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WP9 ITS Mechanics and Cooling. 12 March 2014. Corrado Gargiulo . ITS objectives for 2014 – WP9. Finalization of IB and OB layout IB QM design : Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell IB BARREL QM production based on “pad chips” - PowerPoint PPT Presentation
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WP9 ITS Mechanics and CoolingCorrado Gargiulo
12 March 2014
1. Finalization of IB and OB layout
2. IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell
3. IB BARREL QM production based on “pad chips”
4. OB QM design: Space Frame, Cold Plate
5. OB STAVE QM production based on “pad chips”
…
ITS objectives for 2014 – WP9
EM Engineering Module, Qualification Module (final quality)
1. Finalization of IB and OB layout
2. IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell
3. IB BARREL QM production based on “pad chips”
4. OB QM design: Space Frame, Cold Plate
5. OB STAVE QM production based on “pad chips”
…
ITS objectives for 2014 – WP9
BP outer radius 19
Layer 0 mean radius 23.38
Layer 0 inner boundary >21.8
Middle Layer radius TDR6 / TDR7
Stave width 15+1 (FPC)
Stave length (cold plate) IL 320 (4th IB layer)
IL 290=9.6+270.8+9.6
ML 870= 14.85+840.3+14.85 1066
OL 1502=15.7+1470.6+15.7
(TDR, endorsed)1. Finalization of IB and OB layout Detectors boundary radius@ >21.8mm
Beam Pipe NEW DESIGN 19mm OR
Submitted to LEB commitee for approval
R 19,0
Gap >2.8 mm No change in the ITS layers radius (TDR)
19.0
ITS VS BP
TDR 6
TDR 7
Baseline
Simulation results by the end of March
ITS Outer Barrel
1. Finalization of IB and OB layout
2. IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell
3. IB BARREL QM production based on “pad chips”
4. OB QM design: Space Frame, Cold Plate
5. OB STAVE QM production based on “pad chips”
…
ITS objectives for 2014 – WP9
Flex Printed Circuit
9 PIXEL Chip
Cold Plate
Spaceframe
Inner layer stave 300mm length, 1.6 gram weight
Polyimide tubes ID 1.024mm; wall thickness 25 micron
Inner Barrel
IB Carbon spaceframe
o Stiffness test sag <10 µm
o Thermoelastic test on going
IB
DEVELOPMENT TEST on EM (Engineering Module)o Thermal test OK
10
o Vibrational test >100Hz
167 Hz
status
o Dimensional next
sag
o Production of new spaceframe with high dimensional accuracy new moulds under production
PRODUCTION QM (FINAL QUALITY)
o Production of full barrel (48 staves)
next
on going
11
20µ
70µ
20µ
30µ
45µm
(30µ)
45µm
45µm
Alternative option under investigation to further improve stiffness and thermo-elastic stabilityChange of Carbon fleece with K13D2U(same weight)
EM IB Carbon spaceframe
Carbon paper
K13D2U
M60J
12
QM IB Connectors
DESIGNo 3D, 2D production drawings OK……need validation fro WP6, needs additional considerations on survey strategy
status
nextPRODUCTIONo 100 CONNECTORSo Design and Production of assembly jig, to glue the connector to the spaceframe
Deisgn modified respect to TDR to increase accuracy
provide staves position accuracy
QM IB production Spaceframe+Coldpalte n.48 2014 JULY
Tentative schedule
14
QM IB End-Wheels
DESIGNo 3d, OK…
nextDESIGNo Design and Production of molds for layer assembly
status
…need further consideration on cable and piping routing
15From Antonello & Antoine
QM IB End-Wheels
16
QM IB CYlindrical Support Structure
DESIGNo 3d, OK…
nextDESIGNo Design and Production of molds
status
…needs further consideration on survey targets locations and interface with Service Barrel
QM IB production End-Wheels and CYSS 2014 SEPTEMBER
Production site Bldg 167 new
… ongoing
CERN GS HSEMaterial HazardFire extinguisher
CERN electrical inspection
Ventillation system installation 90m2 clean environment, 18-23°C, 50% humidity
Almost there!
YannickSamuelEvgeny &Viktor
1. Finalization of IB and OB layout
2. IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell
3. IB BARREL QM production based on “pad chips”
4. OB QM design: Space Frame, Cold Plate
5. OB STAVE QM production based on “pad chips”
…
ITS objectives for 2014 – WP9
Outer Barrel
22
DEVELOPMENT TESTo Bending test &FEA sag ≈95µm
o Thermal (150 and 300 mW/cm2), hydraulic test Oko Thermal test on full length coldplate next
o Vibrational test 1st freq=51Hz; dynamic response ongoing
o Thermoelastic test αexp ~ 12 x 10-6 K-
1
On spaceframe (Carbon fiber K13 D2U)
On coldpalte
Outer Barrel stave
o Production of 1 SPACEFRAME+ 2COLDPLATESo Production of EMs
PRODUCTION QM (FINAL QUALITY)
next
status
on goingo Improve stave stiffness Full k13 spaceframe has shown to be too brittle N.2 Produced and tested, spaceframe M55j baseline N.2 Produced and tested, spaceframe M55j with additional layer N.2 Produced and tested, spaceframe M55j with two layers
K13D2U(embedded)
EM OB Carbon spaceframe
0 40 80 120 160 200 2400
50
100
150
200
250
M55j
M55J +M55J+K13
sag [mm]
load
[gr]
0 25 50 75 100 125 150
Lumped mass (test)
Distributed mass (derived from test)
3 point bending test results
Confirmed previous test
2424
20µ
90µ
20µ
30µ
45µm
30µ
70/45µm
45µm
ID=2.67mm, wt=0.065mm
ID=2.00mm;wt=0.032mm
o Option b) Alternative option under investigation to further improve stiffness and thermo-elastic stability
Mould modified (for ID 2mm), Grenoble New 2mm ID pipes arrived K13 from Berkley arrived
o Production of 1 cold plate 1,5m/ID=2mm/option-ao Production of 1 cold plate 1,5m/ID=2mm/option-bo Production of 1 cold plate 300mm for thermal test
for both option a and b
o Option a) Baseline
on goingEM OB Coldplate
SpaceframeQM OB Spaceframe CONNECTOR new design
New design
TDR baseline
Removed spring connection between stave and end-wheels
Ruby sphere
Reference Plane on the End-Wheels
SpringSpring
xx
x
26
DESIGNo EM 3D, 2D production drawings
OK… … need to be validated by WP7,8 and by test
status
nextPRODUCTIONo 20 CONNECTORSo Design and Production of assembly jig needed to glue the connector to the spaceframe
QM OB Spaceframe CONNECTOR revised design
DESIGNo 3d, 2D production drawings OK……needs validation by WP7,8
status
next
QM OB Cold Plate CONNECTOR
PRODUCTIONo 20 CONNECTORSo Design and Production of assembly jig, to glue the connector to the spaceframe
28
EM OB End-Wheels
DESIGNo EM 3d model proposal
status
nextDESIGNo EM 3D design
EW
300mm
300mm
300mm
150mm
300mm
Definition of cooling modularity and cooling scheme
Definition of electrical and hydraulic connection layout
DC-DC converter mechanics and cooling
EM OB End-Wheels
DC-DC
P. Kuijer 2014-3-11
ALI-UPGRADE 3D CAD MODEL overall 3D CAD MODEL available on CERN ITS UPGRADE CAD REPOSITORY
R1_20140311
Next
EM Inner stave & Outer stave -optimize carbon plies lay-up
QM Inner stave & QM Outer stave
-freeze connector design and start production-develop jigs for connector to spaceframe gluing
