Engineering Division 1

PHENIX Vertex Tracker ProductionStatus and Schedule

Eric Anderssen, LBNL

Engineering Division

Outline

• Manpower capabilities, workload, and environment• Description of work, by project

– Generalized production– Brief overview of the steps required for each

deliverable to better understand scheduled tasks– General ties to cost estimates’ line items

• Overall Schedule– PHENIX deliverables share resources with both other

projects and separately funded PHENIX deliverables– Integrated schedule and resource availability

• Detailed Discussion of deliverable Milestones by Account Number– Each deliverable is defined in a SOW, discussion will

be by SOW deliverable• Integration with Future Work

– Layer ¾ supports, Station Disk Supports

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Engineering Division

Manpower Team

• Assembled team has extensive experience with similar structures based on ATLAS and ATLAS Upgrade work to date; most have driven the developments of the technologies employed

• Tom, Mario and Greg are direct reports; Dave Uken by contract; Kurt and Rodney by agreement (as required—others are available)

• Availability is negotiated across projects; currently PHENIX has highest priority

Name Function Expertise

E Anderssen Engineer, PISTAR HFT Project Engineer; ATLAS Pixel Project Engineer; Built STAR TPC Field Cages; 20yrs composite structures

Dave Uken Contract EngineerATLAS Pixel Service Panel integration; Tooling for assembly of ATLAS Pixel Components; 4yrs on ATLAS; 20+ yrs product design

Tom Johnson Tech III, LeadLead Tech ATLAS Pixel; Assembly, Installation, Service Termination ATLAS Pixels; All composite deliverables for ATLAS Pixel; 10yrs LBNL

Mario Cepeda

Tech IIILead for ATLAS Upgrade work; 35yrs at LBNL (numerous projects, many for Bevatron Biomed); All composite deliverables for ATLAS Pixel

Greg Klever Tech I Trainee

Kurt Krueger Tech III, matrixed20+yrs race car/motorcycle fabrication; 10yrs at LBNL; Fabricated all bent tube services for ATLAS Pixel; 5yrs ATLAS Assembly

Rodney Post Tech III, matrixedHead of LBNL Optics shop; 30+yrs at LBNL; 7yrs ATLAS Assembly

Engineering Division

Strip Pixel Tube Production

• Tubes stored dry after cleaning before bonding• Production rate faster than assembly rate, not on

critical path• Initial yield problem solved—rejects had non-

compliant barb-end bends

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Engineering Division

Strip Pixel Foam Core

• All foam blanks complete• After bonding blanks to bottom

face-sheet, trough for tube is machined

• Assemblies are batched up to this phase to allow more efficient interaction with Shop

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Engineering Division

Ready for Machining

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Engineering Division

Strip Pixel Stave Bond Stations

• 4 bond stations, 2 Long/2 Short, used for every bond operation

• Aim for one operation all tools each day• Rate will drop in half once short staves

are complete• Have been losing Mondays in winter—

tool/table temps below 61F out of tolerance– Facilities looking into re-programming

controller for HVAC

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Engineering Division

Strip Pixel Stave Assembly Status• Status Spreadsheet updates

~weekly and posted• “Percent Complete” is only a

rough metric; ignores rejects• Reports only ‘Assembly’ of the

components• All component and tooling

manufacture is 100% complete• Each box averages~1hr labor

~130hrs total• ETC ~$16k

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Engineering Division

Strip Pixel Tube Production Status

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• Separate Sheet in previously mentioned spreadsheet

• Nominally for internal tracking rather than reporting—aimed at assuring sufficient tube availability to support stave assembly

• Boxes in first column are ~1hr, remaining boxes thru geometry check ~0.5hr each ~50hrs

• ETC ~$7k

Engineering Division

Strip Pixel Stave ETC

• Funds Remaining ~$29k, ETC ~$23k• Burn rates in Dec, Jan feuled by fabrication of parts and tooling• Remaining 180hrs limited by tooling and cure-cycles• 130hrs of assy is critical path, max burn rate ~4hrs/day

~32days remaining.– Batch machining and survey accelerates this some– After completion of Short Staves, rate drops to 2hrs/day

(only 2 tools), balanced with batching…

• Earliest finish 1-April, more likely Mid-April10

Engineering Division

Barrel Space Frame Tooling

• Assembly and trim tooling completed late Jan– Will need to modify for shorter support beams

• Lamination tool delivered last rather than first; proved difficult to fabricate

• Lamination tool delivered last week; needs surface work (polish) to remove/round dings from rolling shell

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Engineering Division

Barrel Space Frame Components

Components Required

• 2 Half Shells• 4 Support Beams• 4 Gusset plates

• Gusset plates complete• Support beam plate complete, in

shop for machine to shape– Need to re-program cut-paths after

recent change in design

• Half shell laminates take 1day each to cure, another 2 to trim– First article is used for practice

• Bonded assy is a 1day operation after dry fit of parts

• Expect completion by end of March– Need to schedule work around trips

to BNL—I should be present for final bond and tooling modifications

• Prefer to delay—shell is fragile w/out L4 support or equivalent– May need to design/fab temp

support if required earlier

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Engineering Division

Pixel Layer 1 Support

• 4 total; 2left, 2right• 2 right assemblies complete• 2 left require stave mount bonding• Left-handed blocks bumped to

machine Strip Pixel Stave inserts• Received parts yesterday• 2 bond operations required to

complete• Should be complete early next

week

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Engineering Division

Pixel Layer 2 Supports

• All core-panel assemblies complete

• All blocks bonded onto panel assemblies in one operation

• Also expect completion next week

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Engineering Division

Barrel Space Frame and Pixel Supports

• $37k remaining, ETC ~$25k (need to add mods/reinforcement if required)• This is a ‘Fabrication’ account, i.e. money arrived via Fin, but estimated at

WFO rates. Burn rate is lower due to lower overhead– Included prototype Strip Pixel Staves for ~$15k

• ~160hrs to complete, 112 on critical path (Space Frame), again tooling limited, max ½ time burn rate, 28days for earliest completion

• Earliest Completion April 1 for Space Frame; Pixel supports as noted earlier

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Engineering Division

Pixel Staves

• 40 acceptable staves complete• $1.5k remains in account after making 2 more

omegas• No more M55J on hand to fabricate more• Sufficient parts to assemble 2 additional

staves, $1.5k barely sufficient• More than 2 requires more material, for

omegas and thermal planes, and machining more mount blocks

• Plan to dry-fit staves still at LBNL onto Pixel Barrel Mounts after their completion next week

• Will send them onto RIKEN shortly thereafter

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Engineering Division

FVTX Sensor Backplanes• ~2wk delay on initial startup this year

– Material (all) moved offsite over break to mitigate risk of freezer failure during shutdown

– Delayed transfer back until monitoring upgrade was complete

• First test panel delivered 8L/9S wedges– Bag-side of laminate not within flatness spec

• Second test panel complete; wedges being machined– Used caul-plate on bag-side—improved flatness, but part ~100m too

thin (add back removed central 0)– Improve part density (expect more than 8/9)– Expect to ship next week; will finalize interface to DB at that time

• If parts survey flat, will launch production of plate fabrication (2d/plate, ~8plates)– Will machine first plate immediately, but prefer to batch machine rest

in 2 batches after the first plate, (3 batches total, 4 if yield is an issue)

• Assuming successful survey, first production batch ships week of 8-March; remaining batches every 2 wks thereafter as required

• Detailed schedule relies on interface with shop; minimizing batches minimizes uncertainty

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Engineering Division

FVTX Support Cages• Contract for tooling design in works

– Design changes to support beam need to propagate to model before assembly tooling designed

– Can start on lamination tool, but won’t issue to shop without updated model for verification (due diligence)

• Problem with CN60 order ($20k)– FVTX needs ~6sqm; was in stock last May when originally

quoted– Fabric supplier out of stock on pre-woven material; min

order from Fabric vendor is 50sqm. Costs ~$500/sqm (note vendor supplies Tencate)

– Investigating sharing cost with other programs that will require CN60 (STAR/ATLAS)

– Will investigate buying dry, impregnating only what’s required

• Late May, Early June delivery not unreasonable– Need to propagate in schedule—only got thru wedges in

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Engineering Division

L34 Support Status

• Same cost model as Pixel Barrel Supports, similar labor cost, increased materials

• Waiting for M55J quote; requested at same time as CN60 quote

• Can likely issue SOW/Estimate by end of week• Work not yet scheduled but understand June

delivery desired • Crude estimate of 8-10wks production duration

from onset of funding

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