pixel support tube production readiness review parts overview

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 1

ATLAS Pixel Support Tube PRR: Parts

Pixel Support Tube Production Readiness Review Parts Overview

Alexis SmithFebruary 18, 2003

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 2

ATLAS Pixel Support Tube PRR: Parts

Overview

Schematic of Pixel Support Tube assemblyList of PartsMethod of production for each part• Materials• Tools• Lay-up procedure• Cure procedure• Pre-assembly processingComparison of prototype to production parts

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 3

ATLAS Pixel Support Tube PRR: Parts

Schematic of PST Assembly

• The Pixel Support Tube Assembly comprises the shell, the rails on which the pixel detector slides, the mount connections to the SCT, and the thermal isolation system

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 4

ATLAS Pixel Support Tube PRR: Parts

List of Parts

• PST Shell Laminate– Forward Shell (2)– Barrel Shell (1)

• PST Flange Assembly– Flange (6)– Backing Ring (6)

• Mount Pad (6)• Flat Rail (9)• Vee Rail (3) • Hoop Stiffener (57)

• Heater System Assembly – Heaters (108)– Mount Pad Circuits (6)– Wires (357)

• Various machined and other parts– Pixel mount– Mount block– Mount insulator shim– Mount insulator pad– Wire harness– Adhesive – Connector

• (Flexures)

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 5

ATLAS Pixel Support Tube PRR: Parts

Shell Laminate

• Fiberglass mat, EX1515U, [0,0,+60,-60]S

• 8-ply symmetric lay-up of YSH-80 (carbon) and AQ-II (fiberglass) with a layer of fiberglass mat to prevent carbon particle liberation

• Plies are cut to allow for axial and circumferential interweaving

0 degree

60 degree

-60 degree

-60 degree(2nd layer

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 6

ATLAS Pixel Support Tube PRR: Parts

Shell Laminate

• 0 plies laid-up separately and with tension

• -60 and +60 plies stacked and pre-compacted before lay-up

• Stack is compacted on mandrel after each new layer application

• Heater panels layed-up as last step before cure

• Prototype: plies interleaved in the hoop direction

• Production: plies interleaved in hoop and axial directions

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 7

ATLAS Pixel Support Tube PRR: Parts

Shell Laminate

• Production mandrel will be 2500 mm long• Production shell laminates shall be 457.5 mm OD• Barrel shell length: 1631 mm• Forward shell lengths: 2276.5

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 8

ATLAS Pixel Support Tube PRR: Parts

PST Flange Assembly: Flange

• [+/-45, +/-45, +/-45]• 3-ply involute lay-up of CN60 strips with 2/3 overlap of

each strip• Lay-up on flange tool with collar

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 9

ATLAS Pixel Support Tube PRR: Parts

Trimming of Flange

• Flange lip is trimmed to size with a router on a trim plate

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 10

ATLAS Pixel Support Tube PRR: Parts

PST Flange Assembly: Backing Ring

• [0/90,+/-45, 0/90,+/-45, 0/90,+/-45, 0/90,+/-45]S

• 16-ply lay-up of CN60 cloth in alternating orientations• Total post-cure thickness is 4 mm• Lay-up a large ring out of which the backing ring is cut

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 11

ATLAS Pixel Support Tube PRR: Parts

Trimming of Backing Ring

• Water-jet cut backing ring out of large lay-up• Cut bevel with router on the same trim plate as the

flange

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 12

ATLAS Pixel Support Tube PRR: Parts

Mount Pad

• [0/90,0/90,+/-45, +/-45, 0/90,+/-45, 0/90, +/-45, +/-45, 0/90,0/90]

• 11-ply quasi-symmetric lay-up of CN60 cloth• Darts are used to ensure proper conformance to tool

shape

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 13

ATLAS Pixel Support Tube PRR: Parts

Mount Pad

• Part is trimmed on a custom vacuum chuck

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 14

ATLAS Pixel Support Tube PRR: Parts

Flat and Vee Rail

• EX1515, [0/90, 0/90, 0/90, 0/90, 0/90, 0/90, 0/90]• 1 ply of EX1515 followed by 7 plies of P30 cloth• Stacks of 3-4 plies are pre-compacted before being

layed-up• Part trimmed to length on the tool• Tool is supported during cure to minimize out-of-

straightness

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 15

ATLAS Pixel Support Tube PRR: Parts

Hoop Stiffener

• [+/-45,0/90,+/-45]• 3-ply CN60 lay-up• Dart to ensure proper conformance to tool shape• Made in 3 parts

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 16

ATLAS Pixel Support Tube PRR: Parts

Heater Panel

• Custom-made part supplied by vendor

• Kapton with copper sputter-coated on both sides, Aluminum foil on one side, polymer coverlay on the other side. Heater traces and connection pads etched onto copper.

• 4 positive leads and 1 negative to allow for multiple connection possibilities

• Connection points for EMI shielding

• Jumper across mount pad area

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 17

ATLAS Pixel Support Tube PRR: Parts

Heater Panel

• Shell with co-bonded heater panels

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 18

ATLAS Pixel Support Tube PRR: Parts

Flexure Mounts

• 3 Flexures, 1 Solid Block• Made of Titanium• Still in design phase

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 19

ATLAS Pixel Support Tube PRR: Parts

Machined and Other Parts

• Pixel mount• Mount block• Mount insulator shim• Mount insulator pad• Wire harness• Adhesive (Hysol 9396)• Connector

FEBRUARY 2003Pixel Support Tube A. Smith LBNL 20

ATLAS Pixel Support Tube PRR: Parts

Comparison of Prototype to Production Parts

• Successfully built all composite parts except hoop stiffeners– Shell laminate with heater panels– Flange and backing ring– Flat and Vee rails– Mount pads

• Length of shell prototype is shorter and shell lay-up method is slightly different. Plies will be the same.

• All other components are equivalent to production parts.