W&M work packages Mike Kordosky, Je ff Nelson, Tricia Vahle NSF - - PowerPoint PPT Presentation

W&M work packages

Mike Kordosky, Jeff Nelson, Tricia Vahle NSF mid-scale proposal for APAs planning workshop 11 June, 2019

W&M particle physics

• Neutrino experimental group faculty

– Mike Kordosky – Jeff Nelson – Tricia Vahle

• Current neutrino group includes

– 2 postdocs, searching one right now – 4 PhD students (RA’s + add’l MS’s) – Many undergrads (graduate 35 BSs/ year)

• Hadronic experimental group faculty

– Todd Averett – David Armstrong – Keith Griffioen – Bob McKeown – Justin Stevens

• Subatomic theory group (8 faculty)
• Machine shop

– 2 FT staff (Henninger, Bensel)

• Henninger is lead tech

– $20/hr (costed) – CNC and conventional machining – Welding – Student shop

• Maker’s space

– 3D printing (many materials), 3D scanning, laser cutters, instrumentation lab – 2 9-mo professional faculty (Frey & Yang)

• Dedicated sofu-wall clean room
• Chemical workroom
• 3 additional 12’x24’ neutrino labs
• High Bay [slide]

Small Hall, High Bay Lab

• 40fu x 60 fu crane

coverage

• 7.5 ton crane

– 16fu hook height

• 54fu wide door

– On loading dock (mullions move)

• Forklifu
• Single pass ventilation
• Chemical storage
• Sealed fmoor and walls
• Plumbed LN2 nearby

Some past W&M projects

pdf with more projects included in a separate document

• Jeff Nelson

– L2 for MINOS FD installation – L2 for MINOS magnets, coils, DSS & prototyping – MINOS ve and vu WG convener – L2 for MINERvA scintillator planes/towers – Scintillator for CLAS-12 PCAL – MINERvA test beam detector planes – MINERvA inclusives WG convener – TPC coordination for DUNE 35t HV test – ProtoDUNE HV assembly stations & fjxturing

• Mike Kordosky

– MINERvA prototype commissioner – MINERvA AC, Flux WG convener – Lariat DAQ/trigger – ProtoDUNE cold cameras/lighting – DUNE ND design study & CDR editor

• Tricia Vahle

– MINOS & NOvA AC – NOvA NDOS installation – NOvA readout acceptance testing & commissioning (FD + ND lead) – Current NOvA co-spokesperson

Summer 2009 MINERvA team (2/3rds)

Fleets of undergrads, professional staff, term staff…

W&M scope of work

• APA shipping frames

& hardware

– Coordinating with the Liverpool group (Peter Sutcliffe et al.) – Liaison PSL and SURF/ SDSD engineering on design integration – Initial prototype for APA pairing tests at AR (ASAP; CY 2019) – Trial runs at SURF (cage available August ‘20) – Production for US factories

• APA U/V frame boards

– Outfjtting facility – Board production – Cleaning/baking – Gluing tooth boards – Cleaning – QC & packaging – Shipping to factories –

Shipping frame use cases

• Factory packaging and prep for shipment [SBND pix]
• Getting to SD

– “Truck, ship, truck” or just “truck”

• Acceptance testing, long term storage at SDWF (warehouse)
• Transport to the head frame, slinging below cage [slide]
• Shafu transport; removal from shafu; transport to cavern
• Pre-testing and staging in cavern [slide]
• Into the SAS and clean room for mating/instrumenting

[slide]

• Return to the surface, warehouse, disposal/return shipping

Requirements document

https://edms.cern.ch/document/2165518/1 3 sections

• Overview
• Description of the use cases with current

installation model

• Specifjcations derived from the use cases

Drafu for comment – posted last week

Current design

Structural shipping frame welded steel construction

Concept based on SBND experience in UK

• DUNE crate concept

similar to SBND but with 2 APAs on sides

• Protective panels
• Coil spring dampening
• Structural frame
• Instrumentation
• Removable side frames
• Heat sealed bag
• Anchored to a pallet
• Tarping
• [UK version gets walls]

Shock isolators (coil springs) at 4 locations per APA

Loading onto shafu based on SURF experience

• We will work with SDSD to design a

Zimmerman (Zimmer) cart (their scope)

– Surface rail system – Factorizes rigging & frame functions – Includes wheels for movement in the drifu and for on/off loading – Include mount points for shafu guides timbers – Include anchor points for cables to bottom of cage and horizontal tugger – Underground truck provided

• Tiis concept makes the

slung-load operation consistent with standard SURF practices

Upper connection is base of cage (hoist acts as the upper winch)

Stages in cavern: testing, short-term storage, PSs, pairing

Hall: Tes;ng in a clean hut & storage (up to 12 APAs) SAS PD, ma;ng in clean room

In the SAS/clean room

• Tie frame/vertical cart is rolled into the SAS
• It is cleaned
• PDs installed with protection panels in place
• Need to lifu APAs out of the shipping frame and onto the APA

assembly frame

– pre-lifu to relieve tension, remove springs, move to tower

Shipping frame production model

Model for pre-proposal

• APA crate production in industry with W&M

coordination of the production

• QA/QC provided by W&M lead technician (8 hr per

frame)

• Tie basis of the cost estimate (c.f. DUNE-

docdb-10683) is benchmarked on a conceptual crate design, and the cost per crate is derived from component costs and production labor estimates in the UK. (Same vendor as SBND)

• Shipping costs for the crates are assumed to be

included the APA wiring site budgets.

• Assume to be single usage because APA production

is signifjcantly ahead of installation. Model for the full proposal

• Pallets produced by crating manufacturer in Port of

Norfolk area

– Staged production to match need at factories – Alternative is in-house production – QA/QC provided by W&M lead technician (1 hr per pallet)

• Welded central frame produced in fab shop

– Can put 4 per fmat bed – Staged production to match need at factories – QA/QC provided by W&M lead technician (8 hr per frame)

• Side frames made from 80:20; produced on campus

– Undergrad effort with GS/PD/PI supervision

• Clear plastic protective panels produced at local water-jet

cutter and hardware added at W&M

• Cable springs & sensors purchased at W&M
• Bagging material and heat sealers provided at factories.
• W&M pays shipping to factories

– Pallets and structural frames direct from vendor – Other parts from W&M crated kits – Included smaller crates and coordination

• Assume that half of the Mod 1 crates get reused for Mod 2

Assumes part-;me PI and/or postdoc coordina;on Work done by ;me first Mod 1 crates returned to factories

U/V boards

• Procure boards
• Board QC
• Clean/bake
• Epoxy on tooth strips
• Cure in fjxtures w/ venting
• QC of glued board
• Bag cleaned fjnal parts

Geometry boards: (foot & side): 60 min per board Head boards: add 30 or 40 min more for pins

• Incoming inspection, cleaning,

prep for processing: 10

• Tooth strip cutting, handling,
• rganizing for production: 10
• Attachment of tooth strips,

removal of excess epoxy: 20

• Dimensional check, excess

epoxy removal, spot cleaning: 10

• Mask solder pads, bag, place in

inventory, fjnal inspection, package for storage or shipping: 10

• U:

– 20 head – 10 foot – 42 side

• V:

– 20 head – 10 foot – 42 side

• Tiat’s 144 per APA

– 21,888 boards total

• 4 years of production

– Average 22 per shifu

• Plan on infrastructure for ~2x

– UG effort bump in summers

Costing model

• Effort and M&S based on PSL experience (BOE docdb-10689)

– Labor includes: incoming inspection, cleaning, prep for processing, pin insertion, tooth strip cutting, solder pad masking, epoxying tooth strips, dimensional checks, excess epoxy removal, spot cleaning, fjnal inspection, and packing for storage/shipping

• Tie board production labor model at W&M assumes:

– Half of work completed by undergrads

• We assumes happens at 50% efficiency WRT technician in pre-proposal

– *evolve to 67% in consistent fjnal model with other sites

• 82.0* (85.4*) hours for U (V) boards per APA
• Students are costed at $12.50/hour (FICA in summers); 8 students averaged over year

– 10hr/wk in term, 40hr/wk summers

– Technician effort for remainder

• 41.0 (42.7) hours per APA
• Lead tech + term technical staff within instrumentation shop (2 FTE)
• Costed as recharge personal at $20/hour (i.e. fully loaded)

– Postdoc and grad student coordination of inventories/QA/tracking/shipping

• Professional faculty collaboration possible too
• Base grant supported
• Purchasing

– Postdoc + PIs

Facilities board production

• Clean room

– 24’ x 36’ lab – 20’ x 20’ class 100,000 clean room

• Sofu wall, tiled roof

– 2 vented workstations; single basin wet lab – Ultrasound cleaner – Space used for cleaning, baking, gluing, curing

• Chemical prep room across hall

– Outgas any surplus epoxy and clean up materials

• Tiree 24’ x 12’ labs across hall

– Shelving on both long walls – Vented workstation; single basin wet lab – Space used for storage, inspection, packaging – Vacuum + inert purge heat sealer (up to 36” capacity)

Outfjtting needs

• Fixtures – 44 units [slide]
• Precision scale and gluing stuff [slide]
• Washing stations
• Ovens
• Curing cabinets with venting
• Clean-ish room
• Inspection equipment [slide]
• Press
• Data entry PCs or tablets
• Vacuum/purge bag sealer
• Lots of shelves, googles, gloves, and kimwipes!
• Pre-proposal budget was a WAG

R&D opportunities – epoxy

• Current epoxy process is based on hand

application and spreading

– Nice video from PSL

– https://youtu.be/xiZBX5cq46c

• Can automate that with a

glue machine

– Locally developed engine for a 3D collagen printer

• Based on pipetting head with

fjne threaded stage

• Temperature controlled enclosure
• Open source g based code

– Use our pneumatic dispenser epoxy machine based on to understand fmuid mechanics (optimize needle)

• Can use barrel of pre-mix or dual pack with static mixer

– Defjne feed rate, tip diameter (1.5mm slot), movement speed to make a uniform continuous bead at reasonable pressure – Hardware is about $3k – Effort is in tuning the movement/feed/start+stop

• Stock parts
• Tech, 2 UG, and prof faculty

R&D opportunities – inspection

• Current is based on 2D profjle projector

– Manual process is somewhat time consuming even for an experienced tech – e.g. Mitutoyo 172-810-10A Profjle Projector – Semi automated system is $10k

• Would like to evolve to 3D to measure

fmatness and to measure

– Measurements of the machined edges – Looking for better than the 0.1mm tolerances – Can automate w/ CNC 3D vision machine ($40k) – Can automate with 3D scanner ($24k)

• Effort to interpret the scanner’s solid model output
• PSL investigating; good enough resolution?
• Good enough resolution at reasonable price?

– Could make hybrid a laser based z system with x-y based

• n standard 2D steppers and

R&D opportunities – prep/curing/cleaning

• Need to invest in sufficient units

units to meet capacity

• 40 jigs (can run 2-shifus in summers)
• Rack system with jigs vertical to improve

packing fraction

• Move to better substrate than tefmon
• Large oven/wash
• Chop saw and fjxtures for cutting strips
• Develop costing over next two weeks