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IBL Integration Activities & Future plans

Overall FEA on IBL @ Geneva (in convergence with Seattle) News from IST prod @ Composite Design Integration jigs and related pieces 2011 schedule

Impacts / 2013 Schedule

University of Geneva: G.Barbier, F.Cadoux, A.Clark, D.Ferrère, C.Husi, M.Weber

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Overall FEA… Simplified STAVES

CAD model: IST and Beam pipe not shown

FE model: IST hidden for clarity…

FE Model: STAVE as shell (sandwich material)

The goal is to have comparison with other FE models …as for the Stave program

End ringMiddle ring

Service loads…

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Overall FEA… Simplified STAVES

Boundary conditions (BC’s) between IBL and PIXEL

BC

BC

Blocking / 1 end of Beam Pipe…the opposite one is free!

Free?Bellows…

Inner links between IST and BP

IST: 6600mm long, K13C fiber at [0,20,-20,90,90,-20,20,0]

1G

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Overall FEA… Simplified STAVES

Preliminary results show NO issue / BP sagging and IBL sagging

Overall sagging:350 microns on BP

IBL region

IBL region…seems very stable!

Colin’s FEA (max deflection): 287 micronsFEA from Geneva: 350 microns

…as a first comparison! No fine tuning between models so far…

Need tests on IST proto for correlations

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Overall FEA… Correlation works to be done soon!

Tests and FEA’s on a first IST prototype (short sections from Composite Design)

IBL region

Proto sent to CERN for Mock up (M55J fiber)

T300 prepreg

Tests performed @ LAPP(thanks to Pierre!) on: T300 proto (0,6mm thick) M55J proto (0.5mm)

Tests performed @ LAPP(thanks to Pierre!) on: T300 proto (0,6mm thick) M55J proto (0.5mm)

FEA gives: 1.5mm for 30N applied Test gives: 1.5mm for [25-28N]…about 10% difference!

Testing to be done soon to check bending stiffness (on longer proto!)

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News from IST prod @ Composite Design

Based on the first mandrel (1m long) …which leads to 870mm long IST first! Check the surface quality (as seen it’s good… to be measured / Peek pieces) Check the circularity and dimension (ongoing at CERN metrology) Comparison between T300 and M55J fibers (done) Validate the whole process and de molding (quite easy!)

The mandrel Prepreg wrapping

Before extraction

In the autoclave (IST in upright position!)

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News from IST prod @ Composite Design

Next steps on IST prototyping work: Challenge is to go to 2200mm long IST segment (3 segments to get to 6600mm IST) Needs to work on junctions (including the gluing, centering to guarantee straightness…) 2500mm mandrel to be manufactured (85mm / h8 precision) + other mold for junctions Start with one segment…then go step by step (1 junction after the other)

Quotation on has been received from Composite Design (order will be placed soon …still need to get a metrology from CERN)

junction

Working in parallel development with Seattle is necessary (sharing of experience to get to the final results…) Seattle is dedicated to K13C prepreg for IST and shielding foil lamination on IST (final unit) Composite Design is a back up solution and provides protos, dummy IST for mock up, and half pipe for Integration stand and Beam pipe container (no VHM fiber here!)

Gluing

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Stave jig

Jig schedule in 2011:-1 prototype to test all the steps in 2011 (in aluminum, May 2011)-14 + spares to come later (beginning of 2012)

Jig schedule in 2011:-1 prototype to test all the steps in 2011 (in aluminum, May 2011)-14 + spares to come later (beginning of 2012)

Loading tool

Integration jigs and related pieces

Former design as shown by Didier

Latest design according to Stave new design

To be interfaced with …

Central body: 1300m

m

3 fixations over the stave length…to be checked in the wire bonding process

Middle point

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Stave jig

Integration jigs and related pieces

Pin for location M1.6 or M2To get access from below

Central pin (with clip)

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Support frame

Half pipe as a rotating cradle

STAVE driver

PRELIMINARY STUDY

Main concerns (Integration stand for Integration onto Beam Pipe)

Beam pipe Container made of dummy IST’s

Milestone: beginning of 2012 to save time for testing…means 1 year from now (only 6 months for development!)…Gerard will re start in March 2011, BUT it’s tight! A common development with Grenoble has been identified here

7m long is mandatory at this stage

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Integration activities Summary of 2013 Schedule

Target: Early 2012 to start training, tuning,…

Beam pipe container (development @ Composite design)

1 Validation on Stavelets

Early April 2011 to validate the principle and launch a longer jig

2 Going to Stave0 length (Based on official design…no turning back)

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June-July 2011 (to start loading on Stave 0)Could be used and checked for Heater loading @DPNC…Need earlier!

Linked to IST development (April-May 2011)and Grenoble interfaces

Stand design and fabricationStave mounting systemMay be need of Dummy Bpipe?

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Last but not least… IBL Support Structure REVIEW coming soon…

When ? On March, 24 this yearWhere ? @ CERNWho is involved ? Marzio, Heinz, Giovanni, Raphael, Franck, and the reviewers among:- Ray Veness - Mark Gallilee- Neal Hartman- Eric Anderssen- Antti onnela- Ian Wilmut

The goal of the review is to:- Sign off the IBL layout, envelops and interfaces- Confirm interfaces to the beam pipe- Review and go-ahead for support structure elements (IST, support rings,…)- Review of integration and installation tooling concept

Still need to define to which level of details do you want us to go…time is short!