atlas pixel detector september 2002 n. hartman lbnl 1 pixel support tube: cost and production...

September 2002 N. Hartman LBNL 1

ATLAS Pixel Detector

Pixel Support Tube:Cost and Production Schedule

September 2002



PST Deliverables

• 3 Composite tubes• 6 Bonded composite flanges• Full Length insertion rails• Mount pads at forward and barrel (8 total)• PST Supports (8 flexures)• Pixel detector supports (kinematic, 4 total)• Heaters and EMI shielding (continuous over length)

• PST must be delivered as three bonded assemblies• Barrel mount pads are bonded while in dry fit with SCT• Forwards must be mounted to guarantee alignment

• All must be delivered by June ’04• Installation work costed in separate installation plan• SCT installation is Sept. ’04



Full Schedule

• Note schedule is in calendar years, not fiscal• Production estimate is rough (will know better by

end of Q1 FY03)• Based on delivery date of 6/1/04 to CERN• SCT installation date 9/1/04 (3 months slack time)


ATLAS Pixel DetectorPrototype Schedule

Current Progress

• Note schedule is in calendar years, not fiscal


ATLAS Pixel DetectorPrototype Items

• Shells– Completed

• Rails – Partially Complete – foot long rails have been made– Lead time of long rail tool is critical– Rail riders must be addressed

• Flanges– To be outsourced, not yet complete

• Hoop Stiffeners– May not be prototyped (fabricate during production phase only)– Schedule is already tight without them

• Mount Pads/Flexures– Mount pads require flat plate material from flange fabrication– If vendor cannot supply in time, must make mount pad material in house

• PST Assembly (bonding)– Designing bond tooling is critical item (lead time for machining)– Actual assembly can slip a little and overlap with long rail fabrication


ATLAS Pixel DetectorProduction Summary

• Prototyping– Continues through Q1 of FY03, but 3 month “slack” exists in Q2 of

FY03, while full size mandrel is being machined– Q1 of ’03 is staffed with Research Assistant (FTE) and MT (1/2 FTE)– All production tooling produced in near-final form in prototype phase,

except for mandrel– Prototype flange production contract covers tooling that will be used

to fabricate production flanges as well (but under additional contract)• Production

– Begins in Q3 of FY03, Continues to Q4 of FY04– Production time is staffed with MT (1/2 FTE)– PST Barrel constructed first, in case needed for dry fit with SCT earlier

than expected, though many parts will already be made for all sections

– Complete PST Delivered June of 2004


ATLAS Pixel DetectorImportant Milestones

• Production Readiness Review– December 9, 2002 – CERN

• Full Size Mandrel and Material Ordered– January 7, 2002

• Production Material Delivered– February, 2002

• Mandrel Delivered– March, 2002

• Production Begins– April 1, 2002

• Barrel PST Completed– September 14, 2002

• Forward PST’s Completed– June 1, 2002

• Fit-up with SCT (mount pads bonded in place?)– June, 2002

• SCT/PST Installed– September, 2002


ATLAS Pixel DetectorPotential Risks

• Prototyping– Problem with rail riders– Delay of bond or rail tooling– Delay of flange fabrication (contract)

• Production– Delays or problems in mandrel machining– Prototype delay eating into production time– Delay in working out mount pad bonding

scheme with SCT– Delay in SCT schedule pushing back

completion of PST (if dry fit is required for bonding to complete PST)



Cost Summary

ETC02 FY03 FY04 TotalPrototyping

Shop/Labor $0 $0 $0Materials $0 $0 $0

ProductionShop/Labor $143 $12 $155Materials $202 $0 $202Totals $345 $12 $357

ETC03 FY03 FY04 TotalPrototyping

Shop/Labor $101 $0 $101Materials $12 $0 $12

ProductionShop/Labor $56 $85 $141Materials $36 $54 $90Totals $206 $139 $345

• Costs in FY02 $K

• ETC02 to ETC03 very similar overall costs

• Schedule delay of about 6 months

• Production moved from FY03 to FY03/FY04

• Prototyping extended into FY03

atlas pixel detector september 2002 n. hartman lbnl 1 pixel support tube: cost and production...

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