NSF Mid-Scale Proposal: CE Interface Hardware John Jablonski, Michael Mooney Colorado State University DUNE APA Workshop June 11 th , 2019 1
Scope Scope ♦ Scope of CE interface hardware package covers fabrication and quality control of following APA components: • CE mount brackets (20 per APA) • CE tees (9 middle and 2 end per APA) • CE clamps (18 middle and 4 end per APA) • Structural support tees (2 per APA) ♦ Not included: • CE boxes (supplied by BNL) • Yoke (PSL?) ♦ Current plan: CSU and PSL to split package (76 APAs each) ♦ See Leland Greenler’s slides for more detailed drawings 2
Component Details Component Details ♦ Many thanks to PSL (especially Leland Greenler and Bob Paulos) for providing drawings for us to use to obtain our cost estimate ♦ Summary table of versions of drawings used: Component Drawing Version CE Bracket 8760 B 085 Middle CE Tee 8760 B 088 End CE Tee 8760 B 087 Middle CE Clamp 8760 B 092 End CE Clamp 8760 B 091 Structural Support Tee 8760 B 077 3
CE Brackets CE Brackets 20/APA 4
Middle CE Tees Middle CE Tees 9/APA 5
End CE Tees End CE Tees 2/APA 6
Middle CE Clamps Middle CE Clamps 18/APA 7
End CE Clamps End CE Clamps 4/APA 8
Structural Support Tees Structural Support Tees 2/APA 9
CSU Technical Design Facility CSU Technical Design Facility ♦ Established March 1993 to work on SSC straw tracker • David Warner, Director (Since 1993) • John Jablonski, Senior Technician (Since 1995) ♦ Significant roles in many projects, including: • BaBar – drift chamber (molded components, stringing tools), streamer tube (HV wire harness, many molded components) • Pierre Auger Observatory – water tank liners, PMT enclosures • T2K P0D (Pi0 detector) – system design, scintillator bar fabrication, mechanical structure, installation tooling • High Altitude Water Cerenkov (HAWC) – design and fabricate water containment vessels (65,000 gallons!), PMT installation tooling • DUNE – technical leadership, photon detector system; fabricated ProtoDUNE-SP PD system ♦ Draws student interns from both physics and engineering ♦ Strong, well-established contacts with machining and fabricating facilities along Colorado Front Range and beyond 10
Work Plan Work Plan ♦ CSU work to be performed by skilled technician, machinist, and undergraduate students (physics and ME) with some work handled by outside vendors • Outside vendors: cutting/shaping/welding of stainless steel • CSU: precision work (e.g. drilling holes, cleaning, quality control) ♦ Vendors: • Sterling Edge – middle CE clamps • Rocky Mountain Westy – CE tees, CE brackets, end CE clamps • Gulley Metal Services – structural support tee ♦ CSU labor: roughly 2 FTE undergraduates, 0.5 FTE technician, and 0.3 FTE machinist ♦ Uncosted scientific support: oversight by PI (Mooney) 11
Cost Estimate Cost Estimate ♦ Prepared two cost estimates: • “CSU Machine” – cheaper option with more work at CSU • “Gulley Complete” – vendors do as much work as possible ♦ Second cost estimate serves as cross check ♦ Complete cost estimate tables below for reference CSU Machine Gulley Complete 12
Cost Estimate (cont.) Cost Estimate (cont.) ♦ Total cost estimate for both options: • “CSU Machine” – $1,650 per APA, $125k for 76 APAs • “Gulley Complete” – $4,000 per APA, $300k for 76 APAs ♦ Pre-proposal numbers: $7,160 per APA, $545k for 76 APAs ♦ Numbers build in student/technical labor (including logistics), vendor fees, minor equipment purchases, and quality control CSU Machine Gulley Complete 13
Timeline Timeline ♦ Nominal plan is to follow nominal APA production schedule • Year 1: 23/2 APAs • Years 2-4: 33/2 APAs • Year 5: 30/2 APAs ♦ In principle, this timeline can be significantly accelerated • Vendors will do work in bulk, leaving parts for CSU students/technicians to complete • Reasonable pace once parts are at CSU: 1 APA per 3 days • Assumes technician/machinist working on other things as well • Even faster during summer when undergraduate students are more available ♦ This package is probably one of the first that can be delivered 14
Quality Control Quality Control ♦ One need for full proposal: more discussion of QC for all APAs ♦ Preliminary thoughts on QC plan for CE interface hardware: • Deburring • Use of go/no go gauges for component interfaces • Check flatness of structural support tees • Weld QC – need qualification specifications from engineering design • Load testing – same as above ♦ Have means at CSU to perform ultrasonic cleaning procedure using same protocols as for ProtoDUNE-SP components • Not currently built into cost estimate ♦ Can also bag finished/cleaned components at CSU using plastic bag welding facility • As done for T2K, Auger, and HAWC 15
Open Questions Open Questions ♦ Quality assurance – before timeline of proposal, but a few options for early process QA worth thinking about immediately (all of which CSU is able to fabricate parts for): • Ash River test (October 2019) • APA/CE/PDS integration test @ CERN (April 2020) • Component production for ProtoDUNE-SP-II (starts July 2020) ♦ Cleaning/bagging – should this be done locally before shipping? If so need to build into cost estimate (and can do at CSU) ♦ Shipping – where do we send finished parts? • Seems like South Dakota Logistics Warehouse is appropriate place as we would do final assembly/integration at SURF? • Do APA production centers need structural support tees earlier, for moving/storing APAs? ♦ Not for this proposal, but who is providing CE interface hardware for UK APAs? 16
BACKUP SLIDES 17
CSU Machine Shop Equipment CSU Machine Shop Equipment ♦ Haas TM2 CNC Milling Machine ♦ Haas TL1 CNC Lathe ♦ Bridgeport 2J Manual Milling Machine ♦ Turn-Pro GS-18V Manual Milling Machine ♦ Rockwell Model 20 Drill Press ♦ 6000 lb. Arbor Press ♦ Multiple Belt Sanders & Scotch Brite Wheels (for deburring) 18
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