1-2 September 2005 1J A Hill – EID RAL

EE End Cap Mechanical Design

ECAL EE End CapEngineering

CMS-UK Collaboration MeetingBrunel University September 1-2 2005

1-2 September 2005 2J A Hill – EID RAL

ECAL EE End Cap components

BACKPLATE

SUPPORT RING

SUPERCRYSTALS THIS FACE

PATCH PANELS

ENVIRONMENTAL SHIELD

1-2 September 2005 3J A Hill – EID RAL

EE End Cap Mechanics 2005 Highlights

End Cap Dee's have now been successfully fitted to both YE+ (Sept 04) and YE- (Feb 05) ends of CMS detector.

New contract agreement for the supply of four ‘new’ support rings signed agreed

in May 2005. Production of Environmental Screen in Russia.

Progress in the layout and design of major End Cap components, Electronics units

and related service support systems.

End Cap services have been fitted to both YE+ and YE- using the final design of the End Cap Patch Panels.

1-2 September 2005 4J A Hill – EID RAL

ECAL End Cap – at CERN during 2005

• End Cap Major components trial fitted to YE- in February 2005.• Like the YE+ fitting the assembly was successful with all EE/HE fixtures holes (bar one) being clear to fit.• Major dimensional gaps between HE/EE/ES checked manually, clearance as expected.• The final design layout of the End Cap Patch Panels was presented to CERN in early 2005, have now been used on the dummy End Caps for the service routing of all cables.

• ‘Dummy’ End Caps have been fitted to both YE+/YE- ends to allow the routing and laying out of End Cap and Preshower services.• A decision has been made to introduce a flexible link between the End Cap cooling connections on the Patch Panels to the ECAL service trays, RAL has provided a specification for this requirement.

1-2 September 2005 5J A Hill – EID RAL

ECAL EE Endcap Support Rings Production

All four rings ‘cold rolled’ at Barnshaws, July 2005.

‘Rough’ machining of ring section at TM Engineers, August

2005.

• A new contract was placed with TM Engineers in May 2005, delivery at CERN for first pair expected October 2005, second pair December 2005.• Base material supplied by ALCOA in 4 sections 350mm x 200mm x 7.7metres lengths.• Sections ultrasonically inspected for flaws, none found.• Each section cold rolled to correct internal radii (tolerance within 5mm of 1.65m rad).• All rolled section have been stress relieved by heat treatment.• Sections are currently undergoing rough machining, a further heat treatment may follow prior to final machining (note that 82% of material is machined away!).• RAL staff to witness final load test….

1-2 September 2005 6J A Hill – EID RAL

ECAL EE End Cap component Production

• EE End Cap Environmental screen under construction at Energia, Moscow.• Environmental screen produced as single circular component before ‘splitting’.• Procurement and engineering dealt with by IHEP Protvino, RAL engineers provide

support.• Delivery of both End Cap shields due at CERN October/November 2005.• Castings of 100ch and 75ch cooling bars produced.• Machining of all cooling bars in progress, delivery to CERN believed to be 2006...

Open section of outer shield showing the cooling circuit.

‘Complete’ section of outer shield.

Arrangement of prototype 100ch cooling

bars.

1-2 September 2005 7J A Hill – EID RAL

ECAL EE End Cap Build – Layout

BACKPLATE

SUPPORTRING

VFEELECTRONICS

MODERATOR

END CAP DEE SIDE VIEW

~3.6m

1-2 September 2005 8J A Hill – EID RAL

ECAL End Cap Build - Layers

Arrangement at the Rear of the End Cap Backplate

Backplate Cooling, fitting of patch panels, FOM

Protection plates, HV support

End Cap inner Shielding, Front Moderator

Protection plates, LV support

Mechatronics Support plates

Umbilical connection, VFE Mothercards/support frames, LV

distributionMechtronics cooling system,

internal flow and return manifoldsVFE, LV and FE cards attachment, Inner Moderator

Data/trigger fibre boxes plus support

Rear Moderator, closure of End Cap

1-2 September 2005 9J A Hill – EID RAL

ECAL End Cap Build - Progress

Detailed drawings of End Cap Moderator system complete.Tender to be dealt with by IHEP Protvino, production in Russia late 2005/early 2006.

Development of internal manifold systems approaching prototype stage however progress now

on hold due to problems encountered on ECAL Barrel cooling.

Drawings of current Mechatronics scheme, approaching prototype stage. Development model being produced with machined components from Bristol and Imperial.

1-2 September 2005 10J A Hill – EID RAL

ECAL End Cap - 2006 Schedule

1. Production Drawings – Work continues, where possible, towards producing detailed drawings for the manufacture of End Cap components in the region behind the Backplate. The final design of many items are still on hold pending decisions on umbilical design, Mechatronics cooling, HV and LV service routing and LED pulsing system. The current plan is to release all major production drawings by summer 2006.

2. 2006 Test Beam – The announcement of this will allow the many of the working components to be manufactured to a level between prototype and final production. This includes the electronics cooling system and manifolds, various support plates as well as its supporting structure. Drawings for the 2006 test beam components must be completed by April 2006 as the components will be required for the November 2006 test run.

3. During 2006 it is hoped to use the existing backplates and support ring in the Crystal Palace to further develop the routing and final loom schemes for HV, LV and fibre routing. Procedures for the use of the Super Crystal assembly manipulator to be understood and documented.

1-2 September 2005 11J A Hill – EID RAL

ECAL End Cap - Summary

Good Progress to date

• New contract for End Cap Support Rings, completion by December 2005• Dry fitting of End Cap Major Mechanics to both ends of CMS a success• End Cap Services have been fitted on both YE- an YE+• End Cap Environmental shields to be delivered Autumn 2005• Drawings available for End Cap Moderator system, manufacture to begin Winter 2005• Order placed for VFE cooling bars

Further progress required

• Design of region behind the backplate progressing but requires input and assistance from other ECAL members

Attention essential….

• Decisions and direction required on engineering for Mechatronics cooling