Gantry Module Assembly TOB

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Gantry Module AssemblyTOB TEC

• Dean White
• University of California, Santa Barbara

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Talk Overview

• Gantry Personnel
• New 5th floor clean room
• Gantry design
• Gantry module precision
• Gantry production capabilities
• Summary

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Gantry Module Assembly Personnel

• Technicians Andrea Allen
• David Staszak
• Post-doc Russel Taylor
• Engineers David Hale
• Dean White
• These are the key people in module assembly.
  They also are involved to greater and lesser
  degrees in other areas of module production.

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New 5th Floor Clean Room

• Reasons for new 5th floor clean room
• Temperature stability of /- 1deg C needed for
  gantry.
• Availability of Emergency Power.
• Future need of high-bay clean room for Rod
  Production

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New 5th Floor Clean Room

• Better than class 10,000 clean room.
• Main production room (5324) has new gasket sealed
  grid ceiling and lighting.
• Hard wall anteroom entrance added in room 5332.
• New compressed air drier, filters and clean
  copper piping was added in the building core to
  deliver clean/dry air to clean rooms.
• 45,000 of University funds were used for these
  improvements.

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Gantry Design

• BREIF DISCUSSION OF UCSB GANTRY AND MODUDE
  ASSEMBLY TOOLING

Gantry image recognition system and electronics.
Aerotech AGS 1000 gantry X,Y,Z U (rotational)
positioning system
Vacuum/Pressure control values
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Gantry Design Assembly Plates

• CERN style assembly plate

Laminated assembly plate Vacuum chuck plate PVC
support and vacuum posts
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Gantry Design Assembly Plates

• Vacuum chucks and vacuum transfer lines on
  gantry base plate

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Gantry Design Assembly Plates

• ASSEMBLY PLATE TEFLON PADS ARE MACHINED TO
  FINAL HEIGHTS (/- 25um) REFERENCED OFF OF FEET
  ON BOTTOM

Vacuum channels and o-ring grove machined into
assembly plate for each sensor
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Gantry Design Assembly Plates
Assembly plate feet that rest on vacuum chucks -
precision machined flat and parallel
Sensor vacuum Hybrid vacuum Hybrid supply
vacuum
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Gantry Design Assembly Tooling

• TOB / TEC HYBRID AND SENSOR PICK-UP TOOLS.

TOB HYBRID BRIDGE
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Gantry Design Assembled Modules

• 3 completed modules on the assembly plate.

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Gantry Precision - Sensors
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Gantry Precision - Hybrids
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Gantry Production Assembly Time

• Rough module assembly timeline using two people
  for producing 15 modules / day. (this probably
  could be increased for short periods, but over
  the long run it would be hard to do more than
  this in an 8 hour day)

Technician One 8-900 Survey modules, install
into carrier
plates for 5 plates (50 min) 9-945 Run
1st assembly plate (45 min) Break 10-1045 Run
2nd assembly plate 11-1145 Run 3rd assembly
plate 12-100 Lunch 1-145 Run 4th assembly
plate 2-245 Run 5th assembly plate Break 3-500 M
ake-up time for assemblies with
problems
Technician Two Load assembly plate, DB entry,
glue prep (50min) Prepare 2nd assembly
plate Prepare 3rd assembly plate Prepare 4th
assembly plate Prepare 5th assembly
plate Prepare parts for next days assembly
plates Receive parts, DB transfers, maintenance,
etc.
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Gantry Production Capabilities TOB

• 5 TOB R-phi assembly plates commissioned during
  2003
• 1 TOB Stereo assembly plate commissioned during
  2003

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Gantry Production Capabilities TEC

• 1 TEC R6 assembly plate fully commissioned
  (designed and built over the last 2 months of
  2003).
• Part of new responsibilities for TEC module
  assembly at UCSB.

TEC hybrid tool
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Gantry Production Capabilities Additional
Assembly Plates

• 10 more module assembly plates in different
  stages of design and construction
• 2 more TOB R-phi plates dwgs are in the Physics
  machine shop
• 2 more TOB stereo plates dwgs are in the
  Physics machine shop
• 2 more TEC R6 plates dwgs are in the Physics
  machine shop
• 2 TEC R5N plates design in progress
• 2 TEC R5S (stereo) design in progress
• These 10 plates the 7existing plates will give
  us the capability to build 2750 TOB and
  1000-2000 TEC modules (R6, R5N R5S) at UCSB.
• Switching between assembly plate types is easily,
  so modules can be built from whatever parts that
  are available.

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Summary

• During 2003
• New 5th floor clean room installed
• Production of TOB and TEC modules, that are will
  within specification, has been accomplished on
  the UCSB gantry.
• New assembly plate design developed here at UCSB.
• 79 modules assembled on gantry.
• Fabrication of multiple assembly plates of
  modules/day (4) has been demonstrated.
• Gantry team is ready for 150 module production
  run over 2 weeks that will begin the last week of
  January 2004.