Pixel Support Tube and Related

1
Pixel Support Tube and Related

• November 9, 2001
• Pixel Day
• E. Anderssen, LBNL

2
Overview

• Status of Work, technical and other
• PST and Supports
• Pixel Supports
• Service/Beampipe Supports
• Immediate plans
• Prototyping in 02
• Discrepancies
• All along the way

3
Chain of Support for PST to Cryostat
Side C
Side A
ID Flat Rail
View from topall Tube Supports are Horizontal
and Co-planar
TRT
SCT
PIXEL
SUPPORT
TUBE
Support Positions are shown, But constraint
conditions are Not indicated here.
ID Vee Rail
Properties TBD
Constraint TBD
4
Support Conditions of Beampipe

• Beampipe Cruciform Supports align with Stiffest
  part of PSTthe end flanges
• All support planes on frame are wires allowing
  longitudinal (axial) float
• One Z-Fixture is foreseen to take up ATLAS
  Access/Opening loads

5
Pixel Support Tube Mockup

• Mockup in three pieces to simulate independent
  parts of tube
• Goal is for full length of entire tube to
  simulate all installation scenarios
• Detector rails are removable, should modification
  be necessary
• Intend to run installation tests in 02

6
Rail Design in Support Tube
Vee and Flat rails were chosen to provide
pseudo-kinematic support for the detector during
delivery to the support points Rails are used
only for delivery, not support
mockup
7
PST Important Features
10
45
End Support
30
Hoop Hat Stiffeners (section view)
Bolt flanges
End Supports
Sct mount pads
End Plugs (1 mm equiv. carbon sheet)
8
Support Flange Bonded Assembly
Old design - now gone for independent thermal
barrier
Flange Face (machined layup)
Stiffeners (layups)
T-nuts (bonded)
Flange base (Layup)
9
Slider design - materials testing

• Friction Tester nearing completion
• Applies variable pressure
• Measures angular acceleration
• Slides sample against interchangeable disk of
  given material

Mass provides normal force
position is movable along arm
M
arm hinge
turntable (carbon disk)
slider to be tested
Encoder on shaft measures acceleration
M
10
Gravity Sag Calculations
Carbon
Glass
 
DY .57 mm
DY 1.6 mm
Whole Tube Sags at ends during operationit is
intended to remove this sag when Reattaching
supports after installation of Forward ID ? Note
Sag is with Package in placemuch less without
11
Reaction Loads On SCT
Vertical Bending Both Ends
Horizontal Bending
12
Flexure Block interface to SCT Penetration
SCT Thermal Barrier Penetration
This interface must take same loads as applied to
FlexureWill know them well after Joint Model is
run
?Will look at simple feasibility with current
(infinite stiffness) loads ?Will iterate size if
indicated by ROM calculation
13
Flange Envelope
May change By 5mm to 806?new structure added
Interlink
796?800
785?792
811
775?780
806
SCT BARREL 3
765
SCT Forward Envelope
261
260
257?259.5
251
248
requested Changes
245?246
242
244
240
Barrel Mount Flange
Pixel Support Tube (Barrel Region)
Pixel Support Tube (forward)
795?799
700
Dimensions from 11 ID Layout May 01
14
Flange Envelope
Interlink
800
811
806
792
SCT BARREL 3
780
765
SCT Forward Envelope
261
260
255
252
251
shim
254
246
shim
242
244
240
Barrel Mount Flange
Pixel Support Tube (Barrel Region)
Pixel Support Tube (forward)
799
700
New Proposed Envelopesnot yet agreed
15
Z-Flexure (Side A)
View Direction
Thermal Barrier squeezed in here
Metal Insert Bonded in
Cut Plane
Access hole Thru Service Rail
Dowel pins have line fit
Insulator (G10) or Al203
Gap filled After picture
Support Tube Mount Pad M55J
16
Pixel Supports
17
Pixel Package Assembly
Mockup Pixel Frame shown
18
Tension/Compression Transmission through
structures not services
Clips register to Buttons on Frame and
Service/Beampipe support structure Gaps allow
Phi offsets of up to /- 1mm while only 0.25mm
longitudinally
19
Wire Planes supported by Pulleys
Wires not modeled, beampipe not shown
20
Tubes route cables to BarrelSeparate blocks at
Forward end
21
Services Supported By Framework
22
Service quarter panels supported by framework
23
Need to adjust length of Tube or Support Plane
location of VI
24
Outside view of patch Panel
25
Section View of patch Panel
26
Barrel End of Support Structure
27
PST Prototyping Plans

• Short Mandrel
• 1 foot long - 1 for glass, 1 for carbon
  aluminum or steel
• Dry-run in autoclave to determine thermal
  response
• Determine final diameters from test layups
• Full Size Mandrel (forward length)
• Quotes already received
• Approximately 14,000 to 20,000 USD
• 8 Weeks delivery
• Plans to Fabricate forward prototype in glass
• All flanges and rail features
• Use for production forwards if diameters are
  correct
• Implications of Glass Forwards/Carbon Barrel on
  prototyping plans must be more fully assessed
• Insertion Testing

28
PST Prototypes in ETC 02

• Includes
• Friction Testing
• Material Test Panels
• Foot Long prototypes
• End-Plug Prototype estimated as ½ production
  total
• Gray area
• Calling first Forward Tube a prototypeProduction
  monies all in FY03, but need to order tooling
  and start fab in 02
• Missing prototype flexure mounts (as noted in
  1.1.1.1.3.5)
• Prototype End Plate buried in Frame estimate,
  but included Pixel mounts (5k 01, 10k 02)
• Monies for assembly testing of Insertion mockup
  spread over a few efforts and called testing
  hard to track if appropriate levels have been
  assigned

29
Service Support Prototypes 02

• Now includes Beam Vacuum Support Structure
• Prototype in 02 already includes bond
  fixtureneed to increase cost some to account for
  additional scope of VI support, but this saves
  overall by not having entire extra fixture for VI
  support
• Intention for 02 to build 1 quarter panel
  support and 2 service panelsstill valid
• Need to build Full VI support for both
  installation testing and to support services
• Needs to be real for use in case pixels are
  late
• Needs to have real rail interface (unless
  replaceable interface)
• Need to add cost to this section of WBS, or make
  new WBS for Beam pipe support

30
Recent Changes and Estimate of Impact

• Change of Forwards to Quartz fiber 30k
• Additional Shell tool 14-20k
• Additional Hat stiffeners 120-160 Man hours
  M-tech
• Introduction of Independent SCT Thermal Barrier
  35k
• Throw away 3-4 man months LBL/Junior Eng Design
  time
• Accrue additional 2-3 man months re-design of
  Flange/Flexures
• Increase in scope to include Beam Vacuum Supports
  110k
• Design time not assessed
• Attempt to use/re-use as much fixture costs as
  possible
• Estimate 25k Material/200hr Shop/300hr M-tech
  (REAL) 03
• Estimate 10k Material/200hr Shop/300hr M-tech
  (prototype) 02
• (Est. based on cost of End Plug and fixturing,
  using same tool as service panel support
  structure
• PST End Support (former Beam Vacuum Support) not
  included in cost estimates yet.
• PPI/Endplug Thermal barrier increase in
  Complexity
• Current Estimate based on segmented flat panel.
  Cost will increase if tool is needed to make
  other than a flat shape.