production of forward rpc gaps cms forward rpc edr (10/10/2002 – 11/10/2002) seong jong hong...
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Production of Forward RPC Gaps
CMS Forward RPC EDR(10/10/2002 – 11/10/2002)
Seong Jong HongKODEL, Korea University
Contents
• CMS Forward RPC Gaps• Mechanics of Forward RPC Gaps• Gap Assembly Procedure / Quality Insurance• Factory Overview• Factory Layout• HV/Ground Electrodes Production• PET Coating Facility• Gap Assembly Facility• Gap Test• Capacity of Gap production• Cost Estimation• Production and Delivery• Summary
CMS Forward RPC Gaps
• RE1/1 36 (10 。 Detector) × 2 (L, R) × 3 = 216 • RE1/2 36 (10 。 Detector) × 2 (L, R) × 3 = 216 • RE1/3 36 (10 。 Detector) × 2 (L, R) × 3 = 216• Spare (10%) 65 RE1 total 713 238 uncut gaps, 475 cut gaps • RE2/1 18 (20 。 Detector) × 2 (L, R) × 3 = 108 • RE2/2 36 (10 。 Detector) × 2 (L, R) × 3 = 216 • RE2/3 36 (10 。 Detector) × 2 (L, R) × 3 = 216 • RE3/1 18 (20 。 Detector) × 2 (L, R) × 2 = 72 • RE3/2 36 (10 。 Detector) × 2 (L, R) × 3 = 216 • RE3/3 36 (10 。 Detector) × 2 (L, R) × 3 = 216 • RE4/1 18 (20 。 Detector) × 2 (L, R) × 2 = 72 • RE4/2 36 (10 。 Detector) × 2 (L, R) × 3 = 216 • RE4/3 36 (10 。 Detector) × 2 (L, R) × 3 = 216 • Spare (10%) = 220 Total 2416 805 uncut gaps, 1611 cut gaps
Mechanics of Forward RPC Gaps
RE 1/1 3-D
Vertical Cross Section
Edge Spacer Coin Spacer
Gas Connection Gas Pipe
Gap Assembly ProcedureQuality Insurance
Bakelite electrode preparation
Procedure Quality Insurance
Cut bakelite into right size Bakelite surface inspection
Bakelite resistivity measurement
Check the size of bakelite
Silk-ink coating on the bakelite Resistivity measurement every batch
Protective PET coating over the silk-ink coating
Edge spacer preparation
Coin spacer preparation
Procedure Quality Insurance
Molding by external vender Thickness and width check
Thickness : 2.0 ± 0.02 mm
Surface scratching with sand paper Thickness and width check
Thickness : 2.0 ± 0.02 mm
Procedure Quality Insurance
Machining by external vender Thickness and diameter check
Thickness : 2.0 ± 0.02 mm
Scratching with sanding machine Thickness and diameter check
Thickness : 2.0 ± 0.02 mm
Gas inlet/outlet preparation
Procedure Quality Insurance
Molding by external vender Thickness and hole dimension check
Thickness : 2.0 ± 0.02 mm
Gap assembly
Procedure Quality Insurance
Gluing and assembly Epoxy lifetime check : 6 months in the refrigerator
Amount of glue : guaranteed by the glue dispenser
Assemble in the clean room(Class : 104-105 particles/ft3 ).
Pressurizing device monitoring during curing (14 hours)
Pressure : guaranteed by the water height
Factory Overview
• Located at Ilsan near the Kimpo airport.• Two buildings. Each building : 180 m2.• The first building has - Bakelite storage area - Bakelite cutting facility - HV/Ground electrode production facility - Mylar coating facility• The second building consists of - Gap assembly facility area (class : 104-105 particles/ft3) - Chamber assembly tables - Gap and chamber storage area - Chamber testing room• Clean shoes inside the factory• Clean gap assembly : class : 104-105 particles/ft3
• Controlled temperature (20 ± 5 Celsius) and humidity (40 ± 10%) - Bakelite, gap and chamber storage area• All the other area inside factory : temperature (20 ± 5 Celsius)
Factory Layout
Bakelite Cutting Facility
- Cut bakelite weekly- Can cut up to 10 sheets
HV/Ground Electrodes Production
Uniformity of resistivity - RE2/1 uncut gap - within 10%
- Cell size : 5×5 cm2
PET Coating Facility
• Protection of HV and ground electrodes and electrical insulation of HV and ground electrodes. - 2 sheets of 250 m on HV side - 1 sheet of 250 m on ground side• The PET coating facility consists of - Free roll conveyor set to guide the bakelite to the laminating set. - Laminating set - Belt conveyor set to guide the mylar coated bakelite from the laminating set• The laminating set consists of - PET unwinding roller - Hot melt heater - Nozzle for applying adhesive to bakelite - Knife for keeping adhesive thickness uniformly - Rubber coated roller and steel roller to press the PET film on the bakelite
- Current problem : Weak adhesive strength - Operating temperature of of hot melt glue : ~ 80° C- When hot melt applied to the bakelite, temperature of hot melt drops quickly- We will heat the bakelite with infrared lamp
Gap Assembly Facility
• The gap assembly facility consists of seven epoxy curing frames, an optical table for gap assembly, a lifting device and a pressurizing device • Each epoxy curing frame - consists of an optical table and a gap-pressing device - can cure 1 uncut gaps or 2 cut gaps • Gap assembly optical table - designed to produce various sizes of gaps using jigs - attached to the moving frame riding on rail • Lifting device moves each assembled gap on the optical table to individual epoxy curing frame• Pressurizing device - provides uniform pressure to the assembled gaps during epoxy curing - consists of an air vessel made of special rubber, and air supply equipment which provides air for the air vessel and maintains constant air pressure in the air vessel
Air inletPressure
Frame
Optical table
Gap Jig
Optical table
Pressing device
Spacer grinder Gap storage area
Gap Test
Test Criteria
Gas leakage Less than 5 hPa leakage for 10 minutes under –20 hPa
Epoxy strength No loss of coin spacer under +20 hPa for 5 minutes
Current Uncut gap : below 1 A
Cut gap : below 2 A
Gap test facilities are being designed now
Capacity of Gap Production
• Work hour : 8 hours/day
• Working days : 250 days/year - Part preparation : 100 days/year - Gap assembly : 150 days/year
• Gap production capacity (with 6 storages) - The gap assembly facility has 7 storages - 3 uncut gaps/day × 150 days/year = 450 uncut gaps/year - 6 cut gaps/day × 150 days/year = 900 cut gaps/year
• Total number of gaps for CMS forward RPC
- 805 uncut gaps, 1610 cut gaps
Cost Estimation
Section Gaps Angle
(Degree)
Unit Price
(CHF)Total
NumberTotal Price
(CHF)
RE1/1 3 10 550 80 44,000
RE1/2,3 3 10 1,000 160 160,000
Subtotal 204,000
RE2/1 3 20 800 40 32,000
RE3,4/1 2 20 600 80 48,000
RE2,3,4/2,3 3 10 1,000 480 480,000
Subtotal 560,000
Total 764,000
Bakelite cost not included
Production and Delivery
Year 2 0 0 3 2 0 0 4 2 0 0 5
Month 1 2 3 4 5 6 7 8 910
11
12
1 2 3 4 5 6 7 8 910
11
12
1 2 3 4 5 6 7 8 910
11
12
RE 1/1
(80)
RE 1/2
(80)
Delivery
RE 1/3
(80)
Delivery
RE N/1
(120)
RE N/2
(240)
Delivery
RE N/3
(240)
Delivery
RE 1/2, RE 1/3 : Delivery to ChinaRE N/2, RE N/3 : Delivery to Pakistan
Production capability 9 RPCs/Week, 36 RPCs/Month
Schedule
Packing
• Custom-made box - consists of 4 shelves - 10 sets of gaps on each shelf 1 set : 1 uncut gap, 2 cut gaps• Individual packing of 10 sets• Shock watch• To China : 4 boxes• To Pakistan : 12 boxes
Summary
• Most of the gap production facilities are tested and
satisfactory• PET coating facility is being tested• Facilities for quality insurance and gap test are being designed • Funding for RE 1 station has been secured and production
schedule has been confirmed by funding agency• Funding for other stations has been committed by funding
agency, but has no detailed plan
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