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Pixel Support Tube WBS 1.1.1.1.3.5 Santa Cruz Cost Workshop July 9, 2003

Pixel Support Tube WBS 1.1.1.1.3.5 Santa Cruz Cost Workshop July 9, 2003. Pixel Support Tube (PST) Overview. PST Structure 3 Independent composite tubes Joined together with bonded flanges Mounted on specially designed flexures Support detector insertion rails

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Pixel Support Tube WBS 1.1.1.1.3.5 Santa Cruz Cost Workshop July 9, 2003

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  1. Pixel Support TubeWBS 1.1.1.1.3.5Santa Cruz Cost WorkshopJuly 9, 2003 N. Hartman LBNL

  2. Pixel Support Tube (PST) Overview • PST Structure • 3 Independent composite tubes • Joined together with bonded flanges • Mounted on specially designed flexures • Support detector insertion rails • Laminated with heater/EMI foils • Key Cost Points • Actual expenditures match ETC03 estimates very well • ETC03 to ETC04 costs show substantial decrease • Assumptions • Prototyping finishes Q4 of FY03 (almost finished now) • Production begins simultaneously in Q4 of FY03 • Remaining Prototype/Production time is staffed with MT (1/2 FTE) • All costs in FY03 $K N. Hartman LBNL

  3. PST Deliverables • 3 Composite tubes • 6 Bonded composite flanges • Full Length insertion rails • Mount pads at forward and barrel (8 total) • PST Supports (8 flexures) • Pixel detector supports (kinematic, 4 total) • Heaters and EMI shielding (continuous over length) • All must be delivered by September - December ’04 • SCT installation is ~Dec. ’04 • Barrel mount pads are bonded using transfer jig from SCT (must be done during initial barrel assembly – about September ‘04) • Full PST must be present at LBL for dry-fit (summer ’04) • Installation work costed in separate installation plan N. Hartman LBNL

  4. PST Key Structures – Barrel Tube Hoop Stiffeners Shell Flanges Mount Pads Mount blocks Insertion Rails N. Hartman LBNL

  5. Shell Laminate with New Heater Panels N. Hartman LBNL

  6. Full length rails N. Hartman LBNL

  7. Mount Pads N. Hartman LBNL

  8. Flanges Backing Ring Bonded and Drilled flange On PST shell Flange face N. Hartman LBNL

  9. Bond Jig Barrel Length Bond jig Production jig setup for Prototype length PST shell N. Hartman LBNL

  10. PST Production Mandrel Shop Cart Autoclave Cart Rotation Head Detail N. Hartman LBNL

  11. FY03 Cost Tracking • Prototype Budget shows under-spending • Rail tooling (which was moved to prototyping budget) completed at lower cost with simpler tools • Production Budget shows over-spending • PST Mandrel costs increased to include additional carts and handling hardware • Overall FY03 Budget is “on-track” so far N. Hartman LBNL

  12. FY04 Costs N. Hartman LBNL

  13. Key Cost Points • Substantial Savings in Tooling and Fabrication • Rail designs simplified and tooling fabricated for reduced cost offsite (~20K savings) • Flange tooling simplified (26 parts reduced to 2) and fabricated onsite (~40K savings) • Some budget “re-allocated” • Insertion mechanism (see next talk) sub-task created • About 25K from PST budget “moved” to insertion mechanism prototyping and production N. Hartman LBNL

  14. Schedule Milestones - Slippage • Production Readiness Review • February 18, 2003 • Production Material Delivered • April 14, 2003 -> May 25, 2003 • Mandrel Delivered • May 1, 2003 -> June 9, 2003 • Production Begins • May 1, 2003 -> August 1, 2003 • Barrel PST Completed • September 14, 2003 –> December 1, 2003 • Forward PST’s Completed • June 1, 2004 • Pixel System Dry-fit (PST, BP Support, service panels, pixel frame) • July, 2004 – August, 2004 • Fit-up with SCT (transfer jig bonded) • September, 2004 • SCT/PST Installed • December, 2004 – January, 2005 N. Hartman LBNL

  15. Summary • Current Status • All tooling currently fabricated except for hoop stiffener tool and rail bonding jig (hoop stiffener tool is in shop now) • Prototyping • Must bond rails into prototype shell using rail bonding jig by end of FY03 • Production • Plan to begin barrel shell production by August 1 (3 months late) • Personnel • FY03 • Require 1 FTE until FY04 (476 hours) • Research assistant (350 hours) and part of Mech Tech available • FY04 • Require ½ FTE for all of FY04 (1032 hours) • Research assistant (550 hours) and part of Mech Tech available • Budget • Current spending (FY03) is on-track with last cost estimate • Redesigns of fabrication tooling and processes have saved about 70K from budget – these can be used to offset increases in other mechanics areas (particularly insertion mechanism) N. Hartman LBNL

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