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Development of Mechanical Prototype for Future Experiments at CERN

This project focuses on the design and construction of a mechanical prototype at CERN, aimed at demonstrating the feasibility of innovative construction techniques. The objectives include setting up basic infrastructure, experimenting with materials and assembly procedures, and ensuring precision in panel planarity and parallelism. The prototype consists of a full-wedge small sector quadruplet with specific thickness specifications, gas distribution mechanisms, and advanced gluing tests. Collaborative efforts from CERN, Dubna, and Lecce facilitate this initiative, which emphasizes real-world application and scalable design for future projects.

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Development of Mechanical Prototype for Future Experiments at CERN

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  1. MM mechanical prototype Work progress at CERN G. Sekhniaidze/J. Wotschack

  2. Purpose • Demonstrate feasibility • Setup of basic infrastructure • Gain experience with • construction/assembly ideas/schemes • Materials • Procedures • Precision (panel planarity, parallelism of skins, …) • Produce objects that can be measured • Establish an Assembly Manual G. Sekhniaidze/J. Wotschack

  3. CERN mechanical prototype (1) • Full-wedge small sector quadruplet • Eta and stereo doublet • Drift gap spacers: 5 mm • Total thickness: 70–80 mm • Gas distribution • Mesh? G. Sekhniaidze/J. Wotschack

  4. CERN mechanical prototype (2) • All panels of equal thickness: 11-12 mm • Standard Al profiles of t=10 mm as frames with special angular inserts • Skins = 0.5 mm (FR4) • Two possible scenarios: • Al honeycomb of t=10 mm expanding glue PB250/SD5604 glue gaps ≈ few 100 µm • Foam panel of t=10 mm plastic mesh of t=100-200µm glue Araldite 2011 G. Sekhniaidze/J. Wotschack

  5. Gluing test (1) Step 1 – FR4 skins were placed on the table Step 2 – Glue (Araldite 2011) has been applied and distributed on the surface Step 3 – Plastic mesh placed on the surface G. Sekhniaidze/J. Wotschack

  6. Gluing test (2) Step 4 – Al profiles and the foam panel with the glue on them were placed on the mesh Step 5 – FR4 skin has been cut around “half panel” G. Sekhniaidze/J. Wotschack

  7. Gluing test, second skin Step 1 – Araldite AY-103 (more fluid) has been applied to the second skin and “half panel” Step 4 – “half panel” placed on the second skin and mesh G. Sekhniaidze/J. Wotschack

  8. Dimensions 70 – 80 mm Dead area: 50 mm Space for electronics: 50 mm 10+ 10+ 10+ 10+ 10+ Eta strips 20 mm Stereo strips Electronics boards 5 5 5 5 Space for electronics (50 mm in phi) MM multiplet stack (10+: 11 or 12 mm) G. Sekhniaidze/J. Wotschack

  9. Collaborative effort • CERN, Dubna, Lecce … • Drawings and calculations: Lecce and CERN • Infrastructure and tooling: CERN • Technical work: CERN, Dubna, Lecce • Evaluation: all (two summer students for mechanical) G. Sekhniaidze/J. Wotschack

  10. What could/should be included • Realistic materials and glues • Realistic thickness and segmentation of PCBs • Space for on-chamber electronics boards • Simplified cooling and cabling channels • We foresee to insert heating wires into the cooling channels to simulate electronics/cooling • Gas channels and seals (to allow for gas pressure tests) • Mesh frame (but not necessarily the mesh) • T-sensors (a few) to allow for test measurements • Other ??? G. Sekhniaidze/J. Wotschack

  11. The table • Size: 4 x 2.5 m • Flatness: ≤ 20 µm • Location: B16 • Available: Wednesday G. Sekhniaidze/J. Wotschack

  12. Using Skin suction Tool Vacuum Clarinet gas X 5 Vacuum Vacuum Vacuum Rohacell honeycomb Precision insert Skin (G10) Expansive glue Precised shim G. Sekhniaidze/J. Wotschack

  13. Stiff-back • Simple stiff-back structure with suction heads (following small test structure) used for 2 x 1 m2 prototype • CERN-DT group is working on a more final system using a perforated honeycomb structure with a perforated lower skin • Work in progress • Small 50 x 50 cm2 system under construction • Large system if prototype successful 60 mm G. Sekhniaidze/J. Wotschack

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