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KM3 design to cost

Mechanic optimization . KM3 design to cost. Design to cost. What is it and Why? Cost Models Approach Cost Analysis and Optimization Simple Mechanical Optimization Recovery System PM repartition (hypothesis) Embedded PM Data link. KM3 Design to cost. What and Why?.

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KM3 design to cost

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  1. Mechanic optimization KM3 design to cost Beurthey Stéphan/CPPM/IN2P3

  2. Beurthey Stéphan/CPPM/IN2P3 Design to cost • What is it and Why? • Cost Models Approach • Cost Analysis and Optimization • Simple Mechanical Optimization • Recovery System • PM repartition (hypothesis) • Embedded PM • Data link

  3. Beurthey Stéphan/CPPM/IN2P3 KM3 Design to cost What and Why?

  4. Beurthey Stéphan/CPPM/IN2P3 What is it? (design to cost) • Industrial approach: • Design is driven by the cost; • Design respect only requirements. Cost Analysis Interesting concept? yes Risk Analysis New Concept New Architecture no Requirement Analysis Concept rejected

  5. Beurthey Stéphan/CPPM/IN2P3 Why? The cheapest detector The biggest detector Cost reduction On known concept (ANTARES)

  6. Beurthey Stéphan/CPPM/IN2P3 KM3 Design to cost Cost Models Approach From the buoy to the Junction Box

  7. Field of work Buoy 30% of the global ANTARES cost cost reduction potential Sea operation system Structure (OMF) Cable Connectors Container (LCM,SPM) Release system Sphere (OM) Inter link BSS

  8. Cost dependences Detector Architecture PM repartition: 3, 6 PM/storey? Distance between storey: 12, 30m? Concept (Antares, Nemo, Nestor, …) Sea operation constraints: Deployment Connection Structure and Cable strength, … Sea constraints: Corrosion: Aluminium, Titanium, … Pressure, … Data transmission Copper, fibre, … Integration: connectors, penetrators, …? … Cost optmization needs interactions with others products

  9. Approach System approach: Cost reduction have impact on others products Cost models: Fast cost evaluation in function of the concept/design Iterate with data transmission, physics, sea operations, integration, … Cost model sensitive to: Material Design Spatial PM repartition Connectors/penetrators Data transmissions Electronics compacity Sea operation constraints Recovery Flotability …

  10. ANTARES cost ANTARES cost/line: 530k€ Cost on defined perimeter Beurthey Stéphan/CPPM/IN2P3

  11. Model Strategy Introduce sensitive parameters Parametric Models Fit these models with ANTARES cost Beurthey Stéphan/CPPM/IN2P3

  12. Beurthey Stéphan/CPPM/IN2P3 Mechanical models Machining cost Weight C_x=M_x. cmat + Cmachining Material cost Product cost Possibility of several materials/Part

  13. Weight r: density (4500 Ti) P: Pressure (250b) Re: tensile strength (900MPa Ti) Velec: electronic volume (16l) H: high of storey (2m) F: line traction resistance (18T) Flot: line floatability (1800Kg) Beurthey Stéphan/CPPM/IN2P3

  14. Machining cost Beurthey Stéphan/CPPM/IN2P3

  15. Manufactured product models PM model 1100€/PM PM is not included in this model Beurthey Stéphan/CPPM/IN2P3

  16. Manufactured product models Data link model Number of connexion cable cost (€/m) C_cable=L.ccable+Nconnec.cconnec Connection cost (connector or penetrator) link cost link length Possibility of different connections/Link Beurthey Stéphan/CPPM/IN2P3

  17. Cable cost Beurthey Stéphan/CPPM/IN2P3

  18. Connection cost Price of moulding is included *: Estimation Beurthey Stéphan/CPPM/IN2P3

  19. Mechanics Cost Analysis and Optimization KM3 design to cost Beurthey Stéphan/CPPM/IN2P3

  20. Simple Mechanical optmization • Ti  Al: -15k€ • LCM: • OMF: • Design improvement: -10k€ • -20% on OMF height: • -20% on flotability: • -20% on BSS weight: 2x if we use today Ti price K€ 22 30 23 30 K€ Cost reduction/line: -25k€ Small cost reduction (<5%) on constant perimeter Cost on defined perimeter System Approach Beurthey Stéphan/CPPM/IN2P3

  21. Release system cost • BSS release system: 5k€ • Release : 22K€ • IL connexion: 49k€ • (Boat recuperation: 30k€) Cost reduction/line: -76k€ (15%) (106k€ with boat) On defined perimeter Needs of this system/Line cost Low cost system? Beurthey Stéphan/CPPM/IN2P3

  22. PM repartition Influence • 6 PM/storey • 12 storeys • 28m between storey • 100m BSS/first storey • IL 500m • Same BSS/ANTARES • LCM, OMF: x2 bigger • 10 Water block Line with nearly the number of PM and length of ANTARES 67 116 • Data link • Sphere+supports 166 • LCM, SPM/SCM • OMF • BSS 33 • Release system 22 • Boy 16 • IL+connexion 108 Cost/line: 460k€ 25 35 30 23 -65k€ (15%)/ANTARES On defined perimeter Beurthey Stéphan/CPPM/IN2P3

  23. Embedded OM • 6 PM/storey • 12 storeys/line • 2 Embedded PM with LCM: • OM link: -1800€/storey • sphere: -1800€/storey • OM Support: -1500€/storey • Sphere machining: -? • LCM: -2000€/storey • Add Al torus of 20kg:+1000€/storey On defined perimeter • 6 PM/storey • 12 storeys -75k€/ligne (-15%) Beurthey Stéphan/CPPM/IN2P3

  24. Data link • 6 PM/storey • 12 storeys • 28m between storey • 100m BSS/first storey 25MHz/storey  2 fibers/2 power : 10k€ (4 cables:130+210+300+390 m) 8 Optical connections: 16k€ 7 pairs cable : 3k€ (30mx8 cables) 16 Connexions 3k€ (4 wires) 32k€/ligne (-38k€) Connector integration time reduce

  25. Coïncidence: 25kHz/storey 12 pairs cable 10k€ (500m) + 12 Breakout: 1,5k€ + 12 Connections 2,5k€ (4 wires) + 1 connection 0,5k€ (24 wires) Data link • 6 PM/storey • 12 storeys • 28m between storey • 100m BSS/first storey Twisted Copper Connector integration time reduce 15k€/ligne (-55k€)

  26. TiAl: 15k€ Design improvment: 10k€ Release system: 76k€ 6PM/storey: 65k€ Embedded PM: 75k€ Copper Data link: 55k€ ~300k€ • 6 PM/storey • 12 storeys • 28m between storey • 100m BSS/first storey Optimized Line ANTARES line cost: 530k€ New line cost: 240k€ -55% On defined perimeter

  27. One more step for optimization  cable <30mm Compact line Cost deployment reduction

  28. Conclusions: Optimization up to 50% with design to cost system approach “Well known” proposed solutions but risk analysis should be done (in progress) Iterations with physics, sea operation, data transmission and integration needed (in progress) Development cost should be taken into account Others optimization should be studied: Sea operation with compact line Oil IL (cheap connectors), Jumper IL take away

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