WP9 ITS Mechanics and Cooling

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WP9 ITS Mechanics and CoolingCorrado Gargiulo

12 March 2014

1. Finalization of IB and OB layout

2. IB QM design: Space Frame +Cold Plate, End-Wheel, Cylindrical Structural Shell

3. IB BARREL QM production based on “pad chips”

4. OB QM design: Space Frame, Cold Plate

5. OB STAVE QM production based on “pad chips”

ITS objectives for 2014 – WP9

EM Engineering Module, Qualification Module (final quality)

BP outer radius 19

Layer 0 mean radius 23.38

Layer 0 inner boundary >21.8

Middle Layer radius TDR6 / TDR7

Stave width 15+1 (FPC)

Stave length (cold plate) IL 320 (4th IB layer)

IL 290=9.6+270.8+9.6

ML 870= 14.85+840.3+14.85 1066

OL 1502=15.7+1470.6+15.7

(TDR, endorsed)1. Finalization of IB and OB layout Detectors boundary radius@ >21.8mm

Beam Pipe NEW DESIGN 19mm OR

Submitted to LEB commitee for approval

R 19,0

Gap >2.8 mm No change in the ITS layers radius (TDR)

ITS VS BP

Baseline

Simulation results by the end of March

ITS Outer Barrel

Flex Printed Circuit

9 PIXEL Chip

Cold Plate

Spaceframe

Inner layer stave 300mm length, 1.6 gram weight

Polyimide tubes ID 1.024mm; wall thickness 25 micron

Inner Barrel

IB Carbon spaceframe

o Stiffness test sag <10 µm

o Thermoelastic test on going

DEVELOPMENT TEST on EM (Engineering Module)o Thermal test OK

o Vibrational test >100Hz

167 Hz

status

o Dimensional next

o Production of new spaceframe with high dimensional accuracy new moulds under production

PRODUCTION QM (FINAL QUALITY)

o Production of full barrel (48 staves)

on going

(30µ)

Alternative option under investigation to further improve stiffness and thermo-elastic stabilityChange of Carbon fleece with K13D2U(same weight)

EM IB Carbon spaceframe

Carbon paper

K13D2U

QM IB Connectors

DESIGNo 3D, 2D production drawings OK……need validation fro WP6, needs additional considerations on survey strategy

status

nextPRODUCTIONo 100 CONNECTORSo Design and Production of assembly jig, to glue the connector to the spaceframe

Deisgn modified respect to TDR to increase accuracy

provide staves position accuracy

QM IB production Spaceframe+Coldpalte n.48 2014 JULY

Tentative schedule

QM IB End-Wheels

DESIGNo 3d, OK…

nextDESIGNo Design and Production of molds for layer assembly

status

…need further consideration on cable and piping routing

15From Antonello & Antoine

QM IB End-Wheels

QM IB CYlindrical Support Structure

DESIGNo 3d, OK…

nextDESIGNo Design and Production of molds

status

…needs further consideration on survey targets locations and interface with Service Barrel

QM IB production End-Wheels and CYSS 2014 SEPTEMBER

Production site Bldg 167 new

… ongoing

CERN GS HSEMaterial HazardFire extinguisher

CERN electrical inspection

Ventillation system installation 90m2 clean environment, 18-23°C, 50% humidity

Almost there!

YannickSamuelEvgeny &Viktor

Outer Barrel

DEVELOPMENT TESTo Bending test &FEA sag ≈95µm

o Thermal (150 and 300 mW/cm2), hydraulic test Oko Thermal test on full length coldplate next

o Vibrational test 1st freq=51Hz; dynamic response ongoing

o Thermoelastic test αexp ~ 12 x 10-6 K-

On spaceframe (Carbon fiber K13 D2U)

On coldpalte

Outer Barrel stave

o Production of 1 SPACEFRAME+ 2COLDPLATESo Production of EMs

PRODUCTION QM (FINAL QUALITY)

status

on goingo Improve stave stiffness Full k13 spaceframe has shown to be too brittle N.2 Produced and tested, spaceframe M55j baseline N.2 Produced and tested, spaceframe M55j with additional layer N.2 Produced and tested, spaceframe M55j with two layers

K13D2U(embedded)

EM OB Carbon spaceframe

0 40 80 120 160 200 2400

M55J +M55J+K13

sag [mm]

0 25 50 75 100 125 150

Lumped mass (test)

Distributed mass (derived from test)

3 point bending test results

Confirmed previous test

70/45µm

ID=2.67mm, wt=0.065mm

ID=2.00mm;wt=0.032mm

o Option b) Alternative option under investigation to further improve stiffness and thermo-elastic stability

Mould modified (for ID 2mm), Grenoble New 2mm ID pipes arrived K13 from Berkley arrived

o Production of 1 cold plate 1,5m/ID=2mm/option-ao Production of 1 cold plate 1,5m/ID=2mm/option-bo Production of 1 cold plate 300mm for thermal test

for both option a and b

o Option a) Baseline

on goingEM OB Coldplate

SpaceframeQM OB Spaceframe CONNECTOR new design

New design

TDR baseline

Removed spring connection between stave and end-wheels

Ruby sphere

Reference Plane on the End-Wheels

SpringSpring

DESIGNo EM 3D, 2D production drawings

OK… … need to be validated by WP7,8 and by test

status

nextPRODUCTIONo 20 CONNECTORSo Design and Production of assembly jig needed to glue the connector to the spaceframe

QM OB Spaceframe CONNECTOR revised design

DESIGNo 3d, 2D production drawings OK……needs validation by WP7,8

status

QM OB Cold Plate CONNECTOR

PRODUCTIONo 20 CONNECTORSo Design and Production of assembly jig, to glue the connector to the spaceframe

EM OB End-Wheels

DESIGNo EM 3d model proposal

status

nextDESIGNo EM 3D design

Definition of cooling modularity and cooling scheme

Definition of electrical and hydraulic connection layout

DC-DC converter mechanics and cooling

EM OB End-Wheels

P. Kuijer 2014-3-11

ALI-UPGRADE 3D CAD MODEL overall 3D CAD MODEL available on CERN ITS UPGRADE CAD REPOSITORY

R1_20140311

EM Inner stave & Outer stave -optimize carbon plies lay-up

QM Inner stave & QM Outer stave

-freeze connector design and start production-develop jigs for connector to spaceframe gluing

WP9 ITS Mechanics and Cooling

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