14-dec-15s.movchan straw manufacturing and qc1 straw manufacturing procedure and qc tape and straw...

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Jun 14, 2022 S.Movchan Straw manufacturing and QC 1 Straw manufacturing procedure and QC tape and straw parameters specification conditions of straw production: “clean room” status seam QC by microscope plans Presented by S.Movcha

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  • *S.Movchan Straw manufacturing and QC*Straw manufacturing procedure and QC

    tape and straw parameters specification conditions of straw production: clean room status seam QC by microscope plans

    Presented by S.Movchan

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Tape specification

    spool # (001-999)batch # (01-99)roll and tape visual inspection ok! or commentsmylar typehomogeneousmylar thickness (36.0+/-0.075) melastic elongation limit > 2 kg (H=80%, T=23 degree)damage limit> 5 kg (H=80%, T=23 degree) tape width (31.6+/-0.1) mmtape length (100 300) m(Cu+Au) thickness of coating (750+/-50) Aresistance (35+/-5) Ohm/m

    oil on surface exist?No or comments shipment list scan of list

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Straw specificationStraw dimensions and properties: (D0)- (9.770.05) mm elliptic shape - 0.1 mm (diff. D1 and D2 from D0)seam width- (0.6 0.2) mmseam shape- good (visual inspection)length- 2100 mm active area (total-(2400 1) mm at dP=0 Bar) non straightness - 0.2 mm (dP=1 Bar) increasing- (0.04 0.01) mm per dP=1 Bar overpressuregas leakage - < 0.003 cc/min (N2 at dP=1.5 Bar for repair straw) skin resistance R- (35 5) Ohm/m

    elongation 1- 1 mm at dP=1 Bar overpressureelongation 2- 4 mm at F=1 kg overpressure test- dP=3 Bar @ 10 mincyclic test - N=10 cycles (dP: 0->3Bar->0)long term test - > 3 months at dP=1.2 Bar seam tensile test- > 5 kg (t.b.d.)

    Production technology and rate: ultrasonic welding20 straws per shift

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Conditions of straw manufacturing clean room with control T=(23+/-1) degree, humidity H=(65+/-5)%, clean (dust control) and atmospheric P+10 mbar control the set up of the machine (each day): ultrasonic generator amplitude and clock ultrasonic head pressure to Al tape tape friction tension and speed of transport mechanics flush inert gas of welding region (by ionization gun, clean anvil and tape from dust) automatically check seam quality by microscope with video camera (simultaneously with welding) for each straw cut 2 samples (start and end) and to do seam test by tensile test machine using box for straw transportation and storage

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Clean roomS is about: S=(3.5x6)=21 m2Dust class (6-7) ISOOverpressure inside few mbarTemperature and humidity will be stable and record to DB

    Special shoes, clothes, glovesAntistatic floor rug

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Equipment and tools inside Clean room Equipment: temperature sensor humidity sensor atmospheric pressure sensor counter of a number of dust particles in air air flow meter straw manufacturing machine based on ultrasonic welding oscilloscope (amplitude measurement) frequency meter (check ultrasonic generator freq.) sensor for measurement pressure of ultrasonic head to tape sensor for measurement tape friction sensor for measurement temperature inside of seam ionization gun (clear anvil from dust)

    tensile machine for seams quality control microscope with video camera -> on-line QC -> seams photos -> DB* computer optical microscope -> for visual seam quality check -> DB bar code generator (for straw labeling)* DB data baseTools: ultrasonic head clean tools set of calibers for straw diameter measurement-> DB tool for straw length calibration (based on scissors)box for straw transportation1 or 2 boxes for straws mass storage

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC***Straw welding machine, heard and anvil

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Straw machine with microscope + oscilloscope

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Ultrasonic generator control frequency: F=38 kHz amplitude: U=40 V

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Seam shape QC by microscopeGood seam shapeBad seam shape

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC* Gun with ionization air: for clean of anvil and tape from dust

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Weld seam visual QC

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC***go - no go gauge for straw diameter check

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC* Tool for straw length calibration (based on scissors)L=(2400+/- 1) mm

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Tools for straws QC (continue) Outside of Clean room: stand overpressure test (dP=3 bar) -> DB tool for assembly straw with end plugs tool for straw non straightness measurement (based on video camera) tool for nipples installation tool for straw filling with Nitrogen before storage long term test with dP=(1.5-2) bar (inside storage boxes) stand straw gas leak measurement -> DB tools for straw reparation etalon/reference metal straw (no gas leak) set of etalon straws (for straw gas leak measurements)

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Overpressure QC

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Straw assembly with end plugsOption 1:Straw assembly based on optical bench(L.Glonty design)Option 2:Machine for straw assembly(Yu.Fedotov design)

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Straw (with end plugs) non straightness QCMethod:- straw is rotate on flat table visual control of straw deformations- preliminary straws sortingMethod: straightness calibration by wire video camera + data processing

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw status*Straw diameter and non straightness measurement

    S.Movchan Straw status

  • *S.Movchan Straw manufacturing and QC*Straw long term test (1-3 months) = damage + gas leakUsed nipple from bake well

    dP=1.5 Bar at (1-3) months

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Straw gas leak value measurement (if needed)Straw gas leakage measurement standbased on diff. manometer

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*Plans Straws:

    QC of straw production (Dubna) Sep -Feb 2010

    mylar order (CERN) Aug-Sept 2009

    mylar (Cu+Au) coating(CERN)- Oct - Dec 2009

    mylar cutting on rolls (CERN) Jan - Feb 2010

    straw end plug production (4000 sets CERN) Jan-May 2010 1600 straws manufacture and QC tests (4 months) start July 2010 (Dubna) storage 4x400 straws under pressure (Dubna)- start Aug. 2010

    S.Movchan Straw manufacturing and QC

  • *S.Movchan Straw manufacturing and QC*ConclusionTape and straw specifications fixed

    Preparation of Clean room with temp., hum. and dust control - in progress

    Straw QC procedures well defined

    Part of tools already exist

    Additional tools for straw production, assembly and QC - in design

    Order of needed sensors, tensile machine, ionization gun in progress

    Plans: certification straw manufacturing procedure June 2010 start straw mass-production July 2010

    S.Movchan Straw manufacturing and QC