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Module Assembly Procedures Chiho Wang Duke University. Module Assembly Procedure. Mount shell in assembly frame. assuming shell is cut to length, inner insulation is in place, and all the holes are made ... Install & glue cooling tubes
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Module Assembly Procedures Chiho Wang Duke University
Module Assembly Procedure • Mount shell in assembly frame. • assuming shell is cut to length, inner insulation is in place, and all the holes are made ... • Install & glue cooling tubes • Insert middle partition in module shell. Mount partition on assembly frame. • Insert radiator & partition from both sides of module. Mount partition on assembly frame as they go in. • Radiators can be held with several plastic rods going through straw holes to keep them aligned during the process. • Attach HV plate. • HV plate should have been fully assembled, including: • gluing all layers together. • HV resistor • capacitor sockets • kapton HV strip • HV tested
Module Assembly Procedure • Test HV between HV plate and shell. • Insert straws. Remove plastic rods. • Cover straw end with arrow head to avoid radiator material getting in the straw. • Alternate insertion direction in adjacent straws • Start from center, work spirally outward (or in a randomized order) • Fix HV plate and shell with a few drops of super glue • Align straw ends, and fix straws to HV plate with a small drop of super glue. • The drop of glue should be inside the HV plate hole, NOT on HV plate surface. • Apply glue to only one side of the straw. It’s to temporarily hold the straws in place. • Glue partitions to shell • Use Araldite 106. Control glue amount, so not to overflow to straws. • Cut partition ears and remove module from frame. (Now or later, either way)
Module Assembly Procedure • Insert and glue endplug + insert end wire support. • Hold endplug with a tweezers through the hole • smear a strip of conductive glue on endplug, ~ 60º wide • Insert endplug with glue facing toward HV pad. • Smear down overflow glue along straw and continue to HV pad. Apply a little more glue between straw and HV pad as needed. • Insert wire support into endplug • Glue wire support to endplug • put a small drop of Tra-bond 2115 between wire support and endplug and let it sip in. • Check HV connections. • Seal gap between straw and HV plate. • Use Araldite 106. • Should cover all around between straw and HV plate. Be sure to also cover between straw and endplug. Ok to cover over conductive glue. • Careful, not to cover capacitor sockets
Module Assembly Procedure • Pot back of HV plate with Tra-bond 2115 for gas seal • First use white rtv (removable) temporarily seal around shell--HV plate--cooling tube crack, any place that the glue may leak out. • Pull back radiator to avoid blue while potting • stick pins into sockets to avoid glue from getting in. • Watch the bottom of HV plate. Remove glue that leaks through, so that they don’t form a lump and block the straw or socket. • Insert capacitor barrel to HV plate • Attach tension plate • Components need be ready on tension plate: eyelet, resistor,sockets, gas fittings. • Temporarily fix tension plate with a few drops of supper glue.
Module Assembly Procedure • Stringing wire: • Mount module on stringing station with tension measurement setup (AF generator, speaker, scope …etc) • Attach wire length spacer in front of module. • Unroll sense wire with wire break onto pre-tension / length setting jig. • Attach temporary eyelet / taper pin for length setting. • Push lead wire through straw. • Run sense wire through ultra-sound cleaner and attach to lead wire (with super glue). • Turn on ultra-sound cleaner. Pull lead wire and bring sense wire through ultra-sound into straw. • Tension wire. (+~10gm to compensate pull in) • Pin wire at the end away from weight first. • Pin wire at the end near the weight. • Measure wire tension (re-pin near end if needed) • Cut off extra length wire. • Apply a drop of tra-bond 2115 on pin / eyelet for gas seal and strength at end of the day.
Module Assembly Procedure • Seal tension plate with Araldite 106. • around the edges • around capacitor barrel • Install capacitor • Insert capacitor with connecting sockets. • Insert capacitor ground wire to tension plate ground socket. • Bend wire to capacitor and solder to capacitor • Test HV • Inject RTV into capacitor barrel to reduce chance of HV surface break down. • Optionally, flow a thin coating of tra-bond 2115 on tension plate for gas seal • Do not do this with module standing vertical. Glue can get into tension plate and seal the straw. • Watch out not to seal sockets holes. • Gas leak test.
