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Finalization of Inner and Outer Barrel Design for ITS: QM Production Goals for 2014

This document outlines the objectives and design finalization efforts for the Inner and Outer Barrel (IB and OB) layouts in the ITS project for 2014. It includes the detailed design of quality modules (QM) focusing on the Space Frame, Cold Plate, and the production processes based on 'pad chips'. The report addresses specific parameters such as barrel dimensions, material properties, and the testing protocols required for engineering validation, including thermal and vibrational testing results. The ongoing development will ensure high-dimensional accuracy in the assembly of components crucial for the project's success.

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Finalization of Inner and Outer Barrel Design for ITS: QM Production Goals for 2014

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  1. WP9 ITS Mechanics and Cooling 12 March 2014 Corrado Gargiulo

  2. ITS objectives for 2014 – WP9 Finalization of IBand OBlayout IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell IB BARREL QM production based on “pad chips” OBQM design: Space Frame, Cold Plate OB STAVE QM production based on “pad chips” … EMEngineeringModule, QualificationModule(finalquality)

  3. ITS objectives for 2014 – WP9 Finalization of IBand OBlayout IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell IB BARREL QM production based on “pad chips” OB QM design: Space Frame, Cold Plate OB STAVE QM production based on “pad chips” …

  4. Finalization of IB and OB layout (TDR, endorsed) • BP outer radius19 • Layer 0 mean radius23.38 • Layer 0 inner boundary >21.8 • Middle Layer radius TDR6 / TDR7 • Stave width15+1(FPC) • Stave length (cold plate) IL 320 (4th IB layer) • IL 290=9.6+270.8+9.6 • ML 870= 14.85+840.3+14.85 1066 • OL 1502=15.7+1470.6+15.7 Detectors boundaryradius@ >21.8mm

  5. Beam Pipe NEW DESIGN 19mm OR • Submitted to LEB commitee for approval

  6. ITS VS BP Gap >2.8 mm No change in the ITS layers radius (TDR) R 19,0 19.0

  7. ITS Outer Barrel Baseline TDR 6 TDR 7 Simulation results by the end of March

  8. ITS objectives for 2014 – WP9 Finalization of IB and OB layout IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell IB BARREL QM production based on “pad chips” OB QM design: Space Frame, Cold Plate OB STAVE QM production based on “pad chips” …

  9. Inner Barrel FlexPrinted Circuit 9 PIXEL Chip ColdPlate Spaceframe Inner layer stave 300mm length, 1.6 gram weight Polyimide tubes ID 1.024mm; wall thickness 25 micron

  10. IB Carbon spaceframe IB status DEVELOPMENT TEST on EM (Engineering Module) sag • Thermal test OK • Thermoelastic test on going • Stiffnesstest sag <10 µm • Vibrational test >100Hz • Dimensional next 167 Hz next PRODUCTIONQM (FINAL QUALITY) • Production of new spaceframe with high dimensional accuracy • new moulds under production • Production of full barrel (48 staves)

  11. EM IB Carbon spaceframe on going M60J Alternative option under investigation to further improve stiffness and thermo-elastic stability Change of Carbon fleece with K13D2U (same weight) 45µm 20µ Carbon paper 30µ (30µ) 70µ 45µm K13D2U 45µm 20µ 11

  12. QMIB Connectors providestaves position accuracy status DESIGN • 3D, 2D production drawingsOK… …needvalidationfro WP6, needsadditionalconsiderations on surveystrategy next PRODUCTION • 100 CONNECTORS • Design and Production of assemblyjig, to glue the connector to the spaceframe Deisgnmodifiedrespect to TDR to increaseaccuracy

  13. QMIB production Spaceframe+Coldpalte n.48 2014 JULY Tentative schedule

  14. QMIB End-Wheels status DESIGN • 3d, OK… …need further consideration on cable and piping routing next DESIGN • Design and Production of molds for layer assembly

  15. QMIB End-Wheels From Antonello & Antoine

  16. QMIB CYlindricalSupport Structure status DESIGN • 3d, OK… …needs further consideration on survey targets locations and interface with Service Barrel next DESIGN • Design and Production of molds

  17. QMIB production End-Wheels and CYSS 2014 SEPTEMBER

  18. Production site Bldg 167 new … ongoing CERN GS HSE MaterialHazard Fireextinguisher CERN electricalinspection Ventillationsysteminstallation 90m2cleanenvironment, 18-23°C, 50% humidity

  19. Evgeny &Viktor Samuel Yannick Almostthere!

  20. ITS objectives for 2014 – WP9 Finalization of IB and OB layout IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell IB BARREL QM production based on “pad chips” OBQM design: Space Frame, Cold Plate OB STAVE QM production based on “pad chips” …

  21. Outer Barrel

  22. Outer Barrel stave status DEVELOPMENT TEST On spaceframe (Carbon fiber K13 D2U) • Bending test &FEA sag ≈95µm • Vibrationaltest 1st freq=51Hz; dynamicresponseongoing On coldpalte • Thermoelastic test αexp ~ 12 x 10-6 K-1 • Thermal (150 and 300 mW/cm2), hydraulic test Ok • Thermal test on full lengthcoldplatenext next PRODUCTIONQM (FINAL QUALITY) • Production of 1 SPACEFRAME+ 2COLDPLATES • Production of EMs

  23. EM OB Carbon spaceframe on going • Improve stavestiffness • Full k13 spaceframe has shown to be too brittle • N.2 Produced and tested, spaceframe M55j baseline • N.2 Produced and tested, spaceframe M55j with additional layer • N.2 Produced and tested, spaceframe M55j with two layers K13D2U(embedded) 3 point bending test results Confirmedprevious test Lumped mass (test) Distributed mass (derived from test)

  24. EM OB Coldplate • Production of 1 cold plate1,5m/ID=2mm/option-a • Production of 1 coldplate1,5m/ID=2mm/option-b • Production of 1 cold plate 300mm for thermaltest for both option a and b on going • Mould modified (for ID 2mm), Grenoble • New 2mm ID pipes arrived • K13 from Berkley arrived • Option b) Alternative option under investigation to further improve stiffness and thermo-elastic stability • Option a) Baseline 45µm 20µ 30µ 30µ ID=2.67mm, wt=0.065mm ID=2.00mm; wt=0.032mm 90µ 70/45µm 45µm 20µ 24

  25. Spaceframe QMOB SpaceframeCONNECTOR new design New design Removed spring connection between stave and end-wheels x TDR baseline Spring Spring x x Ruby sphere Reference Plane on the End-Wheels

  26. QMOB SpaceframeCONNECTOR revised design status DESIGN • EM 3D, 2D production drawingsOK… … need to be validated by WP7,8 and by test next PRODUCTION • 20 CONNECTORS • Design and Production of assemblyjigneeded to glue the connector to the spaceframe

  27. QMOB ColdPlateCONNECTOR status DESIGN • 3d, 2D production drawingsOK… …needsvalidation by WP7,8 next PRODUCTION • 20 CONNECTORS • Design and Production of assemblyjig, to glue the connector to the spaceframe

  28. EM OB End-Wheels status DESIGN • EM 3d model proposal next DESIGN • EM 3D design

  29. EM OB End-Wheels • Definition of cooling modularity and cooling scheme • Definition of electrical and hydraulic connection layout • DC-DC convertermechanics and cooling 300mm 300mm 300mm P. Kuijer 2014-3-11 300mm DC-DC 150mm EW

  30. ALI-UPGRADE 3D CAD MODEL overall 3D CAD MODEL available on CERN ITS UPGRADE CAD REPOSITORY R1_20140311

  31. Next EM Inner stave & Outer stave -optimize carbon plieslay-up QM Inner stave & QM Outer stave -freezeconnector design and start production -developjigs for connector to spaceframegluing

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