DOE REVIEW 1/20/04 – Dean White 1

Gantry Module AssemblyTOB & TEC

Gantry Module AssemblyTOB & TEC

Dean White

University of California, Santa Barbara

DOE REVIEW 1/20/04 – Dean White 2

Talk OverviewTalk Overview

• Gantry Personnel

• New 5th floor clean room

• Gantry design

• Gantry module precision

• Gantry production capabilities

• Summary

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Gantry Module Assembly PersonnelGantry Module Assembly Personnel

• Technicians: Andrea Allen

David Staszak

• Post-doc: Russel Taylor

• Engineers: David Hale

Dean White

These are the key people in module assembly. They also are involved to greater and lesser degrees in other areas of module production.

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New 5th Floor Clean RoomNew 5th Floor Clean Room

• Reasons for new 5th floor clean room:

• Temperature stability of +/- 1deg C needed for gantry.

• Availability of Emergency Power.

• Future need of high-bay clean room for Rod Production

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New 5th Floor Clean RoomNew 5th Floor Clean Room

• Better than class 10,000 clean room.

• Main production room (5324) has new gasket sealed grid ceiling and lighting.

• Hard wall anteroom entrance added in room 5332.

• New compressed air drier, filters and clean copper piping was added in the building core to deliver clean/dry air to clean rooms.

• ~$45,000 of University funds were used for these improvements.

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Gantry DesignGantry Design

BREIF DISCUSSION OF UCSB GANTRY AND MODUDE ASSEMBLY TOOLING

Aerotech AGS 1000 gantry X,Y,Z & U (rotational)

positioning system

Gantry image recognition system and electronics.

Vacuum/Pressure control values

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Gantry Design – Assembly PlatesGantry Design – Assembly Plates

• CERN style assembly plate

Laminated assembly plate

Vacuum chuck plate

PVC support and vacuum posts

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Gantry Design – Assembly PlatesGantry Design – Assembly Plates

Vacuum chucks and vacuum transfer lines on gantry base plate

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Gantry Design – Assembly PlatesGantry Design – Assembly Plates

ASSEMBLY PLATE TEFLON PADS ARE MACHINED TO FINAL HEIGHTS (+/- 25um) REFERENCED OFF OF FEET ON BOTTOM

Vacuum channels and o-ring grove machined into assembly plate for each sensor

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Gantry Design – Assembly PlatesGantry Design – Assembly Plates

Assembly plate feet that rest on vacuum chucks - precision machined flat and parallel

Sensor vacuum

Hybrid vacuum

Hybrid supply vacuum

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Gantry Design – Assembly ToolingGantry Design – Assembly ToolingTOB / TEC HYBRID AND SENSOR PICK-UP TOOLS.

TOB HYBRID BRIDGE

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Gantry Design – Assembled ModulesGantry Design – Assembled Modules

• 3 completed modules on the assembly plate.

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Gantry Precision - SensorsGantry Precision - Sensors

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Gantry Precision - HybridsGantry Precision - Hybrids

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Gantry Production – Assembly TimeGantry Production – Assembly Time

• Rough module assembly timeline using two people for producing 15 modules / day. (this probably could be increased for short periods, but over the long run it would be hard to do more than this in an 8 hour day)

Technician One:

8-9:00 Survey modules, install into carrier plates for 5 plates (50 min)

9-9:45 Run 1st assembly plate (45 min)

Break

10-10:45 Run 2nd assembly plate

11-11:45 Run 3rd assembly plate

12-1:00 Lunch

1-1:45 Run 4th assembly plate

2-2:45 Run 5th assembly plate

Break

3-5:00 Make-up time for assemblies with problems

Technician Two:

Load assembly plate, DB entry, glue prep (50min)

Prepare 2nd assembly plate

Prepare 3rd assembly plate

Prepare 4th assembly plate

Prepare 5th assembly plate

Prepare parts for next day’s assembly plates

Receive parts, DB transfers, maintenance, etc.

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Gantry Production Capabilities TOB

Gantry Production Capabilities TOB

• 5 TOB R-phi assembly plates commissioned during 2003

• 1 TOB Stereo assembly plate commissioned during 2003

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Gantry Production Capabilities TEC

Gantry Production Capabilities TEC

• 1 TEC R6 assembly plate fully commissioned (designed and built over the last 2 months of 2003).• Part of new responsibilities for TEC module assembly at UCSB.

TEC hybrid tool

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Gantry Production Capabilities Additional Assembly Plates

Gantry Production Capabilities Additional Assembly Plates

• 10 more module assembly plates in different stages of design and construction:

• 2 more TOB R-phi plates – dwgs are in the Physics machine shop

• 2 more TOB stereo plates – dwgs are in the Physics machine shop

• 2 more TEC R6 plates – dwgs are in the Physics machine shop

• 2 TEC R5N plates – design in progress

• 2 TEC R5S (stereo) – design in progress

• These 10 plates + the 7existing plates will give us the capability to build 2750 TOB and 1000-2000 TEC modules (R6, R5N & R5S) at UCSB.

• Switching between assembly plate types is easily, so modules can be built from whatever parts that are available.

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Summary Summary

• During 2003:• New 5th floor clean room installed

• Production of TOB and TEC modules, that are will within specification, has been accomplished on the UCSB gantry.

• New assembly plate design developed here at UCSB.

• 79 modules assembled on gantry.

• Fabrication of multiple assembly plates of modules/day (4) has been demonstrated.

• Gantry team is ready for 150 module production run over 2 weeks that will begin the last week of January 2004.