brick components r&d and mass production lead emulsion cs plastic components bam bms
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OPERA SPSC meeting April 2007. CERN, Geneva, Switzerland. Brick Production and Detector filling status report. S. Buontempo OPERA Technical Coordinator. Brick components R&D and mass production lead emulsion CS Plastic components BAM BMS - PowerPoint PPT PresentationTRANSCRIPT
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• Brick components R&D and mass production• lead• emulsion• CS• Plastic components
• BAM • BMS • Brick Production and Detector Filling schedule
Brick Production and Detector filling status report
S. BuontempoOPERA Technical Coordinator
OPERA SPSC meeting April 2007 CERN, Geneva, Switzerland
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Brick components R&D and mass production : Lead
Lead types studied before final choice:
pure lead
Pb + Ca (0,07%)
Pb + Ca (0,04%)
Pb + Sb
Pb Colaminated with pure lead
PbCa colaminated with pure lead
Studies on:
Alpha activity
Chemical compatibility with OPERA emulsion films
Mechanical performance (planarity, uniformity in thickness,
stickiness, shape)
First choice (Mar06): PbCa Colaminated (problems in
mass prod. Rate and shape)
Final choice (Aug06): Pb+Ca(0,04%)
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Lead vs emulsion chemical compatibility tests & radioactivity
2 months 33°C ( controlled humidity storage)
ChemicalVacuum Spider
Alpha activity
Pb+ Ca 0.07% No(Fog Up)
Yes Yes(<30 cm2/day)
Pb+Ca 0.04% No(Fog Up)
Yes Yes(<30 cm2/day)
PbCa colaminated
with pure lead
Yes Yes Yes(<30 cm2/day)
Pb+ Sb 2.5% Yes Yes No(Surface Po migration)
PbSb colaminated
with pure lead
Yes Yes No(Surface Po migration)
Pure Pb Yes yes No(Surface Po migration)
Best candidates
Brick components R&D and mass production : Lead
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Brick components R&D and mass production : Lead
Mass production in JL Goslar firm (Germany)
Custom production line for punching, washing and packaging was
designed, constructed and is now operational.
Upper limit in daily production 45000 pieces (800 bricks)
in 3 shift/day mode. Now operational at 1 shift/day.
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30000 plastic pallets produced1 pallet = 1 brick (56 plates)
1000 custom transportation boxesProducedBoxes are “lead cartridge for BAM”
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Brick components R&D and mass production : Emulsion
About 9 millions pieces produced by Fuji Film Company and delivered to Nagoya University
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Produ-ction
Beam exposure
Develop-ment
Initial sensitivity
Refreshing
Produ-ction
Beam exposure
Development
Characteristic of refreshing (after refreshing)
Sensitivity of refreshed film
Production
Beam exposure
Development
Refreshing
G.D. 36/100μm
F.D. 1.3/1000μm 3
Performance of refreshed emulsion films for OPERA
Condition : 30 98℃ % 3days
G.D. Under 8/100μm
F.D. 2.1/1000μm 3
G.D. 35/100μm
F.D. 1.5/1000μm 3
Brick components R&D and mass production : Emulsion
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Brick components R&D and mass production : Emulsion
construction 2003 Apr-Decoperation 2004 Jan ~ 2006 Mar
Finished: 150,000 BricksUnder treatment: ~7,000 BricksTotal 9,000,000Films.
Emulsion Refreshing Facility in Tono Mine (Japan)
24 refreshing Units
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• CS (Changeable Sheet) is a tracking detector to match the TT with brick track. 1CS for 1ECC.
• Refreshing lab equipped in LNGS to remove all the tracks taken during trip to Europe
• CS box design optimized to guarantee planarity with brick, easy removal and 5 years positioning
• 23,000 CSs were produced in 2006
• The production speed was 1,700/day at Maximum.
• Next production will start end of March.
• 15000 CS boxes available now in LNGS, rest being produced
CS
CS
Brick components R&D and mass production : Changeable Sheets (CS)
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Brick components R&D and mass production : Plastic components
Brick mechanical packaging demanded for custom metal and plastic
components:
Al frame to keep the brick closed under 3 bar pressure (spider)
Plastic protection
Plastic cover
Requested performances:
minimal additional mass around the brick,
cover must be flat and rigid to keep the 3 bar pressure for 5 yeas,
plastic protection must be flat, but foldable on the corners
All test measurements were done in the framework of BAM activity
Chemical compatibility tests done with samples produced using list of
candidate materials
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DE
RL
ING
PP
OM
OP
ER
AC
LE
NE
PO
LIT
EN
E
FLE
XIR
EN
E
MO
PLE
N
NY
PA
+E
LA
ST
OM
NY
PA
6+
EL
+30
%fibG
L
NY
PA
6+
30%
fib
GL
NY
PA
6+
50%
fib
GL
Refe
rence
5
10
15
20
25
30
35
Gra
ins/(
10
m)3
Fog densityD
ER
LIN
G
PP
OM
OP
ER
AC
LE
NE
PO
LIT
EN
E
FLE
XIR
EN
E
MO
PLE
N
NY
PA
+E
LA
ST
OM
NY
PA
6+
EL+
30%
fibG
L
NY
PA
6+
30%
fibG
L
NY
PA
6+
50%
fibG
L
Refe
rence31.5
32.0
32.5
33.0
33.5
34.0
34.5
35.0
35.5
36.0
36.5
37.0
37.5
38.0
Gra
ins/1
00
m
Sensitivity
Studies on the compatibility of plastic components and OPERA emulsions.• Plastic cover and side protection 2 months storage @ 33° C2 months storage @ 33° C
Brick components R&D and mass production : Plastic components
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Brick Assembly Machine (BAM)
The BAM was conceived to maximize the brick quality stability in a
mass production mode. Goal was to produce 206000 in 1 year
(equivalent to 936 bricks/day 4 drums/day)
Long R&D work done on vacuum vs mechanical packaging
Specs document was defined for both cases solution. Tender was
closed in jan 2005.
TecnoCut firm (Italy) participated in the final studies for final choice
Mechanical solution was the final choice (may 2005) to secure:
piling precision
long term stability
brick robustness
The proposed solution based on anthropomorphic robots: very first
application of this in particle physics domain intellectual and
capital investment for future large detectors
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Status of BAM layoutBAM layout
BAM lead-drum room
BAM clean-light ro
om
BAM clean-dark room
5 piling pressing stations
Lead unpacking
Lead transportation
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Brick Assembly Machine (BAM)
Pictures bam in light, clean room and bam in dark,
BAM Lead-Drum
room
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Brick Assembly Machine (BAM)
BAM in Light,
clean room with white
light
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Brick Assembly Machine (BAM)
BAM in dark, clean room with white/red light
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Brick Assembly Machine (BAM) BAM construction started in march 2005 in firm site (Pavia, Italy).
Planned construction and commissioning time in firm was 13
months.
Delivery expected in GS by April 2006, postponed to June 2006 due
to lead decision.
Delay in lead choice decision interfered with final layout and
commissioning of piling section. First “final” lead choice was PbCa
Colaminated.
Construction completed in firm by summer 2006 with commissioning
of single units.
Decision to install anyway in GS in summer 2006 to secure the brick
pilot production for beam time in October 2006.
Installation and preliminary commissioning in LNGS completed in
October (a part drum station, being a separate order).
Commissioning phase of full line was delayed by the new problems
of stickiness found in colaminated lead and real emulsions
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Brick Assembly Machine (BAM) Pilot production in GS in October 2006 good for physics and for
mechanics:
800 bricks produced in 3 weeks with many new problems in
lead/emulsion stickiness.
Brick skating performance were not as good as in prototyping
because of brick shape defects which were demanding thicker skate
solution
CS box mechanically positioned on the brick was unstable in case
of too strong pressure and friction during detector filling phase
Net effects were:
a revision of the piling station cycle with addition of pulse
compressed air on both emulsion and lead pile. Resulting in factor 2
in piling time (from 3 to 6 min /brick) and 1 operator needed per
each piling station.
Additional job in pre-treatment of lead boxes with compressed air
to open the piles.
Need to change the skates with thicker material (Tyvek)
Need to glue the CS boxes
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Brick Assembly Machine (BAM)
New skate and CS box gluing additional machines being constructed
(delivery by April07) (eliminating present manual operations in BAM
in light)
6 min/brick/station = 50 bricks/hour is present theoretical upper
limit
x 14h/day = 700 bricks theoretical upper limit (2 shifts mode and 2h
lost for lab access and BAM loading). Our present goal is to secure
468 (2 drums) a day ( with 33% ineff.)
To secure 702 real brick/day (3 drums) with some contingency we
plan to increase theoretical limit by 25% (margins exist) and reduce
inefficiency by 10%.
BAM performance
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Brick Assembly Machine (BAM)
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Brick Manipulator System (BMS)
Responsibility of LAPP-
Annecy (IN2P3/CNRS)
System based on industrial
automates,
Profibus ground bus, C++
supervision and DB management
softwares.
One manipulator on each side of the
detector, portico and vertically
moving platform
R&D, mechanical construction,
cabling and tests at LAPP,
installation in Gran Sasso:
December 2005, March 2006.
Commissioning going on.
5000 real bricks inserted in OPERA
till last week
Running needs: 1 expert + 1 skilled
operator per shift
Present performance (no contingency): insertion of 2 drums (468 bricks) in one shift of 8 hrs
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Brick Manipulator System (BMS)
Loading station and drumfor brick transfer
Draw bridge for brick insertion
Storage Carrousel
Digital camera for positioning
Vacuum sucker vehicle to retrieve bricks
Electric jack to insert bricks
Portico
Manipulating platform
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Brick Manipulator System (BMS)
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Brick Production and Detector filling schedule
Since last march 12th 2 shift/day mass production started.
9350 bricks produced till
last week
Technical stops were
planned to update parts
of BAM piling section
3 (2) days stops were
needed in week 13 (15)
due lack of empty drums
(to BMS stop)
Now we monitor the
BAM/BMS stability and
fatigue
Internal Milestone: Produce/insert 10000 bricksin detector by April SPSC-LNGSC week
Brick Production
0100020003000400050006000700080009000
10000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Weeks
Brick
s brick sum
weekly bricks
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Brick Production and Detector filling schedule
Final Goal: Produce 150000 bricks by end of April 08
1 drum/shift (468 brick/day) is feasible. Strong dependence by operator skill and storage units (drums) availability. We have to check now the production stability performance.
2,5 drum/day (585 bricks/day) is technically feasible now with software improvements in the BMS procedure to be implemented in next technical stops 3 drums/day (702 bricks/day) demands for:- improvements in BAM piling and wrapping station speed, evaluated in next 6-8 weeks during technical stops- 2 shift running mode on BMS operation
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Brick Production and Detector filling schedule
Detector filling schedule in 3 BAM/BMS rates (with 15% contingency time):
Rate run start (sept 15th) run stop (nov 15th) det. completed
(+21 weeks) (+30 weeks) 150000 bricks
2 drums/day 50680 68986 sept 12th 08(2034 bricks/week) ( 372 evts)* (+70 weeks)
2.5 drums/day 58315 81202 June 20th 08(2543 bricks/ week from june 1st 07) ( 441 evts)* (+58 weeks)
3 drums/day 59334 86802 May 2nd 08(3052 bricks/week from sept 1st 07) ( 465 evts ) * (+41 weeks)
* : number of CNGS events in the bricks for 1019 pot