![](media/image1.jpeg){width="1.0909722222222222in"
height="0.7118055555555556in"}

**Procurement Plan for the ATLAS Pixel Detector Disk Support Rings**

**William O. Miller, W. K Miller**

September 19,2001

  ------------- --------------- ------------------------- ----------------
                Name:           Phone & E-Mail            Signature:

  Main Author:  William O.                                
                Miller                                    

  Approved:     William O.                                
                Miller                                    
  ------------- --------------- ------------------------- ----------------

**Abstract**

This document outlines the procurement plan for the subject composite
ring, which is used to support an array of 8-pixel disk sectors. This
plan covers the fabrication and inspection of the production rings, as
well as the qualification of the production tooling.

Revision Log

  ---------- --------------- --------------- -----------------------------------
  **Rev.**   **Date**        **Author(s)**   **Summary of Revisions/Comments**

  \-         Month date,                     Initial release.
             year                            

                                             
  ---------- --------------- --------------- -----------------------------------

Table of Contents

***1. Introduction [4](#introduction)***

2\. Work Statement [4](#work-statement)

2.1 Phase 1-*Fabrication of Qualified C-Channels for Phase 2*
[4](#phase-1-fabrication-of-qualified-c-channels-for-phase-2)

2.2 Phase 2-*Fabrication of Ring Component Parts and Qualification of
Pre-Production Ring*
[4](#phase-2-fabrication-of-ring-component-parts-and-qualification-of-pre-production-ring)

2.3 Phase 3- *ATLAS Pixel Detector Production Disk Support Rings*
[5](#phase-3--atlas-pixel-detector-production-disk-support-rings)

3\. Preliminary Assembly and Inspection Procedure
[5](#preliminary-assembly-and-inspection-procedure)

3.1 Bond fixture (Step 1, sheet 7)
[5](#bond-fixture-preparation-step-1-sheet-7)

3.2 Face sheet #1 Alignment (Step 2, sheet 6)
[5](#face-sheet-1-alignment-step-2-sheet-6)

3.3 C-Channels bonded to Face sheet #1(Step 3, sheet 5)
[5](#bonding-of-c-channels-to-face-sheet-1step-3-sheet-5)

3.4 Install Face sheet #2 (Step 4, sheet 4)
[6](#installation-of-face-sheet-2-step-4-sheet-4)

3.5 Install the mount tabs, 4 places. (Step 5, sheet 3)
[6](#installation-of-the-mount-tabs-4-places.-step-5-sheet-3)

3.6 Installation of the Composite Ring Bushings
[7](#installation-of-the-composite-ring-bushings)

3.7 Bonding of Ring Bushings (Step 7, sheet 1)
[7](#bonding-of-ring-bushings-step-7-sheet-1)

3.8 Composite Ring Washers Installation (Step 7, sheet 1)
[7](#composite-ring-washers-installation-step-7-sheet-1)

3.9 Packaging of the Ring [7](#packaging-of-the-ring)

3.10 Inspection of the Ring at LBNL [8](#inspection-of-the-ring-at-lbnl)

3.11 Inspection Records [8](#inspection-records)

3.11.1 Inspection Record #1 -- Limit Dimension for Facesheet Lying Flat
on Graphite Plate
[8](#inspection-record-1-limit-dimension-for-facesheet-lying-flat-on-graphite-plate)

3.11.2 Inspection Record #2 -- Limit Dimension for C-Channel Bonded to
Ring Face Sheet
[8](#inspection-record-2-limit-dimension-for-c-channel-bonded-to-ring-face-sheet)

3.11.3 Inspection Record #3 -- Limit Dimension for Second Face Sheet
Bonded to C-Channels
[8](#inspection-record-3-limit-dimension-for-second-face-sheet-bonded-to-c-channels)

3.11.4 Inspection Record #4 -- Limit Dimension for Mount Tab
[9](#inspection-record-4-limit-dimension-for-mount-tab)

3.11.5 Inspection Record #5 -- Limit Dimension for Bushing Seated in
Graphite Fixture Counterbore
[9](#inspection-record-5-limit-dimension-for-bushing-seated-in-graphite-fixture-counterbore)

3.11.6 Inspection Record #6 -- Limit Dimension for Washer Bonded to Face
Sheet #2
[9](#inspection-record-6-limit-dimension-for-washer-bonded-to-face-sheet-2)

3.12 Assembly Step Illustrations [10](#assembly-step-illustrations)

4\. References [13](#references)

4.1 Drawing List [13](#drawing-list)

# Introduction

It is desired that the ATLAS Pixel Detector Disk Support Ring production
be accomplished in three phases (reference LBNL Drawing 21F5224). The
first phase is concerned with setting the appropriate "toe-in"
dimensions for the matched metal/rubber mold used to fabricate the ring
C-Channels. The second phase is the assembly of a pre-production ring,
which is used to qualify part acceptance. This phase confirms the
quality of all tooling to be used in the final production of 6-disk
support rings. Phase 3 is concerned with the production of 6-rings,
which are delivered to the ATLAS Pixel Detector Project

# Work Statement

## Phase 1-*Fabrication of Qualified C-Channels for Phase 2*

The vendor shall: (1) procure the necessary materials, and (2) fabricate
the matched metal molds for producing the C-Channels segments, inner and
outer, 2-each. Prior to molding the C-Channels, the molds will be
inspected by the vendor and the inspection records submitted to LBNL[^1]
for production approval. Vendor shall then mold and final machine sets
of 2-each C-Channels, 2 inner and 2 outer. The vendor shall: (1) inspect
the C-Channels, (2) recommend mold rework, if necessary, and (3) submit
this information with recommendations to LBNL. Based on concurrence with
LBNL the vendor shall modify, as required, the inner and outer mold
inserts to eliminate "toe-out" of the C-Channel skirts (within "toe"
limits prescribed in LBNL drawings 21F5244 and 21F5254).

After tool modifications have been accepted by LBNL, the vendor shall
produce once again 2-inner and 2-outer C-Channels for final evaluation.
After receiving approval from LBNL, vendor shall mold and final machine
complete sets of inner (4) and outer (4) C-Channels for the Phase 2,
pre-production ring.

## Phase 2-*Fabrication of Ring Component Parts and Qualification of Pre-Production Ring*

This phase consists of several parts: (1) fabrication of precision
bonding tooling and alignment jigs, (2) procurement of piece parts for
7-rings (exclusive of C-Channels), and (3) the assembly of one
pre-production ring. Procurement of ring piece parts is limited to
machining of the carbon-carbon ring face(s), and fabricating the sector
bushings and ring mount tabs. Vendor shall procure all piece parts in
phase 2 and thereby secure quantity pricing.

One pre-production ring shall be assembled using the C-Channels produced
in Phase 1. The vendor shall inspect the ring and submit the ring and
inspection records to LBNL for review. The vendor shall document all
modifications and or deviations to the assembly procedure that were
utilized in producing the pre-production ring.

## Phase 3- *ATLAS Pixel Detector Production Disk Support Rings* 

Vendor shall: (1) mold C-Channel sets for 6 rings, and (2) assemble
6-production rings using piece parts produced in phase 2, using the
assembly and QC procedures approved in Phase 2.

# Preliminary Assembly and Inspection Procedure

The vendor shall submit a procedure outlining the plans for assembly and
bonding of the ring prior to initiating the ring assembly in Phase 2.
This procedure will include dimensional inspection steps.

## Bond Fixture Preparation (Step 1, sheet 7)

1.  A mistress gauge (fabricated by LBNL) using 5-pins is used to bond 3
    sector bushings at one time. The following steps are used to set the
    mating bushings in the graphite tooling plate.

2.  Mistress gauge installs to the graphite plate from front using two
    3/16" dia. pins; the 3 brass bushings are installed and bonded from
    rear of plate. This is done to critically position the 3-bushing
    pattern to itself, and less critically to the other bushing
    patterns.

3.  Bonding bushings in graphite plate to critical tolerances will be
    done by vendor.

4.  *√* CMM Inspection of Graphite Bond Fixture with Bushings will be
    done after the bushings have been bonded in place. LBNL approval is
    required before proceeding.

## Face Sheet #1 Alignment (Step 2, sheet 6)

5.  Prior to bonding -- the graphite plate must be kept on a granite
    table during entire bonding process. Graphite plate inspected --
    dust, lint, dirt wiped and air-blown from surfaces.

6.  Face sheet #1 is placed on graphite plate, sheet 6. *√ A height
    gauge will be used to determine that the face sheet is flat on the
    graphite plate --an inspection report will be filled out.*

7.  Face sheet #1 is angularly oriented on graphite plate using four
    0.281" gauge pins. Use at least 3-0.281" pins for alignment (see
    step 2 on sheet 6).

8.  *√ All C-Channels will be inspected and approved prior to
    incorporating them into a composite ring.*

##  Bonding of C-Channels to Face Sheet #1(Step 3, sheet 5)

9.  Four C-channels are clamped to their aluminum clamping tools (same
    process as used before for the fabrication of earlier rings).

10. The C-Channel/Clamp assemblies are positioned in place using 3/16"
    gauge pins. A dry run fit will be done with all C-Channels in place.
    C-Channels should be appropriately marked to match graphite plate
    (so they may be removed and replaced later).

11. *√ When dry run fit is complete, inspect using a height gauge,
    measure and record the height of the top flange of all the
    C-Channels; determine that they all are coplanar (and at the correct
    height).*

12. All outer C-Channels and inner C-Channels are bonded in one setup.
    Sequentially place the C-Channels around ring circumference. After
    the Outer C-Channels bond adhesive is finished curing, bond the scab
    plates. This step is repeated for the inner channels. When bonding
    the C-Channels use a Caul plate to apply vertical force to the
    C-Channels. If the vendor chooses to bond one C-Channel at a time,
    LBNL requests notification of this change before proceeding.

13. Apply adhesive to both surfaces when bonding C-Channels (pre-test
    procedure to control adhesive overflow: note the face sheet's
    profile now falls short of C-Channel major/minor radius); do not
    remove this assembly from graphite plate to wipe away excess
    adhesive. If necessary use a hot-knife to remove excess adhesive
    after all ring bonding steps are complete.

14. Note there is less clearance between C-Channel flanges in this ring.
    Therefore it is recommended to remove the C-Channels clamp-nuts
    after each set of four are bonded in place - rather than trying to
    remove them all after the C-Channels have been bonded in place
    (remove the clamp nuts, but leave the pinned clamp in place to
    provide external support to C-Channel during bonding). Nuts for
    final channel are carefully removed at bushing scallop area.

## Installation of Face Sheet #2 (Step 4, sheet 4)

15. Install face sheet #2. Again, 4X 0.281" pins angularly orient the
    second face sheet. Use at least 3- 0.281" pins for alignment.
    Control amount of adhesive used to prevent overflow.

16. Use the Caul plate to apply constant pressure on face sheet while
    bonding. Note, care must be taken with excess adhesive flowing out
    past face sheet and adhering to Caul plate.

17. *√ After Face sheet #2 adhesive has cured, run the height gauge
    around the surface of face sheet #2(an indication of ring thickness)
    -- fill out inspection report.*

18. Mark orientation of ring on graphite fixture. Remove C-Channel
    clamps. Plug all C-Channel clamp holes with adhesive.

19. Remove ring and weigh ring.

## Installation of the Mount Tabs, 4 places. (Step 5, sheet 3)

20. Install the ring on graphite fixture using previous angular
    orientation. Use height gauge to verify ring position (compare to
    past data) and that it is flat on graphite fixture.

21. Do a dry fit of the Mount Tabs in position and constrained by the
    bond blocks. Note that each bond block has a number that corresponds
    with its correct position on the graphite fixture.

22. The critical alignment of the Mount Tabs is done using a 0.250"
    (thru graphite plate) and 0.125" pin (thru bond block); the bond
    block is positioned by two 0.187" pins (thru the graphite plate).
    The 0.250" dia pin positions the Mount Tab in X, Y; the 0.12" dia
    pin establishes the Z elevation for the Mount Tab.

23. The Mount Tabs should now be ready for bonding. First, the Mount Tab
    is pinned to the bond block then inserted into position. \*Care must
    be taken to prevent adhesive from getting into the 0.250" dia Mount
    Tab pin-hole (these 4X pin holes become a physical datum for the
    ring). See step 5 on sheet 3.

24. Once the Mount Tabs are bonded in position, remove the bond blocks.
    With the ring still pinned to the graphite fixture, insert four
    0.125" dia. pins into the radial holes in the Mount Tabs. *√ Use a
    height gauge to record the height of the 4 pins - fill out
    inspection report.*

25. Remove the composite ring shell from the graphite plate (remove
    0.250" dia. pins). Weigh ring.

## Installation of the Composite Ring Bushings

26. Push 0.120" dia. pins into graphite plate bushings.

27. Install composite ring bushings on pins. Note: make sure no hair,
    lint or dust is in the counterbores of the graphite plate prior to
    installing bushings. Bushing surfaces should have been abraded and
    cleaned prior to bonding.

28. Push all bushings flat against counterbored surface.

29. *√ Use a height gauge to record the height of all of the tops of the
    bushings relative to the graphite fixture face (all bushing heads
    should be coplanar) -- fill out inspection report.*

30. Apply adhesive on the ring facing just in the bushing area of
    contact and the bushing flange; now re-install composite ring shell
    atop bushings using correct orientation (see step 6 sheet 2).

31. *√ Using a height gauge, verify that the surface of face sheet #2 is
    flat against the graphite fixture by measuring the height of ring
    surface. Fill out an inspection report.*

## Bonding of Ring Bushings (Step 7, sheet 1)

32. Put the Caul plate on ring facing #2 and to apply force during
    bonding. Before placing the Caul plate, inspect to see that no
    bushing vertical height has changed.

33. Do not remove ring assembly to remove excess adhesive; ring not to
    be removed until washers have been bonded in place.

## Composite Ring Washers Installation (Step 7, sheet 1)

34. Bond the Composite ring washers. The Caul plate may or not be used

35. *√ After the washer adhesive is dry, use the height gauge to record
    each washer height from the face of the graphite plate -- fill out
    inspection reports.*

36. Push the 24X 0.120" pins out through the back of the graphite plate,
    and remove the composite ring from the graphite plate.

37. Weigh and record ring mass.

## Packaging of the Ring

38. The ring shall be individually sealed in a polyethylene close
    fitting bag and stored for shipment to LBNL. The bag shall contain a
    copy of the inspection records for the ring assembly. The ring
    serial or record number shall be clearly visible for the outside.

39. Ring(s) shipment to LBNL shall be in a foam-filled wooden box, with
    foam separators between each ring for protection.

## Inspection of the Ring at LBNL

40. The ring will be inspected using a LBNL CMM inspection system. All
    hole positions and co-planar feature of the bushing heads will be
    determined. The 0.125" hole position of each Mount Tab will be
    determined. General dimensions to determine the "per print" ring's
    physical size will be taken.

## Inspection Records

Dimensions are in inches, with \[ \] enclosing dimension in mm's.

![](media/image2.wmf)

### Inspection Record #1 -- Limit Dimension for Facesheet Lying Flat on Graphite Plate

![](media/image3.wmf)

### Inspection Record #2 -- Limit Dimension for C-Channel Bonded to Ring Face Sheet

![](media/image4.wmf)

### Inspection Record #3 -- Limit Dimension for Second Face Sheet Bonded to C-Channels

![](media/image5.wmf)

### Inspection Record #4 -- Limit Dimension for Mount Tab

![](media/image6.wmf)

### Inspection Record #5 -- Limit Dimension for Bushing Seated in Graphite Fixture Counterbore

![](media/image7.wmf)

### Inspection Record #6 -- Limit Dimension for Washer Bonded to Face Sheet #2

## Assembly Step Illustrations

![](media/image8.wmf){width="5.788194444444445in"
height="3.998611111111111in"}

![](media/image9.wmf){width="5.788194444444445in"
height="3.998611111111111in"}

![](media/image10.wmf){width="5.788194444444445in"
height="3.998611111111111in"}

![](media/image11.wmf){width="5.788194444444445in"
height="3.998611111111111in"}

![](media/image12.wmf){width="5.788194444444445in"
height="3.998611111111111in"}

![](media/image13.wmf){width="5.788194444444445in"
height="3.998611111111111in"}

![](media/image14.wmf){width="5.788194444444445in"
height="3.998611111111111in"}

# References

## Drawing List

  ------------------ ------------------ ---------------- ---------------- ----------------------------
  [Project Number    [LBNL Drawing      [TITLE LINE      [TITLE LINE      [TITLE LINE 3]{.underline}
  (ATLAS Drawing     No.]{.underline}   1]{.underline}   2]{.underline}   
  No)]{.underline}                                                        

  ATL-IP-ED-0059     21F5104            ATLAS PIXEL      SECTOR MOUNTING  RING BOND FIXTURE ASSEMBLY
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0060     21F5114            ATLAS PIXEL      SECTOR MOUNTING  RING BOND FIXTURE PARTS
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0060     21F5114            ATLAS PIXEL      SECTOR MOUNTING  RING BOND FIXTURE PARTS
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0061     21F5124            ATLAS PIXEL      SECTOR MOUNTING  RING CAUL PLATE
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0062     21F5134            ATLAS PIXEL      SECTOR MOUNTING  C-CHANNEL CLAMP PARTS
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0062     21F5134            ATLAS PIXEL      SECTOR MOUNTING  C-CHANNEL CLAMP PARTS
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0063     21F5144            ATLAS PIXEL      SECTOR MOUNTING  RING MOUNT-TAB BOND BLOCK
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0064     21F5154            ATLAS PIXEL      SECTOR MOUNTING  C-CHANNEL MACHINING CLAMPS
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0064     21F5154            ATLAS PIXEL      SECTOR MOUNTING  C-CHANNEL MACHINING CLAMPS
                                        DETECTOR         RING TOOLING     

  ATL-IP-ED-0065     21F5164            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     ASSEMBLY

  ATL-IP-ED-0066     21F5174            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0066     21F5174            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0066     21F5174            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0067     21F5184            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0067     21F5184            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0067     21F5184            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0067     21F5184            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0068     21F5194            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     ASSEMBLY

  ATL-IP-ED-0069     21F5204            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0069     21F5204            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0069     21F5204            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0070     21F5214            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0070     21F5214            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0070     21F5214            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0070     21F5214            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL MOLD FIXTURE
                                        DETECTOR         RING TOOLING     PARTS

  ATL-IP-ED-0071     21F5224            ATLAS PIXEL      SECTOR MOUNTING  RING ASSEMBLY
                                        DETECTOR         RING             

  ATL-IP-ED-0071     21F5224            ATLAS PIXEL      SECTOR MOUNTING  RING ASSEMBLY
                                        DETECTOR         RING             

  ATL-IP-ED-0072     21F5234            ATLAS PIXEL      SECTOR MOUNTING  RING FACE SHEET
                                        DETECTOR         RING             

  ATL-IP-ED-0073     21F5244            ATLAS PIXEL      SECTOR MOUNTING  OUTER C-CHANNEL
                                        DETECTOR         RING             

  ATL-IP-ED-0074     21F5254            ATLAS PIXEL      SECTOR MOUNTING  INNER C-CHANNEL
                                        DETECTOR         RING             

  ATL-IP-ED-0075     21F5264            ATLAS PIXEL      SECTOR MOUNTING  RING MOUNT-TABS AND SECTOR
                                        DETECTOR         RING             MOUNT BUSHINGS
  ------------------ ------------------ ---------------- ---------------- ----------------------------

[^1]: Or a representative designated by LBNL