Yehonathan and Tega found that the new PR3 and SR3 delivered in 2020 is in fact 3/4" in thickness (!). Digging the past email threads, it seems that the spec was 10mm but the thickness was increased for better relieving the residual stress by the coatings.
There are a few issues.
1. Simply the mirror is too thick for the ring. It sticks out from the hole. And the mirror retainers (four plastic plates) are too far from the designed surface, which will make the plates tilted.
2. The front side of the mirror assembly is too heavy and the pitch adjustment is not possible with the balance mass.
Some possible solutions:
- How about making the recess deeper?
In principle this is possible, but the machining is tricky because the recess is not a simple round hole but has "pads" where the mirror sits. And the distance of the retainer to the thread is still far.
And the lead time might become long.
- How about making new holes on the ring to shift the clamp?
Yes it is possible. This will shift the mirror assembly by a few mm. Let's consider this.
- How about modifying the wire blocks?
Yes it is equivalent to shift the holes on the ring. Let's consider this too.
1. How to hold the mirror with the retainer plates
[Attachment 1] The expected distance between the retainer plate and the threaded hole is 13.4mm. We can insert a #4-40 x L0.5" stand off (McMaster-Carr 91197A150, SUS316) there. This will make the gap down to 0.7mm. With a washer, we can handle this gap with the plate. Note that we need to use vented & silver plated #4-40 screws to hold the plates.
[Attachment 2] How does this look like when the CoM is aligned with the wire plane? Oh, no... the lower two plates will interfere with the EQ stops and the EQ stop holders. We have to remove them. [Attachment 3]
We need to check with the suspension if the EQ stop screws may hit the protruded optics and can cause chipping/cracking.
2. Modifying the wire block
[Attachment 4] The 4x thru holes of the wire block were extended to be +/-0.1" slots. The slots are too long to form ovals and produce thin areas. With the nominal position of the balance mass, the clamp coordinates are y=1.016 (vertical) and z=-2.54mm (longitudinal).
==> The CoM is 0.19mm backside (magnet side) and 0.9134 mm lower from the wire clamping points. This looks mathematically doable, but the feasibility of the manufacturing is questionable.
[Attachment 5] Because the 0.1" shift of the CoM is large, we are able to make new #2-56 thread holes right next to the original ones. The clamp coordinates are y=1.016 (vertical) and z=-2.54mm (longitudinal).
==> The CoM is 0.188mm backside (magnet side) and 0.9136 mm lower from the wire clamping points. With the given parameters, the expected pitch resonant frequency is 0.756Hz
- Modify the metal ring to shift the #2-56 threads by 0.1"
- The upper two retainer plates will have #4-40 x 0.5" stand off. Use vented Ag-coated #4-40 screws.
- The lower two are to be removed.
- Take care of the EQ stops.
- Of course, the best solution is to redesign the holder for 3/4" optics. Can we ask Protolab for rapid manufacturing???
Why did we need to place the mass forward to align the 1/4" thick optic?
We were supposed to adjust the CoM not to have too much adjustment. But we had to move the balance mass way too front for the proper alignment with a 1/4" thick optic. Why...?
This is because the ring was designed for a 3/8" thick optic... It does not make sense because the depth of the thread holes for the retainer plate was designed for 1/4" optics...
When the balance mass is located at the neutral position, the CoM coordinate is
x 0.0351mm (x+: left side at the front view)
y 0.0254mm (y+: vertical up)
z 0.4493mm (z+: towards back)
So, the CoM is way too behind. When the balance mass was stacked and the moved forward (center of the axis was moved forward by 0.27"), the CoM coordinate is (Attachment 6)
This makes sens why we had to move the balance mass a lot for the adjustment.