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Pixel Support Tube PRR: Assembly, Production, Schedule February 2003 PowerPoint Presentation
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Pixel Support Tube PRR: Assembly, Production, Schedule February 2003

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  1. Pixel Support Tube PRR:Assembly, Production, ScheduleFebruary 2003 N. Hartman LBNL

  2. Overview • Assembly Breakdown Structure (ABS) • Assembly Processes and steps • Assembly flow • Parts required • Tooling required • Production Information • Tooling status • Production plan • Resources • milestones • Schedule N. Hartman LBNL

  3. Assembly breakdown structure (ABS) Barrel PST assembly shown; b.s. = barrel shell. N. Hartman LBNL

  4. Assembly Steps and Procedures N. Hartman LBNL

  5. Assembly Flow – How is the PST Assembled? Barrel Shell Flat Rail V-Rail Barrel Shell with flanges 1 1 Backing Ring Mount Pad 1 barrel shell structural 2 4 1 Flange Asm barrel shell w/ mount pads 5 Flange Face barrel shell w/ SCT Mounts Hoop Stiffener Insulator 3 1 Hoop Element 4 1 SCT Mount Block Asm SCT Mount Block N. Hartman LBNL

  6. Backing Ring Single piece skirt and face (L shape) Flange Cross Section STEP 1 – Flanges Assembled Backing ring • Process • Flange masked • Adhesive applied (bondline controlled with glass beads) • Backing ring weighted with caul plate • Assembly drilled with hole jig • Tooling required • Caul plate (Fabricated) • Drill jig (Fabricated) • QA Steps • Weigh parts before and after for resin content • Inspect datum hole positions after machining Flange Face N. Hartman LBNL

  7. Bond Jig Details Accurate holes on horizontal diameter Of flange provide references for all Bond operations. Bars provide length Reference only (invar) Gussets provide perpendicularity N. Hartman LBNL

  8. STEP 1a – Flanges Bonded to Shell • Process • Flange and jig masked • Shell centered in bond gap with shims • Flange sealed to bond jig • Adhesive applied behind flange • Adhesive pulled through joint with vacuum (from front) • Tooling required • Bond Jig (Fabricated for prototype length) • Barrel and Forward Length Spacer Bars (needed) • QA Steps • Remove from jig and weigh (resin control) • Inspect parallelism and flatness of flanges after bonding N. Hartman LBNL

  9. STEP 2 – Hoop Stiffeners and Rails Bonded to Shell • Process • Hoop Stiffeners • Applied before rails • Shell masked • Hoops assembled in place, as single bonded units, 3 parts at a time • Glass beads used to control bond line • Compression strap used to fixture while curing • Rails • Rails are affixed to ladder structure that runs through PST shell (with vacuum) and references to pins on flange plate • Adhesive applied to shell • Rail tool lowered into place • Tooling required • None for stiffeners (self-fixturing) • Vacuum rail jig attachment (needed) • QA Steps • Remove from jig and weigh (resin control) • Inspect positions of rails at flange ends (to ensure alignment when PST sections are mated) N. Hartman LBNL

  10. STEP 3 – Mount Pads Bonded to Shell/Flanges • Process • Machined mount pads affixed to bond jig extensions (referenced to accurate pins on flange plate) • Shell and mount pad masked • Adhesive applied to mount pad (bondline controlled by fixture) • Mount pad/jig extension moved into place • Tooling required • Bond jig extensions (fabricated) • QA Steps • Remove from jig and weigh (resin control) N. Hartman LBNL

  11. STEP 4 – Mount Block Locations Transferred from SCT to Mistress Gauge • SCT mistress gauge blocks register to PST Interface penetrations • Carbon fiber tooling bar Frame is bonded to them and supported in SCT barrel while adhesive cures Frame Gauge blocks N. Hartman LBNL

  12. STEP 4a – Mount Block Locations Transferred from Mistress Gauge to PST Bond Jig • Blocks machined to Surveyed position of PST mounts (relative to IP_Nominal) • Balls register Mistress gauge in proper orientation • Bond in SCT_Interface Transfer Feature N. Hartman LBNL

  13. STEP 4b – Mount Blocks Bonded to Insulators • Process • Both parts masked • Adhesive applied to mount block • Glass beads used to control bondline • Tooling required • None, self-fixturing • QA Steps • Weigh (resin control) • Measure thickness Fiberglass Insulative shim Mount block N. Hartman LBNL

  14. STEP 4c – Mount Block Assy’s Bonded to Shell/flanges Attachment surface to jig Backside of bond surface • Process • Inside of mount pad and mount block masked • Mount block inserted through mount pad, bolted to jig • Adhesive injected between mount pad and mount block bond surfaces • Tooling required • Bond Jig attachment pieces (Needed) • Mount block interfaces bonded into jig attachment with SCT mistress gauge in place (needed) • QA Steps • Remove from jig and weigh (resin control) • Survey positions of mount locations to SCT N. Hartman LBNL

  15. STEP 5 – Pixel Mount Blocks Bonded to PST Pixel Mount Ramp • Process • Outside of mount pad and pixel mount block masked • Mount pad affixed to jig that transfers position from SCT mount block jig • Adhesive injected between Pixel mount block and mount pad • Tooling required • SCT mount block tooling – used for both pixel and SCT mount blocks, as they are defined relative to each other (needed) • QA Steps • Remove from jig and weigh (resin control) • Survey positions of mount locations (including planarity) N. Hartman LBNL

  16. Sample Assembly Follower Raw material data (out time, date, remaining mass) are kept in log book at freezer. N. Hartman LBNL

  17. Production Planning N. Hartman LBNL

  18. Status of Tooling Items • Existing • Flange Tools • Face piece • Backing ring • Assembly (bonding) • Machining fixtures • Flange bond plates to PST • Mount Pad • Layup tool • Machining fixture • Mount pad bond parts to PST • Rails • Full length tool • Needed • Mandrel (Procure) • Cylinder • Cart • Stand • Mount bonding (In house) • SCT Mistress gauge • Bond jig attachments • Pixel mount bond parts • Rails (In house) • Bonding tool (vac fixture) • Hoop Stiffeners (In house) • Layup tool Main Bond Jig Parts are already fabricated N. Hartman LBNL

  19. Procurements/Responsibilities • Tooling • Only mandrel and carts/stands will be outsourced • Engineering design by outside vendor – complete • Awaiting quote for fabrication • Estimated delivery is 8 weeks • All other tooling fabricated in-house • Material • All material from Bryte technologies – ex1515 cyanate ester resin • Usual delivery time is 3-4 weeks • Material to be ordered by March 14 • Heater panels from outside vendor • Composite Parts • All parts made in-house, by LBNL technical staff N. Hartman LBNL

  20. Mandrel and Autoclave Carts Production Mandrel and cart have been designed and quoted by outside vendor - ~32K USD N. Hartman LBNL

  21. Production Resources • Manpower • 3 technicians now trained in composites • Schedule assumes ½ FTE technician over production period • Facilities • Autoclave (1.5 m id x 3 m long) • CNC ultra high-precision machining • Coordinate measuring machine • Cold storage (-40 Celsius, 3 m x 5 m) • Dedicated Layup facility (10 m x 10 m) N. Hartman LBNL

  22. Important Milestones • Production Readiness Review • February 18, 2003 – CERN • Full Size Mandrel and Material Ordered • March 1-14, 2003 • Production Material Delivered • April 14, 2003 • Mandrel Delivered • May 1, 2003 • Production Begins • May 1, 2003 • Barrel PST Completed • September 14, 2003 • Forward PST’s Completed • June 1, 2004 • Pixel System Dry-fit (PST, BP Support, service panels, pixel frame) • July, 2004 • Fit-up with SCT (transfer jig bonded) • September, 2004 • SCT/PST Installed • January, 2005 N. Hartman LBNL

  23. Full Schedule N. Hartman LBNL

  24. Potential Risks • Prototyping • Problems with rail riders – not yet designed (pixel and beampipe/services) • Production • Delays or problems in mandrel machining • Delay in mount transfer from SCT • Problems in schedule or performance of pixel package dry fit N. Hartman LBNL