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PVC Module Production (2.5)Ken Heller
University of MinnesotaMay 8, 2012
Minerba Betancourt, Jianming Bian, Tom Chase, Dan Cronin-Hennessy, Ben DeYoung, James Geddes, Chris Kluge, Susan Lein, Tina Lorsung, Jarek Nowak, Greg Pawloski, Jim Parker, Nathaniel Pearson, Ron Poling, Nick Raddatz, Dominick Rocco, Kanika Sachdev, Alex Smith, Brian Sherwood, Dick Wildberger, Robyn Woolands, Jan Zirnstein
+ 170 undergraduates typically 15 hrs/wk(~ 240 is full staffing)
TechnicianAccountingEngineerPhysicist
Manifold Parts
DOE IPR May 8, 2012 Ken Heller WBS 2.5 2
Raceway holder
3
End Seal Parts
DOE IPR May 8, 2012 Ken Heller WBS 2.5
Module Production Status
• All machines & QA – operating.
• All molds & dies – completed and in production.
• Parts – flowing in.
• QA, process, & inventory software – operating
• Asynchronous 2 to 1 operation – in production
• Module production – ramping up
• Management of students working part time (170 students working a minimum of 10 hrs/wk) – in operation
• Module shipping – 4 planes (48 modules) to Ash River on schedule
• Factory floor – filling up
DOE IPR May 8, 2012 Ken Heller WBS 2.5 4
Slow ramp-up for first month - 123 good modules producedInitial process adjustments to minimize• Fiber damage• Optical connector leaks • Outer seal leaks• Visual inspection flaws
Module Factory Stable 2 to 1 Production
DOE IPR May 8, 2012 Ken Heller WBS 2.5 5
3277 complete 2 to 1 (8.5 blocks = 29% of far detector)
Failure rates overallFlatness – 0.7%End Cut – 0.7%
Failure rates April Flatness – 0% (125 done)End Cut – 1.6 % (125 done)
Peak 2 to 1 production rate 38/day (average needed 24/day)
Slowing 2 to 1 production to put effort into module production
Factory and annex are almost full
2 to 1 storage annex
2 to 1 operation
Scenes from the Factory Floor
DOE IPR May 8, 2012 Ken Heller WBS 2.5 6
Production floor Production floor
Stringing stations Gluing extrusions
Scenes from Production – Final Stages
DOE IPR May 8, 2012 Ken Heller WBS 2.5 7
Painting Stacking finished modules
Closed fiber testing Packing
Scenes from Production
DOE IPR May 8, 2012 Ken Heller WBS 2.5 8
Pressure testing Fly cutting Sealing endplate
Open fiber testing Stringing
Production Snap Shot
DOE IPR May 8, 2012 Ken Heller WBS 2.5 9
In full production each step would have the 24 modules/day.
A single module goes through all the steps in 6 days.
snou
t
string
open
fiber test
open
fiber test
flycut
open
fiber test
optical con
nector leak
open
fiber test
Inn
er seal cover
Inn
er seal end
plate
closed fib
er test
end
plate sq
uaren
ess
Inn
er seal leak
outer seal
closed fib
er test
pain
t
final in
spection
stack
pack
ship
2to1
flatness
trim en
d
trim en
d
length
outer seal leak
One day production process5/7/12
Production Progress
DOE IPR May 8, 2012 Ken Heller WBS 2.5 10
Fiber: 12Optical connector: 16
Failures week 2
Fiber: 13Final inspection: 1
Failures week 3
Fiber: 6Optical connector: 1Fly cut: 1
Failures week 4
Fiber: 4Final inspection: 1
Failures week 1
Fiber: 2Optical connector: 1
Failures week 5
Goal is 120/wk
166 good modules
Goal is 2%
Ken Heller WBS 2.5 11
Module Parts Received
DOE IPR May 8, 2012
Plastic Part module units (12500) %Manifold Cover 388 (382 = 1 block) 3End Plate 3372 27Top Raceway 541 4 Bottom Raceway 536 4Top Fiber Tray 9662 77 Generic Fiber Tray 2570 21 Bottom Fiber Tray 4464 36Raceway Cover 3422 27Raceway Support 3919 31Snout Front 3300 26Snout Back 3300 26Manifold Side Seal 3919 31End Plate Side Seal 3920 31Optical Connector 12544 100Fiber Ring 12891 100External Center Seal 12500 100
Redesign of Manifold Cover & ToolingAnalysis & Testing
DOE IPR May 8, 2012 Ken Heller WBS 2.5 12
Tight fit 10 mil gap
Ang Lee (Fermilab) FEA
New cover and clamp design - max stress between 1000 & 1400 psi.
Measured material strength between 6400 & 5100 psi.
Manifold Cover Strength Tests
DOE IPR May 8, 2012 Ken Heller WBS 2.513
5000
5200
5400
5600
5800
6000
6200
6400
6600
6800
7000
Mor
e0
1
2
3
4
5
6
Tensile Strength in psiN
umbe
r
Manifold Cover Ultrasound Scans
DOE IPR May 8, 2012 Ken Heller WBS 2.5 14
Section 1
Section 2
No flaws observed in structure or strength of manifold covers
Vigilance is the Price of NOnA
DOE IPR May 8, 2012 Ken Heller WBS 2.5 15
http://www.animal-photos.org/photo/2673.html
It’s all about QA/QC• Parts inspected when received• 2 to 1
• Flatness• Length• Squareness• Glue strength
• Fiber• Continuous as strung• Open ended after stringing• After fly cutting• After sealing
• Fly cut dimensions• Optical connector leak check• Inner seal leak check• Outer seal leak check• Final visual inspection, fiber test,
dimension check• Glue strength• Chemical compatibility3 QA audits by Fermilab project staff
Training
Cross section cuts to check glue flow
DOE IPR May 8, 2012 Ken Heller WBS 2.5 16
Cross-section cut every 0.05”Snout Joints
Optical connector Cross-section cut every 0.015”
Scintillator Interaction Testing
DOE IPR May 8, 2012 Ken Heller WBS 2.5 17
Alphaonly
Noise RunScintillatoronly
Ratio of Compton to alpha to take out phototube variationPulse height
cou
nts
Test all glue types and all parts
Risks and Mitigation
DOE IPR May 8, 2012 Ken Heller WBS 2.5 18
Parts do not meet specifications
Have manufacturer pay attention to their QC and remake parts. Adequate parts are buffered so should not cost production time. Add weekend production if necessary.
Utility rates increase for factory Project contingency held to cover up to a doubling of utility rates.
Extrusion delivery interruptedFactory already has over 6 months of stored extrusions so should not cost production time if extrusion factory can make up the deliveries later.
Unable to ship completed modules
Factory stores several months of completed modules so should not cost production time if shipments can resume.
Module production interrupted Factory stores several months of completed modules so detector assembly can continue. Weekend production can make up the time.
Module Shipping/Receiving Damage
DOE IPR May 8, 2012 Ken Heller WBS 2.5 19
Visual inspection of modules at Ash River by module factory personnel found damaged fiber.
5 modules (21%) in stack 16 modules (25%) in stack 2
Investigation plan
Ship 1 stack of modules to Ash River and back to module factory
Monitor shock and temperature
Check for fiber damage
Autopsy any damaged modules to determine location of damage
All good leaving factory
Looking Ahead
Expand staffing from 170 to ~210 students in Fall
20DOE IPR May 8, 2012 Ken Heller WBS 2.5
Ramp up to 24 modules/day (now at 12) – end of May
Summer means easier management controlfewer students (~70) working full time
Get to ~ 2% module failure rate (now at 7%)
Production ramp up going wellprocess improvements decrease defectsrate increasing
Investigate and eliminate fiber damage in shipping
Gluing seals & snouts Stringing
Unloading extrusions