Global%20Supports%20PRR

1
Global SupportsPRR

• W.O. Miller, R. Smith, W.K. Miller, R. Baer
• HYTEC
• G. Gilchriese, E. Anderssen, N. Hartman, F.
  Goozen
• LBNL

• Objectives
• Disk Ring Status
• Production Readiness of Frame Components

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Nomenclature
Center Frame Section (1)
Disks (6)
End Section (2)
Disk sectors (8)
Interior Barrel Layers (3)
Internal End Cone (2)
Disk Rings (6)
(B-Layer and Services not shown)
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Ring mount
Disk Support Ring
Ring
Sector cooling tubes
C-Channels 4 arc segments around the perimeter
8-sector disk
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Disk Ring Production

• Production Activities
• Mold Qualification Phase I
• Precision compression molded C-Channels
• Requires confirmation of cavity dimensions
• 2 outer and 2 inner C-Channels molded with
  YSH50/RS-3 cyanate ester resin
• 4 segments for the outer and 4 segments for the
  inner
• 1st Article Ring Qualification Phase II
• Presently inspecting graphite bonding fixture via
  CMM at LBNL
• Phase II activity will start in February 2002
• Production Progressing as Planned

• Development Ring Tested in Disk Frame Section
• Confirmed our approach
• Mounting approach
• Mounting precision
• Repeatability of mounts
• Frame/mount stiffness

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C-Channel Mold (Segment)
Silicone rubber forces the composite to conform
to the mold profilereversed the process from
before
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C-Channel Mold Trials
Typical Inspection Report for First Article

• Verification of
• critical dimensions
• Radii
• Toe-in
• In-grain twist
• Measurements taken as molded and after trimming

Edges to be trimmed Inner and outer radii and arc
length
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C-Channel Status

• Surface texture excellent
• Wall thickness well controlled
• Preliminary dimensional measurements look quite
  good- although this investigation is still
  proceeding
• C-Channel not completely trimmed, ½ moon cut-outs
  for the ring bushings left off
• Desired dimensional control in several areas 50
  to 130 microns (2 to 5mils)
• Dimensions are to be achieved after trimming one
  edge (radius) of the channel to the proper radius
  and two ends to form a 90 degree arc.
• Effect of mold strains
• Part cures at elevated temperature in Al mold
• Difference between as molded state and mold
  dimensions is evident
• Difference after trimming the radius is more
  pronounced
• More parts must be made to demonstrate
  consistency
• Results to date
• Insufficient data to suggest a change in mold
  radius is necessary
• Other dimensional features are quite good

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Global Support Frame PRR
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Global Supports-Readiness

• Tasks Completed
• Extensive design studies defining structural
  approach and material choices
• Prepared finite element model of complete system
• Static stiffness
• Dynamic stiffness (vibration)
• Torsional stiffness (insertion considerations)
• Prototyped Structures-(500mm diameter frame)
• Disk Frame Section
• End Cone
• Disk Support Ring and Mounts
• Conducted Individual Component and Integrated
  Tests
• Disk Support Ring with development sectors
• Disk Support Ring in Frame Section
• End Cone with Frame Section
• Completed CDR and FDR on all components
• Completed Production Drawings and Plans

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Topical Characteristics
Outer Frame

• Global Support Structure
• 2.85kg composite sandwich structure, fully
  assembled with detectors and services estimated
  to be 26.8kg
• K1392U fiber/EX1515 Byrte Technology resin and
  graphite fiber honeycomb for maximum frame
  stiffness
• Assembled by joining 3-subassemblies with self
  indexing features
• 2-Disk Sections
• 1-Barrel Section
• Interfaces Resolved
• End Cone to Barrel Shells (IVW)
• External mounts to Pixel Support Tube
• Space for Services routing and egress

Disk
End cone
End Plate
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Design Confirmation Studies

• Objectives
• Demonstrate ability to predict microstrains to
  level necessary for qualifying stable structures
• Confirm our predictions of static and dynamic
  stiffness
• Typical results
• Frame sag 12microns for 26.8kg
• Frame natural freq. 89Hz
• Torsional sag- 3pt supports 61?m
• Disk ring stiffness-1N load normal to ring
  1.66mm/N

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End Cone Prototype

• Salient construction points
• End Cone for 500mm frame design
• P30Carbon-carbon facings, 0.44mm
• XN50/cyanate ester graphite fiber honeycomb, 4mm
  thick
• YSH50 quasi-isotropic laminate for outer supports
  and inner tabs
• Static component tests
• Individually, as well as mounted on frame
  section(_at_LBNL)

White paint on short tab for holographic
measurements
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End Cone/Frame Test

• LBNL test results with end cone in place
• Axial load 1.125inch from end of long tab--
  15.4?m/N
• HYTEC end cone separately
• Axial load 1.125inch from end of long tab--
  16?m/N

Barrel section mounting tabs and dial indicator
measuring displacement
Note disk sector support ring
12 Sector Frame-500mm dia.
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Frame Procurement Steps
Now that prototype investigations and final
drawings have been completed

• Remaining tasks Leading to Release of Procurement
  Orders are
• Review and incorporate comments from PRR
• Finish detail drawing review
• Release drawings and post in EDMS
• Review letters of interest from prospective
  vendors
• Resolve any concerns about LBNL supplied tooling
• Procurement Orders
• Release Request For Quote (RFQ) to composite
  fabricators
• Release RFQ(s) for tooling
• Select composite fabricator(s) and tooling
  vendors
• Assembly and QC Plans
• Work with vendor (s) to produce a coordinated
  fabrication and assembly plan
• In process inspection at vendors and LBNL
• Posting of the final plan documents in EDMS
• Complete assembly and inspection at LBNL

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Schedule
Disk Support Ring and the Global Support
Components Delivery Schedule is doable, but tight