workshop on field quality steering of the dipole production cern, 20-21 march 2003
DESCRIPTION
Workshop on Field Quality Steering of the Dipole Production CERN, 20-21 March 2003. Status and trends of the various components affecting the Field Quality. (20 minutes) F. Bertinelli AT/MAS. Components supplied 1/2. Components supplied 2/2. Delivery plan per CMA. - PowerPoint PPT PresentationTRANSCRIPT
Field Quality Workshop - Components - F. Bertinelli 1
Workshop on Field Quality Steering of the Dipole Production Workshop on Field Quality Steering of the Dipole Production CERN, 20-21 March 2003CERN, 20-21 March 2003
Status and trends of the various components affecting the Field Quality
(20 minutes)
F. Bertinelli AT/MAS
Field Quality Workshop - Components - F. Bertinelli 2
Components supplied 1/2Components supplied 1/2
Contract no.
Component Supplier % produced
Kit 1 F313 Copper wedges Outokumpu (FIN) 27
Kit 2
F307Austenitic steel for collars
Nippon Steel (JP) 39
F316
F317Collars
Malvestiti (IT)
FUG/FSG (DE)15
F386 Cold bore tubes DMV (IT) 39
Field Quality Workshop - Components - F. Bertinelli 3
Components supplied 2/2Components supplied 2/2
Contract Component Supplier % produced
Kit 3
F245Low-carbon steel for yoke laminations
Cockerill (BE) 40
F314
F315Yoke laminations
FUG/FSG (DE)
ELAY (ES)20
F312Non-magnetic steel for end-yoke laminations
Kawasaki Steel (JP) 85
F319
F318End-yoke laminations
Malvestiti (IT)
ELAY (ES)20
F338 Shells Butting (DE) 11
F398 End covers Metso (FIN) 15
F389 N-line tubes DMV (IT) 57
F482 Copper tubes (HET) Outokumpu (FIN) 23
Heat Exchanger Tubes CERN - EST 8
Field Quality Workshop - Components - F. Bertinelli 4
Delivery plan per CMADelivery plan per CMA
Components Delivery Model for ALSTOM (October 2002)
0
50
100
150
200
250
300
350
400
450
Jan-00 Jul-00 Jan-01 Jul-01 Jan-02 Jul-02 Jan-03 Jul-03 Jan-04 Jul-04 Jan-05 Jul-05 Jan-06 Jul-06
Years
Nu
mb
er o
f d
ipo
le u
nit
s
Kit 2 delivery schedule for Alstom
C.M. delivery schedule for Alstom
F316+F317 Effective dispatch and current delivery schedule for Alstom
Field Quality Workshop - Components - F. Bertinelli 5
Nippon Steel: permeabilityNippon Steel: permeability
NIPPON Austenitic Steel
1.0015
1.0020
1.0025
1.0030
1.0035
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
B(T)
Per
mea
bil
ity
87834 L Reference 23350 T 23351 L 23351 T 23696 L
Specifications LHC-MB_A-CI-0017
Room Temperature
Nippon Austenitic Steel - 0.1 T
1.0015
1.0020
1.0025
1.0030
1.0035
0 5 10 15 20 25 30 35
N.
Per
mea
bil
ity
Specifications LHC-MQ-CI-001
Field Quality Workshop - Components - F. Bertinelli 6
Copper wedges: 1/4Copper wedges: 1/4
Profile 3 (new), nominal dimension 1.70
1.66
1.67
1.68
1.69
1.70
1.71
1.72
1.73
Batch number
Dim
ensi
on
(m
m)
The symptom …… measurements at
CERN …
Field Quality Workshop - Components - F. Bertinelli 7
Copper wedges: 2/4Copper wedges: 2/4
Effect of drawing dye wear: approx. 0.01 mm
Action: completely replaced the 4 extrusion and 4 drawing dyes with new ones
Batch 14: produced Nov. 2001 Batch 30: produced Sept. 2002
Field Quality Workshop - Components - F. Bertinelli 8
Copper wedges: 3/4Copper wedges: 3/4
CERN and Outokumpu measurements
Field Quality Workshop - Components - F. Bertinelli 9
Copper wedges: 4/4Copper wedges: 4/4
Profile 3 (new), nominal dimension 1.70
1.66
1.67
1.68
1.69
1.70
1.71
1.72
1.73
14-f15
-f16
-f17
-f18
-f19
-f20
-f21
-f22
-f23
-f24
-f25
-f26
-f27
-f28
-f29
-f30
-f31
-f32
-f33
-f34
-f35
-f36
-f37
-f
Batch number
Dim
ensi
on
(m
m)
Outokumpu measurements: historical statistics
Profile 3 (new), nominal dimension 7.79
7.78
7.79
7.80
7.81
7.82
7.83
Batch number
Dim
ensi
on
(m
m)
Field Quality Workshop - Components - F. Bertinelli 10
Collars: 3D measuring methodCollars: 3D measuring method
Field Quality Workshop - Components - F. Bertinelli 11
Collars: historical data MalvestitiCollars: historical data Malvestiti
• process under control
• collar dimension within tolerance
Field Quality Workshop - Components - F. Bertinelli 12
Collars: historical data FUG-FSGCollars: historical data FUG-FSG
FSG will supply the raw machine data to CERN (ASCII format) and CERN will process it
Field Quality Workshop - Components - F. Bertinelli 13
Collars: Smartscope measuring methodCollars: Smartscope measuring method
• Smartscope/Smartfit (Malvestiti) measurement of an FSG collar (batch 47, random selection)
• best fit of measured geometry w.r.t. nominal geometry
• results stable w.r.t. FSG tool approval (April 2001)
Field Quality Workshop - Components - F. Bertinelli 14
Collars: validation of 3D measuring methodsCollars: validation of 3D measuring methods
Measurements of the same collar, type A1: Malvestiti measurement - FSG measurement
-0.1
-0.08
-0.06
-0.04
-0.02
0
0.02
0.04
0.06
0.08
0.1
D1
C4_
X
C5_
X
C6_
X
C7_
X
D2
SY
6
SY
8
D16
D19
P71
P80
D26
C8_
X
C9_
X
D29
D32
D35
D38
D41
D46
D49
D52
D55
D60
D63
D66
D69
D72
D75
D78
D81
D84
D87
Points
[mm
]
random collar from FUG-47
random collar from FUG-18
• probe geometry (strong dependance on cut quality)
• support and positioning of collar for measurement (?)
• selection of reference axes (?)
• format of results (e.g. geometrical tolerances)
Measurements of the same collar, type A2: Malvestiti measurement - FSG measurement
-0.1
-0.08
-0.06
-0.04
-0.02
0
0.02
0.04
0.06
0.08
0.1
C5_XC6_X D1
C7_DC8_D P25 Sy5 P41 Sy7 D18
D23D34
D37D40
D43D60
D63D66
D69D46
D49D52
D73D76
D79D56
D59D82
D85
Points
[mm
]
random collar type A2 from FUG-47
Field Quality Workshop - Components - F. Bertinelli 15
Collars: cut qualityCollars: cut quality
Field Quality Workshop - Components - F. Bertinelli 16
Collars: random sample vs acceptance valuesCollars: random sample vs acceptance values
4 collars coming from the batch MAL20040
-0.100
-0.080
-0.060
-0.040
-0.020
0.000
0.020
0.040
0.060
0.080
0.100
D1
C4_
X
C5_
X
C6_
X
C7_
X
D2
SY
6
SY
8
D16
D19
P71
P80
D26
C8_
X
C9_
X
D29
D32
D35
D38
D41
D46
D49
D52
D55
D60
D63
D66
D69
D72
D75
D78
D81
D84
D87
Points
[mm
] MALNew-MAL1
MALNew-MAL2
MALNew-MAL3
4 collars coming from the batch FUG47
-0.1
-0.08
-0.06
-0.04
-0.02
0
0.02
0.04
0.06
0.08
0.1
D1
C4_YC5_D
C7_XSY2 D9
D16D20
P78 D26
C8_YC9_D D32
D36D40
D46D50
D54D60
D64D68
D72D76
D80D84
D88
Points
[mm
] FugNew-Fug1
FugNew-Fug2242
FugNew-Fug4485
Field Quality Workshop - Components - F. Bertinelli 17
Collars: repeatability of resultsCollars: repeatability of results
24-02-03_Measurement-Acceptation_Measurement
-0.100
-0.080
-0.060
-0.040
-0.020
0.000
0.020
0.040
0.060
0.080
0.100
D1
C4_
X
C5_
X
C6_
X
C7_
X
D2
SY
6
SY
8
D16
D19
P71
P80
D26
C8_
X
C9_
X
D29
D32
D35
D38
D41
D46
D49
D52
D55
D60
D63
D66
D69
D72
D75
D78
D81
D84
D87
Points
[mm
] MAL20040
MAL20046
New_Measurement-Acceptation_Measurement
-0.1
-0.08
-0.06
-0.04
-0.02
0
0.02
0.04
0.06
0.08
0.1
D1
C4_
X
C5_
X
C6_
X
C7_
X
D2
SY
6
SY
8
D16
D19
P71
P80
D26
C8_
X
C9_
X
D29
D32
D35
D38
D41
D46
D49
D52
D55
D60
D63
D66
D69
D72
D75
D78
D81
D84
D87
Points
[mm
]
FUG-47
FUG-18
FUG-8
FUG-23
FUG-28
FUG-38
Field Quality Workshop - Components - F. Bertinelli 18
Collars: what next?Collars: what next?
• “Trimicron” machine: not the solution for a better knowledge of collar geometry
• if necessary, obtain more knowledge using Smartscope, then use 3D to monitor stability of production
• follow-up the differences in measurement method
• try to reduce the uncertainty from ± 0.04 to ± 0.02 (is it worth it?)
Field Quality Workshop - Components - F. Bertinelli 19
ConclusionsConclusions
• “ … We need to implement:– SPC quality control common for all contracts and reporting
– a regular cross-check at CERN of measurements done by Suppliers (priority: collars, end covers, shells): i.e. an investment but extra costs
– Check state of components stored since years …..”
There is a real risk of “blindness from numbers”, i.e. rely too much on paperwork from Suppliers – risk of “routine”
From November 2002 Magnet Review…
Continue to improve quality of components (not only geometry…)