atlas pixel detector february 2003 n. hartman lbnl 1 pixel support tube prr: assembly, production,...

February 2003 N. Hartman LBNL 1

ATLAS Pixel Detector

Pixel Support Tube PRR:Assembly, Production, Schedule

February 2003



Overview

• Assembly Breakdown Structure (ABS)• Assembly Processes and steps

– Assembly flow– Parts required– Tooling required

• Production Information– Tooling status– Production plan

• Resources• milestones

– Schedule



Assembly breakdown structure (ABS)

1 Barrel PST Assembly1 Adhesive PST1 Solder8 Barrel Wire Harness

16 Strain Relief Blocks8 Connectors

1 B.S. With Pixel Mounts1 Adhesive PST1 Pixel Mount Block -XA1 Pixel Mount Block -XC1 Pixel Mount Block +XA1 Pixel Mount Block +XC

1 B.S. with SCT Mounts1 Adhesive PST

4 PST Mount Block Assy1 PST Mount Insulator Shim1 PST Mount Block

1 B.S. with Mount Pads1 Adhesive PST4 Barrel Mount Pads

1 B.S. Structural1 Adhesive PST

12 Hoop Hat Stiffeners1 Vee Rail Barrel1 Flat Rail Barrel

1 B.S. with Flanges1 Adhesive PST

2 B. Flange Assembly1 Adhesive PST1 Flange Backing Ring1 Flange

1 PST B.S. Laminate1 Shell Laminate

28 Heater Panels

Barrel PST assembly shown; b.s. = barrel shell.



Assembly Steps and Procedures


ATLAS Pixel DetectorAssembly Flow – How is the PST Assembled?

21

1

Backing Ring

Flange Face

Flange Asm

Barrel Shell

Barrel Shell with flanges

barrel shell structural

barrel shell w/ mount pads

barrel shell w/ SCT Mounts

5

3

Hoop Element

Hoop Stiffener

11

4

Flat RailV-Rail

Mount Pad

Insulator

SCT Mount Block Asm

1

14

SCT Mount Block



STEP 1 – Flanges Assembled

Flange Cross Section

Single piece skirt and face (L shape)

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

Backing ring

Flange Face



Bond Jig Details

Accurate holes on horizontal diameter Of flange provide references for all Bond operations.

Bars provide lengthReference only (invar)Gussets provide perpendicularity



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


ATLAS Pixel DetectorSTEP 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)


ATLAS Pixel DetectorSTEP 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)



• 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

STEP 4 – Mount Block Locations Transferred from SCT to Mistress Gauge



• 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

STEP 4a – Mount Block Locations Transferred from Mistress Gauge to PST Bond Jig



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



STEP 4c – Mount Block Assy’s Bonded to Shell/flanges

• 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

Attachment surface to jigBackside of bond surface



STEP 5 – Pixel Mount Blocks Bonded to PST

Pixel MountRamp

• 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)



Sample Assembly FollowerPart ID

Part Name Vee Rail Barrel

Part Number 25O113

Project Number ATL-I-ED-0008

Serial Number

Tooling IDTool Part #

Tool Serial #

Position on Tool

Material ID Mat 1 Mat 2 Mat 3

Type Name EX1515 P30 Fiberglass mat, 10 gsm

Batch/Serial #

Certification Ref

Process IDProcess Doc Ref

Cure Cycle Spec

Resin Control method

CPC-NT serial #

QUALITYMass Pre-Process

Mass Post-Process

Resin Removed

Survey Data File Ref

Raw material data (out time, date, remaining mass) are kept in log book at freezer.



Production Planning



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



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



Mandrel and Autoclave Carts

Production Mandrel and cart have been designed and quoted by outside vendor - ~32K USD



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)



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



Full Schedule



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

atlas pixel detector february 2003 n. hartman lbnl 1 pixel support tube prr: assembly, production,...

Documents

atlas pixel detector

hartman lbnl

flange plate shell

shell process flange

masked shell

pst shell

flange adhesive

jig adhesive