UM Chamber Production UM Chamber Production
20.4
Team for Module 0: Team for Module 0: Zhou Zhou , , Thun Thun , Diehl, , Diehl, Tarle Tarle , Levin, , Levin, Kouba Kouba , , Weaverdyck Weaverdyck , ,
Schick, Schick, Xu Xu , , Ouyang Ouyang , Lu, Li, , Lu, Li, Degenhardt Degenhardt , , Overhiser Overhiser
Team for mass production: Team for mass production: Zhou Zhou , , Kouba Kouba , , Hou Hou , , Tarle Tarle , Levin , Levin
4 junior technician 4 junior technician s, 2 undergraduate students s, 2 undergraduate students
June 1, 2000
UM Chamber production
Chamber assembly facilities Chamber assembly facilities
• • Assembly room ( Temp controlled to 1 degree) Assembly room ( Temp controlled to 1 degree)
• • Granite table (flatness ~ 20 microns) Granite table (flatness ~ 20 microns)
• • Vacuum system with large reservoirs Vacuum system with large reservoirs
• • Large spacer assembly table Large spacer assembly table
• • 9 precision combs ( 2 angle ones) 9 precision combs ( 2 angle ones)
• • 10 sets of sphere blocks 10 sets of sphere blocks
• • Large Large stiffback stiffback frame frame
• • Automatic glue machine and control system Automatic glue machine and control system
• • Remote control overhead crane Remote control overhead crane
• • Two large rolling tables Two large rolling tables
Michigan Chamber
Michigan Chamber
Assembly Station
Assembly Station
Chamber assembly room
Constructed in part of physic
s high bay. The floor has
been
reinforced to hold a 27,000 kg
granite plate.
Granite Plate
A 6.4x2.9x0.76 m
3
granite plate with 20 m m flatn
ess installed.
Flatness verifie
d by BCAL and external company
.
HVAC unit
controls temperature ( – 0.5 û
C) & humidity (45 – 5%).
Crane
with remote?control and fine
position adjustment ha s been in
stalled.
Vacuum system
for comb and stiffback inst a
lled and leak checked . Features
2 large cap acity pumps (560 li
ter /min) each with 300 liter re
servoir.
Granite Plate
Vacuum Pumps
Bing Zhou
ATLAS
UM Site Review June 1, 2000
Michigan Chamber
Michigan Chamber
Production Tooling
Production Tooling
We are currently assembling an
d testing our chamber jigging.
C
ombs
Feet are glued on.
Angle com
bs have been surveyed (OK).
Comb
vacuum bar installed/leak chec
ked.
Combs being aligned on gran
ite table.
Sphere Blocks
We surveyed their absolute h
eights (OK).
Sphere
Blocks
EMS5
Comb s
on
granite
Bing Zhou
ATLAS
UM Site Review June 1, 2000
Michigan Chamber
Michigan Chamber
Production Tooling
Production Tooling
Spacer Frame Assembly Table
100 m m flatness. Spacer assem b
ly jigging set up and used to m
ake Module 0 spacer.
Stiffback
Assembled, leaked ch ecked, a
nd ready, exce pt for internal R
ASNIK s.
EMS5 Spacer Frame
Stiffback
Bing Zhou
ATLAS
UM Site Review June 1, 2000
Michigan Chamber
Michigan Chamber
Production Tooling
Production Tooling
Glue
Machine
Chamber Leak Fixture/Electroni
cs
We
are developing a technique
for leak check by mon itoring t
ube gain (gai n is a strong func
tion of pressure, but not tempe
rature).
Glue machine
MPI design with UM
control ele
ctronics/software.
Chamber Handl
ing Fixtures
Designing and making chamber
rotation
frame, transport and s
torage carts.
Bing Zhou
ATLAS
UM Site Review June 1, 2000
June 1, 2000
UM Chamber production
Measurement and monitoring Measurement and monitoring
• • All the critical parameters of the facilities are measured with All the critical parameters of the facilities are measured with high high
precision and checked with different techniques: precision and checked with different techniques:
– – Room temp. profile measured by 30 T Room temp. profile measured by 30 T - - sensors ( to 0.1 deg). sensors ( to 0.1 deg).
Monitoring for chamber production will use 8 T Monitoring for chamber production will use 8 T - - sensors, 1 humidity sensor. sensors, 1 humidity sensor.
– – Granite surface flatness measured by tilt Granite surface flatness measured by tilt - - meter, BCAL, and surveyed by external meter, BCAL, and surveyed by external
companies ( to 5 microns accuracy). companies ( to 5 microns accuracy).
Monitoring: 2 load sensors, tilt Monitoring: 2 load sensors, tilt - - meter, and BCAL (for every chamber). meter, and BCAL (for every chamber).
– – Precision combs are surveyed at Precision combs are surveyed at Brandeis Brandeis before shipping to UM. before shipping to UM.
We surveyed two angle combs by external company using CMM, We surveyed two angle combs by external company using CMM, measured measured
all the comb notch heights using precision rod and micron all the comb notch heights using precision rod and micron - - indicator after the comb feet indicator after the comb feet
are glued ( to a 5 microns accuracy). are glued ( to a 5 microns accuracy).
Monitoring: digital micron Monitoring: digital micron - - indicator (for each chamber). indicator (for each chamber).
– – Sphere block relative positions for 4 different levels are surve Sphere block relative positions for 4 different levels are surve yed at MIT, and re yed at MIT, and re - -
measured at UM (comparison within 5 microns). measured at UM (comparison within 5 microns).
Monitoring: precision gauge blocks, and feeler gauge (for Monitoring: precision gauge blocks, and feeler gauge (for
each chamber). each chamber).
• • Measurements required: repeatable, redundant, easy operation Measurements required: repeatable, redundant, easy operation
June 1, 2000
UM Chamber production
Comb Alignment Measurement Using
Wire--Scope Technique
-10
-5
0
5
10
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 5 respect to wire position, sigma=3.8microns
-10
-5
0
5
10
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 3 respect to wire position, sigma=4.2microns
-10
-50510
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 62 respect to wire position, sigma=4.2microns
-10
-505
10
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 60 respect to wire position, sigma=4.9microns
June 1, 2000
UM Chamber production
Comb Alignment measurement Using
Laser Beam -- CCD Technique
-15
-10-5051015
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 1 respect to beam, sigma=7.7microns
-15
-10-50 51015
0 100 200 300 400
comb position (cm)
micron
Notch 15 respect to beam, sigma=4.8microns
-15
-10-50 51015
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 50 respect to beam, sigma=6.8microns
-15
-10-50 51015
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 62 respect to beam, sigma=5.3microns
June 1, 2000
UM Chamber production
Comb Alignment Using CCD Method
Notch 3
-15
-10-5051015
0 50 100 150 200 250 300 350 400
Comb Position (cm)
Wire position (um)
Notch 3
Notch 5
-10
-5
0510
15
0 50 100 150 200 250 300 350 400
Comb Position (cm)
Wire Position (um)
Notch 5
Notch 60
-15
-10-5051015
0 50 100 150 200 250 300 350 400
Comb Position (cm)
Wire Position (um)
Notch 60
Notch 62
-20
-15
-10
-5
0
510
15
20
0 50 100 150 200 250 300 350 400
comb Position (cm)
Wire Position (um)
Notch 62
June 1, 2000
UM Chamber production
Comb Height Measurement Using
Laser Beam -- CCD Technique
-20
-1001020
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 1 respect to beam, sigma=11.1microns
-20
-100
10
20
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 15 respect to beam, sigma=2.9microns
-20
-10010 20
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 50 respect to beam, sigma=4.8microns
-30
-20
-10
0
10
20
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 62 respect to beam, sigma=10.7microns
June 1, 2000
UM Chamber production
Comb Alignment measurement Using
Laser Beam -- CCD Technique
-15
-10-50
5
10
15
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 1 respect to beam, sigma=7.7microns
-15
-10
-5
0
5
10
15
0 100 200 300 400
comb position (cm)
micron
Notch 15 respect to beam, sigma=4.8microns
-15
-10-5
0
5 1015
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 50 respect to beam, sigma=6.8microns
-15
-10-50
5
10
15
0 50 100 150 200 250 300 350 400
comb position (cm)
micron
Notch 62 respect to beam, sigma=5.3microns
June 1, 2000
UM Chamber production
Integration of assembly tools Integration of assembly tools
1. 1. Construct and test the vacuum manifolds both for Construct and test the vacuum manifolds both for stiffback stiffback and for combs. and for combs.
Check & fix the vacuum leak for each individual section. Check & fix the vacuum leak for each individual section.
2. 2. Assemble the Assemble the stiffback stiffback panels on granite table by sucking the vacuum suction panels on granite table by sucking the vacuum suction
plates under vacuum to ensure the flatness of the plates. Each p plates under vacuum to ensure the flatness of the plates. Each p anel connected anel connected
to the lifting structure with 2 adjustable springs such that the to the lifting structure with 2 adjustable springs such that the relative positions of relative positions of
the panels are tunable. the panels are tunable.
3. 3. Mount two glue rails on the granite table in parallel (to 200 mi Mount two glue rails on the granite table in parallel (to 200 mi crons). And mount crons). And mount
the glue gantry to the rails with smooth motion along rails. the glue gantry to the rails with smooth motion along rails.
4. 4. Place 9 combs on the granite table, initially using a 2.4m long Place 9 combs on the granite table, initially using a 2.4m long parallel bar against parallel bar against
the rails, measure the 2 ‘crossing line’ lengths to the same wit the rails, measure the 2 ‘crossing line’ lengths to the same wit hin 1 mm. Hold hin 1 mm. Hold
down the H down the H - - blocks on the granite table, and engage the combs into the H blocks on the granite table, and engage the combs into the H - - blocks blocks
for fine tuning the comb alignment positions. for fine tuning the comb alignment positions.
5. 5. Measure and shim all the comb heights to 25 microns, then hold d Measure and shim all the comb heights to 25 microns, then hold d own combs on own combs on
the granite table. ( The angle comb heights should be 13 microns the granite table. ( The angle comb heights should be 13 microns lower.) lower.)
6. 6. Mount two 50 micron wires on the granite table, above the combs, Mount two 50 micron wires on the granite table, above the combs, parallel to the parallel to the
glue rails. Using micro glue rails. Using micro - - scope to view the comb V scope to view the comb V - - positions relative to the wire positions relative to the wire
positions. Using H positions. Using H - - blocks (with shims) to align the comb positions to 10 microns. blocks (with shims) to align the comb positions to 10 microns.
7. 7. Re Re - - check the comb height and the lateral positions using BCAL ( ‘la check the comb height and the lateral positions using BCAL ( ‘la ser wire’). ser wire’).
June 1, 2000
UM Chamber production
Integration of assembly tools Integration of assembly tools
8. 8. Mount the sphere blocks on granite table, check the level 1 heig Mount the sphere blocks on granite table, check the level 1 heig ht. ht.
9. 9. Shim the Shim the stiffback stiffback ‘sliders’ distances to match the sphere block height, such that ‘sliders’ distances to match the sphere block height, such that
the the stiffback stiffback vacuum suction plates are in the same plane, and all have correc vacuum suction plates are in the same plane, and all have correc t t
glue gaps between the plates and the first layer tubes. glue gaps between the plates and the first layer tubes.
10. 10. Tune the Tune the stiffback stiffback long AL side plates that connect all the 5 panels to ensure the long AL side plates that connect all the 5 panels to ensure the
‘origin’ corner of the ‘origin’ corner of the stiffback stiffback will touch the sphere first and the ‘axis’ corner of the will touch the sphere first and the ‘axis’ corner of the
stiffback stiffback will touch the sphere the 2 will touch the sphere the 2
nd nd
when lower down the when lower down the stiffback stiffback to sit on the to sit on the
sphere blocks. Pin the angle sphere blocks. Pin the angle stiffback stiffback panels to the long side plates to fix the panels to the long side plates to fix the
frame. frame.
11. 11. Measure the sphere block and Measure the sphere block and stiffback stiffback relative height and lateral shifting relative height and lateral shifting
positions for different level the the sphere block towers to ens positions for different level the the sphere block towers to ens ure the tube layer ure the tube layer
relative positions are correct in the assembly. relative positions are correct in the assembly.
12. 12. Assemble the spacer frame, and install / test the RASNIK in Assemble the spacer frame, and install / test the RASNIK in - - plane alignment plane alignment
system. system.
13. 13. Align the glue machine horizontal motion guiding disks to the tu Align the glue machine horizontal motion guiding disks to the tu bes that sucked bes that sucked
on the combs. Tune the nozzle positions, and pin the nozzles to on the combs. Tune the nozzle positions, and pin the nozzles to the glue heads. the glue heads.
14. 14. Glue machine dry run to check the glue pattern, and to test the Glue machine dry run to check the glue pattern, and to test the control programs. control programs.
15. 15. Practice runs: Practice runs: stiffback stiffback operations and glue two dummy tube layers exactly follow operations and glue two dummy tube layers exactly follow
the real operation procedures. the real operation procedures.
June 1, 2000
UM Chamber production
Start Module 0 Assembly Start Module 0 Assembly
• • Start the Module 0 assembly : May 22, 2000. Start the Module 0 assembly : May 22, 2000.
– – Check the comb alignment: good to 5 microns Check the comb alignment: good to 5 microns
– – Check the comb height: good to 8 microns Check the comb height: good to 8 microns
– – Check the sphere block positions: good to 5 Check the sphere block positions: good to 5 micons micons
• • Place the first layer of tubes on the combs by a clocking device Place the first layer of tubes on the combs by a clocking device , ,
and used the feeler gauges to check the endplug, and tube and used the feeler gauges to check the endplug, and tube
gaps. gaps.
• • Checked the endplug ‘planarity’: good to 7 microns. Checked the endplug ‘planarity’: good to 7 microns.
• • Glued the first layer tubes together Glued the first layer tubes together
• • Glued the aluminum plates (5) to the first layer Glued the aluminum plates (5) to the first layer
• • Measured the Measured the stiffback stiffback positions after the gluing. positions after the gluing.
All the operations went very smoothly! All the operations went very smoothly!
We will finish the module 0 construction by June 20, 2000. We will finish the module 0 construction by June 20, 2000.
June 1, 2000
UM Chamber production
Height Measurement of Tubes
on the Comb
1.65
1.71.751.8
1 11 21 31 41 51 61
Notch
Height (mm)
Height of Comb A1, sigma=7microns
1.65
1.71.751.8
1 11 21 31 41 51 61
Notch
Height (mm)
Height of Comb A2, sigma=10microns
June 1, 2000
UM Chamber production
Stiffback Stiffback Position Measurement Position Measurement
Lateral position (mm) Lateral position (mm)
SW NW SE NE SW NW SE NE
L1 L1 3.520 2.794 19.520 19.170 3.520 2.794 19.520 19.170
L2 L2 18.540 17.816 4.505 4.152 18.540 17.816 4.505 4.152
D D 15.020 15.022 15.015 15.018 15.020 15.022 15.015 15.018
Consistent with spec: 15.018 mm Consistent with spec: 15.018 mm
Height position (mm) Height position (mm)
L1 L1 179.951 180.642 180.068 179.436 179.951 180.642 180.068 179.436
L2 L2 205.977 206.657 206.070 205.455 205.977 206.657 206.070 205.455
D D 26.026 26.015 26.002 26.019 26.026 26.015 26.002 26.019
Consistent with spec: 26.012 mm Consistent with spec: 26.012 mm