summary the process and the components the tooling production back log estimation the handles and...
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Summary The process and the components The tooling Production back log estimation The handles and the estimated cost and delayTRANSCRIPT
Summary
• The process and the components• The tooling • Production back log estimation• The handles and the estimated cost and delay
Clarification
Collared coil production
Cold Mass production
CERN
Back logFrom the measurement that triggers feed back to the moment
when the corrected dipole gets to the same kind of measurements
The components Ifrom SC Cable to Poles
Copper wedges
SC cable
End Spacers
Chips and wedge tips
Inter-layer spacers
winding
curing
Coil Pole
CERNCERNCMACMA
The components IIFrom Poles to Collared Coil
Shim retainer4 Poles Quench
heatersGround
insulation
2 Dipoles
Shims
CollarsCollaring
1 Collared Coil
Collaring Rods
Collar packs
Jeumont /Alstom Tooling
Winding machine
Winding machine
6In.Man.
6Ou.Man.
Curing press + mould
Curing press + mould
JeumontPMM
Collaring press
6In
Shells
6Out.
shells
Ansaldo Tooling
Winding machine
Winding machine
Winding machine
Spare Winding machine
6In.Man.
6Ou.Man.
Inner layermould
Outer layermould
Curing Press
Collaringpress
CERNPMM
Curing Press
BNN Tooling
Winding machine
Winding machine
Winding machine
Winding machine
6In.Man.
6Ou.Man.
Curing press + inner layer
mould
Curing press + outer layer
mould
BNNPMM
Collaring press
Back Log Estimation
Total Back Log (number of collared coil)
Production back log (Tprod X Rprod)Component stock back log
Collared Coil Production time divided in main phases firm I
0 30 60 90 120 150 180 210 240 270 300 330 360
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Col
lare
d C
oil n
umbe
r
Days
Winding timeWinding / Collaring time
Collared Coil Production time divided in main phases firm II
0 30 60 90 120 150 180 210 240 270 300 330 360
123456789
101112131415161718192021222324252627282930313233
Col
lare
d C
oil n
umbe
r
Days
Winding time
winding/collaring time
Collared Coil Production time divided in main phases firm III
0 30 60 90 120 150 180 210 240 270 300 330 360
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
Col
lare
d C
oil n
umbe
r
Days
Winding timeWinding / Collaring time
Number of collared coil in parallel production
0
1
2
3
4
5
6
7
8
9
01-08-02 16-08-02 31-08-02 15-09-02 30-09-02 15-10-02 30-10-02 14-11-02 29-11-02 14-12-02 29-12-02 13-01-03 28-01-03 12-02-03 27-02-03 14-03-03
Dates
Num
ber o
f col
lare
d co
ils w
ound
at t
he s
ame
time
firm 1 firm 2 firm 3
Production back log estimation
Firm 1 collared coils week/CMAs1 collared coils week/CMAs 3 collared coils week/CMAs3 collared coils week/CMAsWinding Winding back logback log
Assembly Assembly back logback log
Tot back Tot back loglog
Winding Winding back logback log
Assembly Assembly back logback log
Tot back Tot back loglog
F I 55 77 1212 1212 1818 3030F II 99 66 1515 1010 2020 3030
F III 1313 55 1818 1717 99 2828
Total 2727 1818 4545 3939 4747 8888
The handles and their estimated cost and delay
Polar shims• Delay of intervention: approx. 1 week to 4 weeks of
production (shim procurement time)
• Cost of the intervention: max some thousands of CHF (1 set of shims about 1500 CHF, the cost will be equal to the number of set of shims not usable)
Pole measurement
Dipole assembly Collaring
Shims
Mid plane insulation• Delay of intervention:
– Change of ground insulation: 1.5-2 month of production (stock and intervention at the sub supplier)
• Cost of the intervention:average price to prepare ground insulation 9000 CHF/CC possible extra costs from 150 to1800 CHF/CC. Total extra cost: 200.000 CHF to 2.000.000 extra costs (i.e. 15 minutes more per layer is 300.000 CHF)
Pole measurement
Dipole assembly Collaring
Ground insulation
Copper wedges• Delivery of modified copper wedges from the
decision (14 working weeks)• Modification of end spacer:
– Machined pieces about 14 working weeks– Injected pieces longer
For costs see after
Copper wedges
SC cable
End Spacers
Chips and wedge tips
winding
New component productionCopper wedges
New geometryDrawings
New tooling
Approvalmanufacturer's
drawingsProduction
Acceptance
Expedition to CMA
5 days
10 days
30 days
20 days
1 day
5 days
Total time 70 Work. Days
T0
Previous experience and cost estimation
• Decision 15/07/01• Drawing cross section 15/08/01• Delivery of end spacers for 2 CC and chips for 2 CC 15/11/01• Delivery of new profile for 10 magnet each CMAs: 30/11/01• Delivery of spacers 10 CC per CMAs 20/12/01• Delivery of molded chips 01/02/02
• Cost I: 50 batches of copper wedges (500 magnets, i.e. cable delivered for 3/8) produced up to now. 7000 CHF/profile for tooling
• Cost II: at least only for end spacers 150.000 CHF (engineering + components)• Cost III: quality problems
Correction of the magnetic length with nested laminations
• We can correct the magnetic length acting on the number of nested lamination
• 10 cm of extra nested lamination (Delta Bdl 7 units):– 10 cm more nested laminations: +660 CHF/CM– 10 cm less iron lamination: -150 CHF/CM– 10 cm net cost 1 magnet : +510 CHF/CM
• For 1 CMAs: about 200.000 CHF• Other possible schemes:
– Nested laminations transfer between CMAs– Use of special full non magnetic laminations
Change Material delivery time
back log
Production back log
Total
Polar shims 12 CC12 CC36 CC36 CC
3 CC3 CC12 CC12 CC
3 -12CC3 -12CC12-48 CC12-48 CC
Mid plane insulation
24 CC24 CC72 CC72 CC
3 CC3 CC12 CC12 CC
27 CC27 CC84 CC84 CC
Copper wedges
14 CC14 CC140 CC140 CC
45 CC45 CC88 CC88 CC
59 CC59 CC230 CC230 CC
Laminations 12 CM12 CM48 CM48 CM
24 CM24 CM24 CM24 CM
36 CM36 CM72 CM72 CM
Acknowledgements
• F. Bertinelli, C. Lanza, A .Schiappapietra, E. Todesco
• The whole MAS-MD and MAS-MA sections