APA Ground Meshes Dr. Lucien Cremaldi L. Cremaldi Universiy of - - PowerPoint PPT Presentation

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APA Ground Meshes Dr. Lucien Cremaldi L. Cremaldi Universiy of - - PowerPoint PPT Presentation

Nov 09, 2023 210 likes •372 views

APA Ground Meshes Dr. Lucien Cremaldi L. Cremaldi Universiy of Mississippi Dr. Don Summer APA Construction and Proposal Workshop Dr. David Sanders Fermilab, June 11, 2019 Dr. Gavin Davies (NOvA+nearDUNE) M APA Ground Meshes Material

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SLIDE 1

APA Ground Meshes

  • L. Cremaldi Universiy of Mississippi

APA Construction and Proposal Workshop Fermilab, June 11, 2019

  • Dr. Lucien Cremaldi
  • Dr. Don Summer
  • Dr. David Sanders
  • Dr. Gavin Davies (NOvA+nearDUNE)

M

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APA Ground Meshes

Scheduling 8/1/2020 2021 2022 2023 2024 total APA 23 33 33 33 30 152 Meshes 460 660 660 660 600 3040 Material Type Mesh Wire mm Aperture mm Open Area % Weight Kg m^2 Proposed SS 304 20x20 0.089 (3.5 mil) 1.17 84.87 0.10 UK Vendor: Locker Wire Weavers Ltd. 1200 off part: 294-10320 @ £146.50 each 1800 off part: 294-10314 @ £146.50 each Delivery schedule: Approx: 20-22 weeks from order (mesh will take approx. this long to weave) Terms: To be agreed. $190.45 per mesh US Vendors: 1) Unique Wire Weaving, Hillside, NJ 2) GKD-USA, INC. Cambridge, MD 3) Edward J. Darby & Son, Inc. Philadelphia,PA 4) Banker Wire & Iron Works, Milwaukee, W 5) McNichols, Tampa FL

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NSF MidScale pre-Proposal

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SLIDE 3

https://edms.cern.ch/ui/#!master/navigator/document?P:100233194:100324720:subDocs Dimensions 996mm x 1131 mm ( 39.2” x 45.6” ) 10mm x 20mm x 1.5mm tubing 3/4 “x 3/8” x 1/16”

  • 8. TENSIONING

1 3 3 3 4 2 3 3 3 5

head

mounting bracket

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SLIDE 4

SS frames are welded. Mesh tensioned and resistance welded.

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Locker Process:

  • Tubing for frame cut and drilled outside and shipped to Locker.
  • Wire mesh purchased outside and shipped to Locker.
  • Frames welded in house.
  • Screens stretched and welded to frame. 2 welds on top + 1 weld on side.
  • Frames inspected and cleaned. (QC Manchester)

Assembly at Locker Wire (UK)

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SLIDE 5

5

welds

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SLIDE 6

Seam Weld Stainless Steel Mesh with and PG2 Hand Piece Attachment $6-8K ??

Sunstone AC 5 KVA Welder https://sunstonewelders.com/videos/100914-ss-mesh-welds-with-ac5-kva-and-pg2/ https://sunstonewelders.com/product/5-kva-ac-spot-welder/ https://sunstonewelders.com/product/pistol-grip-single-probe-hand-piece-pg2-with-roll-spot/ 6

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SLIDE 7

7

$16/m

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SLIDE 8

https://www.twpinc.com/tcpdf/pdf/create.php?prod_id=3613 8

$800/100ft $25/sqm

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SLIDE 9

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Packing & Shipping (unit=20 meshes)

$300/pallet $30/box

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SLIDE 10

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Mesh Production

  • A. Fabricate meshes in the US.

Waiting for a quote from Unique Wire Weaving, Hillside, NJ. My estimate: 4m tubing (material) $60 - $100 tubing machining & welding (frame) $80 - $150 1 hr labor 1 m2 mesh material $20 - $100 Stretch & weld mesh $80 - $150 1 hr labor $240 - $500/mesh

  • B. Purchase 600 meshes/yr from Banker Wire (UK) at $190/mesh

and ship to the US. Estimating $500 shipping per APA (20meshes) adds +$25 to mesh cost. Must be negotiated with Banker Wire(UK). $225/mesh

  • C. Hybrid plan- 50% US meshes + 50% UK meshes. May be safest?

Still working on pricing, large inquiries like these take some time to get wire pricing for. I will follow up with it. Bill Bard, Unique Wire

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SLIDE 11

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Schedule 8/1/2020 8/2021 2022 2023 2024 2025 total APA 23 33 33 33 30 152 Meshes Setup/Stockpiling 460 660 660 660 600 3040 Scenario-1 160 60/mo 60/mo 60/mo 60/mo Scenario-2 400 55/mo 55/mo 55/mo 55/mo

Mesh Schedule Mesh QC

  • Insure outer dimension and hole

±1/2mm pattern correct – jig stands.

  • Frame flatness test.

±5mm

  • Mesh flatness test.

±1mm

  • Mesh tension test.

< 1mm deflection ½ kG

  • Screen inspection.

No loose ends

  • Wipe test of screen and tubing.

Little or no residue

  • Anti-static cleaning

vacuum or dry air

  • Label and bag (plastic).
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SLIDE 12

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Research wing

Facilities

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SLIDE 13

13

Clean Room

Facilities

Past Projects

  • Babar CsI ECAL
  • CMS HCAL/Pixels
  • Pierre Auger Tank Liners
  • MICE Aerogel Ckov + Targets

Clean Room Shop

C l e a n R

  • m

1 S t

  • r

a g e L a b

350 sqft

L a b

Lewis Hall Basement Floor

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5 yr Budjet

Package Unit cost Units Comment Total Grounding mesh (fasteners) $3,809 152 APAs (20 meshes) (UK quote) $578,968 (???) Ship to wiring centers* $240/APA 152 APAs motor freight $36,480 Technical Labor $78.85/hr (0.03 FTE/y) 260 hours jigs + maintenance $20,500 Student Labor (AY) (2 mo summer) $15/hr 1520 hours (1/2 hr per mesh) QC $22,800 Materials & Supplies* $200 QC rigs (clean tent) materials $1000 $1000 $5/APA 152 APAs QC $1520 $50/APA 152 APAs packing/skid $7600 Equipment $1000 1 anti-static vac system $1000

* new costs

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SLIDE 15

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Personnel

Project Leader(s): Lucien Cremaldi/Don Summers uncosted Deputy Leader: David Sanders scientist uncosted Technical: Scot Watkins machinist <0.05 FTE + uncosted Undergrads: 1 or 2 Grad student 1 base grant request

  • US Mesh more expensive than Asian markets. US fabrication costs unclear.

Should we be producing prototypes?

  • Banker Wire (UK) may be the best option?
  • Best to charge Fedex Freight directly to winding centers.
  • Risk – Having a two mesh producers may be a safer road.
  • Risk - NSF or DOE base funding not straightforward.

Final Comments/Risks