# Presentation: 185931

## Production Overview

_**Engineering Design Review**_
_**November 16, 17, 18, 1998**_
_**CMS Cathode Strip Chambers**_
_**by: Nelson Chester**_
_**CSC Project Engineer**_
**General Production Flow**
**Schedule **
**Prototypes**
**Production**
**Tooling Status**
**Floor Plans and Building Layouts**
**Equipment and Assembly Status**
**Quality Assurance Plans and Activities**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Quality Assurance Methodology

**Use the **_**infrastructure already in place at Fermilab**_** and within Technical Division (TD) that has led to the success of past mass production projects**** ****(the Main Injector Magnet Program being the last).**
**Create and follow a ****Compact Muon Solenoid-Cathode Strip Chamber (CMS-CSC) Specific Quality Implementation Plan (SQIP)**** with oversight by the TD Quality Assurance Officer and implemented by the Fermilab Project Site Management as approved by the CMS Project Management.**
**Integrate Quality Assurance and Quality Control into all aspects of the Fermilab CMS-CSC Project as defined in the CMS-CSC SQIP.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Ionizing Air Cleaner

**Cleans finished Anode Panel just prior to assembly into Chamber**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Fermilab Responsibilities

**Procurement of Chamber Parts**
**Receiving Inspection**
**Panel Milling:**
**Mill Strips, Cathode and Anode Artwork**
**In-process Inspection**
**Chamber Assembly:**
**Clean Panel Surfaces**
**Check Panel Resistance and Capacitance**
**Glue Gap Bars, Guard Strips to the Panels**
**Wind Anode Wire, Glue and Solder Them in Place**
**Tension Test**
**Attach Discrete Electrical and Mechanical Components**
**HV Test in Air**
**Stack Panels, Seal w/RTV and Attach Frame**
**HV Test and Train**
**Sample Test on Cosmic **
**Pack & Ship**
**Chambers to FAST Sites at U. F. & U. C.**
**Kits to IHEP & PNPI**
**Repairs:**
**As Necessary**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Project Quality Plan

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Quality Assurance Integration

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Quality Plan Cross Reference

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Panel Gluing Station

**A computer controlled mixing and dispensing system places precise amounts of epoxy onto each panel in precise locations as required.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Hand Connected Parts

**Anode wire Protection Boards and Filtering Capacitors are hand soldered to Anode Panels.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Hand Soldering Details

**Detail shows typical type of hand soldering work being done;  Because of MTBF of Protection Board, a plug-in adapter is being reconsidered.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Chamber Assembly Table

**Chamber Assembly Table**

**Assembly Table design allows technicians easy access around and under edges of chamber for easy attachment of frame.   Also shown are redesigned central gap bars which maintain central plane spacing.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Frame Assembly

**Chamber P2’ (ME 2/2) is shown assembled with frame attached.  Note the main alignment pin and critical mounting plate assembly.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Cosmic Ray Test Stand

**Can accommodate up to 4 chambers at a time on racks that slide in and out for easy loading and unloading.  Trigger Scintillators  are shown above and below chambers.  At Fermilab this equipment will be set up in Lab 7.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Wire Tension Machine

**Electronically excites wires, measures and converts natural frequency into tension.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Anode Panel & Winding Machine Controls

**Winding Machine in operation;  Tension pressure gage can be seen in lower right  corner.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Anode Wire Soldering Machine

**Overhead view of machine being set up in MP9.  It is capable of soldering 1000 wires in a little more than   1 hr. taking about 5 hrs to complete one large panel.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Anode Panel Gluing & Clamping

**These machines place precise amounts of epoxy glue on panels to bond wire fixation boards and guard strips;  Boards are clamped in place to maintain uniform solder pad to panel surface height.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Tension Test Machine

**Under panel a transducer excites wires and measures their natural vibration frequency;  A computer  accounts for wire length and calculates wire tension. **

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Anode Wire Soldering Machine

**Shown with a test piece of panel in MP9 this machine uses a concentrated beam of intense light to melt precise amount of solder to bond anode wire to circuit pad of anode wire fixation board.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Anode Panel Gluing Table

**MP9 entrance doorways are being covered to prevent dust from entering the building;  Panel clamping table is shown at the lower left.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Anode Panel Winding Machine

**For largest panel winds 1000 turns of wire in about 4 hrs.  for a max. capacity of 2 panels per shift.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Panel After Winding

**Section of Anode Panel with Winding Combs and Wire Fixation Board**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Winding Machine Controls

**Precisely controls winding speed, feed, and wire tension;  Allows machine to run both forward and reverse if adjustments are needed.**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Chamber & PanelCounts

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

##      Production Milestones

**April, 1999****             -    ****ME2, 3 / 2 Design Finalized &****	****	****            ****Panel Production Begins**
**October, 1999****        -     ****Production of ME 2, 3/2**
** ****	****                                       ****Chambers begin**
** **
**October, 2000    ****    -    ****Complete Assembly and Test ****	****	****            of**** ****23  Chambers****	****	****      -     ****Begin Production of Smaller                                 ****	****	****            Panels forForeign Site Assembly**
**January, 2001****       -      ****Begin Chamber Production****	**
**                                             ****at Foreign Sites**
**October, 2003****        -    ****All 148 ME2, 3 / 2 Chambers****	****	****            Assembled and Tested;****	****	****            All Parts “Kits” Shipped**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Prototype Schedule

**01 Nov.  ‘98****	****Aging CSC Dwgs. Comp; Parts Ordered**
**20 Nov.  ‘98****	****P2’ Proto.  Assembled (ME2/2)**
**20 Dec.  ‘98****	****ME 2, 3 /2 Chamber Design Complete**
**01 Jan.  ‘99****	****P3 Proto.  Assembled @ FNAL (ME2/1)**
**15 Jan.  ‘99****	****ME 2, 3 /2 Chamber Design Review**
**01 Feb.  ‘99****	****Aging CSC Proto.  Assembled**
**01 Feb.  ‘99****	****ME 2, 3/2 All Drawings Released**
**01 Mar. ‘99****	****P2’’ All Parts Ordered (ME 2, 3 /2)**
**15 Mar. ‘99****	****Panel Production Site Readiness Review**
**01 Apr.  ‘99****	****P4 Proto.  Drawings Complete (ME 1/2)**
**01 Jun.  ‘99****	****P2’’ Proto.  Assembled (ME2/2)**
**01 Jul.   ‘99****	****P3’ Proto. Sent to PNPI w/Tooling (ME 2/1)**
**15 Sep.  ‘99****	****Chamber Assembly Site Readiness Review**
**01 Oct.  ‘99****	****P5 Proto.  Drawings Complete (ME 3/1)****	****	****	****P6 Proto.  Drawings Complete (ME 1/3)**
**	****	****	****P4 Proto. Assembled @ FNAL (ME 1/2)**
**01/07/00****	****P4’ Proto. Sent to IHEP w/Tooling (ME 1/2)**
**01/09/00****	****P5’ Proto. Sent to PNPI w/Tooling (ME 3/1)**
**	****	****	****P6’ Proto. Sent to IHEP w/Tooling (ME 1/3)**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Skin and Panel Costs

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Annual Production Deliverables

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

##                      Production Material    Status

_**Panel Material- WBS 1.1.3.2.4.1 - 4.5**_
**In Fermi Inventory****	**
**3100 5’ x 12’ Sheets (Skins) GE      @ $164.40 ea    = $510,400**
**1100 4’ x 12’ Sheets (Skins) GE      @ $131.74 ea    = $144,914**
**84 Ship Crates, GE, 50 shts. ea.      @ $120.00 ea    = **_**$  10,080**_
_**	**__**	**__**	**__**	**__**	**_**   **_**Total         **_**      **_**$665,394**_
**Ordered Material**
**14 Panels from Plascore - 5’ x 12’   @ $550.00 ea     = $  7,700**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Planned Production Flow

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Production CapabilitySummary(Single Shift Operation)

**Avail.  Days**** = ****260 Days - 10 Hol. - 5 Vac. =**** ****245 Open Plant Days**** ****	****                ****(Max. Days Machines Run) = ****100%**
_**Panel Production - Lab 8**_**	**
**	**
_**Axxiom Machined Panels:**_**               Req’d. / yr:  = 721 Panels Max.**
**	****	****               ****Capacity  @  4 - 6 per Day =  ****180 Days Max. **
**	****	****	****	****                    ****=  **_**74% of Capacity**_
_**Gerber Machined Panels:**_
**Req’d. Long   = 265 Panels  @ 2.4 Panels  / Day =  110 Days to Complete**
**Req’d. Short  = 353 Panels  @ 3.0 Panels  / Day =  **_**118 Days**_** to Complete**
**	****	****      **_**Capacity @ 2.4 / 3 Panels**_** / Day =   ****228 Days to Complete ****	****	****	****                   =   **_**93% of Capacity**_
_**Chamber Assembly - MP 9**_**:****	**
**	****	**
**50 Chambers Assem.  / yr.  Req’d.    =   ****One / Week Conservative Capability**
**Anode Panel Prep., Wind, Solder    =****  Three /Week  Conservative Capability**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Production Labor (techs)

_**Lab 8**__**	**__**	**__**	**__**	**_**    **_**FTE’s**_
**	****Axxiom Machine****	****	****     0.7**
**	****Gerber Machine****	****	****     1.0**
_**	**_**Inspect, Clean, & Wrap****	****     1.0**
**	**_**Handling & Shipping**__**	**__**	**__**     0.3**_
_**	**__**	**__**	**__**	**__**	**__**	**__**3.0**__**	**_
_**MP 9**_
_**	**_**Panel Preparation****	****	****     1.6**
**	****Anode Winding****	****	****     1.0**
**	****Machine Soldering****	****         ****	****     1.0**
**	****Hand Work****	****	****     ****	****     1.5**
**	****Assembly****	****	****	****     1.5**
**	****Test ****	****	****	****     ****	****     1.0**
_**	**__**Handling & Shipping **__**	**__**	**__**      0.4**_
_**	**__**	**__**	**__**	**__**	**__**	**_** **_**8.0**_

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

##            FNAL            Production Support Personnel

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Tooling Summary

**Panel Preparation Tooling Complete and Ready:**
**Axxiom Machine**
**Gerber Machine**
**Major Assembly Tooling Complete:**
**Gluing Station**
**Epoxy Curing Station**
**Anode Wire Winding Station**
**Anode Wire Gluing Station**
**Anode Wire Soldering **
**Ionized Air Cleaner**
**Carts, Racks, and Assembly Tables:**
**Anode Panel Cart Complete**
**Panel Table Cart Complete**
**Assembly Table Complete**
**Sealing (RTV) & Transport Cart Being Assembled**
**Quality Assurance Tooling**
**Panel Vendor Inspection Tooling Under Development**
**Anode Panel Tension Tester Complete**
**HV Test and Train Instrumentation Complete**
**Cosmic Ray Test Station Now Being Built**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS

## Summary

_**Conclusions:**_
**Design Requirements Well Understood****	**
**Design and Manufacturing Process Optimized for Mass ProductionManufacturing Requirements Identified****	**
**Good Experience and Knowledge Gained from Completion of Three + Full Size *****"Large" *****CSC Prototype Chambers****	**
**Adequate Manufacturing and Support Facilities in Place **
**Adequate Component Storage and Handling Capability in Place****	**
**Adequate Knowledgeable Labor, Supervisory, and Support Staff Available****	**
_**Concerns:**_**	**
**Axxiom and Gerber Machine Performance and Reliability**
**Consistency of Panel Vendor Manufacturing Process**

- CMS CSC EDR:  Nov. 16, 1998                           by:  N. Chester,     File: CMS