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GLAST Large Area Telescope: Tracker Subsystem WBS 4.1.4 6D: Composite Panel Fabrication Thomas Borden Stanford Linear Ac PowerPoint Presentation
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GLAST Large Area Telescope: Tracker Subsystem WBS 4.1.4 6D: Composite Panel Fabrication Thomas Borden Stanford Linear Ac - PowerPoint PPT Presentation


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Gamma-ray Large Area Space Telescope. GLAST Large Area Telescope: Tracker Subsystem WBS 4.1.4 6D: Composite Panel Fabrication Thomas Borden Stanford Linear Accelerator Center Tracker Subsystem Engineer tborden@slac.stanford.edu. Agenda. Facilities Tray Description and Types

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Presentation Transcript
slide1

Gamma-ray Large Area Space Telescope

GLAST Large Area Telescope:

Tracker Subsystem

WBS 4.1.4

6D: Composite Panel Fabrication

Thomas Borden

Stanford Linear Accelerator Center

Tracker Subsystem Engineer

tborden@slac.stanford.edu

agenda
Agenda
  • Facilities
  • Tray Description and Types
  • Manufacturing Flow Plan
  • Tooling
  • Quality Assurance
  • Trays Production and EM Results
  • Conclusions
facilities
Plyform SpA, Varolo Pombia; Prime Contractor to INFN for Tray Fabrication and Assembly,

Subcontractor for closeout machining

Subcontractor for insert machining

INFN Pisa; ESPI Test of bare panels

Holographic test

System can detect de-lamination defects in face sheets, between face sheet and honeycomb and between face sheets and closeouts

Centrotecnica, Milan; Tray vibration testing of panels with bias circuits and tungsten

Qualification levels

Verification of fundamental frequency

Workmanship

Facilities

Carbon-Fiber Wall

manufacturing plan
Manufacturing Plan

Production Flow Diagram

Machine Closeouts (outside Vendor)

Incoming Material receiving Inspection ref I.L. 02-105

Dimensional Verification of Closeouts

Face Sheet Lay-up ref I.L. 02-106

Install Inserts ref I.L. 02-117 &

I.L. 02-118

Assembly of Face Sheet with Honeycomb with Redux 312 UL

Dimensional Verification of inserts

Assembly of Face Sheet/Honeycomb and Closeouts ref I.L. 02-118

Dimensional Verification and ESPI Testing (workmanship)

manufacturing plan1
Manufacturing Plan

Production Flow Diagram Cont.

Assembly of Bias Circuits to Panel Ref I.L. 02-118

Assembly of Tungsten to Panel Ref I.L. 02-118

Final Trimming and Cleaning Ref I.L. 02-116

Final Dimensional Verification, weighing and QA

Workmanship Vibration Testing at Centrotechnica

Ship to INFN Ref I.L. 02-119

All assembly processes per LAT-PS-01584

tooling
Tooling
  • All assembly tooling documented and released
  • All assembly tooling, and procedures, “proof tested” with EM hardware
  • Additional copies of “standard” tray tooling in production
  • Sufficient tools available to support production rate of 10 standard, 4 thick, one top and one bottom tray(s) a week
tooling1
Tooling

Tray assembly bottom plate

Tray assembly top plate

tooling2
Tooling

Closeout bars

tooling3
Tooling

Closeout Insert

Assembly Tool

quality assurance
Quality Assurance
  • All processes controlled by ISO approved procedures at Plyform (I.L. 02-111, I.L. 02-112, I.L. 02-113)
  • Regular INFN-Pisa oversight at Plyform
  • Data Base Developed
  • Nonconformance Reporting
    • Plyform nonconformance reporting system per I.L. 02-
    • LAT-PS-01584 specifies the following major Nonconformance reporting limits require halting production:
      • Rejection during dimensional inspection of more than 4 of the trays produced out of a continuous sample of 40 trays.
      • Rejection during dynamical tests of more than 4 of the trays produced out of a continuous sample of 40 trays.
      • Accidents resulting in irreparable physical damage (serious enough for tray rejection) to more than 2 of the trays produced out of a continuous series of 40 trays.
data base
Data Base
  • Main form:
  • select tray type
  • access all tray data
  • Tray data sheet:
  • assembly data
  • bare panel measurements
  • final tray measurements (TBD)
  • subcomponents IDs and data
  • click on buttons to access details

Luca Latronico – INFN Pisa

data base continued
Data Base continued
  • Bare panel dimensions (after clicking on dimensions button):
  • plots measurements of reference points along tray structure
  • plots sides BD/AC
  • flatness, orthogonality, parallelism seen by moving slide bar

Luca Latronico – INFN Pisa

Luca Latronico – INFN Pisa`

data base continued1
Data Base continued

Each submask containing detail measurements data and has a clickable legend for reference – MCM legend shown here for example

Luca Latronico – INFN Pisa

data base continued2
Data Base continued

Connected to Ladders DB – this mask tracks ladders IDs, location and currents (pre-encapsulation and post-encapsulation) as measured at G&A/Mipot.

Location/names given according to LAT-TD-00376 convention, e.g.:

F – Front Side

B - Back Side

0 - connected to FE 0 side

….

3 – connected to FE 23 side

Luca Latronico – INFN Pisa

slide17

GLAST:Gamma Ray Large Area Telescope

Trays Production

&

E.M. Results

R. Bagagli

INFN - sez. Pisa

slide19

E.M. Results: ASSEMBLING IMPROVEMENTS

  • 1) Dimensional Check procedure on the tool:
  • measure the tool in six points with a caliber
  • fill a form to compare the reference values with the measured values
  • If measured values are otuside ±0.03mm, then the operator has to adjust the lateral wall and to check again the value
slide20

E.M. Results: ASSEMBLING IMPROVEMENTS

Glue-line on the sandwich with dispenser on the bonding area (to avoid no-bonding area)

Vacuum bag at standard temperature (to avoid air inclusion)

  • The glue fills all the bonding area
  • The exceeding quantity goes out and will be removed in Refining Step
slide21

Upper plate

Reference wall

Tray

Skin

Lower plate

Tray assembly tools

Tungsten assembly tool

Tray assembly tool

Tray assembly rate capability: 3 trays/day

Trimming tool

Kapton assembly tool

slide28

Bare Panel: N.D.I. Test

ESPI: Thermal Loads very effective to detect bare panel defects

Skin-closeout debonding

Honeycomb crash

Honeycomb – Skin debonding

slide29

TG07: Bare Panel + W + Bias Plane

ESPI: Vibration TEST

817Hz first resonance mode

1860Hz second resonance mode

conclusions
Conclusions
  • All documentation in place.
  • Database in place.
  • Production Readiness Review scheduled for April 15, 2003.
  • All tray materials needed are delivered or on order and will be available before need date.
  • Tray production will begin on May 1, 2003