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DUNE FD APA Production Planning Update

DUNE FD APA Production Planning Update. 5 February 2018 Daresbury Lab APA Workshop. Bob Paulos – PSL Alan Grant – Daresbury Laboratory Pam Marr Laundrie - PSL. How fast can we go?. That depends On what we know about how long it takes today

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DUNE FD APA Production Planning Update

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  1. DUNE FD APA Production Planning Update • 5 February 2018 Daresbury Lab APA Workshop Bob Paulos – PSL Alan Grant – Daresbury Laboratory Pam Marr Laundrie - PSL

  2. How fast can we go? • That depends • On what we know about how long it takes today • How much improvements to process will speed things up • What assumptions one makes about “factory style” construction • An analysis by shift reveals that it currently takes about 64** shifts to build an APA

  3. Shift Comparisons Oct ‘17– Jan ‘18 • Mesh • X • V • U • G • 030 Components • Pack > Crate • OCT(est)Latest APAs • 6 5.5 • 10 9 • 16 • 20 17 • 20 9 • x 4.5 • x3 • 80 64

  4. Proposed Process Improvements – APA Assembly / Construction • Winder Head • Tension Feedback / Clutch • Compensator Latch-Up • Interface Arms • Full Plane vs ½ Plane Wind • ½ Way Tension Eliminated • Board Epoxy/Gluing Process • Stencil Material(s) • Multiple Stations (V, U, Cover) • Improved Dispensing Techniques • 2216G – Pre-Forms to be investigated • All Operations - In WINDER • Minimize Transfers • Eliminates (some) Set-Up Times • Automated Soldering • Must work on 4-5 planes • Soldering Head on the Winder ? • Rosin Core solder Flux = MESS • Tension Measurements • Different Equipment Configuration • Faster Process • Modular Mesh Design • • Utilize “window screen” approach

  5. Estimated Time Savings per Improvement • Est. Time Savings • Winder Head2 • Interface Arms 5 • All Operations in Winder1 • Gluing Process Improvements 3 • Tension Measurement Method 2 • Automated Soldering XX • Modular Mesh3Total = 16

  6. Construction schedule assumptions • - Assume 150 APAs built in US and 150 in UK • - With improvements to winding, tension measurements, board mounting and epoxy: 64 shifts => 50 shifts per APA • - This model also assumes that frames with mesh and boards fully processed are available on time (don’t starve the factory for parts) • - Assume three* production lines in both US and UK • - Each production line includes a winder and all necessary tooling and operates 2 shifts per day, 48 weeks per year (maintenance and holidays), 10 APAs per production line • - 150 APAs can be built in ~2.5 years (2021 – mid 2023) * Was four in August 2017

  7. Beyond APA Construction • To meet the APA construction schedule, each factory will have to not only have the requisite resources and space, they will need a reliable source of materials to build with. • There are many ways to divide this effort up, we present one way. Nonetheless, we need to identify responsible institutions for each item and work on a plan for supply rather soon. • We also have discussed a number improvements to the APA process in previous slides. Again, we need to decide who is responsible and others than can provide technical help on each of these items.

  8. Beyond APA Construction – Material Supply Work Packages • 1) Frame Construction • • This effort requires specialized resources and skills – metrology, weld shop with certified welders, technician support, large assembly area, proper tooling, etc. • • At least two approaches are viable: procure completed frames delivered ready to use, or procure all major machined and welded elements then assemble and survey in-house • • Recommend two sources of frames for the project, one in the US and one in the UK. In the US, PSL should take this on given their long history in the design and building of frames. • 2) Mesh Construction • • It is highly likely that we will want to explore and implement a new approach to mesh installation that uses a modular “window screen” . This will effort will require some early engineering to work out the detail design of the frames and how they mount. An institution with SBND experience may be ideal.

  9. More Material Supply Work Packages • 3) Wire Procurement (and spools) • • A somewhat straightforward task, but, needs a reasonable level of engineering/QA oversight. Spools are part of this effort as the supplier will wind directly onto our winder head in the quantity we need for efficient winding. • 4) Comb Procurement • • Should be straightforward. A supplier exists, modest level of QA is required. • 5) Side and Foot Board Procurement • • These boards require an understanding of the mechanical requirements and the operations that a vendor will perform. Electrical traces but no components. ~180 per APA, so for 150 APAs about 27,000 boards total => big QA and documentation effort....

  10. More Material Supply Work Packages • 6) Wire Bonding Boards • • Outsource these boards and provide QA and inspection. • 7) G bias and Adapter Boards • • Outsource these boards. Modest complexity. Will require QA, and inspection. Limited testing of bias boards. • 8) CR Boards • • These boards are quite unique because of HV components, thickness, leakage requirements. Many man-months of engineering and source selection have already gone into these boards. I propose that PSL continue to take this task on for DUNE. • 9) Winders and Tooling • • The approach taken will likely be dependent on factory capabilities and needs. More discussion needed.

  11. Process Improvements • Interface Arm Improvement • • This effort is already underway and is being led by Daresbury. PSL will participate. • 2) Mesh Improvements/Change to Modular Design • • Design and prototype changes to mesh installation that allow smaller (~1.2 x 1.2m) mesh frames that can be easily installed in less time and with modest tools. This approach could easily save more than a day per APA in install time. • 3) Epoxy Process Improvements • • Improved tooling or different approach to accelerate cure or ease epoxy handling. Investigate pre-forms. • 4) Improvements to Winder Head • • This effort is being led by Daresbury now and Kevin/PSL will participate. Improved tension control and feedback, better clutch, improved compensator.

  12. More Process Improvements • 5) Automated Soldering • • This should be investigated. We are less certain that this is viable and/or will have a high enough benefit compared to the costs. • 6) Electrical Tension Measurements • • This is already underway at Manchester (Diego et.al.). This could provide a big benefit if the process can be performed safely on a DUNE APA and the APA board stack is redesigned to accommodate this type of testing. • 7) All Operations in Winder • • Requires design of custom platforms that are easily moved in and out of place and protect winder from epoxy spill or solder splash. • 8) Winder Maintenance Plan • • PSL and Daresbury will collaborate.

  13. Shift Details

  14. Mesh Installation 8757 003 • Mesh Installed - (4) Sessions • Mesh attach jig attached to frame • Mesh panel placed onto frame in jig • Stretch - add Hold down bars / clamps • Double track tape applied • 2216 G painted along entire perimeter • inner / outer tape removed • (2) Conductive Epoxy spots applied • Overnight (12hr)epoxy cure cycle • Hold down bar / clamps removed • Excess mesh cut / removed • Perimeter of Cut edge inspected / vacuumed for stray wires • Finished edge re-taped 1” buffer zone • 2216 G is then applied (painted on) to seal the edge / overnight cure • (multiple personnel 5 – 6 ) • Sequence is repeated 4 X Requires ( 4 ) consecutive Shifts

  15. Comb Base Assembly(s) Installation 8757 003 • (4) Comb Base Assemblies across each Side of APA (8) total • (2) Install jigs, 48 hr operation Currently • DAY 1 • DAY 1 AM (2) Comb Base Assemblies Installed • DAY 1 PM (2) more Assemblies Installed • Overnight Cure • -------------------------------------------------------------------- • DAY 2 ( APA is flipped 180 degrees - Horizontally ) • DAY 2 AM (2) Comb Base Assemblies Installed • DAY 2 PM (2) more Assemblies Installed • Overnight Cure • CONSIDER MORE TOOLING / Decrease SHIFTS • 4 Assemblies Installed (Day 1) AM • 4 Assemblies Installed (Day 1 ) PM • Currently 1.5 Shifts to Complete

  16. X Layer 8757 002 • X - Layer Process Steps • Board Installation (Fasteners) • Transfer APA from Cart to Winder • Set Up Winder + BeCu wire quality check • WIND – entire 1st Half X - Layer • (Check wire tension once per board) • Measure pre-solder Tension Sample (100% ~ 1.5 hr) • Transfer APA from Winder to Cart • Tape / Solder all terminations (Install sm. Jack) • Flip Interface Frame • Install (5) remaining FOOT boards + Transition Bds • Transfer APA from Cart to Winder • Set Up Winder • WIND – entire 2nd Half X - Layer • Measure pre-solder Tension Sample (100% ~ 1.5 hr) • Transfer APA from Winder to CART • Tape + Solder (Install sm. Jack) + Trim excess wire • TEST – Continuity / Isolation / Leakage • Transfer APA from Cart to Winder • Measure 100% Post Solder Tension • Transfer APA from Winder to CART • ( 5 ) X – Transition Boards • X – Head Boards seen on both A + B sides of the APA (9) Shifts – US APA 3

  17. Frame Assembly w/ Four Wire Layers 8757 002 X Layer - Photos • APA being lifted back into the Process Cart after 1st Half X – Layer Winding has been completed. • Small CAPO installed for Tension Testing

  18. V Layer 8757 002 • V-Layer Process Steps • Board Installation • (20) Head / (10) Foot = Epoxy Process • (21) Each Side = Fasteners Only • (7) Transition Boards (for Winder) • Comb Installation (40) = Epoxy Process • Transfer APA from Cart to Winder • Set Up Winder + BeCu wire check • WIND – entire 1st Half V - Layer • (Check wire tension once per board) • Measure pre-solder Tension Sample • Transfer APA from Winder to Cart • Install small Jack (APA to Interface Frame) • Tape / Solder all terminations • Flip Interface Frame • Re-Install Transition Boards w/ new TSB • Install (5) more FOOT boards - Epoxy Process • Install remaining SIDE Boards (if needed) • V-Layer Process Steps (Continued) • Transfer APA from Cart to Winder • Set Up Winder • WIND – entire 2nd Half V - Layer • (Check wire tension once per board) • Measure pre-solder Tension Sample • Transfer APA from Winder to CART • Install small Jack (APA to Interface Frame) • Tape / Solder all terminations • Trim excess wire ends • TEST – Continuity / Isolation / Leakage • Transfer APA from Cart to Winder • Measure 100% Post Solder Tension • Transfer APA from Winder to CART (16) Shifts – US APA 3 excess retension (~2 )

  19. V - G Layer Operations - Photos • Proposed Operations • Moved to WINDER • Soldering • Gluing • Trimming Excess Wires • Electrical Testing • Head Board w 2216 G, then the striker tool fills in the stencil pattern, and pin-cover is removed prior to installation. • Soldering – occurs at each Layer • Applying 2216 G to a V-Comb, this operation occurs at V, U, G, and for the Comb Caps.

  20. U - Layer 8757 002 • U-Layer Process Steps • Board Installation • (20) Head / (10) Foot = Epoxy Process • (21) Each Side = Epoxy Process • (7) Transition Boards (for Winder) • Comb Installation (40) = Epoxy Process • Transfer APA from Cart to Winder • Set Up Winder + BeCu wire check • WIND – entire 1st Half U - Layer • (Check wire tension once per board) • Measure pre-solder Tension Sample • Transfer APA from Winder to Cart • Install small Jack (APA to Interface Frame) • Tape / Solder all terminations • Flip Interface Frame • Re-Install Transition Boards w/ new TSB • Install (5) more FOOT boards Epoxy Process • Install remaining SIDE Boards (if needed) • U-Layer Process Steps (Continued) • Transfer APA from Cart to Winder • Set Up Winder • WIND – entire 2nd Half U- Layer • (Check wire tension once per board) • Measure pre-solder Tension Sample • Transfer APA from Winder to CART • Install small Jack (APA to Interface Frame) • Tape / Solder all terminations • Trim excess wire ends • TEST – Continuity / Isolation / Leakage • Transfer APA from Cart to Winder • Measure 100% Post Solder Tension • Transfer APA from Winder to CART (17) Shifts – US APA 3

  21. G Layer 8757 002 • G-Layer Process Steps • Board Installation • Transfer APA from Cart to Winder • Set Up Winder + BeCu wire quality check • WIND – entire 1st Half G-Layer • (Check wire tension once per board) • Measure pre-solder Tension 100% • Transfer APA from Winder to Cart • Tape / Solder all terminations • Flip Interface Frame • Install (5) remaining FOOT boards • Transfer APA from Cart to Winder • Set Up Winder • WIND – entire 2nd Half G-Layer • Measure pre-solder Tension 100% • Transfer to CART / Tape + Solder / Trim… • TEST – Continuity / Isolation / Leakage • Transfer APA from Cart to Winder • Measure 100% Post Solder Tension • Transfer APA from Winder to Cart • ( 5 ) G –HeadBoards seen on both A + B sides of the APA • G –TransitionBoards (9) Shifts – US APA 3

  22. APA w/ Four Wire Layers - G Layer Photos • Equipment set-up for Tension testing. • Finished APA w / Four Wire Layers wound – sitting in Winder. • APA being moved to Red Rack for FARO measurements of Layer – to Layer spacing of wire planes.

  23. FACTORY APA 8757 030 • Configuration Shipped to CERN • An APA (Frame w 4 Wire Layers) • ( 9 ) types of Cover Boards installed to seal all solder joints on 4 sides of APA • Hardware attached for Cold Electronics installation (at USA + CERN) • Hardware attached for Structural Lift / Hanging purposes (at USA + CERN) • Ships Separate (YOKE + electronics) • Factory APA • A ‘cleaned’ Yoke is fit tested below. • Cover boards are epoxied to Head bds

  24. FACTORY APA 8757 030 COMPONENTS • YOKE - (shipped separately) • All Components • Cleaned • Assembled • Checked for FIT to APA • Structural Tests • Packed separately • CE (Fastener)Hardware • Various Brackets for CE and associated electrical hardware • Cleaned / Assembled • Checked for FIT to APA • Some shipped attached to APA • Some packed separately (2.5) Shifts for Mechanical

  25. FACTORY APA 8757 030 COMPONENTS • SHV Board installed. Cover boards taped and installed. • CR boards on the APA. • And a mock-up of the completed board stack. • Wire harness creation on an extra Head Tube.

  26. FACTORY APA 8757 030 Electrical Hardware • Electrical Components • (20) Adapter Board Assy • (20) CR PC Board Assy • (20) G Bias Filter BdAssy • (1) SHV Distribution Assy • Side A Bias Wire Harness • Side B Bias Wire Harness • PCB Components • Assembled in other Clean Areas • Installed in Clean Tent Area • Some attached for shipping • Some shipped separately (2) Shifts – US APA 3 For installation activity

  27. Hardware to Attach APA to Crate for Shipment • Wiring Harnesses installed, some CE hardware supports, and RED side covers that will allow panels to be installed to protect the wire layers during shipment. • (3) Shifts to cover APA for Shipping

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