production of forward rpc gaps cms forward rpc edr (10/10/2002 – 11/10/2002) seong jong hong...
TRANSCRIPT
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Production of Forward RPC Gaps
CMS Forward RPC EDR(10/10/2002 – 11/10/2002)
Seong Jong HongKODEL, Korea University
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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
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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
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Mechanics of Forward RPC Gaps
RE 1/1 3-D
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Vertical Cross Section
Edge Spacer Coin Spacer
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Gas Connection Gas Pipe
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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
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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
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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
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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)
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Factory Layout
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Bakelite Cutting Facility
- Cut bakelite weekly- Can cut up to 10 sheets
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HV/Ground Electrodes Production
Uniformity of resistivity - RE2/1 uncut gap - within 10%
- Cell size : 5×5 cm2
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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
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- 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
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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
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Air inletPressure
Frame
Optical table
Gap Jig
Optical table
Pressing device
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Spacer grinder Gap storage area
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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
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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
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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
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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
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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
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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