Field Quality Workshop - Components - F. Bertinelli 1 Workshop on Field Quality Steering of the Dipole Production CERN, 20-21 March 2003 Status and trends.

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Presentation transcript:

Field Quality Workshop - Components - F. Bertinelli 1 Workshop on Field Quality Steering of the Dipole Production CERN, March 2003 Status and trends of the various components affecting the Field Quality (20 minutes) F. Bertinelli AT/MAS

Field Quality Workshop - Components - F. Bertinelli 2 Components supplied 1/2 Contract no. ComponentSupplier% produced Kit 1F313Copper wedgesOutokumpu (FIN)27 Kit 2 F307 Austenitic steel for collars Nippon Steel (JP)39 F316 F317 Collars Malvestiti (IT) FUG/FSG (DE) 15 F386Cold bore tubesDMV (IT)39

Field Quality Workshop - Components - F. Bertinelli 3 Components supplied 2/2 ContractComponentSupplier% produced Kit 3 F245 Low-carbon steel for yoke laminations Cockerill (BE)40 F314 F315 Yoke laminations FUG/FSG (DE) ELAY (ES) 20 F312 Non-magnetic steel for end-yoke laminations Kawasaki Steel (JP)85 F319 F318 End-yoke laminations Malvestiti (IT) ELAY (ES) 20 F338ShellsButting (DE)11 F398End coversMetso (FIN)15 F389N-line tubesDMV (IT)57 F482Copper tubes (HET)Outokumpu (FIN)23 Heat Exchanger TubesCERN - EST8

Field Quality Workshop - Components - F. Bertinelli 4 Delivery plan per CMA

Field Quality Workshop - Components - F. Bertinelli 5 Nippon Steel: permeability

Field Quality Workshop - Components - F. Bertinelli 6 Copper wedges: 1/4 The symptom … … measurements at CERN …

Field Quality Workshop - Components - F. Bertinelli 7 Copper wedges: 2/4 Effect of drawing dye wear: approx mm Action: completely replaced the 4 extrusion and 4 drawing dyes with new ones Batch 14: produced Nov Batch 30: produced Sept. 2002

Field Quality Workshop - Components - F. Bertinelli 8 Copper wedges: 3/4 CERN and Outokumpu measurements

Field Quality Workshop - Components - F. Bertinelli 9 Copper wedges: 4/4 Outokumpu measurements: historical statistics

Field Quality Workshop - Components - F. Bertinelli 10 Collars: 3D measuring method

Field Quality Workshop - Components - F. Bertinelli 11 Collars: historical data Malvestiti process under control collar dimension within tolerance

Field Quality Workshop - Components - F. Bertinelli 12 Collars: historical data FUG-FSG FSG will supply the raw machine data to CERN (ASCII format) and CERN will process it

Field Quality Workshop - Components - F. Bertinelli 13 Collars: Smartscope measuring method Smartscope/Smartfit (Malvestiti) measurement of an FSG collar (batch 47, random selection) best fit of measured geometry w.r.t. nominal geometry results stable w.r.t. FSG tool approval (April 2001)

Field Quality Workshop - Components - F. Bertinelli 14 Collars: validation of 3D measuring methods probe geometry (strong dependance on cut quality) support and positioning of collar for measurement (?) selection of reference axes (?) format of results (e.g. geometrical tolerances)

Field Quality Workshop - Components - F. Bertinelli 15 Collars: cut quality

Field Quality Workshop - Components - F. Bertinelli 16 Collars: random sample vs acceptance values

Field Quality Workshop - Components - F. Bertinelli 17 Collars: repeatability of results

Field Quality Workshop - Components - F. Bertinelli 18 Collars: what next? “Trimicron” machine: not the solution for a better knowledge of collar geometry if necessary, obtain more knowledge using Smartscope, then use 3D to monitor stability of production follow-up the differences in measurement method try to reduce the uncertainty from ± 0.04 to ± 0.02 (is it worth it?)

Field Quality Workshop - Components - F. Bertinelli 19 Conclusions “ … We need to implement: –SPC quality control common for all contracts and reporting – a regular cross-check at CERN of measurements done by Suppliers (priority: collars, end covers, shells): i.e. an investment but extra costs –Check state of components stored since years …..” There is a real risk of “blindness from numbers”, i.e. rely too much on paperwork from Suppliers – risk of “routine” From November 2002 Magnet Review… Continue to improve quality of components (not only geometry…)