Engineering Division 1

Mechanical and Integration

CD0 Walkthru, 19-Dec, 2007Eric Anderssen, LBNL

Engineering Division

Mechanics Integration and Design

• HFT Pixel Structures, Cooling, and Insertion Mechanics (Service Supports)

• Integration and Support of IST Structures and Services

• Global Supports Design, Integration with FGT and SSD (Support Cones)

• Interface Definition and Control• Configuration Control and Documentation• Eventually: Production Planning, Cost, and

Schedule

2

Engineering Division

Production Planning

• This is obviously too early to present any form of production plan

• Cost and Schedule estimations do rely on at least some assumptions

• A crude schedule of what is needed when exists

• LBNL has the capability to fabricate all of the proposed mechanical structures if required

• This is not to say we know who will build what or where they will be built

• Goal is to have a model of the distributed production and assembly planning by CD1

3

Engineering Division

Configuration Control• Nothing in place at present, but needs are

small until layout is optimized fully• Have sought to generate ‘layout drawings’

showing sections of STAR’s IFC and associated detectors (J. Scheblien sp?)– Goal is to have controlled envelope drawings of

sections of HFT in each configuration (changes by run year)

• Intent on leveraging ‘e-room’ and ‘Windchill’ PDM software tools in support of this effort– Each allows for versioning, revision control and

approval processes for normal and CAD documents with external access by collaborators

• Establish controlled Requirements Documents• Have in place at least skeletons by CD1

4

Engineering Division

Interfaces

• HFT has both Internal and External Interfaces• Internal Interfaces are easier to control, and are well

managed by the concurrent design team– Will add rigor to this with controlled drawings later—

after geometry settles• External Interfaces are not wholly in hand• HFT will support the Beam Pipe—no solid design for this

exists• FGT needs to modify current support cone, as does HFT

—close coordination is required• SSD requires that concurrent modification of end cones

by both HFT and FGT consider its support• Other Detectors, e.g. FTPC or others as yet unnamed

may impinge upon design envelopes• Need to establish Configuration Control of Envelopes,

thus Interfaces First

5

Engineering Division

Global Integrating Structures

• FGT requires a new West Cone in ’09, but SSD wants to be in during the ’08 run if possible

• New West Cone (NWC) needs to be available by ’09, but East Cone can still be used

• NWC + old East Structure must be able to support SSD

• HFT requires a new East Cone, or at least a modified East Cone

• Following is a proposal which meets these conditions

6

Engineering Division

Cut Apart Current Cones August 2009

• Old East Cone and most of Beams to be reused to support New West Cone

• Old West cone refurbished into New East Cone in Berkeley• Cut Carbon Elliptical Beams avoiding Al Insert

7

Send to BerkeleyKeep at Brookhaven

Engineering Division

Modified East Cone and Install with New West Cylinder

• View as Temporary Fix—Should be ACAP (as cheap as possible)– Supports end of New West Cone/FGT– Replicates Old Beam Pipe Interfaces– Includes SSD if required – Only for summer ’09 to ‘10

• Wholly Machined/Bonded Solution– Tooling to locate Buck Plate while bonding is

required…

Buck Plate aimed forEasy Swap of replacement

Some Tooling Required…

~1.5m

8

Engineering Division

Goal—Swap-in Replacement and Install pixels – summer 2010

Should BeSame Length

New East Cone with Cylindrical Shell made from Old West Cone

Swap in by matching Bolted Interface to New West Cone…

ModificationWill Take UpLength…

Include SSD interface On Shell

9

Engineering Division

ISC fits inside and is supported by the cone

ISC supports IST on outsideISC ISC supports pixel and beam pipe inside

Inner Support Cylinder (ISC)

10

SSD Supported on outside

Engineering Division

HFT Pixel Mechanics

• Contracted ARES company for analysis on cooling, precision mount design and refinement of ladder stability.– Phone meetings weekly

• First results – – We will need Sub-Ambient Cooling– Simplified Precision Mount– Sector Stability seems adequate

• First stage report due in March– Results of Thermo-Structural Stability– Kinematic mount design

• Move toward construction of prototypes—later verification against models

11

Engineering Division

Pixel support structure

2.5 cm radius

8 cm radius

Inner layer

Outer layer

End view

ALICE style carbon support beams (green)

12

Engineering Division

Sector/ladder design

thinned MAPS chips2 cm by 2 cm, 50 µm thick

multilayer aluminum kaptonflex circuit cable for signal and power thin carbon composite substrate

carbon composite support beam

13

Engineering Division

Conceptual mechanical design

14

Engineering Division

Pixel placement concept

• Detector assembly slides in on rails• Parallelogram hinges support the two detector halves while

sliding• Cam and follower controls the opening of the hinges during

insertion and extraction• Detector support transfers to kinematic dock when positioned at

the operating locationpixel support hinges

cam followers and linear camslide rails

sliding carriage

kinematic dock

15

Engineering Division

Cam guided insertion operation

Open Closed

16

Engineering Division

Hinge analysis

17

Engineering Division 18

Engineering Division 19

Engineering Division

Two sector patch installation – summer 2010

• Requires that all of delivery system, and kinematic mounts are available by then

• New Beam Pipe, ISC, and Modified East Cone• Production Electronics and additional stave assemblies can lag

20