pvc module production (2.5) ken heller university of minnesota may 8, 2012 minerba betancourt,...

PVC Module Production (2.5)Ken Heller

University of MinnesotaMay 8, 2012

Minerba Betancourt, Jianming Bian, Tom Chase, Dan Cronin-Hennessy, Ben DeYoung, James Geddes, Chris Kluge, Susan Lein, Tina Lorsung, Jarek Nowak, Greg Pawloski, Jim Parker, Nathaniel Pearson, Ron Poling, Nick Raddatz, Dominick Rocco, Kanika Sachdev, Alex Smith, Brian Sherwood, Dick Wildberger, Robyn Woolands, Jan Zirnstein

+ 170 undergraduates typically 15 hrs/wk(~ 240 is full staffing)

TechnicianAccountingEngineerPhysicist

Manifold Parts

DOE IPR May 8, 2012 Ken Heller WBS 2.5 2

Raceway holder

3

End Seal Parts

DOE IPR May 8, 2012 Ken Heller WBS 2.5

Module Production Status

• All machines & QA – operating.

• All molds & dies – completed and in production.

• Parts – flowing in.

• QA, process, & inventory software – operating

• Asynchronous 2 to 1 operation – in production

• Module production – ramping up

• Management of students working part time (170 students working a minimum of 10 hrs/wk) – in operation

• Module shipping – 4 planes (48 modules) to Ash River on schedule

• Factory floor – filling up


Slow ramp-up for first month - 123 good modules producedInitial process adjustments to minimize• Fiber damage• Optical connector leaks • Outer seal leaks• Visual inspection flaws

Module Factory Stable 2 to 1 Production


3277 complete 2 to 1 (8.5 blocks = 29% of far detector)

Failure rates overallFlatness – 0.7%End Cut – 0.7%

Failure rates April Flatness – 0% (125 done)End Cut – 1.6 % (125 done)

Peak 2 to 1 production rate 38/day (average needed 24/day)

Slowing 2 to 1 production to put effort into module production

Factory and annex are almost full

2 to 1 storage annex

2 to 1 operation

Scenes from the Factory Floor


Production floor Production floor

Stringing stations Gluing extrusions

Scenes from Production – Final Stages


Painting Stacking finished modules

Closed fiber testing Packing

Scenes from Production


Pressure testing Fly cutting Sealing endplate

Open fiber testing Stringing

Production Snap Shot


In full production each step would have the 24 modules/day.

A single module goes through all the steps in 6 days.

snou

t

string

open

fiber test

open

fiber test

flycut

open

fiber test

optical con

nector leak

open

fiber test

Inn

er seal cover

Inn

er seal end

plate

closed fib

er test

end

plate sq

uaren

ess

Inn

er seal leak

outer seal

closed fib

er test

pain

t

final in

spection

stack

pack

ship

2to1

flatness

trim en

d

trim en

d

length

outer seal leak

One day production process5/7/12

Production Progress


Fiber: 12Optical connector: 16

Failures week 2

Fiber: 13Final inspection: 1

Failures week 3

Fiber: 6Optical connector: 1Fly cut: 1

Failures week 4

Fiber: 4Final inspection: 1

Failures week 1

Fiber: 2Optical connector: 1

Failures week 5

Goal is 120/wk

166 good modules

Goal is 2%

Ken Heller WBS 2.5 11

Module Parts Received

DOE IPR May 8, 2012

Plastic Part module units (12500) %Manifold Cover 388 (382 = 1 block) 3End Plate 3372 27Top Raceway 541 4 Bottom Raceway 536 4Top Fiber Tray 9662 77 Generic Fiber Tray 2570 21 Bottom Fiber Tray 4464 36Raceway Cover 3422 27Raceway Support 3919 31Snout Front 3300 26Snout Back 3300 26Manifold Side Seal 3919 31End Plate Side Seal 3920 31Optical Connector 12544 100Fiber Ring 12891 100External Center Seal 12500 100

Redesign of Manifold Cover & ToolingAnalysis & Testing


Tight fit 10 mil gap

Ang Lee (Fermilab) FEA

New cover and clamp design - max stress between 1000 & 1400 psi.

Measured material strength between 6400 & 5100 psi.

Manifold Cover Strength Tests

DOE IPR May 8, 2012 Ken Heller WBS 2.513

5000

5200

5400

5600

5800

6000

6200

6400

6600

6800

7000

Mor

e0

1

2

3

4

5

6

Tensile Strength in psiN

umbe

r

Manifold Cover Ultrasound Scans


Section 1

Section 2

No flaws observed in structure or strength of manifold covers

Vigilance is the Price of NOnA


http://www.animal-photos.org/photo/2673.html

It’s all about QA/QC• Parts inspected when received• 2 to 1

• Flatness• Length• Squareness• Glue strength

• Fiber• Continuous as strung• Open ended after stringing• After fly cutting• After sealing

• Fly cut dimensions• Optical connector leak check• Inner seal leak check• Outer seal leak check• Final visual inspection, fiber test,

dimension check• Glue strength• Chemical compatibility3 QA audits by Fermilab project staff

Training

Cross section cuts to check glue flow


Cross-section cut every 0.05”Snout Joints

Optical connector Cross-section cut every 0.015”

Scintillator Interaction Testing


Alphaonly

Noise RunScintillatoronly

Ratio of Compton to alpha to take out phototube variationPulse height

cou

nts

Test all glue types and all parts

Risks and Mitigation


Parts do not meet specifications

Have manufacturer pay attention to their QC and remake parts. Adequate parts are buffered so should not cost production time. Add weekend production if necessary.

Utility rates increase for factory Project contingency held to cover up to a doubling of utility rates.

Extrusion delivery interruptedFactory already has over 6 months of stored extrusions so should not cost production time if extrusion factory can make up the deliveries later.

Unable to ship completed modules

Factory stores several months of completed modules so should not cost production time if shipments can resume.

Module production interrupted Factory stores several months of completed modules so detector assembly can continue. Weekend production can make up the time.

Module Shipping/Receiving Damage


Visual inspection of modules at Ash River by module factory personnel found damaged fiber.

5 modules (21%) in stack 16 modules (25%) in stack 2

Investigation plan

Ship 1 stack of modules to Ash River and back to module factory

Monitor shock and temperature

Check for fiber damage

Autopsy any damaged modules to determine location of damage

All good leaving factory

Looking Ahead

Expand staffing from 170 to ~210 students in Fall

20DOE IPR May 8, 2012 Ken Heller WBS 2.5

Ramp up to 24 modules/day (now at 12) – end of May

Summer means easier management controlfewer students (~70) working full time

Get to ~ 2% module failure rate (now at 7%)

Production ramp up going wellprocess improvements decrease defectsrate increasing

Investigate and eliminate fiber damage in shipping

Gluing seals & snouts Stringing

Unloading extrusions

pvc module production (2.5) ken heller university of minnesota may 8, 2012 minerba betancourt,...

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