# Presentation: 661200

## Endcap Muon  System - FNAL 

**Giorgio Apollinari**
**Technical**
**April 29-30, 1999**

## Outline - Site Manager

**Presentations**
**Yuri Pishialinikov**
- Lab 8 Status
- Panel/Chamber measurements
- R&D - QA/QC Tools for Panel  production
**Oleg Prokofiev**
- PNPI Tooling & Shipment/Plans for Russia
- Wire QA/QC
- Definition of HV Training (discussion)
**Giorgio Apollinari**
- Gluing Proposal
- P2’’ (ME234/2) Production Status
- ME1/2 Status
- MP9 Setup

## FNAL Gluing Proposal 

**Propose to glue all panels (anode/cathode) and “dry-assemble” chambers before shipment to PNPI-IHEP.**
**Scenarios**
- Ship all chamber parts in kits (frames in bulk) without cleaning and assembly
- Clean and glue all panels at FNAL, “dry-assemble” the chamber and use final “Shipping Crates” for shipment.
**Why**
- Anode Bar/Guard Strip gluing is one of the most critical operation in CSC construction
**	****Chamber Requirement****	****	****	****Performance**
**Cleanliness/Glue Amount****	****	****Dark Current**
**Height over Cathode Plane****	****	****HV Plateau**
**Uniformity of Application****	****	****Gas Leak**

## FNAL Gluing Proposal 

**Pros**
- Effective use of tooling in one place, no need for shipment of assembly aids.
**Cleaning Machine**
**G10 Parts Cleaning **
**Glue Dispenser Machine**
- Use “Shipping Crate” for all shipments (FNAL-PNPI,IHEP and PNPI,IHEP-CERN).
**Develop only one kind of bag to prevent panel (chamber) oxidation/deterioration for the oversea shipment.**
**Full *****chamber protection***** available also for FNAL-PNPI,IHEP shipment.**
- Full QA/QC of chamber/frame interface on 100% of the shipment. Vendor mistakes are an internal (USA) issue.
- Standard FNAL QA/QC on panel gluing
**Epoxy life-time under control**
**QA/QC Measurements**
- Good synergy between task and estimated manpower

## FNAL Gluing Proposal 

**Cons**
- Cost of Tooling
**Need extra clamping tables. **
- Cost of manpower.
**Cost Analysis**
- Cost Increases
**4 FNAL, 2 PNPI and 4 IHEP chambers/month****	****	**
**Panel Cleaning/Chamber Assembly****	****5 to 6 FTE**
**	****	****	****	****	****	****(2 techs  / 3 years)**
**Kit preparation for frames****	****	****1.5 FTE**
**	****	****	****	****	****	****(0.5 techs / 3 years)**
**Total Cost Increase:****	****	****	****~310-410 (FY97) k$**
- Cost Decreases
**Less crating (50 crates)/custom costs****	****~50 k$**** ****	****	**
**Less engineering time****	****	****	****0.25 FTE ~ 25 k$**
- Total Cost				**230 - 330 k$**

## P2’’ Production Status 

**Engineering Drawings**
- Design Review February 1998
- Design Changes/Additions
**Alignment System **
- Extra holes on top Cathode Panel
**Test Strip Connectors**
**End Guard Strip Change (HV problem) **
**Anode Protection Board**
- Head-on connector
- Status
**Chamber/Common parts****	****Released**
**Frame Drawings****	****	****Released (UW)**
**Assembly Drawings****	****	****Being Checked**
**Electrical Drawings****	****	****Being Compl. **
- Anode Protection Boards
- Complete Chamber Electrical Scheme

## P2’’ Production Status 

**After**

**Before**

**Clearing gas sleeves**

## P2’’ (and Tooling) Drawings

**DCS **
- Document Control System
**Release drawings for procurement**
**Official source for paper copies**
**Historical record of changes & controlled versions**
- Released ( i.e. signed-off) drawings availability:
**Paper copies**
- DCS released -to-date drawings
- Only certain source of up-to-date drawings
**CAD  ( and EPS ? ) Versions**
- Available on the WEB at FNAL site
_**Not officially maintained**_
- Unreleased Drawings
**Not available  ( i.e. visit FNAL - IB2 )**

## P2’’ Production Status 

**BOM (Bill Of Material)**
- List of components in WBS format making up a chamber
- BOM ready for all chambers, largely common
- Major specifications and sub-assemblies identified
**Resistors (leads bending)**
**Capacitors (leads bending)**
**Cathode Connectors**
**Anode protection boards**
**Copper foils for grounding**
- Minimum stock quantities (8 chambers) for common components

## P2’’ Production Status 

## P2’’ Production Status 

**Procurement**
- Goal:
**Procurement of material for**
- 2 chambers		P2’’ + 1 spare chamber (1st 				production chamber ?)
- 1 anode panel		Insurance on assembly mistakes 			(see P3 experience) or 				replacement for bad P2’ plane
- Tooling and QA/QC Tools
**Lab 8****	****	****	****Axxiom bits on order**
**	****	****	****	****	****Gerber bits available**
**MP9****	****	****	****Ready**
**QA/QC ****	****	****	****Mostly available. ****	**

## P2’’ Production Status 

**P2’’ Production Status **

**Procurement (continued)**
- Materials
**Wire****	****	****	****Available**
**Panels****	****	****	****Available, machined by May 15****th**
- Small Axxiom-Gerber program changes
- 			Alignments plates mounting
- 			Extra alignment grooves (Yuri)
**Gap bars****	****	****	****UF - May 1****st**** **
**Anode bars****	****	****	****Artwork released**
**	****	****	****	****	****no files to vendor (programs lost !)**
**	****	****	****	****	****Alternative: use old bars design**
**	****	****	****	****	****@ FNAL by May 15-20****th**
**Anode Protection Boards****	****New design just released**
**	****	****	****	****	****@FNAL by May 30****th**
**Other Components****	****	****Some available (R,C), other to be procured**
- Start cathode assembly on ~ May ~10-15th
- Start anode assembly on ~ May  20th
- 		**P2’’ Ready****	****	****	****June 20****th ****- 25****th**

## ME1/2 Status 

**Design **
- Solution of conceptual design problems
**High density at Cathode Connectors**
**Location of test strip connectors**
**Location of gas input-output lines**
- Conceptual problems to be solved
**Alignment plate - Cathode Electronic location (Dave E.)**
- Specific Drawings available
**Wire fixation bars**
**Anode - Cathode artwork**
- Drawings to be worked-on
**Gap bars , insulation strips, etc.**
**HV artwork**
**Anode protection board**

## ME1/2 Status 

_**Chamber Assembly**_** **

_**Wire Fixation Bar **_

## Panel  Production Status 

**R&D **
- Procured new flat platens for Plascore (cost decrease based on lower QA at vendor)
- Received new  pilot order of 14 panels
**Measurements**
- Thickness
**In agreement with Specifications**
**Delamination problem (to be solved **
**	****working on Plascore procedures)**
- Flatness
**Local measurement only**
**Problems meeting specs (+/- 10 mils),  released to +/- 15 mils**
**	**** ****i.e. ********G/G ~ 2.8 **
**Continue production of 200 panels for FY99.**

## Setup of MP9

**Present Layout**

## Setup of MP9

**Planned Layout**

## Setup of MP9

**Plans for Panel Cleaning Machine**
**Sample Panels Cleaned **
- 3M R&D Machine
- Wood-working Sander
**Electrical Properties Measurements**
- Interstrip Resistance	OK
**Systematic Visual Inspection****	****	**
- Number of Loose Fibers/Unit Length		Inconcl.
- Copper Burs Presence			Both OK
- Surface Finish				3M Better
- Dust/Chip Removal				Both OK
**Test Chamber Assembly**
**Decision on Specifications/ Procurement****	****Apr.  1999**

## Setup of MP9

**	****	****	****Activity in MP9****	****	****	****When**
**Clean Area Material****	****	****	****in progress**
**Removal machine shop****	****	****in progress**
**Vacuum System Installation****	****July (after P2’’)**
**Complete removal of MI project****	****July**
- 2 ton crane to UF (?)
**Gas System setup****	****	****	****May**
**Assemble P2’’****	****	****	****May-June**
**Assemble PNPI Tooling****	****	****May or July**
**Setup Area for Cleaning **
**	****Machine****	****	****	****	****June**
**Travelers ****	****	****	****	****in progress**

## Setup of MP9

**	****	****	****Travelers****	****	****	**
**Gluing**
- Anode Panels		Spec # 5520-TR-333361
- Upper Cathode		Spec # 5520-TR-333362
- Inner Cathode 		Spec # 5520-TR-333363
- Lower Cathode		Spec # 5520-TR-333364
**Panel Winding****	****	**Spec # 5520-TR-XXXXXX
**Wire gluing ****	****	****	**Spec # 5520-TR-XXXXXX
**Anode Soldering****	****	**Spec #5520-TR-333349
**Panel Cleaning & Meas.****	**Spec #5520-TR-XXXXXX
**Wire Tension Meas.****	****	**Spec #5520-TR-333352
**HV Test (Panel)****	****	**Spec #5520-TR-333351