DSC-G2

(Gearbox Driven Interface)

Load Rating: 2,300 lbs Cantilevered 30” (See dimensional drawing sheets 3-6 for load curves)
Payload Max Swing Radius: 59”
Max Torque (Secondary Axis): 23,000 in-lbs

Product Features

Safety Factor: 3 for Yield & 5 for Ultimate
Rated Load Capacity: Dynamic, 0″ to 4″ eccentricity: 2,300 lbs. (1,043 kg.) Cantilevered 30” (762mm)
Operating Temperature: +32 to +104 °F (0 to +40 °C). Contact factory for special applications with extended operating temperatures.
Materials: Steel and aluminum construction. Stainless steel fasteners.
Gearbox Driven Interface: Non-backdriving (self-locking) low-backlash gearbox rotates the interface via a hand crank. Interface can be pinned in 15° increments for redundant safety. 352 turns of handwheel for one full revolution of interface.
Adjustable Interface Height: Eight bolt positions to ensure that payload CG is close to primary axis of rotation centerline. Four lift points integrated into frame for bolt position adjustment or for lifting empty cradle. Guide blocks included to facilitate adjustment.
Optimized Design: Cradle analyzed with FEA to optimize design to be high capacity yet light weight.

Standard Configuration (For additional options click on “Configure a Flotron Cradle” button above or view dimensional drawing for detailed information)

Finishes/Lubricants: Class 10k (ISO 7 cleanroom compatible finishes) – Cradle powder coated textured Flotron blue color; stainless steel hardware; aluminum parts chem film or hard anodized; Mobiltac 375NC (or equivalent) to all slewing ring teeth; slewing ring inner raceway lubricated with Mobilux EP2 (or equivalent). Fasteners lubricated with Loctite 242 blue or Krytox GPL 207. Gearbox sealed and pressure tested.
Cradle Length: 120” Between Mounting Interfaces. (Special cradle lengths available in 20” increments from standard).
Interface Bolt Pattern: ESPA Grande/MLB interface. 36X ¼-28 UNF threaded holes on a Ø24” bolt circle.

Load Rating: 2,300 lbs Cantilevered 30”

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Payload Max Swing Radius: 59”

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Max Torque (Secondary Axis): 23,000 in-lbs

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Load Rating: 2,500 lbs Cantilevered 30”

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Payload Max Swing Radius: 59”

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Max Torque (Secondary Axis): 10,000 in-lbs

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Load Rating: 700 lbs Cantilevered 24”

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Payload Max Swing Radius: 29”

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Max Torque (Secondary Axis): 10,000 in-lbs

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Miscellaneous

DSC-P2

(Hand Turned/Pinned Interface)

Load Rating: 2,500 lbs Cantilevered 30” (See dimensional drawing sheets 3-6 for load curves)
Payload Max Swing Radius: 59”
Max Torque (Secondary Axis): 10,000 in-lbs

Product Features

Safety Factor: 3 for Yield & 5 for Ultimate
Rated Load Capacity: Dynamic, 0″ to 4″ eccentricity: 2,500 lbs. (1,134 kg.) Cantilevered 30” (762mm)
Operating Temperature: +32 to +104 °F (0 to +40 °C). Contact factory for special applications with extended operating temperatures.
Materials: Steel and aluminum construction. Stainless steel fasteners.
Dual Pinned Interface: Redundant Pins for safety, one spring loaded, one ball lock pin to prevent interface rotation. Interface must be in payload vertical orientation (interface surface parallel to floor as shown) before removing rotation lock pins. Pins cannot be removed in any other orientation.
Adjustable Interface Height: Eight bolt positions to ensure that payload CG is close to primary axis of rotation centerline. Four lift points integrated into frame for bolt position adjustment or for lifting empty cradle. Guide blocks included to facilitate adjustment.
Optimized Design: Cradle analyzed with FEA to optimize design to be high capacity yet light weight.

Standard Configuration (For additional options click on “Configure a Flotron Cradle” button above or view dimensional drawing for detailed information)

Finishes/Lubricants: Class 10k (ISO 7 cleanroom compatible finishes) – Cradle powder coated textured Flotron blue color; stainless steel hardware; aluminum parts chem film or hard anodized; Mobiltac 375NC (or equivalent) to all slewing ring teeth; slewing ring inner raceway lubricated with Mobilux EP2 (or equivalent). Fasteners lubricated with Loctite 242 blue or Krytox GPL 207.
Cradle Length: 120” Between Mounting Interfaces. (Special cradle lengths available in 20” increments from standard).

Interface Bolt Pattern: ESPA Grande/MLB interface. 36X ¼-28 UNF threaded holes on a Ø24” bolt circle.

Leveling Jacks & Caster Jacks

Flotron’s leveling jacks and caster jacks are specifically designed for the aerospace industry to be robust, clean, precise, and easy to use. The jacks are engineered to withstand a simultaneous 1G vertical and 1/2G side load in any direction and maintain SFy=3 and SFu=5. The removable hand crank attaches to a pre-set clutch that features a standard 3/8” or 1/2” square input drive that prevents the jack from being over-torqued. The user does not have to worry about damaging the jack when it gets to the end of stroke. Since the handle is removable, and includes a clutch, the user can power the jack using a non-impact hand drill or air tool (300 rpm max) with a square socket attachment if desired. The hand crank orientation can also be easily reoriented in 90° increments. Instructions for adjustment is on the Jack Options page. For more information, see the associated jack proposal drawings.

Precision Alignment

Cantilevered Precision Tip / Tilt / Rotate with Height Adjustment

Integrating boxes on the underside of a spacecraft without the use of overhead material handling equipment requires precision positioning and lifting capability of a Flotron Assembly Fixture. The lift mechanism, dual stage slide and tip/tilt/rotate stage on this Cantilevered Precision Alignment Fixture provide six degrees of freedom to accomplish this feat. Finishes and lubricants are compatible in an ISO 14644-1, (Class ISO 7) / FED STD 209E (Class 10,000) clean room spacecraft manufacturing environment.

Precision Alignment with Motorized Height Adjustment

The vertical axis of this RF Testing Fixture / Precision Alignment Fixture is powered by an electromechanical lift system with variable speed drive operating through a self- locking (for safety) ACME screw and a worm-gearbox. A spring-set back-up safety-brake is also used for redundancy to ensure no drift occurs from vibration or other outside loads. This Aerospace Tool can be lowered via its caster-jacks onto 3 adjustable tooling balls/pads. The precision tooling ball system can rotate the fixture and load around 3 perpendicular axes until the load is accurately aligned according to the customer supplied laser alignment system. At the rear of the fixture is an electronics rack for supporting the customer's electronics test equipment. The payload interface arm was designed considering the customers unique payload geometry without interfering with the test setup.

Modular Precision Alignment Base Fixture

This RF Test Cart / Precision Alignment Fixture base fixture is intended to be used with a customer provided payload interface. A large lift jack at the rear of the unit allows the technician to orient the customer’s payload interface so that it is perpendicular to the floor during payload integration. The caster jacks lower the Aerospace Tool so that a series of three precision alignment tooling features seat in their respective floor mounted receptacles. A precision slide is than translated at the back to pivot this Pointing Fixture (with payload integrated) and align for an RF testing application.

Precision Alignment, Rotation, Translation and Height Adjustment

This Precision Alignment Fixture / Cantilevered RF Test Fixture incorporates lifting and horizontal translation features to align a payload while it is mounted to a test plane. The rotation gearbox, lift jacks, and translation cross slide are non-back-driving. Tooling rods mounted to the base of the fixture locate the fixture between angle mounts that are bolted to the floor during docking. The mechanical inputs to the rotation, lift, and translation hardware all have locking features to eliminate undesired operator input.

Split Ring Rotation and Precision Alignment

Rotating a large cylindrical payload when interfaces are not available at its ends can in some cases be accomplished with split ring interface hardware. The top two halves of the rings are lifted off with a spreader bar, attached to the payload, and reattached to the bottom two ring halves. The spreader bar is removed, and the cylindrical payload is free to rotate. The Test Fixture is capable of rotating the payload 360 degrees with an angular velocity ranging from 1/10th RPM up to 1 RPM using a UL approved motor and control system via a pendant. A drive shaft drives the base of both rings and four idler wheels on the frames support ring rotation. A tow bar and motorized mover were provided to tow/transport the testing fixture. A leveling jack on the front of the fixture seats in a precision receptacle on the floor for repeatability and the motorized mover can pivot the fixture in an arc around this point.

Single Axis of Rotation for Precision Optical Alignment

This Spacecraft Optical Test Fixture has a single axis of rotation and a load rating of 600 lbs. Similar to the Dual Axis Rotate and Precision Alignment Fixture, this Aerospace Tool is designed to support assembly, integration and test operations in addition to optical alignment. Clearance lockout features, including lock rods, index locking screws, removable leveling feet (not shown), ensure that, when a 10 gram load is applied, the resulting angular deflection is less than 5 arc-seconds. Shock absorbing casters offer payload protection during transportation. Removable forklift tubes are constructed from aluminum material. Push bars provide an ergonomic interface for the technician to transport and navigate the Aerospace Tool (with payload integrated) through hallways and over varying terrains.

DSC-P1

(Hand Turned/Pinned Interface)

Load Rating: 700 lbs Cantilevered 24”
(See dimensional drawing sheets 3-6 for load curves)

Payload Max Swing Radius: 29”
Max Torque (Secondary Axis): 10,000 in-lbs

Product Features

Safety Factor: 3 for Yield & 5 for Ultimate
Rated Load Capacity: Dynamic, 0″ to 4″ eccentricity: 700 lbs. (317 kg.) Cantilevered 24” (609mm)
Operating Temperature: +32 to +104 °F (0 to +40 °C). Contact factory for special applications with extended operating temperatures.
Materials: Steel and aluminum construction. Stainless steel fasteners.
Dual Pinned Interface: Redundant Pins for safety, one spring loaded, one ball lock pin to prevent interface rotation. Interface must be in payload vertical orientation (interface surface parallel to floor as shown) before removing rotation lock pins. Pins cannot be removed in any other orientation.
Adjustable Interface Height: Eight bolt positions to ensure that payload CG is close to primary axis of rotation centerline. Four lift points integrated into frame for bolt position adjustment or for lifting empty cradle. Guide blocks included to facilitate adjustment.
Optimized Design: Cradle analyzed with FEA to optimize design to be high capacity yet light weight.

Standard Configuration (For additional options click on “Configure a Flotron Cradle” button above or view dimensional drawing for detailed information)

Finishes/Lubricants: Class 10k (ISO 7 cleanroom compatible finishes) – Cradle powder coated textured Flotron blue color; stainless steel hardware; aluminum parts chem film or hard anodized; Mobiltac 375NC (or equivalent) to all slewing ring teeth; slewing ring inner raceway lubricated with Mobilux EP2 (or equivalent). Fasteners lubricated with Loctite 242 blue or Krytox GPL 207.
Cradle Length: 60” Between Mounting Interfaces. (Special cradle lengths available in 20” increments from standard).

Interface Bolt Pattern: ESPA Grande/MLB interface. 36X ¼-28 UNF threaded holes on a Ø24” bolt circle.

SFP-759-EML

Large Swing

Large Swing Radius with Mechanical Height Adjustment

In addition to offering the traditional axis of rotation with a large 100” swing radius, this Spacecraft Positioner has synchronized mechanical lifting capability with a single input hand crank. The risers can be raised and lowered with the payload integrated. The design intent of this tool is to position the spacecraft at an ergonomic height for the technicians during assembly, integration and test operations and then provide vertical lifting capability to raise the spacecraft payload and provide swing clearance for ergonomic rotation. This effectively provides technicians access to all sides of the spacecraft during processing. The load capacity of this mechanical ground support equipment is 4,000 lbs considering SFy = 3 and SFu = 5 in addition to a simultaneous dynamic loading condition of 0.5G horizontal (worst case direction) and 1.0G vertical for both stress and stability. The leveling jacks allow the operator to level the Rotation Fixture on uneven floor terrain. The lock rods are rigidly attached between the frame weldment and the rotation axis index plate to eliminate radial backlash.

SFP-747-EML

Payload Interfaces

Turbopump Assembly Rotation Fixture

The 61700 is designed to support a complex geometry payload. The Rotational Holding Fixture has the footprint of an off-the-shelf Flotron Model XD747 with twice the load capacity. The load rating of this fixture was doubled by increasing end frame component cross sections and wall thicknesses in addition to incorporating Flotron’s 800 series hardware and coupling system. Flotron also designed and manufactured the precision tooling that supports the payload. A stainless steel base plate mounts between the fixture interfaces. This heat treated base plate was water-jet cut to match payload geometry and then machined. A set of precision machined brackets mount to the top face of the base plate and a set of precision machined tooling pins interface the payload through these brackets. Two of the bracket assemblies incorporate spherical bearings that are used to assist with angular alignment.

Manual Composite Operations Rotation Fixture

The 45000 is a custom rotational holding fixture that utilizes a gearbox similar in size to that used on our 900 series fixtures. The fixture is designed to support a curved wing skin in a large perimeter frame that was also designed and manufactured by Flotron. Precision mounting of the wing skin to the perimeter frame at the correct angle and true position was accomplished by utilizing a CMM during the welding process and during assembly by incorporating custom designed interface clamps. Precision adjustment capability allows the customer to perform multiple operations at different stations without changing fixtures.

Clean Room Rotation Fixture with CG Offset Cradle

This unit is designed to be similar to the 800 series while meeting custom specifications. It retains the low backlash, stair step resistant gearbox design of the 800 series as well as its stiff high load capacity frame. However, the frame is highly modified in order to meet the customer's requirements. It also includes a special mount for holding and counter balancing the customer's load. The unit is supplied with the clean room option that includes electroless nickel plating on all steel parts, stainless steel hardware, including the caster frames, and high gloss epoxy white paint on the gearbox housing.