# Presentation: 504657

## EMU - Cathode Strip Chambers

**Giorgio Apollinari**
**Fermilab**
**CMS Collaboration Meeting**
**CERN- June 3-9,  2000**

## Outline

**CSC Production Aspects  @ FNAL **
**Chamber - Tooling Engineering **
**Prototyping and  Production Sign-off**
**Foreign Factory (IHEP/PNPI) Setup**
**Factories at FNAL**
**Material**
- Procurement & Inspection
**Labor Experience**
- Inspection & Process Engineering
- Factory Assembly
**Lab 8 Panel Machining**
**MP9 Chamber Assembly**
**Production Readiness Review**
**Schedule**
**Summary and Conclusions**

## CSC Production @ FNAL

** ****Fermilab Site:**
**- panel production**
**- large CSC assembly**

**Procurement**

**Panels**

**Wire**

**Wire fix bars**

***Gap bars (UF)***

**Guard strips**

**Etc.**

**PNPI Site**

**UC Site**

**UF Site**

**IHEP Site**

**Frames/HV Connector (UW)**

**parts and critical tooling**
**(smaller chambers)**

**parts and critical tooling**
**(smaller chambers)**

**large CSCs**

**large CSCs**

**CERN**

**large CSCs+Electronics, tested**
**installation/commissioning**

**large CSCs+Electronics, tested**
**installation/commissioning**

**smaller CSCs+Electronics, tested**
**installation/commissioning**

**smaller CSCs+Electronics, tested**
**installation/commissioning**

**CSC Production @ FNAL**

## CSC Production @ FNAL-FY99

## Chamber - Tooling Engineering

**Chamber Design & Specifications**
**Design all chambers at FNAL and release all drawings in the Document Control System**
- Highest Priority Task
**Release ME234/2          **_**Apr.  ‘99**_** (Mar. ‘99)**
**Release ME1/2****	****          **_**Aug. ‘99**_** (Apr. ‘99)****	**
**Release ME2/1****	****          **_**Nov. ‘99**_** (Jun. ’98) ****	**
**Release ME3/1****	****          **_**Dec. ‘99**_** (Jun. ‘00)****	**
**Release ME1/3****	****          **_**Feb. ‘00**_** (Feb. ‘00)****	**
**Release ME4/1   (if approved) **
**Finalize and Release all Technical Specification**

**Plans:**
- Implemented Change Control Board
**Cost Implications of a Change**
**Schedule Implications of a Change**
- Material
- Manpower
- Integration effort (see D. Loveless talk)
- Assemble at least 1 chamber at FNAL for each new design

**Open Engineering Issues:**
- Design Release does not complete the chamber engineering process. Continuous additions require constant drawing revisions.
**Ex: SIPs, Ground Lugs**
- Integration Finalization on frames
- Design Problems

## Chamber - Tooling Engineering

**Specifications Example**

## Chamber - Tooling Engineering

**“****Design Problem” Example**
**Original design distance between holes too large to provide proper pressure during panel clamping-sealing**
**Problem prevent production procurement and effects**
- frame design
- panel design

**Original Holes**

**“****Configuration Control Board”**
**Controlling Major Changes:**
- Major = potentially effecting labor or material cost at L2 (>10 k$)
**Anode Protection Boards **
**Cathode Protection SIPs**
**Cathode Ground Lugs**
**Approved by L2 Management**

## Chamber - Tooling Engineering

**Tooling**
**~All tooling for FNAL, IHEP and PNPI designed**
- 28 major tools fully documented
- Chamber Shipping Container (FNAL-UF,UCLA and UF,UCLA-CERN) is the last piece of tooling to be designed.

## Prototyping & Production Sign-off

**Prototyping & Production Sign-off**

**Prototyping**
**All Chambers types need to be prototyped at FNAL**
**Goals and Requirements of Prototyping**
- Minimize interference with FNAL Chamber Production
- Allow finalization of design
**Panel Design Sign-off (FNAL Responsibility)**
**Parts Design Sign-off (FNAL-UF Responsibility)**
**Frame Design Sign-off (UW Responsibility)**
- Allow documentation of all Assembly Procedures in the form of Travelers
- Allow use of foreign factories critical tooling to verify the functionality and commission the various devices
- Optimize training of foreign factories Personnel
**PNPI Visitors for ME2/1 Prot.  and  ME3/1 Prot.**
**IHEP Visitors for ME1/2 Prot. And ME1/3 Prot.**
**	****All prototypes to be assembled at FNAL before ME234/2 Production***
** **
*** Date for ME4/1 prototype          Nov-Dec ‘00 before rate ramp-up @ FNAL     **

## Prototyping & Production Sign-off

**Prototyping Schedule**
**ME1/2 Assembled by Jan. ‘00**
**ME2/1 Assembled by Apr. ‘00****	****May ‘00**
**ME3/1 Assembled by May  ‘00****	****Jun. ‘00****	**
**ME1/3 Assembled by Jun. ‘00****	****~ ?? Jul. ‘00 ?? (visitors problems)**
**2 ME234/2 Pre-production  chambers completed**
**2 ME234/2 Pre-production chambers scheduled for Jun ‘00**
**Chamber Production Sign-off**
**Production to be agreed upon by**
**all L2-L3 Managers through the**
**Configuration Control Process**
- ME234/2	Jun.  ‘00
- ME1/2	Aug. ‘00
- ME2/1	Sep. ‘00
- ME3/1	Dec. ‘00
- ME1/3	Sep. ‘00

## Foreign Factory Setup

**Foreign Factory Setup**

**Setting up a Factory implies placing many activities/items under control**
**Tooling **
- _Assembly, Commissioning & Shipment_
- _Operating Procedures_
**Parts Control**
- _Parts Inspection & Shipment_
- Parts Accounting
- Parts Storage and Flow to the Production Floor
**Chamber Assembly Activities**
- _Assembly Procedures_ & _Personnel Training_
- _Definition/tooling for QA/QC Activities_
- Discrepancy Report Scenarios
- Travelers and Measurements Data-basing
- _Underlined __	_Fermilab Responsibilities

## Foreign Factory Setup

**Situation**
**Burocratic Status**
- List of tools available for IHEP and PNPI.
- Signatures in the process of being acquired
**Technical Status**
- PNPI under control
**Carts/Gluing machines shipped in the spring**
**Winding Machine and Tension testing machine used for ME2/1 assembly**
- IHEP
**Problems in getting Chinese visitors to FNAL**
**Delay in Critical tooling setup and ME1/3 assembly**
**PNPI tooling and prototype chambers shipment (almost) on schedule.**
**IHEP tooling and prototype chambers shipment can suffer ~2-3 months delay.**

## Materials - Procurement

**Materials - Procurement**

**Procurement**
**A chamber is naturally divided into “Common Parts” and “Specific Parts”**
- Common Parts (Wire, Resistors, Caps, Connectors,..) with 5-10% spares
**No Risk (Resistors, Caps, Connectors, APB...)**
- Procured for full Production
**Low Risk (Wire, Glue, RTV,...)**
- Procured for 35 ME234/2 Chambers with Option for full procurement to be exercised by June ‘00.
- Specific Parts (Gap Bars, Wire Fixation Bars,..)
**Procured only for:**
- 35 ME234/2 Chambers
- Prototypes for Other Chamber  types

**Preliminary Cost Experience FNAL - Summary**

**Total: 1.247 M$ (actual)  vs   1.293 M$ (estimate)**

## Materials - Inspection

**Materials - Inspection**

**Panel Inspection**
**Flatness Measurements performed with a Laser and a Ping Gauge probe**
- Good Correlation
**Rejection Criteria**
- Pin Gauge > 80 mils
**~14/600 rejected 5’x12’**
**~2/200 rejected 4’x12’**
**~2% ****“rejection”**** factor**

## Materials - Inspection

**Inspection**
**All parts under FNAL or UF responsibility are inspected at FNAL (sampling basis).**
**No part can be declared “ready for production/assembly” until inspection completion:**
- Examples:
**Wire Fixation Bars**
- Still problems with locations of Wire Soldering Pads (require +/- 4 mils position tolerance, receiving up to +/- 10 mils from various vendors)
**Anode Protection Boards**
- Drawings specify Carbon Composition Resistors (good resistance to sparks)
- Vendor installed Metal Foil Resistors.
- Parts have been corrected by the vendor free of charge to FNAL.
**Need to define funding/inspection responsibilities for frames (UW)**

## FNAL Factories - Lab 8

**FNAL Factories - Lab 8**

**71  ME2324/2 Chamber(~47%)**
* *
**15/553 Rejected Panels (2.7%)**

**Y.Pischialnikov (UCLA)**

## FNAL Factories - Lab 8 QA/QC

- Y

- 81st groove

- 1st groove

- 81st groove

- 1st groove

_***Scale***__*** ***_

**X**

_***Rotation***_

_***Off-set***_

*For ~47% of ME234/2 panels, alignment marks analysis shows  good quality and a process under control *

## FNAL Factories - Lab 8 QA/QC

**FNAL Factories - Lab 8 QA/QC**

**	****Excellent correlation between CNN and photogrammetry Measurements**

**Cross-check on strips position after chamber assembly (typically @ CERN)**

## FNAL Factories - MP9

**Planned Layout  - May ‘99**

## FNAL Factories - MP9

**MP9 CSC Factory**

**Panel Lifting Equip. **

**Winding Machine  **

**Soldering Machine  **

## Preproduction Experience 

**ME234/2-001 and 002**
**Started on March 27, ‘00 - Completed on May 30, ‘00**
- Problems
**10 DR written for chamber 001**
- Bad Tension on 200 m wire
- Position of 50 m wires out of tolerance
- Leak rate (5 cc/min)
- Wire fixation bars gluing problems
**5 DR written for chamber 002**
- Bad Tension on 200 m wire
- Wire fixation bars gluing problems
**Various holes are missing/not taped**
- Caught by people with intimate knowledge of the system
**HV Final Connectors missing **
- Due in shortly
**Major lesson**
- One chamber produced in 3.5-4 weeks
- Limiting factor
**Wire Guides Tooling**
- On order, due in by 8/4 for ME234/2

**Good**

**Bad**

## Wire Positioning