Workshop on Field Quality Steering of the Dipole Production CERN, 20-21 March 2003

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


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


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


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


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


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 …



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



CERN and Outokumpu measurements




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


7.78

7.79

7.80

7.81

7.82

7.83

Batch number

Dim

ensi

on

(m

m)


Collars: 3D measuring methodCollars: 3D measuring method


Collars: historical data MalvestitiCollars: historical data Malvestiti

• process under control

• collar dimension within tolerance


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


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)


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


Collars: cut qualityCollars: cut quality


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


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


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?)


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…)

Workshop on Field Quality Steering of the Dipole Production CERN, 20-21 March 2003

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Transcript of Workshop on Field Quality Steering of the Dipole Production CERN, 20-21 March 2003