# Presentation: 882837

## Pixel Support TubeWBS 1.1.1.1.3.5Santa Cruz Cost WorkshopJuly 9, 2003

## Pixel Support Tube (PST) Overview

**PST Structure**
- 3 Independent composite tubes
- Joined together with bonded flanges
- Mounted on specially designed flexures
- Support detector insertion rails
- Laminated with heater/EMI foils
**Key Cost Points**
- Actual expenditures match ETC03 estimates very well
- ETC03 to ETC04 costs show substantial decrease
**Assumptions**
- Prototyping finishes Q4 of FY03 (almost finished now)
- Production begins simultaneously in Q4 of FY03
- Remaining Prototype/Production time is staffed with MT (1/2 FTE)
- All costs in FY03 $K

## PST Deliverables

**3 Composite tubes**
**6 Bonded composite flanges**
**Full Length insertion rails**
**Mount pads at forward and barrel (8 total)**
**PST Supports (8 flexures)**
**Pixel detector supports (kinematic, 4 total)**
**Heaters and EMI shielding (continuous over length)**

**All must be delivered by September - December ’04**
**SCT installation is ~Dec. ’04**
**Barrel mount pads are bonded using transfer jig from SCT (must be done during initial barrel assembly – about September ‘04)**
**Full PST must be present at LBL for dry-fit (summer ’04)**
**Installation work costed in separate installation plan**

## PST Key Structures – Barrel Tube

- Shell

- Hoop Stiffeners

- Mount Pads

- Mount blocks

- Insertion Rails

- Flanges

## Shell Laminate with New Heater Panels

## Full length rails

## Mount Pads

## Flanges

- Backing Ring

- Flange face

- Bonded and
- Drilled flange
- On PST shell

## Bond Jig

- Barrel Length Bond jig

- Production jig setup for
- Prototype length PST shell

## PST Production Mandrel

- Rotation Head Detail

- Autoclave Cart

- Shop Cart

## FY03 Cost Tracking

**Prototype Budget shows under-spending**
- Rail tooling (which was moved to prototyping budget) completed at lower cost with simpler tools
**Production Budget shows over-spending**
- PST Mandrel costs increased to include additional carts and handling hardware
**Overall FY03 Budget is “on-track” so far**

## FY04 Costs

## Key Cost Points

**Substantial Savings in Tooling and Fabrication**
- Rail designs simplified and tooling fabricated for reduced cost offsite (~20K savings)
- Flange tooling simplified (26 parts reduced to 2) and fabricated onsite (~40K savings)
**Some budget “re-allocated”**
- Insertion mechanism (see next talk) sub-task created
- About 25K from PST budget “moved” to insertion mechanism prototyping and production

## Schedule Milestones - Slippage

**Production Readiness Review**
- February 18, 2003
**Production Material Delivered**
- April 14, 2003 -> May 25, 2003
**Mandrel Delivered**
- May 1, 2003 -> June 9, 2003
**Production Begins**
- May 1, 2003 -> August 1, 2003
**Barrel PST Completed**
- September 14, 2003 –> December 1, 2003
**Forward PST’s Completed**
- June 1, 2004
**Pixel System Dry-fit (PST, BP Support, service panels, pixel frame)**
- July, 2004 – August, 2004
**Fit-up with SCT (transfer jig bonded)**
- September, 2004
**SCT/PST Installed**
- December, 2004 – January, 2005

## Summary

**Current Status**
- All tooling currently fabricated except for hoop stiffener tool and rail bonding jig (hoop stiffener tool is in shop now)
**Prototyping**
- Must bond rails into prototype shell using rail bonding jig by end of FY03
**Production**
- Plan to begin barrel shell production by August 1 (3 months late)
**Personnel**
- FY03
- Require 1 FTE until FY04 (476 hours)
- Research assistant (350 hours) and part of Mech Tech available
- FY04
- Require 1⁄2 FTE for all of FY04 (1032 hours)
- Research assistant (550 hours) and part of Mech Tech available
**Budget**
- Current spending (FY03) is on-track with last cost estimate
- Redesigns of fabrication tooling and processes have saved about 70K from budget – these can be used to offset increases in other mechanics areas (particularly insertion mechanism)