Brick components R&D and mass production lead emulsion CS Plastic components BAM BMS

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• Brick components R&D and mass production• lead• emulsion• CS• Plastic components

• BAM • BMS • Brick Production and Detector Filling schedule

Brick Production and Detector filling status report

S. BuontempoOPERA Technical Coordinator

OPERA SPSC meeting April 2007 CERN, Geneva, Switzerland

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Brick components R&D and mass production : Lead

Lead types studied before final choice:

pure lead

Pb + Ca (0,07%)

Pb + Ca (0,04%)

Pb + Sb

Pb Colaminated with pure lead

PbCa colaminated with pure lead

Studies on:

Alpha activity

Chemical compatibility with OPERA emulsion films

Mechanical performance (planarity, uniformity in thickness,

stickiness, shape)

First choice (Mar06): PbCa Colaminated (problems in

mass prod. Rate and shape)

Final choice (Aug06): Pb+Ca(0,04%)

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Lead vs emulsion chemical compatibility tests & radioactivity

2 months 33°C ( controlled humidity storage)

ChemicalVacuum Spider

Alpha activity

Pb+ Ca 0.07% No(Fog Up)

Yes Yes(<30 cm2/day)

Pb+Ca 0.04% No(Fog Up)

Yes Yes(<30 cm2/day)

PbCa colaminated

with pure lead

Yes Yes Yes(<30 cm2/day)

Pb+ Sb 2.5% Yes Yes No(Surface Po migration)

PbSb colaminated

with pure lead

Yes Yes No(Surface Po migration)

Pure Pb Yes yes No(Surface Po migration)

Best candidates


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Mass production in JL Goslar firm (Germany)

Custom production line for punching, washing and packaging was

designed, constructed and is now operational.

Upper limit in daily production 45000 pieces (800 bricks)

in 3 shift/day mode. Now operational at 1 shift/day.

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30000 plastic pallets produced1 pallet = 1 brick (56 plates)

1000 custom transportation boxesProducedBoxes are “lead cartridge for BAM”

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Brick components R&D and mass production : Emulsion

About 9 millions pieces produced by Fuji Film Company and delivered to Nagoya University

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Produ-ction

Beam exposure

Develop-ment

Initial sensitivity

Refreshing

Produ-ction

Beam exposure

Development

Characteristic of refreshing (after refreshing)

Sensitivity of refreshed film

Production

Beam exposure

Development

Refreshing

G.D. 　　　　　　36/100μm

F.D. 　　　　　　1.3/1000μm ３

Performance of refreshed emulsion films for OPERA

Condition : 30 98℃ ％ 3days

G.D. 　　　　　　　 Under 8/100μm

F.D. 　　　　　　　2.1/1000μm ３

G.D. 　　　　　　35/100μm

F.D. 　　　　　　1.5/1000μm ３


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construction 2003 Apr-Decoperation 2004 Jan ~ 2006 Mar

Finished: 150,000 BricksUnder treatment: ~7,000 BricksTotal 9,000,000Films.

Emulsion Refreshing Facility in Tono Mine (Japan)

24 refreshing Units

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• CS (Changeable Sheet) is a tracking detector to match the TT with brick track. 1CS for 1ECC.

• Refreshing lab equipped in LNGS to remove all the tracks taken during trip to Europe

• CS box design optimized to guarantee planarity with brick, easy removal and 5 years positioning

• 23,000 CSs were produced in 2006

• The production speed was 1,700/day at Maximum.

• Next production will start end of March.

• 15000 CS boxes available now in LNGS, rest being produced

CS

CS

Brick components R&D and mass production : Changeable Sheets (CS)

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Brick components R&D and mass production : Plastic components

Brick mechanical packaging demanded for custom metal and plastic

components:

Al frame to keep the brick closed under 3 bar pressure (spider)

Plastic protection

Plastic cover

Requested performances:

minimal additional mass around the brick,

cover must be flat and rigid to keep the 3 bar pressure for 5 yeas,

plastic protection must be flat, but foldable on the corners

All test measurements were done in the framework of BAM activity

Chemical compatibility tests done with samples produced using list of

candidate materials

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fib

GL

Refe

rence

5

10

15

20

25

30

35

Gra

ins/(

10

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Fog densityD

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rence31.5

32.0

32.5

33.0

33.5

34.0

34.5

35.0

35.5

36.0

36.5

37.0

37.5

38.0

Gra

ins/1

00

m

Sensitivity

Studies on the compatibility of plastic components and OPERA emulsions.• Plastic cover and side protection 2 months storage @ 33° C2 months storage @ 33° C

Brick components R&D and mass production : Plastic components

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Brick Assembly Machine (BAM)

The BAM was conceived to maximize the brick quality stability in a

mass production mode. Goal was to produce 206000 in 1 year

(equivalent to 936 bricks/day 4 drums/day)

Long R&D work done on vacuum vs mechanical packaging

Specs document was defined for both cases solution. Tender was

closed in jan 2005.

TecnoCut firm (Italy) participated in the final studies for final choice

Mechanical solution was the final choice (may 2005) to secure:

piling precision

long term stability

brick robustness

The proposed solution based on anthropomorphic robots: very first

application of this in particle physics domain intellectual and

capital investment for future large detectors

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Status of BAM layoutBAM layout

BAM lead-drum room

BAM clean-light ro

om

BAM clean-dark room

5 piling pressing stations

Lead unpacking

Lead transportation

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Pictures bam in light, clean room and bam in dark,

BAM Lead-Drum

room

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BAM in Light,

clean room with white

light

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BAM in dark, clean room with white/red light

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Brick Assembly Machine (BAM) BAM construction started in march 2005 in firm site (Pavia, Italy).

Planned construction and commissioning time in firm was 13

months.

Delivery expected in GS by April 2006, postponed to June 2006 due

to lead decision.

Delay in lead choice decision interfered with final layout and

commissioning of piling section. First “final” lead choice was PbCa

Colaminated.

Construction completed in firm by summer 2006 with commissioning

of single units.

Decision to install anyway in GS in summer 2006 to secure the brick

pilot production for beam time in October 2006.

Installation and preliminary commissioning in LNGS completed in

October (a part drum station, being a separate order).

Commissioning phase of full line was delayed by the new problems

of stickiness found in colaminated lead and real emulsions

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Brick Assembly Machine (BAM) Pilot production in GS in October 2006 good for physics and for

mechanics:

800 bricks produced in 3 weeks with many new problems in

lead/emulsion stickiness.

Brick skating performance were not as good as in prototyping

because of brick shape defects which were demanding thicker skate

solution

CS box mechanically positioned on the brick was unstable in case

of too strong pressure and friction during detector filling phase

Net effects were:

a revision of the piling station cycle with addition of pulse

compressed air on both emulsion and lead pile. Resulting in factor 2

in piling time (from 3 to 6 min /brick) and 1 operator needed per

each piling station.

Additional job in pre-treatment of lead boxes with compressed air

to open the piles.

Need to change the skates with thicker material (Tyvek)

Need to glue the CS boxes

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New skate and CS box gluing additional machines being constructed

(delivery by April07) (eliminating present manual operations in BAM

in light)

6 min/brick/station = 50 bricks/hour is present theoretical upper

limit

x 14h/day = 700 bricks theoretical upper limit (2 shifts mode and 2h

lost for lab access and BAM loading). Our present goal is to secure

468 (2 drums) a day ( with 33% ineff.)

To secure 702 real brick/day (3 drums) with some contingency we

plan to increase theoretical limit by 25% (margins exist) and reduce

inefficiency by 10%.

BAM performance

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Brick Manipulator System (BMS)

Responsibility of LAPP-

Annecy (IN2P3/CNRS)

System based on industrial

automates,

Profibus ground bus, C++

supervision and DB management

softwares.

One manipulator on each side of the

detector, portico and vertically

moving platform

R&D, mechanical construction,

cabling and tests at LAPP,

installation in Gran Sasso:

December 2005, March 2006.

Commissioning going on.

5000 real bricks inserted in OPERA

till last week

Running needs: 1 expert + 1 skilled

operator per shift

Present performance (no contingency): insertion of 2 drums (468 bricks) in one shift of 8 hrs

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Loading station and drumfor brick transfer

Draw bridge for brick insertion

Storage Carrousel

Digital camera for positioning

Vacuum sucker vehicle to retrieve bricks

Electric jack to insert bricks

Portico

Manipulating platform

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Brick Production and Detector filling schedule

Since last march 12th 2 shift/day mass production started.

9350 bricks produced till

last week

Technical stops were

planned to update parts

of BAM piling section

3 (2) days stops were

needed in week 13 (15)

due lack of empty drums

(to BMS stop)

Now we monitor the

BAM/BMS stability and

fatigue

Internal Milestone: Produce/insert 10000 bricksin detector by April SPSC-LNGSC week

Brick Production

0100020003000400050006000700080009000

10000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Weeks

Brick

s brick sum

weekly bricks

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Final Goal: Produce 150000 bricks by end of April 08

1 drum/shift (468 brick/day) is feasible. Strong dependence by operator skill and storage units (drums) availability. We have to check now the production stability performance.

2,5 drum/day (585 bricks/day) is technically feasible now with software improvements in the BMS procedure to be implemented in next technical stops 3 drums/day (702 bricks/day) demands for:- improvements in BAM piling and wrapping station speed, evaluated in next 6-8 weeks during technical stops- 2 shift running mode on BMS operation

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Detector filling schedule in 3 BAM/BMS rates (with 15% contingency time):

Rate run start (sept 15th) run stop (nov 15th) det. completed

(+21 weeks) (+30 weeks) 150000 bricks

2 drums/day 50680 68986 sept 12th 08(2034 bricks/week) ( 372 evts)* (+70 weeks)

2.5 drums/day 58315 81202 June 20th 08(2543 bricks/ week from june 1st 07) ( 441 evts)* (+58 weeks)

3 drums/day 59334 86802 May 2nd 08(3052 bricks/week from sept 1st 07) ( 465 evts ) * (+41 weeks)

* : number of CNGS events in the bricks for 1019 pot

Documents

Brick components R&D and mass production lead emulsion CS Plastic components BAM BMS