# Presentation: 345092

## Pixel Support Tube and Related

**November 9, 2001**
**Pixel Day**
**E. Anderssen, LBNL**

## Overview

**Status of Work, technical and other**
- PST and Supports
- Pixel Supports
- Service/Beampipe Supports
**Immediate plans**
- Prototyping in ‘02
**Discrepancies**
- All along the way...

## Chain of Support for PST to Cryostat

- PIXEL

- SUPPORT

- TUBE

- SCT

- TRT

- _ID Vee Rail_

- _ID Flat Rail_

- _Side C_

- _Side A_

- View from top—all
- Tube Supports are
- Horizontal and Co-planar

- Properties TBD

- Constraint TBD

- Support Positions are shown,
- But constraint conditions are
- Not indicated here.

## Support Conditions of Beampipe

**Beampipe Cruciform Supports align with Stiffest part of PST—the end flanges**
**All support planes on frame are wires allowing longitudinal (axial) float**
**One Z-Fixture is foreseen to take up ATLAS Access/Opening loads**

## Pixel Support Tube Mockup

**Mockup in three pieces to simulate independent parts of tube**
- Goal is for full length of entire tube to simulate all installation scenarios
- Detector rails are removable, should modification be necessary
- Intend to run ‘installation tests’ in ‘02

## Rail Design in Support Tube

- Vee and Flat rails were chosen to provide pseudo-kinematic support for the detector during delivery to the support points
- Rails are used only for delivery, not support

- mockup

## PST Important Features

- Bolt flanges

- Sct mount pads

- End Plugs (1 mm equiv. carbon sheet)

- Hoop Hat Stiffeners
- (section view)

- 30

- 45

- 10

- End Support

- End Supports

## Support Flange Bonded Assembly

- Flange Face (machined layup)

- Flange base
- (Layup)

- Stiffeners
- (layups)

- T-nuts
- (bonded)

- Old design - now gone for
- independent thermal barrier

## Slider design - materials testing

**Friction Tester nearing completion**
- Applies variable pressure
- Measures angular acceleration
- Slides sample against interchangeable disk of given material

**M**

- slider to be tested

- turntable (carbon disk)

- position is movable along arm

- M

- Mass provides normal force

- Encoder on shaft measures acceleration

- arm hinge

## Gravity Sag Calculations

** **

- DY = .57 mm

- DY = 1.6 mm

- Carbon

- Glass

- Whole Tube Sags at ends during operation—it is intended to ‘remove’ this sag when
- Reattaching supports after installation of Forward ID
-  Note:  Sag is with Package in place—much less without

## Reaction Loads On SCT

- Vertical Bending – Both Ends

- Horizontal Bending

## Flexure Block interface to SCT Penetration

- This interface must take same loads as applied to Flexure—Will know them well after
- Joint Model is run

- Will look at simple feasibility with current (infinite stiffness) loads
- Will iterate size if indicated by ROM calculation

- SCT Thermal Barrier Penetration

## Flange Envelope

- Pixel Support Tube (Barrel Region)

- Pixel Support Tube (forward)

- 240

- 261

- 242

- 260

**Dimensions**** from 1:1 ID Layout May ‘01**

- 775**780**

- 765

- 785**792**

- 796**800**

- 795**799**

- 245**246**

- 257**259.5**

- 248

- 811

- 251

- May change
- By ~5mm to
- 806new structure added

- 700

- SCT BARREL 3

- Barrel Mount Flange

- Interlink

- SCT Forward Envelope

- 806

- requested
- Changes

- 244

## Flange Envelope

- Pixel Support Tube (Barrel Region)

- Pixel Support Tube (forward)

- 240

- 261

- 242

- 260

**New Proposed Envelopes—not yet agreed**

- 780

- 765

- 792

- 800

- 799

- 252

- 811

- 251

- 700

- SCT BARREL 3

- Barrel Mount Flange

- Interlink

- SCT Forward Envelope

- 806

- 244

- shim

- shim

- 255

- 254

- 246

## Z-Flexure (Side A)

- Support Tube Mount Pad M55J

- View
- Direction

- Cut Plane

- Insulator (G10) or Al203

- Access hole
- Thru
- Service Rail

- Gap filled
- After
- picture

- Dowel pins have line fit

- Metal Insert Bonded in

- Thermal Barrier squeezed in here

## Pixel Supports

## Pixel Package Assembly

- Mockup Pixel Frame shown

## Tension/Compression Transmission through structures not services

- Clips register to Buttons on Frame and Service/Beampipe support structure
- Gaps allow ‘Phi’ offsets of up to +/- 1mm while only 0.25mm longitudinally

## Wire Planes supported by Pulleys

- Wires not modeled, beampipe not shown

## Tubes route cables to BarrelSeparate blocks at Forward end

## Services Supported By Framework

## Service quarter panels supported by framework

## Need to adjust length of Tube or Support Plane location of VI

## Outside view of patch Panel

## Section View of patch Panel

## Barrel End of Support Structure

## PST Prototyping Plans

**Short Mandrel**
- 1 foot long - 1 for glass, 1 for carbon – aluminum or steel
- “Dry-run” in autoclave to determine thermal response
- Determine final diameters from test layups
**Full Size Mandrel (forward length)**
- Quotes already received
- Approximately 14,000 to 20,000 USD
- 8 Weeks delivery
- Plans to Fabricate forward prototype in glass
- All flanges and rail features
- Use for production forwards if diameters are correct
**Implications of Glass Forwards/Carbon Barrel on prototyping plans must be more fully assessed**
**Insertion Testing**

## PST Prototypes in ETC ‘02

**Includes**
- Friction Testing
- Material Test Panels
- “Foot Long” prototypes
- End-Plug Prototype estimated as 1⁄2 production total
**Gray area**
- Calling first  Forward Tube a prototype—Production monies all in FY’03, but need to order tooling and start fab in ’02
- Missing prototype flexure mounts (as noted in 1.1.1.1.3.5)
- Prototype ‘End Plate’ buried in Frame estimate, but included Pixel mounts (~$5k ’01, $10k ’02)
- Monies for assembly testing of Insertion mockup spread over a few efforts and called ‘testing’  hard to track if appropriate levels have been assigned

## Service Support Prototypes ‘02

**Now includes Beam Vacuum Support Structure**
**Prototype in ’02 already  includes bond fixture—need to increase cost some to account for additional scope of VI support, but this saves overall by not having entire extra fixture for VI support**
**Intention for ’02 to build 1 quarter panel support and 2 service panels—still valid**
**Need to build Full VI support for both installation testing and to support services**
- Needs to be ‘real’ for use in case pixels are late
- Needs to have ‘real’ rail interface (unless replaceable interface)
**Need to add cost to this section of WBS, or make new WBS for Beam pipe support**

## Recent Changes and Estimate of Impact

**Change of Forwards to Quartz fiber— +$30k**
- Additional Shell tool $14-20k
- Additional Hat stiffeners ~120-160 Man hours M-tech
**Introduction of Independent SCT Thermal Barrier +$35k**
- Throw away ~3-4 man months LBL/Junior Eng Design time
- Accrue additional 2-3 man months re-design of Flange/Flexures
**Increase in scope to include Beam Vacuum Supports +$110k**
- Design time not assessed
- Attempt to use/re-use as much fixture costs as possible
- Estimate ~$25k Material/200hr Shop/300hr M-tech (REAL) ‘03
- Estimate ~$10k Material/200hr Shop/300hr M-tech (prototype) ’02
- (Est. based on cost of End Plug and fixturing, using same tool as service panel support structure
**PST End Support (former Beam Vacuum Support) not included in cost estimates yet.**
**PPI/Endplug Thermal barrier increase in Complexity**
- Current Estimate based on segmented flat panel.  Cost will increase if tool is needed to make other than a flat shape.