ATLAS Frame PRR 1 W.O. Miller Feb. 2002 US ATLAS Pixel Detector Global Supports PRR W.O. Miller, R. Smith, W.K. Miller, R. Baer HYTEC G. Gilchriese, E

ATLAS Frame PRR 1W.O. MillerFeb. 2002

US ATLAS Pixel Detector

Global SupportsPRR

W.O. Miller, R. Smith, W.K. Miller, R. Baer

HYTEC

G. Gilchriese, E. Anderssen, N. Hartman, F. Goozen

LBNL

Objectives:•Disk Ring Status•Production Readiness of Frame Components



Nomenclature

Center Frame Section (1)

End Section (2)

Internal End Cone (2)

(B-Layer and Services not shown)

Interior Barrel Layers (3)

Disks (6)

Disk Rings (6)

Disk sectors (8)



Disk Support Ring

Ring

Ring mount

8-sector disk

Sector cooling tubes

C-Channels4 arc segments around the perimeter



Disk Ring Production

• Production Activities

– Mold Qualification: Phase I• Precision compression molded C-

Channels– Requires confirmation of cavity

dimensions– 2 outer and 2 inner C-Channels

molded with YSH50/RS-3 cyanate ester resin

– 4 segments for the outer and 4 segments for the inner

– 1st Article Ring Qualification: Phase II• Presently inspecting graphite bonding

fixture via CMM at LBNL• Phase II activity will start in February

2002

• Production Progressing as Planned

Development Ring Tested in Disk Frame Section

Confirmed our approachMounting approachMounting precision Repeatability of mountsFrame/mount stiffness



C-Channel Mold (Segment)

Silicone rubber forces the composite to conform to the mold profile—reversed the process from before



C-Channel Mold Trials

Typical Inspection Report for First Article

Verification ofcritical dimensions

•Radii•Toe-in•In-grain twist

Measurements taken as molded and after trimming

Edges to be trimmedInner and outer radii

and arc length



C-Channel Status

• Surface texture excellent• Wall thickness well controlled• Preliminary dimensional measurements look quite good- although this

investigation is still proceeding– C-Channel not completely trimmed, ½ moon cut-outs for the ring bushings left off – Desired dimensional control in several areas 50 to 130 microns (2 to 5mils)– Dimensions are to be achieved after trimming one edge (radius) of the channel to

the proper radius and two ends to form a 90 degree arc.

• Effect of mold strains– Part cures at elevated temperature in Al mold– Difference between as molded state and mold dimensions is evident– Difference after trimming the radius is more pronounced– More parts must be made to demonstrate consistency

• Results to date– Insufficient data to suggest a change in mold radius is necessary– Other dimensional features are quite good



Global Support Frame PRR



Global Supports-Readiness

• Tasks Completed Extensive design studies defining structural approach and material choices Prepared finite element model of complete system

Static stiffness Dynamic stiffness (vibration) Torsional stiffness (insertion considerations)

Prototyped Structures-(500mm diameter frame) Disk Frame Section End Cone Disk Support Ring and Mounts

Conducted Individual Component and Integrated Tests Disk Support Ring with development sectors Disk Support Ring in Frame Section End Cone with Frame Section

Completed CDR and FDR on all components Completed Production Drawings and Plans



Topical Characteristics

• Global Support Structure– 2.85kg composite sandwich

structure, fully assembled with detectors and services estimated to be 26.8kg

• K1392U fiber/EX1515 Byrte Technology resin and graphite fiber honeycomb for maximum frame stiffness

– Assembled by joining 3-subassemblies with self indexing features

• 2-Disk Sections• 1-Barrel Section

• Interfaces Resolved End Cone to Barrel Shells (IVW) External mounts to Pixel Support

Tube Space for Services: routing and

egress

End Plate

End cone

Disk

Outer Frame



Design Confirmation Studies

• Objectives

– Demonstrate ability to predict microstrains to level necessary for qualifying stable structures

– Confirm our predictions of static and dynamic stiffness

• Typical results– Frame sag ~12microns for

26.8kg

– Frame natural freq. ~89Hz

– Torsional sag- 3pt supports 61m

– Disk ring stiffness-1N load normal to ring 1.66m/N



End Cone Prototype

• Salient construction points

– End Cone for 500mm frame design

– P30Carbon-carbon facings, ~0.44mm

– XN50/cyanate ester graphite fiber honeycomb, 4mm thick

– YSH50 quasi-isotropic laminate for outer supports and inner tabs

• Static component tests

• Individually, as well as mounted on frame section(@LBNL)

White paint on short tab for holographic measurements



• LBNL test results with end cone in place

– Axial load 1.125inch from end of long tab-- 15.4m/N

• HYTEC end cone separately

– Axial load 1.125inch from end of long tab-- 16m/N

End Cone/Frame Test

Note disk sector support ring

Barrel section mounting tabs and dial indicator measuring displacement

12 Sector Frame-500mm dia.



Now that prototype investigations and final drawings

have been completed

Frame Procurement Steps

• Remaining tasks Leading to Release of Procurement Orders are:– Review and incorporate comments from PRR– Finish detail drawing review– Release drawings and post in EDMS– Review letters of interest from prospective vendors

• Resolve any concerns about LBNL supplied tooling

• Procurement Orders– Release Request For Quote (RFQ) to composite fabricators– Release RFQ(s) for tooling– Select composite fabricator(s) and tooling vendors

• Assembly and QC Plans– Work with vendor (s) to produce a coordinated fabrication and assembly plan

• In process inspection at vendors and LBNL• Posting of the final plan documents in EDMS

– Complete assembly and inspection at LBNL



Schedule

Disk Support Ring and the Global Support Components Delivery Schedule is doable, but tight

Documents

ATLAS Frame PRR 1 W.O. Miller Feb. 2002 US ATLAS Pixel Detector Global Supports PRR W.O. Miller, R. Smith, W.K. Miller, R. Baer HYTEC G. Gilchriese, E