the probe, but it is assumed it would
not be good. Comparisons to fingernails being dragged across a chalk board are appropriate. To preserve test integrity, such a condition must be prevented in the test machine. The
software in the controller goes a long way in this regard, but for redundancy, a pair of
"feet" were added on either side of the contactor. Prior to each contactor plunge, the pneu-
80
PLUNGING MODULE
Flexure
..
0 0
Pin
Pin
00
0
0
0
C3
0
Groove
)
00
OA
0
0
0
0
0
0
Flat
0
Figure 5.6 Top view of plunging module (with the actuating piston removed) showing the two
dimensional kinematic coupling used to align the contactor plate with the plunging module
matic pistons the feet are mounted on are driven down, trapping the foil between the feet
and the plunge plate. After checking a sensor to confirm the feet are extended, the controller cycles the contactor. After the contactor has been withdrawn, the feet are raised, the
foil is indexed, and the process is repeated.
Preventing Foil Motion
Piston
Plunge
Plate
Foot
-09
.o.
000
0
Figure
1
5.7 Front View of phunge sub-system - note the feet
r
/
-
4
81
82
PLUNGING MODULE
Chapter 6
CURRENT SOURCING AND IN-SITU
RESISTANCE TESTING
6.1 Current Sourcing
The tester was designed with the assumption that Cres could be greatly influenced by the
amount of current sourced through each probe (see Chapter 1). In anticipation of this predicted coupling, a contractor was commissioned to build an array of current sources to
independently drive 200 mA through each probe. If the voltage across the whole probe
array had been regulated instead, more current would have flowed through the lower resistance probes. For example, if 36 pins in a 48 pin contactor have a resistance of 2 Q and the
other 12 pins have a resistance of 0.25 0, eight times as much current will flow through
the lower resistance pins. Resistance differences of that order are reasonable, both because
probes can continue to function with resistances that high and because it might be desirable to simultaneously run different cleaning protocols on the same contactor. Since current affects change in Cres, sourcing current in parallel would have created a feedback loop
that would work to make the resistance of each probe equal to that of every other probe.
6.2 In-Situ Resistance Testing
Realistically reproducing spring probe operating conditions serves no purpose if the condition of the probes cannot be monitored. To that end, the tester is equipped with a CIRRIS tester for in-situ four-wire resistance measurement of each of the fifty spring probes.
The two connections to each probe's receptacle are accomplished by soldering the recepta83
84
CURRENT SOURCING AND IN-SITU RESISTANCE TESTING
cles to a circuit board, but the other two connections are somewhat more circuitous. The
return path for the current used in the four-wire test and the second voltage probe connection are both made via the tester frame (Figure 6.1). Naturally, the resistance of this path
was a concern.
Individual
Current
Regulator
Four Wire
Resistance
Tester
L_ uVoltage
Probe &
Receptacle
Probes
Test
Current
Source
and
Return
Graphalloy
Bushings
Foil
Figure 6.1 Resistance test schematic. Note that conduction path includes the frame and bushings.
6.2.1 Worst Case
The worst case resistance for making these connections through the tester frame is if the
current all travels through only one of the Graphalloy bushing sets supporting the web
handling sub-system. It would not have been advisable to transmit current through a ball
(or other rolling element) bearing because of the tendency to arc. But GraphalloyTM (an
alloy of graphite and various metals) bushings had already been selected for their superior
performance at temperature extremes, and bushings do not arc. Furthermore, another
Graphalloy application is as a motor brush material. Low resistance materials are favored
for brushes because any resistance in the brush leads to a direct decrease in motor perfor-
--
ld&
-
-_
r-I..
__ -
7n-
1-
-- ____ I-
In-Situ Resistance Testing
85
mance. To test the Graphalloy's resistance under working conditions, the bench level prototype seen in cross section in Figure 6.3 and pictured in Figure 6.2 was built.
Figure 6.2 Picture of Graphalloy resistance test bench level prototype. Note the heavy gage wire
for current sourcing and the smaller gage wire for four wire resistance measurement.
6.2.2 BLP Results
The resistance of BLP was measured (four wire method) at ambient conditions, at 1500 C,
and after 30 amps had been passed through it. The BLP revealed (and later use of the tester
confirmed) that the line contact inside the bushing had a negligibly small resistance of
only a few milliohms. The resistance rose with temperature, but never exceeded our selfimposed 25 milliohm limit, and once the temperature stabilized, it fell back to-the ambient
level. The resistance increase may have been caused by thermal resistance, but it is not
certain. Because the limit was never exceeded and because a thermal soak was necessary
to prepare the foil, the resistance variation was acceptable.
--
- -
-
86
CURRENT SOURCING AND IN-SITU RESISTANCE TESTING
Test Shaft
Power Supply
Digital
Multimeter
Test Block
Graphalloy Bushing
Figure 6.3 Cross-section of bench level prototype for testing Graphalloy resistance. The BLP was
connected to a power supply to simulate the effects of the current source array driving current
through the contactor. The digital multimeter tested the resistance of the assembly using the fourwire method.
Chapter 7
CONTROLLER SPECIFICATION
The following information was provided to the outside contractor charged with constructing the testing machine control system.
7.1 System Components
Function
Input/Output
Interface
Current
Sourcing Module (CSM)
Sources a regulated
current through the
contactor
Trigger
TTL Active
High
CIRRIS Tester
Measures Contactor
Trigger, End of
Consult CIR-
Cres
Test
RIS Manual
Take-Up
Motor
Stepper Motor
Tensions Foil
DC current
Indexes Foil
Current Set by
Operator
Pulse to Step
Pneumatic
Sub-System
Plunging Module and
Actuator Cooling
See Pneumatic
Schematic
See Pneumatic
ThermocouTemoo
pies
Measure temperatures
of Environmental
Chamber and Actuator
K-type
Rotation Sensor
Foil Sensor
Expansion
Servo
Detect Idler Roller
Rotation
Detect end of foil
Resources on controller for future servo
5-24 VDC
Schematic
87
88
CONTROLLER SPECIFICATION
7.2 System Schematic
The schematic in Figure 7.1 was also furnished to the controls contractor. The contractor
was responsible for furnishing the components inside the dashed box. The contractor
selected to use fiber optic sensors for the rotation and end of foil sensors. The end of foil
sensor was mounted in the stainless steel plate supporting the foil during plunging. The
rotation sensor was mounted as described in Appendix B.
--------
I-- ---otaion
Idler Roller
nter
Stepper
Take-Upore
End of Foil
Sensor
Pneumatic
mContror
Cur rent
Controlled
Power
Take-Up
Motor
Stepper
Mootor
Drive
Expnvionental
S
.Sub-System
Environmental
Chamber
Thermocouple
Supply
Actuator
Thermocouple
Current
Sourcing
Module
L -7'
CIRRIS
Tester
Contactor
5d
10
Lead
Frame Foil
Figure 7.1
dashed box.
Roller
_
Graphalloy
Busings
5
Machine
Frame
System Schematic, the contractor was responsible for the components inside the
Pneumatic Schematic
7.3 Pneumatic Schematic
I
Left Foot
Conditionin gI
L --
-
-
--
-
--
-
-
-
-
-
--
-
--
-i
-
Prk
-
re Sw td
Right Foot
-I
E1-t
i
Contactor Plunger
r
r1
* L~]
FT
<TM/
* L~J
C
rni
DC Motor
HotEL
I-.
Stepper Motor
Hot Exh
Figure 7.2
Expansion Servo
System Pneumatic Schematic. Valve assembly, regulator, etc. supplied by contractor.
Actuators already installed on machine
7.4 Operator Interface
7.4.1 Actions
- Manual Foil Advance
* Manual Plunge
- Manual Cooling Air on/off
- Test Start
0 Test Pause
89
90
CONTROLLER SPECIFICATION
7.4.2 Inputs
TABLE 7.1 Inputs
Soak Time
Source Time
Cycle Time
Temperature Set Point
Description
VTypical
Unit
Delay before first stepper
index operation. Foil must
be thermally soaked
30
minutes
3
seconds
1
second
Time current is sourced
through contactor by CSM
Total index to index time,
not including Cres test by
CIRRIS
Environmental Chamber
Set Point, alarm if out of
range
-50,20,150
C
Temperature Window
Allowable Deviation from
set point
1,2,5,10
0C
Cycles in Test
Number of cycles to run
before test completion
10,000
cycles
C res Testing Interval
Number of cycles between
Cres tests by CIRRIS
Send operator E-mail when
errors encountered
10
cycles
Operator E-mail
Address
string
N/A
7.5 Sequences
7.5.1 Startup
1. Operator enters test parameters
2. Operator initiates test
3. Turn on Stepper
4. Turn on Take-up Motor
5. Start Cooling Air (70 C
6. Open Cooling Valve
7. Wait for Soak Time
Temperature Set Point
300 C)
Data Logging and Operator Alert
91
8. Begin Test Sequence
7.5.2 Test Sequence
1. Sensors
Check Foil Sensor
Compare Thermocouple to Temperature Set Point & Temperature Window
2. Index Foil
Check pressure switch
Pulse stepper motor
Check for rotation
3. Lower Feet
Actuate Feet Piston Valve
Check pressure switch
4. Plunge Contactor
Check pressure switch
Actuate Plunge Piston Valve
5. Source Current
Trigger Switching Array
Trigger Current Sourcing Module
Wait Source Time
Release Current Sourcing Module
6. Test Resistance
Check cycle count (multiple of Cres Testing Interval?)
Trigger CIRRIS
Wait for End of Test signal
7. Raise Contactor
Actuate Plunge Piston Valve
8. Raise Feet
Actuate Feet Piston Valve
Check Pressure Switch
9. End Cycle
Wait out the rest of cycle time
7.6 Data Logging and Operator Alert
When the controller detects an error, it should send E-mail to the address supplied by the
operator stating the nature of the error and the time it occurred. This will facilitate unattended operation of the machine.
92
CONTROLLER SPECIFICATION
Each time the contact resistance of the fifty sites in the contactor is tested, the controller
should record cycle number, the chamber temperature, actuator temperature, and time. At
the head of the file all the test variables should be recorded.
Chapter 8
TEST RESULTS
More than one hundred thousand contactor hits have been made by this point. The witness
marks left on the 90/10 Sn/Pb clad Alloy 42 are the subject of the photos in Figure 8.1 and
Figure 8.2.
Figure 8.1 Wide field view of the witness marks left by the array of spring pins on the 90/10 Sn/
Pb clad Alloy 42 foil (37.5 X magnification)
93
-~
94
-~
TEST RESULTS
Figure 8.2 Tight field view of the witness marks (203 X magnification)
An electrical interaction between the CIRRIS tester and the rest of the system has only just
been resolved, so contact resistance data is now becoming available. To resolve the problem, the machine is electrically disconnected from everything except the CIRRIS during
resistance testing. There is not yet enough data to support conclusive findings, but some
preliminary observations can be made.
To create the first plot in Figure 8.3, the current sourcing array was set to drive the five ten
pin zones of the contactor at 0, 100, 200, 300, and 400 mA respectively. The controller
was programmed to measure resistance every 10 hits. No cleaning was done throughout
the experiment. The data from each set of ten pins was averaged into one curve, and a 149
point moving average was used to smooth the curve. For the second plot, the standard
deviation was computed for each group of ten pins at each measurement cycle. The third
plot represents the results of fitting a linear polynomial to the data from each current
group.
95
Current Groups
0.4-
0 00
00.1
0
50
0
200
300
4000
5000
sooo
2000
300
40
500
60
-
00mA
40-
---
100 mA
--
200 mA
300 mA
400 mA
> 30" 2010CO
A_
0
1000
2000
3000
4000
5000
6000
1000
2000
3000
4000
5000
6000
0.4E
SC.30.203____-
0.1
0
Hit (lOX)
Figure 8.3 A plot of contact resistance vs. number of hits for several different current settings
As expected, the resistance of the pins increases with use. The increase can be most
clearly seen in the plot the of linear regression lines. The trend is slow, but distinctly
upward. Some of the more abrupt peaks in the resistance curves are probably the result of
single pin's poor contact. The spikes in the standard deviation plot support this conjecture,
but more experimentation will be necessary before a specific cause can be assigned. A
troubling aspect of the plot is that the resistance curves tend to move together. At approximately 11,000 hits, at 45,000 hits, and again at 57,000 hits, the contact resistances from
several different current groups all increase. These abrupt change do not coincide with a
standard deviation spike. It is unknown what mechanism drives this system wide phenomenon.
96
TEST RESULTS
As hinted at in Figure 8.3 and borne out in Figure 8.4, the data does not support a link
between increased current and increased resistance. To construct the plot in Figure 8.4, the
mean of the resistance measurements for each pin over the whole data series was plotted
against the current sourced through the pin. Each square is the average of those averages
for a particular current group. Surprisingly, the series with the two highest resistances are
the 400 mA series and the 100 mA series. There are several possible explanations. The
effect of current on resistance may manifest itself very slowly, and 70k hits is simply not
enough data to break out of the noise. Alternatively, the effect of increasing current may
be negligible at the levels being studied. Further experimentation is necessary.
400
0 O0M
0
0 00 0
350 F
0
:300
E
0)250
200
-
150
-
0
c
8 100 -
0
0 Ca2s co
50 F
01
"
0.2
0.3
0.4
0.5
0.6
0.7
0.8
mean resistance over run (ohms)
Figure 8.4 The mean of each pin's resistance measurements is plotted against the amount of current sourced through the pin. The squares represent the average of those averages for each current
group.
The nature of the troubling outlying points in Figure 8.4 can be seen in Figure 8.5. There,
the data for each of the pins in the 100 mA group has been plotted. The only processing
was the same moving average smoothing used in the previous plots. For unknown reasons,
97
the contact resistance of pin 19 is consistently much greater than the resistance of its peers.
An examination of the pin will be made, but it was expected that pin degradation would be
a gaussian process, so pin 19 may be a completely legitimate outlier.
1.4
-
1.2 -
-
1
0.8-
-
o
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
11
12
13
14
15
16
17
18
19
20
0.6-
0.40.2
0
1000
2000
3000
4000
5000
6000
Figure 8.5 Plots of the resistance data for all ten pins in the 100 mA group. For unknown reasons,
the contact resistance of pin 19 is consistently higher than that of the other pins.
98
TEST RESULTS
Chapter 9
CONCLUSIONS
9.1 Future Improvements
Weight. For high and low temperature testing, the tester must be placed inside an environmental chamber. It is too confined inside the environmental chamber to service the tester.
The machine must therefore be removed from the chamber for service. It should be light
enough that one person can place it inside the environmental chamber. This is not presently the case.
Size. The tester was sized and packaged for the environmental chamber within which it
was to be used. Such chambers come in a variety of different sizes and configurations. If
additional testers are to be built, a survey should first be made of the chambers available
on the market to ensure the tester is being designed to fit within as many of them as is reasonable.
Non-Rotating Pistons. The feet that hold the foil during the contactor plunge cycle are
attached to normal (rotating) pistons. Rotation is prevented in that it is not encouraged and
by a not particularly robust guidance system. Non-rotating pistons are available in the
appropriate size, but the lead time is considerable. To improve system robustness, they
should be ordered and installed.
99
100
CONCLUSIONS
Material changes. Many parts of the machine are made from type 304 stainless steel.
This was done to facilitate ease of re-work, because stainless steel resists corrosion
natively, while aluminum parts must be re-anodized after re-work. Many parts could be
fabricated from aluminum without impacting performance, considerably reducing cost
and weight.
Spool Loading. As the spool cores are now designed, it is more difficult than necessary to
load and unload the foil spools. The cores should be re-designed so that the spools and
cores can be detached from their flexible couplings without first removing the spool. A
shoulder should also be added to the spools outer surface to provide a reference edge for
mounting the spools.
Slip Clutch. For debugging purposes, the slip clutch was designed to be adjustable. An
optimum torque setting should be determined, and future incarnations of the slip clutch
should not be adjustable.
Refinement of the Edge Constraint. There exists a failure mode where the foil will slip
beneath the cam followers of the edge constraint. The problem can almost certainly be
fixed by lowering the cam followers. During the design, it was anticipated that the foil
slipping over the cam followers would be more of a problem. The edge constraint was
therefore designed such that the foil struck nearer the bottom than the top of the cam followers. If centering the foil on the edge constraint does not resolve the problem, the cylindrical profile of the cam followers could be altered to a shape contrived to drive the foil
towards the center.
Dirty foil. As delivered by the cladding house, the foil is not clean. Dirt on the foil can
cause spurious contact resistance measurements. Since contacting is nominally done in a
clean environment, the dirt also makes for unrepresentative testing. A cleaning module
should be incorporated on the machine. It could be as simple as a jet of air or a set of
brushes. Or, preferably, the foil manufacturer should be instructed to clean the foil prior to
shipment.
Additional Applications
101
More Contactors. The contactor plunging mechanism and the configuration of the test
head are too refined for testing spring pins. If other types of contactors are to be tested,
they will need to be redesigned. For the time being, only spring pin testing is possible.
9.2 Additional Applications
As mentioned in the title of this thesis, the tester was designed "with Specific Application
to Semiconductor Testing." Other uses are quite imaginable. Generally, tribological testing requiring virgin material is done on a rotating disk employing a record player like
mechanism. As mentioned in Chapter 3, such systems have a rather small amount of surface area. Using a machine more similar to the tester described here would make such testing much easier
9.3 Conclusions
The most technologically interesting aspect of the machine (as opposed to the data it will
generate) is the manner in which the web handling is done. The use of beam type flexible
couplings at zero caster radius to create gimaballing and castering axes is believed to be a
major innovation. The fabrication and mounting of spools whose diameter is on the order
of the width of the web being supported has been greatly simplified. Specialized axially
compliant rollers are no longer necessary. The necessary properties can be created using
readily available machine elements and parts simple enough to be machined from whole
cloth. The use of a spherical bearing as a pinch roller is likely just as important. Because
the web can be pinched without overconstraint, systems that would otherwise need to be
highly tensioned may now be run more forgivingly. Finally, it has been demonstrated that
the principals of kinematic web handling can be used to design a working machine.
102
CONCLUSIONS
REFERENCES
[Bauccio, 1993] Bauccio, Michael and American Society for Metals eds. ASM Metals
Reference Book. 3rd. ed. Materials Park, Ohio: ASM International, 1993.
[Blanding, 1999] Blanding, Douglas K. Exact Constraint: Machine Design Using Kinematic Principles. New York, New York, 1999
[Buch, 1999] Buch, Alfred. Pure Metals Properties: A Scientific-Technical Handbook.
Materials Park, Ohio: ASM International, 1999
[HelicalProducts Company, Inc., 1992] Helical Products Company, Inc., The Helical
Coupling Catalog. Santa Maria, CA: Privately printed, 1992.
[Mills, 1995] Mills, Anthony F., Basic Heat and Mass Transfer. Chicago, IL: Irwin, 1995.
[QA Technology Compnay, Inc., 2000] QA Technology Company, Inc. Product Catalog.
Hampton, NH: Privately printed, 2000.
[Shackelford, 2000] Shackelford, James F., and William Alexander eds. CRC Materials
Science and Engineering Handbook. 3rd. ed. Boca Raton, FL: CRC Press, 2000.
[Shigley, 1989] Shigley, Joseph E., and Charles R. Mischke. Mechanical Engineering
Design. 5th. ed. New York, NY: McGraw-Hill Inc., 1989.
103
104
REFERENCES
Appendix A
THERMAL MODEL RESULTS
Vertical Wall
Ambient Temp (K)
0.12
Length (m)
Air Temperature
Prandtl
223K
-50 0C
248K
-25*C
273K
00C
298K
25 0 C
323K
500C
0.722
0.714
0.707
0.701
0.695
0.690
0.686
0.682
0.680
348K
750C
373K
1000C
398K
423K
125*C
150 0C
293
k
kinematic Delta T
Rayleigh
MU (MA 2/s)
(W/mK)
(K)
Psi
Nusselt (W/mA2K)
35K 2.1 E-02 8.4E+12 Invalid 0.350 9.45E+02
Required
Length
2.380 0.578 m
8.663E-06
1.059E-05
22.5K 2.3E-02 3.0E+06 Valid
0.348 8.94E+01
17.016
1.264E-05
10K 2.5E-02 2.7E+06 Valid
0.346 8.89E+01
18.407 7.470 m
1.482E-05
2.5K 2.7E-02 4.5E+05 Valid
0.345 8.13E+01
18.190 7.559 m
1.712E-05
15K 2.9E-02 1.9E+06 Valid
27.5K 3.1 E-02 2.4E+06 Valid
0.344 8.70E+01
20.899 6.579 m
0.343 8.82E+01
22.671 6.065 m
40K 3.3E-02 2.6E+06 Valid
52.5K 3.5E-02 2.5E+06 Valid
65K 3.7E-02 2.4E+05 Valid
0.342 8.85E+01
24.212
0.341 8.83E+01
0.340 7.94E+01
25.644 5.362 m
24.361 5.644 m
1.955E-05
2.210E-05
2.478E-05
2.758E-05
8.081 m
5.679 m
Top Surface (when working above ambient)
0.0381
Length (m)
Air Temperature
223K
-50*C
0
248K
-25 C
273K
298K
0*C
250C
50*C
750C
1000C
125 0C
150*C
323K
348K
373K
398K
423K
Ambient Temp (K)
Prandtl kinematic Delta T
MU (MA 2/s)
(K)
0.722
0.714
0.707
0.701
0.695
0.690
0.686
8.663E-06
1.059E-05
1.264E-05
0.682
2.478E-05
2.758E-05
0.680
1.482E-05
1.712E-05
1.955E-05
2.210E-05
k
(W/mK)
70K 2.1 E-02
45K 2.3E-02
20K 2.5E-02
5K 2.7E-02
30K 2.9E-02
55K 3.1 E-02
80K 3.3E-02
105K 3.5E-02
130K 3.7E-02
293
Rayleigh
Nusselt
Required
h
(W/mA 2K) Length
1.6E+06 Valid
1.43E+01
7.847
6.3E+05 Valid
1.8E+05 Valid
2.9E+04 Invalid
1.18E+01
7.096 19.4 cm
9.18E+00
6.40E+00
8.50E+00
8.95E+00
9.05E+00
9.OOE+00
8.88E+00
5.985
4.511
6.431
7.244
7.797
8.228
8.587
1.2E+05 Valid
1.5E+05 Valid
1.6E+05 Valid
1.6E+05 Valid
1.5E+05 Valid
17.5 cm
23.0
30.5
21.4
19.0
17.6
16.7
16.0
cm
cm
cm
cm
cm
cm
cm
105
106
APPENDIX A
0.0381
Length
Air Temperature
223K
-50*C
248K
-25 0 C
273K
O'C
298K
323K
348K
250C
50*C
373K
1OOeC
398K
423K
1250C
75 0 C
150 0C
Prandtl
0.722
0.714
0.707
0.701
0.695
0.690
0.686
0.682
0.680
Bottom Surface (when working above ambient)
Ambient Temp (K)
293
kinematic Delta T
MU (MA 2/s)
(K)
8.663E-06
1.059E-05
1.264E-05
1.482E-05
1.712E-05
1.955E-05
2.21 OE-05
2.478E-05
2.758E-05
k
(W/mK)
(h
Nusselt
Nset(W/MA
Rayleigh
70K 2.1 E-02 1.6E+06 Valid
45K 2.3E-02 6.3E+05 Valid
20K 2.5E-02 1.8E+05 Valid
1.5E+01
1.1E+01
10.568 13.0 cm
9.109 15.1 cm
7.209 19.1 cm
4.966 27.7 cm
Valid
7.OE+00
1.OE+01
3.1 E-02 1.5E+05 Valid
1.1E+01
8.670 15.9 cm
3.3E-02 1.6E+05 Valid
1.1E+01
9.357
3.5E-02 1.6E+05
3.7E-02 1.5E+05
1.1E+01
1.1E+01
9.861 13.9 cm
5K 2.7E-02 2.9E+04 Invalid
30K
55K
80K
105K
130K
1.9E+01
Required
2K) Length
2.9E-02 1.2E+05
Valid
Valid
7.599
10.258
18.1 cm
14.7 cm
13.4 cm
Appendix B
WEB HANDLING DETAILS
9.4 Index Roller Wrap Angle
Torque is transmitted to the foil by the capstan effect, and as can be seen from the equation, the greater the wrap angle (0), the greater the tension difference (T, - T2) across
the roller can be:
T2
(9.1)
9.5 Minimum Roller Size
The index and idler rollers cannot be size arbitrarily. Too big, and they won't fit inside the
oven, too small, and the foil will be plastically deformed. Besides making handling the foil
more challenging, such a deformation would invalidate the experimental results. Combining the moment-curvature relation,
1
M
- =
,
(9.2)
and relation of stress to moment in pure bending,
ca
=
My
(9.3)
yields:
107
108
APPENDIX B
_Ey
2p'
(94)
With Equation 9.4, it was found that using rollers with a radius of 1.5" would result in
stress equal to only 10% of the yield stress of DUT material.
9.6 Index Roller Size
As mentioned earlier, a stepper motor is used to drive the index roller. A stepper motor
was chosen because the inherently discreet nature of its motion was perfectly suited to the
application. Some species of DC motor could have been used as a servo instead, but that
would have considerably complicated the control electronics. Running the stepper in half
step mode (400 steps per revolution), a roller with a diameter of 3.183 inches creates index
steps of the required 0.025 inches. This result fit in nicely with the previous calculation to
find the minimum roller size.
9.7 Slip Clutch
To maintain tension in the foil, a slip clutch was attached to the shaft of the supply spool.
The temperature was too great to use a magnetic particle brake, and rotary pneumatic actuators were not capable of continuous rotation. The disk based clutch (Figure 9.1) was
designed based on both the constant pressure and constant wear assumptions. To facilitate
debugging and robustness, the clutch was designed to be adjustable up to twice the anticipated slip torque. To ensure that the necessary temperature extremes could be accommodated, Graphalloy thrust bearings were used for the disks and a stainless steel spring
supplied the compressive force.
Uniform Wear Assumption [Shigley, 646]:
I-F = Fp(D + d),
4
9.5)
109
APPENDIX B
Constant Pressure Assumption [Shigley, 646]:
Fpt(D3 - d)
(9.6)
3(D' - d)
where D is the outer diameter of the disk, d is the inner diameter, p is the coefficient of
friction, and F is the spring force.
THREADED HOLE FOR
FORCE ADJUST
BOSS TO RETAIN SPRING
ASSOCIATED SPRING RAYMOND
(C[225-162-2000S)
GRAPHALL
OY THUT
,,,
,,
O
FRAME PLATE
0
GRAPHALLO
YBUSHINGS-,
0
0.125
,,STIFF
FLEX IBLE
COUPL
X
0.375
DOWELS
ING
STIFF SPOOL ROLLER
Figure 9.1 A cross section of the slip clutch
9.8 Idler Rotation Disk
Designed for use with a fiber-optic sensor, the idler disk resembles a gear. As the indentations around the disk's periphery pass beneath the sensor, the edges are detected. If too
many index cycles pass without the sensor detecting an edge, the controller logs an error
that the foil is not moving, and the test is paused.
110
APPENDIX B
0
Figure 9.2 The idler rotation disk mounted to the shaft of the idler roller. The fiber optic sensor is
mounted in the small hole in the bracket to the right of the disk.
Appendix C
PART AND ASSEMBLY DRAWINGS
The following pages are the part and assembly drawings for the machine.
111
112
APPENDIX C
4
3
THREADED HOLE FOR
FORCE ADJUST
,----BOSS TO RETAIN SPRING
ASSOCIATED SPRING RAYMOND
(C1225-162-2000S)
B
GRAPHALLOY THRUST
WASHERS
4-
FRAME PLATE
GRAPHALLOY BUSH INGS
/
/
,,
/
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0.125 X 0.375 DOWELS
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FLLAILE COUPLING
/
SECT ION
A-A
/
//
~'/
1/
II
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MACH. HOLE TOL.
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.0035 TO .185
STIFF SPOOL ROLLER.1875 TO .246
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x
+.003
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MossachuseIfs Instiufe of Technology
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AL 6061-T651
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2. ALL DIMENSIONS APPLY AFT
3. RENOVE ALL BRRS & SHARP EDGES.
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0.J 375 10-32
UNF-2B CLEARANCE
THRU
0.10
A
0.60
0.66
B
1.75
2X 0.40
0 0.871 +0.000
-0.005
0.955+0.005
-0.000
0.75
I.1A
2X 0.200
SECTION
+0.002
I0.25I -0.000
0.50
A-A
0.250
1. 50-
0.375
-3
A
1
2. 0 3
TOLERANCE
L
!1ki
I
30
MACH. HOLE TOL.
ASS)
.003
.0035 TO
TO .185
.185
1875
TO .246
.250 TO .750
.765 TO 1.000
4
4
3
3
.
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XX
4.004
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-
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-..
*.001
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*
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00 5
s.*
_
INTERPRET PER
ANSI Y14.5
304
Feb-15-2001
DESIGN
MATERIAL
STAINLESS
DRAEW
FINISN
NONE
Mssochuseffs Instilufe of Technology
,
Feb-25-2001 TITLE
A. Sprunt
A. Sprunt
UNLESS OTHERWISE SPECIFIED
1. DIMENSIONS ARE IN INCHES.
Ill Ns
. A.*
I.i4i.t
--
-G4i.C.6,idN.,- MM
M OI
PINCH ROLLER BOSS
Pro/E MODEL FILE
2. ALL DIMENSIONS APPLY AFTER FINISH.
PINCH- ROLLER-BOSS
3. REMOVE ALL BURRS & SHARP EDGES.
(.010 MAT. R. OR CHAMFERI
Pre/E DRAWING FILE
I.HI. BEND RADIUS. MIN. BERD RELIEF.
5. No TOOL MARES.
PINCH-ROLLER-BOSS
6. MACHIMED FIN SH: kY
SIZE 6
ISCALE 1.000
EXCEPT 4" FOR HORIZONTAL MILLING.
MODEL REV
31
DRAW REV
SHEET
I of I
4-
4
3
+ 000
oo'00- 008
.300+008
S-
-
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374
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0.250
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S000
+ 000
200' .000
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-
B
4+.008
350 -. 008
2 X Self locking HelI-Coil
inserts
for 6-32,
1ength, $
300 + 008
008
.150
0.207
±0.005
-250
SCALE
2.000
250
.MATERIAL
DESIGN
GI
UNLESS OTHERWISE SPECIFIED
DIMENSIONSA93INICHES
Property of PERG
INERPRET
PER
91 3.5
CODE IDENT 31413
4
4
3.2
3
2
JuLy-1-2000
. A. Sorut
Masschuseft
,
DRAMN L-J.1-0E
Inofiftue of Technology
, , ",'~
u..
- PRI
A. Spr un f TITLE
TOLERANCES
DC Motor Insultated Extention Shaft
0,0
±0,'S
0,00
ANGLES
PRO/E DRAW FILE
INSUL-EXT-DC-EOTOR
t0,05
± I
SIZE
B
ISCALE
2 0001 SHEET IOFI
4
3
+ 000
O*.0.008
.375
.374
0 .375
+_
B
001
_000
340+. 000
- - 004
+ 008
-.
008
500
+
008
()08
)08
.250
F
344
SCALE
344
MATERIAL
DESIG#
2 X 6-32
x
He I I -Co il
0.207" self lockingi nser t s,
" "
AWS
UNE OHRIE SPECIFE
01MEISIONS ARE IN IN
Property of PERG
$ ± 0.005
IREAPRET PEA AMT VIA s
44
3
3
2
S run
Massachusetfs Institute of
T PF
.
A00
S
TITLE RT
UI
TOLERANCES
G\
2
A
y-E2000
J
Gil
2.000
0,0
0,0O
Technology
'PER"
V.V
DT
Stepper Motor Insulted
Extension
Shaft
i±,15
P4Q/E DRAW fILE
0,05
CODE IDENT 31413 ANGLES ± I
INSULATED-EXT-SHAFT-STEPPER
SlE
8
SCALE
1.000
SHEET
IOF
I
3
4
0.250
0.20
0.500
0.32
2X 00.221 (DRILL 2)
10-32 UNF-28 CLEARANCE THRU
B
0.50
(1.018)
4-
0.278
2X 0.250
RO.24
00.236 [5 mm)
M6 X 0.75 FULL
THREAD THRU
(0.52)
A
MACH
I.000
.0035 TO
185
1.0X
.000
+.004 1.XXX
-. 002 JANGLES
-.002
1875 TO .246
.250 TO 750
.765
4
4
MATORIAL
MATERIAL
HOLE TOL . TOLERANCE
.. 003
1.X
1 .030
TO 1,000
3
3
-
-[ -02
+.007
.
- 002
~
.010
.005
I±
.5*
1
.005
L-
INTERPRET PER
ANSI Y14.5
2
DEDIUM
DESIGN
AL-MD6061-T6511 DIW
Finis"
DRA.
Now- 100000
Nov-10-2000
A.
SP'"r
o-DD
SOV-10-ZOOO
laslilule cE T~h.oIe1y
Mossochue tfs
sinstitute of Techn log
Nassachuselb
""'"i. t'"
IDLER SENSOR BRACKET
A. Sorunf
UNLESS OTHERWISE SPECIFIED
Prod MODEL FILE
1.DIMENSIONS ARE IN INCHES.
.ALL DIMENSIONS APPLY AFTER FINISH.
IDLER-SENSOR-BRACKET
3. REMOVE ALL BURRS & SHARP EDGES.
.010 MAX. N. OR CHAMTER 1
4. MIN. BEND RADIUS.
WIN. BEND RELIEF.
5. NO TOOL MARNS.
"
A. MACHINED FINISH: 7
EXCEPT 4"FOR HORIZONTAL WILLING.
PreE
DRAWING
I ri
1111111
11, 111
1 . II I111111111111mp
MODEL REV
DRAW REV
FILE
IDLER-SENSOR-6RACKET
SCALE 2.000
SIZE B
2
11'
',
IF'2"
'""
----------
SHEET I OF I
3
4
(0.550)
(O02.068)
SEE DETAIL
/118.0
0.05
A
1.622±0.010
(00.876)
B
0. 25
00.159 (DRILL 20) 10-32
UNF-28 FULL THREAD THRU
OO.50
4-
0.10
0 . 22 3±0. 010
20 UTS
~1
RO.05
0.40
0.20
A
u
I
MACH. HOLE TOL.
.0035 TO .185
O 0.12 5±
44
. 010
DETA IL A
SCALE 4.000
3
3
.1875 TO .246
'
*.003
..002
4.004
I
TOLERANCE
.x
XX
1.
*
-. 002 JANGLES
.250 TO .750
-- **
.765 TO 1.000
*.001
-. 002
± .030
1± DIG
T
.005
.5*
-. 00
U
INTERPRET PER
ANSI Y14. 5
2
2
MATERIAL
rNISH
''-II-2000
M'''use'''
DESIGN
N
DRAIN
A. Sprunt
No,-07-ZU000 TITLE
AL 6061-T651
7
I
Insilt
.
I
o' Tec'nology
I
IM
N'
IDLER ROTATION DISK
BLACK ANODIZE
A. Sprunt
OTHERWISE SPECIFIED
Pro/E MOREL FILE
1.DIMENSIONS ARE IN INCHES.
UNLESS
MODEL REV
2. ALL DIMENSIONS APPLY AFTER FINISH.
3. REMOVE ALL BURRS & SHARP EDGES.
1.010 MAX. A. OR CHAMFER)
ID.ER-ROT-DISK
S. NO TOOL MARIS
5. MACHINED FIN SH:
IDLER-ROT-DISK
I.MIN. BEND RADIUS.
EXCEPT '
NiH. BEND RELIEF. ProEd DRAWING FILE
9'
FOR HORIZONTAL MILLIN.
SIZE U
ISCALE
.0}
1.500
DRAW REV
SHEET I or I
0.56+0.0
4
3
4 PLC BC 0 2.672
0.005 00.170 (DRILL 18)
6-32 UNC-28 CLEARANCE THRU
00.281 Li 0.15T
/
A
SECTION
A-A
0. 0 1
0. 56+-0.0
1
3 PLC BC 0L.600
0. 005 00.203
(DRILL 13/64)
10-32 X 0.285
SELF LOCKING
HELI-COIL INSERTS
30-
0 1 . 20
B
300
/
401.050
0.329
-e--
0
O2.00
03.13
0.50
0.750
0
& -- noor
2) *I
10-32 UNF-2B CLEARANCE THRU
00.375 Li 0.20T
2X
(7
221
(D
Pnl
SCALE
MACH. HOLE TOL. 1 TOLERANCE
4.003
TO .185
.0035
-. 002
3
44
3
.765
TO 1.000
.00
4,004 1.GE
I
-. 002 JANGLES
.1875 TO .246
.250 TO .750
± .030
.x.
--
-
00
-.002
t
MATER'AL
.005
ry-I-?000
Ma
sochusetls Insfiluie o( Technology
F,6w
DRAIN
.010
I± .5
A.
m1as.AA.,
F INISH
Ott-16-2000
4
AOIL DIMENSIONS HPPLY AFTER FIN'ISH.
REMOVE ALL BURRS & SHARP EDGES.
1.010 MAX. B. OR CHAMFERS
MIN.BEND RADIUS. MIN. BEND RELIEF.
No TL MARKS.
MACHINED FINISH:
EXCEPT -,!FOR HORIZONTAL MILLING.
INTERPRET PER 1:
ANSI Y14.5 I
~
1. '1.4 '"I",
sE6.;pa.
.
2.
14
dM
8.;Idi~q3,71
TILE
DC Molor End Plug
A. Sprunf
LESS OTHERWISE SPECIFIED
DIMENSIONS ARE INDRAWN
INCHES.
I
_
GDESIGN
1.000
PreoE MOREL FILE
MODEL REV
END-PLUG-DC-MOTOR
Pre/E
DRAWING FILE
END-PLUG-DC-MOTOR
SIZE B ISCALE 1.000
DRAW REV
2
SHEET I OF I
3
4
4
4 X 10-32
0 12
--3. 125. -0
2
clearance hole)
4 X 10-32 x 0.285
se lIf
4'PIc BC O3.774
$ ±0.005
lock ing He ll
Coll inserts
0 12
012
04. 000
B
1l 050' .008
-
.000
0 2.125 +.012
.012
65. 000 0+I. 0000
500 +008
- .008
+ .008
0000
4 X 6-32 clearance, hol e
900-.008
008
4 Plc BC 0 .600
+
0.005
4 P Ic BC 0 2. 625
$ t0 .0 05
SCALE
MATERIAL
DESIGA
JIy-1-2000
GI I
UNLESS OTHERVIIEOIMNSAONS ARE IN
A. Sprunt
ACHES
I
44
3
2
2
CODE
IDENT
MASS.
A . Spr Un t
TOLERANCES
0,0
±0,15
,0
005
0AN0
31413 ANGLES ±
0.750
M ssachuseff
nloof ifute of TechnoIogy
F'iS . Eq-i - 1-.
v ch G,~~
IEll,
S
Property of PERG
3
4-
E
BUILDING 3S7. CABROO
0"
G
9
TITLE
Stepper Motor Shell End Plug
REY
PDAW
SIZE
FILE
END-PLUG-STEPPER
B
SCALE
0001
SHEET I OF
4
3
3
4
B-B
SECT ION
B
75+
I
008
.008
OK.200
R. 188+
+.012
-
.012
0 10
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A
A -A
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12
soo
5k.004
+
-
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004
B
- -A
1450+.005
~
A. Sprunt
GlI
UNiESS OTHERW E PECIF'1S
Property of PERG
TOLERANCES
0,0
NR
44
3
3
2
2
ANSI
TPPE
PES A
I 5
CODE IDENT 31413
0,00
ANGLES
Massohusetts Institute of Technology
11MASS. AVE, a010M
ORAWN 12-.1-00
MA 0213!1
_,IQ , CAM A GEE.
Slepper Mofor Spacer
±0, 15
DRAW FILE
±0,05 PRO/E
I
FLEX-COUPL-SPACER-STEPPER
fE I
SIZE B 1 SCALE 1 .0001 SHEET I OF !
4
3
SECTION B-B
B -9
c6
0
B
B C
0.375 X 2.0 ST AINLESS
STEEL DOWEL PIN
\\\-EDGE CONSTRAINT ARM
A
IMACH. HOLE TOL. TOLERANCE
.0035TO.185
+003
+.003
-.002
.1875TO.246
+.004
-.002
.250TO.750
.±
*
.M
±.05
ANGLES
±.5
SCALE 1.250
4
3
3
FNI
INTERPRET PER
ANSI Y14.5
2
2
DESIGN
AUG-1-2000
DRAWN
A. Sprunt
00-Sep-O
N/A
FINISH
-.005
-.002
MATERIAL
N/A
Masahusett Institute of Technology
_n Ma.. A.. Buding 347% Cdoe,
MA
MIN
TITLE
A. Sprunt EDGE CONSTRAINT ARM ASSEMBLY
UNLESS OTHERWISE SPECIFIED
1. DIMENSIONS ARE IN INCHES.
2 ' ALL DIMENSIONS APPLY AFTER FINISH
3. REMOVE ALL BURRS & SHARP EDGES.
(.010 MAX. R. OR CHAMFER)
4 MIN. BEND RADIUS. MIN. BEND RELIEF.
5NO TOOL MARKS.
e MACHINED INISH:
EXCEPT
f4OR HORIZONTAL MILLING.
Y
Pro/EMODELFILE
4ODELREV
EDGE-CONSTRANT-ARA.ASM
ProlE DRAWING FILE
DRAW REV
EOGE-CONSTRAINT-ARM-ASU
,
SIZEB
SCALE 1.250
1
SHEET I OF
1
3
4
3
4
+ 008
600
_
_ A___
SECTION
590 + 008
008
A-A
_
008
Slip fit for o .125
pin
B
I. 00
008 0
00
50
.008
/+ .004
.1 uu
+.
008
.000 008
-008
1
-
0 004
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rA
-
A
_____
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+.
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4-
-. 008
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7
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12
2 .500 + 0012
300
3 X 300 .008
008
+.008
.008
-
II.,
0 .50000
300_ .008
.
008
.008
.390 (DRILL 25/64)
7/16-20 UNF-26
FULL THREAD THRU
0.50 1
0.50 L_
SCALE
MATERIAL
DESIGN
A.lS runt
OT ERWISE SPECIFIED
D1ENSIONS ARE /I INCHES
UNLESS
Med iu n press of 2" long 0.375" dowel
DRAWN 12-.10-00
Property of PERG
(
10140401 000
44
JOY3-/00
Sfainleoo Sfeed
2
2
CODE
ANSI
IDENT
V14.5
31413
A . Sprun t
TOLERANCES
0,0
±0, 5
0,00
ANGLES
±
1.000
M"
'soahusetts
Edge Constraint Arm
PRO/f DRAWFFLEI
ARM-&EDE-CONSTRAINT
±0, 05
I
Insfitute of Technotog
IITLE
SIZE
B
SCALE
2
I.000 SHEET I OF I
4
3
r
-
I
~-
I
-~ -
H
B
/-EDGE CONSTRAINT BRACKET
~1
I
-
4-
A
GRAPHALLY BUSHINGS
PART NUMBER: 117-6-212
A
SECTION A-A
MACH. HOLE TOL. TOLERANCE
.0035TO.185
.1875TO.246
SCALE 1.500
4
3
+.0
'x
.XX
i.010
+.4
.X
*
'
.25 TO.750
+.005
-.002
BTO01.000
M
+7
-.002
ANGLES
5
± .5
+00 INERPET
ER
INTERPRET PER
ANSI Y14.5
2
DRAWN
FINISH
N0AI
Massechusetts Institute of Technology
AUG-1-200
A. Sprunt
N/A
± 0
-.002
DESIGN
MATERIAL
ES-Sep-01)
A. Sprunt
UNLESSOTHERWISE SPECIFIED
1. DIMENSIONSAREININCHES.
2 ALL DIMENSIONS APPLY AFTER FINISH.
3. REMOVE ALL B3URRS & SHARP EDGES.
(.010 MAX. R. OR CHAMFER)
4. MIN. BEND RADIUS. MIN. BEND RELIEF.
. NO TOOL MARKS.
MACHINED FINISH:
EXCEPT { FOR HORIZONTAL MILLING.
1
7I M-.
A-
eNU.
Is.47
C-ddGeo
MA OEM
TITLE
EDGE CONSTRAINT BRACKET ASSEMBLY
MODEL RE%
ProE MODEL FILE
I
061CONSIAWN-ACKTAS&I
DRAW REV
ProlE DRAWING FILE
EDGE
SIZES0
MASNILSC.A|ET.|A
SCALE 1.502
E
1
SHEET 1 OF I
4
3
4
3
.625
. 624
B
-
Me
2.188±,12
-.012
008
0+
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2 .688
r--
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012
8
3 X 10-32, 2B,
0 12
-0
.0 05
750
I 000+ 008
008
SCALE
250
1.000
' a~Is
MA
fi ALa.
Stainless Steel
UNLESS OTHEAS
SARE
"
PIA
2
44
2
RERPRET
CODE
PER ARsI
IDENT
jey.OWN 0
A. Spr
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MEI
Property of PERG
3
3
.500 .250
.750
VA.
11
1A
I1-J.-LAI0
unt
TOLERANCES
0,0
+0,15
0,00
±0,05
31413 ANGLES
±
I
' Massachusetts
Massachuse t ts
Irstitate
at Technoisgy
Tec hnol
Ins ti tute of
ogy
l
A R3asnx.
....
A CAmARIELE
G-1.01A
ER02139
Pr ....AVE, E 81ILEinE
MnASS.
Edge Constraint Fixed Bracket
PRO/E DRAW
FILE
I
EDGE-CONSTRAINT-BRACKET
SIZE 0 1SCALE 1 0001 SHEET I Of I
4
3
4
3
Self locking Hell-Coil
i n ser t s for
10-32,
0.285" length X 3
O2.000+
3 r I c B C v- 1. 0 0
i:0. 0 05
A
012
012A
50 + 004
.1
-004
- .000
+ 008
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I1
.200±01
2 50
60.00
221+. 004
o004
0
-. 012
A
08
.0
0
A-A
SECTION
.-.0
3 Pl c BC 0 1.600 4±0.005
Poc ketf
08
a re c e ntfer ed
on holIe 5
MATERIAL
DESIGN
Aly-1-2000
UNLESS
OTHERWISE SPECIFIED
DIMENSIOND ARE IN INCHES
SCALE
0.750
INERPRET
2
2
PER
ANSI
115.5
31413
A . Sp r ntf
TOLERANCES
0,0
±O ,15
0,00
ANGLES
±0, 05
+ I
of Technology
itute
P...s"
,A..
7
In
05
02-j
DRAWN
Property of PERG
CODE IDENT
Massachusefts Inst
A. Sp ru nt
GII
3
3
B
120 00
_
I. 450+ 012
12
44
I
.- n(
or
01
-n
R.1875+.000
000
-.
NAol...
0 111
.
TnT
DC Motor Spacer
PRO/E DRAW FILERE
DC-MOTOR-SPACER
SIZE
B
SCALE
1.000
SHEET
IOF
I
3
4
I
----
4
B
0.437
0.436
2.000
'I
0
02.25
i
I
00.375
0.374
0. 38
0.250
(2.630)
SHAFT MAY BE PRESSED INTO
DISK SO LONG AS IT IS
SECURED BY A 00. 125
STAINLESS STEEL DOWEL PIN
.0035 TO .185
.1875 TO .246
.250 TO .150
.765 TO 1.000
4
4
TOLERANCE
MACH. HOLE TOL.
3,2
3
, 003
- 003
-. 002
*
-
005
004
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- 002
* 001
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.
.X
t
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MATERIAL
DESIGM
F~INISH
00'-'2-2000
TRAIn
os
5*
xx
.000
.005
ANGLES
INTERPRET PER
ANSI Y14.5
2
A. Sproot
OTHERWISE SPECIFIED
I. DIMENSIONS ARE IN INCHES.
2 AL DIMENSIONS APPLY AFTER FINISH.
3. REMOVE ALL BURRS A SHARP EDGES.
(.010 MAX. N, OR CHAMFERI
. MIN. BE.N
RADIS. MIN. RBEND RELIEF.
5. NO TOOL NARNS
. MACHINED F S
FiC PT "! FOR HORI7ONTAL MILLING.
UNLESS
~~ ~ ~ ~
11A,
.,d.gIMO.3
f'd'
NA~
MMOO
00-26-2000 IILE
.010
X
MOS3
0ohusotto Institute of Tech~nology
'PEM''
0'''
''M''' E''' '"''
"
A. Sprunt
304 STAINLESS
STIFF DISK SHAFT
Pro/E MODEL FILE
DISK-SHAFT-STIFF
Pro/( DRAITN6 FILE
MODEL
DRAW REV
I
DISK- SHA FT-SE T
SIZE 8
[SCALE 1.0001
REV
I
SHEET I OFI
4
3
0.431
1.875
B
B
0 0.436
0.43
02.25
-
4-
---------
oO.375
0. 374
0.38
0.250
(2.505)
A
SHAFT MAY BE PRESSED INTO
DISK SO LONG AS IT IS
SECURED BY A 00.125
STAINLESS STEEL DOWEL PIN
MACH. HOLE TOL.
.0035 TO .185
o 003
.00
____________-.002
.185
O .46
TOLERANCE
.0
.004
-.
002
~
030
MATERIAL
DESIGN
304 STAINLESS
FIISH
.xxx
±010
.005
ANGLES
+
5
O0-22-2000
A. Sprunt
D.AN
Massachusetts lostitule of Technology
-
ProE
-
3
44
3
.765
TO 1.000
(1.010 MAX. R. OR CHANFERI
002
-.002
INTERPRET PER
ANSI Y14. 5
I.IN ERD RADIUS. MIEN. BEND RELIEF.
S. NONTOOL EARNS.
6. MACHINED FINISH: I
FOCEP
1
FOR NOR17ONTAI MIL N0
MODEL FILE
MODEL
REV
DISK-SHAFT
3. REMOVE ALL BURNS A SHARP EDGES.
0.00i
NA153
.01 479,
6
DISK SHAFT
A. S root
UNLESS OTHERWISE SPECIFIED
I.DIMENSIONS ARE IN INCHES.
2. ALL DIMENSIONS APPLY AFTER FINISH.
.250 TO .750
Sew. A.. hii(M
Oc-26- 2000 TITLER
PreE
0
DORAWIG FILE
DRAW REV
DISK-SHAFT
SIZE 5
ISCALE
1.000
SHEET I OF I
4
3
4
3
A-A
SECTION
O
.250-
+ .005
1.600
+.005
005
63
- . 005
f necessary or expedient,
center feature may be
created by pres sing in a
dowel, so long as it s
secured by a pi n
MedI um press for
0 0.125 dowe I to
s e c Ur e center dowe I
B
.000
0 977+ 005
.300 + 005
005
005
0 375+ 001
4-
150+ 005
005
+ .005
D-
1
2 Plc BC 0l.289
$ ±0.005
SECTION
.375 -. 005
B- B
+
.005
300 .005
-/
2.000 +0 005
o05
I
A
A
I I
S.750 .005
.005
0
250
+.
00 5
.v 1
B
MATERIAL
DESIGN
stainless steel
0 -32 UNF 2b TAP 1 0.250000
#21 DRILL (0.159000) T 0.300000-(H )HOLE
SCALE
I.000
IEAPRET PER
4
4
3
3
DDRAWN
E E
Property of PERG
2
2
ANSI 114.s
CODE IDENT 31413
JIy-20-2000
A.Sprunt
DIAINTAN
24-J.1-00
TOLERANCES
0,0
±0. 15
0,00
ANGLES
±0, 05
± I
Massachusetts Institute of Technolo9y
,
"11
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FILE
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SIZE B SCALE i.000 SHEET I OF I
4
3
170)
(2.
0.450
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375
~-C-~
(0.285)
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;7
11
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4-
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-
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10-32 UNF-2B CLEARANCE THRU
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RO. 10
A
MACH.
HOLE TOL.
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-0.000
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3
3
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TOLERANCE
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-.004
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INTERPRET PER
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2
2
MATERIAL
Al 6061I-T651
FisisDRAWNu
DESIN1 A.g-15-2000
mM spchuserfs Iastitinle o( Tchnlogy
A. Sprunf
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A. S,,u,
UNLESS OTHERWISE SPECIFIED
1.DIMENSIONS ARE IN INCHES.
1.,
.. Nid.
AN
TITLE
~~N.N
OS
STIFF SPOOL KEY
Pre/E MOREL FILE
2. ALL DIMENSIONS APPLY AFTER FINISH.
STIFF-SPOOL -KEY
3. REMOVE AL L BURRS A SHARP EDGES.
(.010 NAX.* . OR CHAMTER)
PreAE DRAWING FILE
4. MIN. BEND RADIOS. MIM. BEND RELIEF.
S. NO TOOL NARKS.
STIFF-SPOOL -KEY
6. MACHINED FINISH: T
EXCEPT !?' FOR HORIZONTAL MILLING.
SIZE 8
ISCALE 2.000
MODEL REV
DRAW REV
2
SHEET I OF I
4
125 +005
005
A-A
SECTION
.250 .
1.700 1005
-0
If necessary or expedient,
center featu re may be crea led
by pressing in a dowel, but only
f t s sec ured with a pin.
Med Iu press for
Q.125 pin to secure
center dowel
B
02. 740
005
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I
300- 005
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150- .005
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B-B
0
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B
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----
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3
0 .250
005
-
3
SECTION
7
03.000 .005
005
S750+
44
300+.005
-005
MATERIAL
Stfa inless Steel
DESIGN 11y-27-2004
A. S
UNLESS 0HERWISE SPECIFIED
0IMENSIONS ARE IN I1NES
Property of PERG
SCALE
0.750
INERPRET
3PER ANSI/-%Y14.5
CODE IDENT 31413
+
005
-00 1
MoCs chusef
Inst
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of Technology
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7
%
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TOLERANCES
I dI
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A 0213
A.
0,00
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± I
PRO/E
S:ZE
er Ro I I er (St i ff
DRAW FILE
STIFF-IDLER-ROLLER
B I SCALE 1.000 SHEET
4
4
3
.004
25+-.004
If necessary or expedient,
center feature may be
created by pressing in a
dowe .
SECTION
B
A-A
375
0
3714
If creat Ing cente r featur e with dowel
press a retaI n ing pin into thi ,
hole.
Hole not nec essary if not
using dowe
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Iy-
300
.400 + 008
008
. 250+ 008
008
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0+ .5
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,
0- 50 p ITCH
DESIGN
mATERIAL
SfainleIs
SCALE
JIy--2A0
1.000
Property of PERG
4
4
3
3
2
IMERPRET PER ANI
IDENT
CODE
CI
.s
31413
TITL
0,00
0, 00
ANGLES
Institute of Technology
?",,-En,-tMial
IRA
lIR.A
MASS . AVE,1.DlEiN 3-47E.
Spoo I
TOLERANCES
0,0
2
Massachusetts
A. S unt
S
A1II1.
Stee
UNILESS OTHERWISE SPECIFIED
GtaIPERG
1al
CAN
I
55"".131
Ier
+0,15
±,
05
±0, 05
± I
ROIL
SIZE
DRAW FILE
SPOOL -ROLLER
B
SCALE
1.000
I
SHEET
IOF I
SECTION
4
3
4
3
.374
C-C
0 1.200 +..2
012
012
.500 .012
B
300 +.008
.008
12
If necessary or exped ient
feature may
be created by pres sing in a dowe I but
cured wi th a pin
se
e
must then
2t
75.00
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4-
S.250+ 008
400+.008
F-
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SECT ION
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not create if not
using dowel.
C
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012
T . 483+ 008
008
Me dIum press for
pi n
.
0 1225
.300
750 .012
012
008
OISIG4
MATERIAL
Stai'nIes s Steel
03. 00 0+. 0 12
SPECIFIED
1 L11 OI EAMS
DIESCSRRECOS
3
44
3
0.750
0"AWN
z-0,,0
MM
P
ARS SIS
II
Massachusetts
00
.
Property of PERG
SCALE
008
-008
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R
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A. Spr cot
TOLERANCES
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TITLE
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Institute
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Technology
RI
M 23
m
Ro I er
± 0 15
±00A5
CODE IDENT 31413 ANG LES ± I
PROIE DRAW FILE
P0E00
IDLER-ROLLER
SIZE
B SCALE
E
1.000 SHEET I OF I
4
3
A =e
00
00
B
0
.250 X 1.0 STAINLESS
STEEL DOWEL PIN
0
0
o
0
0
0
4-
'V
0.1875 X 1.0 STAINLESS
STEEL DOWEL PIN
0
0
0
0
0
0
SCALE
Inferface PIatfe-
0
L I
SECT ION
0.700
MACH. HOLE TOL.
.0035 TO .185
.1875
TO .246
250 TO .750
.765 TO 1,000
44
3
3
TOLERANCE
± .030
+ 003
- .002
.X
+.004
XXX
ANGLES
- .002
.XX
t.5
- 002
-002
DESIGN
DRAWN
FINISH
Aug-1-2000
A.
N/IA
Spr unS
Sep-08-2000
.010
± .005
+ .005
+ .002
MAIERIAL
14ATERIAL
INTERPRET PER
ANSI 0)4.5
2
2
N/A
A. Sprunt
UNLESS OTHERWISE SPECIFIED
1.DIMENSIONS ARE IN INCHES.
2. ALL DIMENSIONS APPLY AFTER FINISH.
3. REMOVE ALL BURRS & SHARP EDGES.
(.010 MAX. R. OR CHAMFER)
A. MIN. DENS RADIOS. MIN. BMEND RELIEF
S. NO TOOL MARRS.
6. MACHINED FINISH:
EXCEPT F/ FOR HORIZONTAL MILLING.
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Massachusett
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Inierface Plate Assemblyl
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Pro/E MODEL FILE
INTERFACE-PLATE-ASM
Prol( DRAWING FILE
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0.500
DRAW REV
I
SHEET I OF I
4
50
-A-
375
0
-
3 X O.159 (DRILL #21)
10-32 UNF-2B FULL THREAD
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. 60
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-A
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~
.384 [9.15 mm]
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220
2,252
250
2.44
.250
SCALE
2 . 250
4. 107
DESIGN
MATERIAL
AlIumi num
5.107
5.50
4
0.750
3
UNLESS OTHEW SPECIE DCA
DIMENSIONS ARE IN INCHES
Property
Aw-
COE
CODE
2
of PERG
Mosoochuseft
A . Sprunt
1
Institute of Technology
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Sp runt I
TOLERANCES
A
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EN INEPRT
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A.g-15-2000
013
TLE
F I x u re Mo u nI
C
PRO/E DRAW FILE
R E BR FLEXURE-MOUNT S
SIZE
I RE
B I SCALE 0. 7501 SHEET I OF I
3
4
....
I
4
X
10-32 UNF-2B CLEARANCE THRU
0.20 V
00.375 L
2 -C2 X 0 .500
If~l
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I
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0
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-C-
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1.000
3 X 0 .159 (DRILL #21) +±0.005
10-32 UNF-2B FULL THREAD 0.3 T
SCALE
1.000
A
MACH. HOLE TOL.
2.00
.0035 TO .185
. 500
.1875 TO .246
+.003
.250 TO .750
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4
4
B
3
TO 1.000
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4o004
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-
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X
*
XX
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OR
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RADIOS.
S. NV TOOL MARKS.
Foot Piston Bracket
AN
A.
Spruni
UNLESS OTHERWISE SPECIFIED
I. DIMENS/ONS ARE /NINCHES.
. MN
INTERPRET PER
3
-. 002
AL
ANg-OH-2000
DESIGN
AL
2. ALL D/MENSIONS APPLY ATTER F/NISH.
3. REMOVE ALL BURRS A SHARP EDGES.
i,010 MAX. R. OR CHAMFER)
+.0>
-.
"ATE
NATO:R/HL
TOLERANCE
Pro/E
MOOEL FILE
FOOT-PISTON-BRACKET
DRAW/N6
N/N. BEND RELIEF. Pro/E
6. MACHINED TIN/SN: 7
EXCEPT 7"/ TOM HORIZONTAL MILLING.
FILE
FOOT-PISTON-BRACKET
SIZE N
ISCALE 1.000
MODEL REV
2
DRAW REV
2
SHEET I OF I
4
3
4
3
37508
008
750+ 008
.008
+ 000
.008
R
70
+ 008
-
400+008
- 008
-
B
004
+.0"
000
008
4+ 008
008
375
008
008
=9--
438
-.
008
008
Quantity: 2
SCALE
MATERIAL
SESIGN
Stainless
A
MELn 4ION E
Property of PERG
INMEPIET PEW
CODE
4
3
2
IDENT
O
NC ES
ANs 4.
31413
MassChusetts
Jo y-t-2000
Steel
ESOHRIESEI E
Sprunt
l
Pch
I AO
13-J.1-
NARA
A. SSprunt
TOLERANCES
5
2.000
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on
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0,0
0,00
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ANGLES
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05
R
PRO/E
DRAW
FILE
FOOT
SIZE B
SCALE
.000
SHEET
OF I
4
3
I
r
SECTION A-A
A -
B
0z
0
0
4-
-K
A
LEFT FLEXURE BRACKET
.250 X 1.0 STAINLESS
STEEL DOWEL PIN
A
MACH. HOLE TOL. TOLERANCE
.0035TO.185
1875 TO246
O
+.0
-.002
4
-.002
DESIGN
MATERIAL
.010
XXX
ANGLES
*
.005
± .5
A. Sprunt
N/A
FINISH
XX
DRAWN
10-Sep-00
SCALE 1.M0
4
4k
3I
3
.250 TO 1.50
.765 TA 1.000
+.07
-.
ALL DIMENSIONS APPLY AFTER FINISH.
2.
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4. MIN. BEND RADIUS. MIN. BEND RELIEF.
INTERPRET PER
.
2
7?IE...
1.NO TOOL MARKS.
MACHINED FINISH:
s.
Y
EXCEPT I4OR HORIZONTAL MILLING.
of Techology
A-. BuidNu.4'A C-Amdu., MA 030
TITLE
A. Sprunt LEFT FLEXURE
N/A
UNLESS OTHERWISE SPECIFIED
ProlE MODEL FILE
1. DIMENSIONS ARE IN INCHES.
SREMOVE ALL BURRS A SHARP EDGES.
-. 0
Institut, of Technology
Massachusetts
- lntte
Ma=
AUG-1-2000
BRACKET ASSY
MODEL RE%
I
FLEXURE-eAACKETAEFT-ASM
Pro/E
DRAW REV
DRAWING FILE
FLEXURE-SRACKET4EFT-ASM
SIZE
B7
SCALE 1.000
SHEET
I
1 OF 1
4
3
IY
-2X
2 X I .9 0 0
-
0.10
0.25
, -OLD TAPPED HOLES
B
0.438
/
/
H
----
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UNF-2B FULL THREAD THRU
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/
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2.00 2. 25
+
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t
~
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4-
0.875
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0.300
- .2 50
3. 75
A
1.00
MACH. HOLE TOL.
.0035 TO .185
.1875 TO .246
0. 50
0.63
.250 TO .150
+.003
-.
002
+.004
-. 002
h-I
TO 1.000
4,3,2
4
3
.X
I
.XX
DXX
ANGLES
-.002
.030
MATERIAL
I
.5"
j
INTERPRET PER
ANSI YI4.5
2
Massachusetts Institute of
...ci
N.im4i. ASN.A..
..
'Ju-01-2000
DRAm
A. Sprunt
Ocf-29-2000 TITLE
Stainless Steel
FINN
'
DESIGN
.010
I .085
__
___
+.007
.765
TOLERANCE
,
.
MXSy
A213
Leff Flexure Brockef
A. SDrunt
UNLESS OTHERWISE SPECIFIED
Pe.IE MODEL FILE
1.DIMENSIONS ARE IN INCHES.
2 ALL DIMN SIONS APPLY AFTER FINISH.
3. REMOVE ALL BURRS & SHARP EDGES.
(.010 MAX. R. ON CHAMFER!
A. MIM. BEND RADIUS. CI.
BEND RELIEF.
5. NO TOOL MANRS.
6. MACHINED FINISH
'F OR HORI7ONTAI WILLING.
FirFP T
Tethnology
Ngl$ A-. 6014..q -4?0 . a , .
VLEXURE-BRACKET-LEFT
Pro/E DRANING FILE
FLEXURE-RACKET-LEFT
SIZE H ISCALE 1.000
MODEL REY
.
2
DRAW REV
2
SHEET I OF I
4
3
I
A
SECTION A-A
SCALE 1.000
0
B
0
0
0
4RIGHT FLEXURE BRACKET
.250 X 1.0 STAINLESS
STEEL DOWEL PIN
A
MACH. HOLE TOL. TOLERANCE
.0035TO.185
.1875TO.246
+.003
.X
-.002
*xx
+.N
002
.XS
.250TO.750
IUNLESS
.S
A NGLES
.5
~
4007
785T
4
3
000
+.0
-.002
INTERPRET PER
ANSI Y14.5
N/A
Masschuset
Institue of T
77M... A. 9M,34
DRAWN
FINISH
.010
Massachusetts InstItute of Technology
UG-I-2000
A UG-1-2&O
NIA
L.030
---
.0
DESIGN
MATERIAL
1H
-Ssp-w
TITLE
A. Sprunt RIGHT FLEXURE BRACKET ASSY
OTHERWISE SPECIFIED
Pro/E MODEL FILE
DIMENSIONS ARE IN INCHES.
ALL DIMENSIONS APPLY AFTI R FINISH.
FLEXURE.ERACKET-RIGHT-ASM
REMOVE ALL BURRS &SHARP EDGES.DARE
(.010 MAX. R. OR CHAMFER)
ProE DRAWING FILE
IMIN. BEND RADIUS. MIN. BEN[ RELIEF.
S5. NO TOOL MARKS.
FLExURE-NRACKEI-RIGT-ASM
i
MACHINED FINISH: LY
EXCEPT
HORIZONT AL S
SIZE
m.
17. 0
CP
ICI
1.
2
3.
SfOR
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Cum*do. MA CRU
B |SCALE 1 0
ODEL RE
DRAWREV
1
SHEET 10F 1
SETIO
4
3
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UNF-2B FULL THREAD THRU
2X 0 0.159 (DRILL 21) 10-32
UNF-2B FULL THREAD 0.375 T
I.
/
OLD TAPPED HOLES
I
B
2X 1.000
-wa
-+
2. 13
2.38
0.225
-
0.438
0.875
RO. 131
0. 300
2. 25
L I.50
I. 2
1.00
0006
(H7)
00. 2500 +0
-0.0000
0. I00.25
3.75
A
MACH.
HOLE TOL.
TOLERANCE
MATERIAL
DES1GN
I
304 STAINLESS
.0035 TO .185
0. 50
0. 63
.1875 TO .246
250 TO .750
.165 TO
4
4
3,2
3
t
1.000
-. 002
+.004 1.XXX
-.002 JANGLES
-002
007
-002
*
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.Ax
.005
I±
5*
L
INTERPRET PER
ANSI Y14. 5
2
r
IMISA
DRAWN
A.1-u1-2000
I
A. Sprunt'
Ott-It-2000
Massachusett institute o- T-chnology
.. ,h0.p111
.i
(.!...i
E,,
TITLE
?I New A:.
.H.9~d4C..ip
oil0130
Right Flexure Bracket
A. Scrunt
UNLESS OTHERWISE SPECIFIED
Pro/E MODEL FILE
SDIMENSIONS ARE IN INCHES.
FINISH.
AFTEREDGES.
FLEXURE-BRACKET-RIGT
N IONS
BURRSAPPLY
I SHARP
S.
ALL DIALL
2.REMOVE
T.01D MAX. R. OR CHAMFER)
Pro.E DRAWING FILE
N. RBEND RELIEF.
4. RIN. BEND RADIUS.
. NO TOOL MARRS.
FLEXURE-BRACKET-RIGHT
H. MACHINED FINISH: k
EXCEPT 1'IFOR HORIZONTAL MILLING.
ISCALE 1.000
SIZE 0
,
MODEL REV
3
DRAW
REV
3
SHEET I OF I
4
3
INSPECT "DIAMETER" HOLES WITH
SUPPLIED PG-100 PIN GAGE
0. 1875
6.0383
4X 00.221 (DRILL 2)
$±0.005 10-32 UNF
26 CLEARANCE THRU
O0.375 Li 0.2007
2X 0.375
-
SLOT WIDTH
PIN HOLE
B
0000
2X 2. 550
\ 00000000
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Sp-ZXZOX
MAOEIAI.0(000
MACH. HOLE TOL.
#.003
.185
.0035 TO
-.002
+.004
.1875-.002
.250 TO .150
.765
4
4
I
3,2
3
TO 1.000
TOLERANCE
.
XX
.XX0
.030
0010
* .005
ANGLES
.005
---.
.5
_______
INTERPRET PER
-.002 I ANSI Y14.5
+.00j
2
OTAINLESS
:1IS0
A. Sprunt
STEEL
1.000
Teclusology
Mosocluisettlo Isfifolt
i2 248-0 0... p aiPO
....
pui.A... coli
Niii
414. C0,i o.. ft 01139
11su.
Sep-29-2000 IILE
o2AN
STEPPER SHELL PIPE
A. Sprut
NATURAL
J-LESS OTHERWISE SPECIFIED
Prelt MOWEL FILE
1.DIMENSIONS ARE IN INCHES.
2. ALL DIMENSIONS APPLY AFTER FINISH.
35- INCH
3. REMOVE ALL BURRS A SHARP EDGES.
(.010 MAX. N. OR CHANFERI
Pt.eE 01A03M FILE
1. MIN. REND RADIOS. MIM. REND RELIEF.
5. NO TOOL MARKS.
STEPPER-SHELL -PIPE
6. MACHIRED FINISH: U'
EXCEPT W FOR HORIZONTAL MILLING.
SIZE
I
MODEL
REV
DRAW
REV
swEECALE
O.F0
I