NSF Mid-Scale Proposal: CE Interface Hardware John Jablonski, - - PowerPoint PPT Presentation

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NSF Mid-Scale Proposal: CE Interface Hardware

John Jablonski, Michael Mooney

Colorado State University

DUNE APA Workshop June 11th, 2019

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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

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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

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CE Brackets CE Brackets

20/APA

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Middle CE Tees Middle CE Tees

9/APA

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End CE Tees End CE Tees

2/APA

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Middle CE Clamps Middle CE Clamps

18/APA

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End CE Clamps End CE Clamps

4/APA

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Structural Support Tees Structural Support Tees

2/APA

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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

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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)

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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

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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

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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

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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

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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?

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BACKUP SLIDES

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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)