APA frames at the University of Iowa

Jane Nachtman, Paul Debbins, Yasar OnelPlus UI machine shop staff and UI students

Introduction/Overview● University of Iowa has years of experience building detectors, and would like

to take this opportunity to help build the DUNE Far Detector.● Facilities at UI Department of Physics and Astronomy

○ NASA-certified machine shops○ NASA-certified electronics shops○ Experienced engineers from UI CMS group, also UI departmental support○ Space

■ our lab (old Van de Graaf experimental area) in Van Allen Hall ■ Warehouse facility just off campus (“Sand Road”), accessible by flatbed semi■ Possible storage facility with loading dock (Independence Road)

● Working with PSL engineers to understand process so as to ensure a uniform high quality frame

● Currently -- machining test of two frame pieces● Plan to build 76 frames in total for Module 1 and 2 of DUNE FD

○ Ship to Yale/Chicago winding and assembly facilities

Equipment Designed, Built, Tested at Iowa

3

CMS HF Calibration Module

2000 Photodetectors characterized at UI

Readout Boxes and Light Guides Light Mixers

ZDC Crane in LHC tunnelCMS Radioactive source

drivers

Prototype Shashlik calorimeter module

UI Proposed Process follows PSL experience● Purchase steel tubing from Atlantic (same vendor for all frames) ● Storage, staging at Van Allen and Sand Road spaces● Welding by UI machinists● Machining in UI shops● Transport between campus buildings by university movers● Cleaning and surveying pieces in Sand Road

○ Also space for storage of shipping containers● Assembly using assembly fixture designed by PSL, or custom fixtures● Metrology of final frame● Packaging for transport (wrap in plastic, containers TBD)● Shipping by semi to Yale/Chicago

Facilities overview ● Our labs in Department of Physics and Astronomy (Van Allen Hall)○ Old Van de Graaf

beam/experimental area● University owns a warehouse

building south of campus (Sand Road)○ Currently used for university

storage○ we can use free of charge

● Van Allen Hall to Sand Road facility -- 6 miles

● Additional facility east side of town○ Old factory, larger, better loading facilities○ But unclear as to condition and availability

Possibility of additional storage space or factory on east side of town (2515 Independence Road)

Need semi access for transport of frames● Our labs in Van Allen are big enough to build frames, but no overhead door● Sand Road facility has overhead door. Independence Road also has loading dock

○ Assembly space as well as storage spaceSand Road facility -- two bay doors, 6400 sq ft Independence Road -- loading dock, 142K sq ft

Our facilities: Machine shops and Lab in Van Allen

Onel and Nachtman’s lab space is labeled 5AC and 5AC-B. Offices for engineers are in 3AC and 4AC. The department’s machine shop is located in 116, with an exit to the loading dock. 1AC, 2AC are Chemical, Vacuum systems, Evaporation equipment for coating materials, 6AC Advanced Photodetector Facility.

Machine shop

Nachtman/Onel lab

Sand Road Facility

● Bays 130 and 140 are available to us

● 6400 square feet● Working with

Safety on factory layout

○ Cleaning○ welding○ Assembly○ Metrology○ Packaging○ storage

Staffing Model at Iowa● PI’s: Jane Nachtman and Yasar Onel (uncosted scientific labor) (Project Mgmt)● Dedicated engineers in our HEP group, supported through projects:

○ Paul Debbins -- already contributing to APA effort (will provide Technical and Production Management/Supervision)

○ Ianos Schmidt -- currently working on CMS upgrade projects○ Mike Miller -- EE/ME

● UI staff engineers○ Other engineers in Physics and Astronomy can be hired as needed

● UI staff machinists (assume 2 FTE)○ Trained machinists provide services to the department, hourly rate

● UI students (assume 2-3 FTE from students, postdoc)○ Talented undergraduate students, both physics and industrial/mechanical engineering majors,

already working in our group■ Assist in cleaning, storage, construction (under supervision), inventory control

○ Graduate students can take on roles in construction, metrology○ Hope to hire a postdoc next year○ Current DOE funding is one graduate student, request postdoc + another student this year

■ Graduate students can be supported as departmental TA’s and still work on this project

Factory Setup Cost Estimate

● Need quotes, lead-time for major equipment

Clean tent Estimate based on PSL costs, inflated for HVAC costs

$96,000

Component cleaning station Informal estimate $25,000

Assembly fixture PSL design/estimate $35,000

Faro coordinate measuring arm

PSL number $34,000

Leica 1200 station, transits, stick micrometer

PSL and online information $15,000

Mobile gantry crane Online information $10,000

Fixtures, tools, shelving Informal estimate $10,000

Setup total $225,000

Frame production schedule● Year 1 starts Aug 2020 (includes setup time)● Need to input lead time for equipment purchase● Our assembly space is available now (Van Allen) and in the fall

of 2019 (Sand Road)● Begin machining short pieces, fixtures in our UI machine shop,

store in Van Allen labs, even if factory setup not complete.● Our preliminary estimates

○ 1.2 weeks/frame machining short pieces○ 1 week/frame machining long pieces + fixtures○ 1 week/frame assembly, metrology, packaging for transport○ These are concurrent activities, so 1 frame/2 weeks is

reasonable○ Will start machining pieces in advance of assembly setup,

to have stock of machined tubes ready for assembly

Year Number of Frames

1 11.5

2 16.5

3 16.5

4 16.5

5 15

Preparation for APA Frame Production● Current effort

○ machining test of two pieces -- UI machine shop setting up for machining

○ learning process from PSL engineers-- Paul Debbins participated in Ash River frame

assembly at PSL● Project planning for full production

○ Acquire space (Van Allen and Sand Road)○ Planning factory setup in conjunction with university

ES&H ○ Consider machining of long beams -- purchase of a

dedicated milling machine?

Purchase of machine for long pieces● Long sides of APA are difficult to mill with existing machines in UI shops (“possible,

but will take a great deal of time, and can introduce more imprecision”)● The idea of buying a machine with a long bed has been brought up, as an

alternative to sending pieces outside to be machined○ We are sending a long side piece to the company (FlexDrill) to be machined as a demo

● A few numbers:○ PSL machining costs $18K/frame; don’t have UI numbers yet○ Consider FlexDrill CNC, TRD 20-02 (shown by Dan Wenman in Jan ‘19 Collaboration

meeting)■ Cost $160K - $210K (some numbers that I have seen going around)■ We are currently setting up to machine one long and one short piece -- will give us

better estimates of machining time■ Need to understand total machining time for a full frame■ We think it would be cost effective to purchase a dedicated long-bed machine

● Would also give us more control over the schedule, quality