US CM EMU - FNAL Site G.Apollinari - Lyon Sep. `98

1. US CM EMU - FNAL Site G.Apollinari - Lyon Sep. `98 Status of the FNAL Site (also visit http://tdpc01.fnal.gov/uscmsemu) Chamber R&D Engineering Status Procurement Status Status of Setup of FNAL Site Factories Pre-Production Prototypes Schedule/Site Organization

2. Chamber Assembly Need: Evaluation of flatness Plane Gap Uniformity (+/- 12 mils) Dry Assembly of M234/2 Pro-production Prototype Test of Assembly Table Chamber Deflection in Horizontal & Vertical Position Effects on Plascore Specifications Wire Quality Luma vs. Sylvania just started, presentation on D0 gold flaking problem Panel Cleaning Machine Needs in progress Chambers R&D

3. Chambers R&D • Panels Measurements • Panels flat of a 5x10 granite table under their own weight • Measured bowing in the y (acceptable) and x (un-acceptable) directions

4. Chamber Sagging Final Assembly bottom panel straight (~5 mils) top panel sags (70 mils) Sagging - 5 mils - 50 mils - 70 mils - 72 mils Buttons - 76 mils - 40 mils Gap Bars Sag (~70 mils) Flat (to ~5 mils) Chambers R&D

5. Chamber Sagging Buttons-Gap Bars difference Sagging Button effect - 5 mils NA Gap Bar ( ~ 375-376 mils) - 50 mils - 20+/-5 mils ~ 378 mils - 70 mils - 40+/-5 mils Tape (~ 2 mils) - 20+/-5 mils - 72 mils - 40+/-5 mils - 76 mils - 40 mils NA Chambers R&D ~374 mils Still ~30 mils unexplained

6. Panel flipped over Chambers R&D • Panels Deformation • We believe the PLASCORE panels we are working with have a ~1/32” (20-30 mils) bow in the 5’ direction • String Measurements on free standing panels. • Laser Tracker measurements on granite table (see slide) • Under gravity, for a single panel sitting on the gap bars • Q: Which kind of force is a sagging panel exerting on the next lower panel through the button ? Sag (~0 mils) Sag (~40 mils)

7. Weight (Gravity) Fishing Scale Chambers R&D • Panels Deformation • Measured the displacement vs. force for a panel surface by pulling or pushing close to the button hole location (for both orientations of a panel). • For small displacements: ~ 1 lb./1 mil elastically • Q: Which kind of deformation do we have close to a button hole for forces of the order of 10-20 lb. ? • Instron Measurements at TD Material Lab

8. Chambers R&D • Grooves Depth • Issue • Avoid “skips” during the machining of the panels • Grooves of different depths are exposing approximately the same amount of G10 fibers • Panels with grooves of different depths have the same mechanical strength.

9. Engineering Status • Work in Progress • Tooling • Finalization of Carts Drawings and Assembly Tools • Gerber and Axxion transport cart • In-process Panel Trans. & Solder • Chamber assembly Table • Chamber Transport and RTV Gas Sealing Cart • Tooling Design for Plascore QA/QC • PLASCORE had no in-process QA capability • Release for Procurement of the Cosmic Test Stand • FNAL & FAST Sites

10. Engineering Status • Work in Progress • Chambers • M234/2 Drawings Check • Completed by V. Razmyslovich • Check and finalize Engineering Drawings & generate Bills of Material • Started Activity on IHEP. PNPI drawings expected by mid Oct. 98

11. Engineering Status • Goal • Engineering Drawings completed and released for ME234/2 by Dec. 98 • Plan • Receive Wisconsin frames drawings by end Sep. 98 • Integrate Chamber Frames in Oct. 98 • Ready to proceed for the release pending approval by L2. • Estimate 2-3 weeks for implementation of engineering changes • November EDR • Presentation of the current status, including all the information provided to FNAL

12. Procurement Status • Major/Critical Procurements • PLASCORE Panels • Requirements and Specifications Understood.. • Available Panels: • Fail our specs in a “single panel” measurements on a granite table. • Sagging problems in “gap bars constrained” configuration prevented us from measuring a 10 mils bowing over 2 feet. • the Receive Wisconsin frames drawings by end Sep. 98 • Visit to PLASCORE (Aug. 98): • PLASCORE has no tooling for QC. FNAL will provide it (~ Sep. ‘98) • PLASCORE identified 3 areas of possible improvements: • Core Cutting on 5 feet wide table • Core Thickness measurement • Control of the area of pressure on the Gluing Press • Will order 14 panels with the above-mentioned improvements

13. Procurement Status • Major/Critical Procurements • Wire • Specification writing based on D0 experience. • R&D on 1-2% Gold-Tg SYLVANIA wires. • R&D of flaking gold ? Which QC/QA does LUMA apply ? • Good QA Plane needed. • Panel Cleaning Machine • Impossible to do R&D on final chamber • Will make systematic measurements on interstrip resistance and water retention on sample panels.

14. Pre-Production Schedule • Pre-production Milestones • ME234/2 pre-production chamber ready Nov. 16 `98 • ME2/1 pre-production chamber ready Dec. 8 `98 • All pre-production chambers produced at MP9, with the final tooling and training the final assembly crew.

15. Pre-Production Schedule Example of List of Tasks (from schedule) for the Winder Setup • Thursday September 3, 1998 • Curtis Donner reassembles the electrical control of the winding machine. • Friday September 4, 1998 • John Korienek & Jon Blomquist setup the winding machine. • 50 (bad) mm wire in Jon’s possession • Oleg Prokofiev/Evgueni Borissov mount a panel for the test • Karen Kephart sets up the N2 pressure needed for the winding machine • Monday September 7, 1998 • Jon Blomquist winds a test panel • Oleg Prokofiev/Glenn Smith eye-witness the procedure • Week September 7-11, 1998 • Glenn Smith transfers all the panels the to MP9 • Glenn Smith transfers the Winding Machine to MP9 • Week September 14-16, 1998 • Glenn Smith, Evgeni Borissov, Kurtis Donner and Jon Blomquist setup the winding machine in MP9. • Sherry Harrold and Oleg Prokofiev wind a panel with bad wire, for a tension measurement by the Purdue people.

16. Site Organization • Team Organization • TD/PPD Agreement • essential for • tooling support • tooling engineering for foreign sites • Lab8, Lab 7 (PPD) and MP9(TD) interactions • Organization Structure

17. FNAL Sub-sites Lab 8 Gerber and Axxion Cutting MP9 Chamber Assembly Kit Preparation Lab 7 Cosmic Testing Chamber Repair Storage Need to be worked out Setup of FNAL Site Factories Production Flow

18. Lab 8 Axxion Machine Head Alignment problems (PPD) Gerber Machine Floor Plan Available No Panel Cleaning Machine in Lab 8 (for now !) Panel Handling Tooling(Deering) Purpose Great Lakes (FNAL demo) Anver ( being contacted) Plans and Discussions: Vendor and scheme choice by end-September PPD-TD Cost Sharing (i.e. Tooling vs. Building Modifications) Setup of FNAL Site Factories

19. MP9 20% of the building available to CMS-EMU All major mfg. tooling delivered to MP9 (winder excluded). Tooling setup in progress Clamping Table Oct. 98 Gluing Table to be assembled & fixed Solder Machine ready Wire Gluing Machine ready Ionized Cleaner ~ready Tension Measurement ready Clean Area ~ready Setup of FNAL Site Factories

20. MP9 Setup of FNAL Site Factories Wire Tension and Position Measurement Soldering Machine

21. MP9 Clamping and Gluing Tables Clean Area

22. MP9 Pictures actually taken in Lab 6 Setup of FNAL Site Factories Winding Machine: operational and ready to be moved

23. Lab 7 Setup of Cosmic Test Stand: space clearing floor modification space allocation Drawings Ready procurement for FNAL cost estimate for FAST sites Assembly by end-Oct. Setup of FNAL Site Factories

24. Setup of FNAL Site Factories Cosmic Stand Setup (FAST Sites)

25. Lyon Issues • Chamber Production • Start Chamber production after electronics finalization. • P4 ready for Summer ‘99, chamber production starting on Fall ‘99. • Engineering - FNAL Responsibilities • Project Engineering: definition of responsibilities between FNAL (production) and Wisconsin (Integration). • FNAL responsibilities for Foreign Sites. • EDR • Formal Reviewing ending with green light for production. • Wisconsin (Integration) organize preparation for EDR.