Beurthey Stéphan/CPPM/IN2P3 16/04/07 KM3 design to cost Mechanic optimization

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Design to cost What is it and Why? What is it and Why? Cost Models Approach Cost Models Approach Cost Analysis and Optimization Cost Analysis and Optimization Simple Mechanical Optimization Simple Mechanical Optimization Recovery System Recovery System PM repartition (hypothesis) PM repartition (hypothesis) Embedded PM Embedded PM Data link Data link

Beurthey Stéphan/CPPM/IN2P3 16/04/07 KM3 Design to cost What and Why?

Beurthey Stéphan/CPPM/IN2P3 16/04/07 What is it? (design to cost) Industrial approach: Industrial approach: Design is driven by the cost; Design is driven by the cost; Design respect only requirements. Design respect only requirements. New Concept New Architecture Requirement Analysis Risk Analysis Interesting concept? no Concept rejected Cost Analysis yes

Beurthey Stéphan/CPPM/IN2P3 16/04/07Why? The biggest detector Cost reduction On known concept (ANTARES) The cheapest detector

Beurthey Stéphan/CPPM/IN2P3 16/04/07 KM3 Design to cost Cost Models Approach From the buoy to the Junction Box

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Container (LCM,SPM) Cable Connectors Structure (OMF) BSS Buoy Release system Sphere (OM) Sea operation system Inter link Field of work 30% of the global ANTARES cost cost reduction potential

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Cost dependences Detector Architecture Detector Architecture PM repartition: 3, 6 PM/storey? PM repartition: 3, 6 PM/storey? Distance between storey: 12, 30m? Distance between storey: 12, 30m? Concept (Antares, Nemo, Nestor, …) Concept (Antares, Nemo, Nestor, …) Sea operation constraints: Sea operation constraints: Deployment Deployment Connection Connection Structure and Cable strength, … Structure and Cable strength, … Sea constraints: Sea constraints: Corrosion: Aluminium, Titanium, … Corrosion: Aluminium, Titanium, … Pressure, … Pressure, … Data transmission Data transmission Copper, fibre, … Copper, fibre, … Integration: Integration: connectors, penetrators, …? connectors, penetrators, …? … Cost optmization needs interactions with others products

Beurthey Stéphan/CPPM/IN2P3 16/04/07Approach System approach: System approach: Cost reduction have impact on others products Cost reduction have impact on others products Cost models: Cost models: Fast cost evaluation in function of the concept/design Fast cost evaluation in function of the concept/design Iterate with data transmission, physics, sea operations, integration, … Iterate with data transmission, physics, sea operations, integration, … Cost model sensitive to: Cost model sensitive to:  Material  Design  Spatial PM repartition  Connectors/penetrators  Data transmissions  Electronics compacity  Sea operation constraints  Recovery  Flotability …

Beurthey Stéphan/CPPM/IN2P3 16/04/07 ANTARES cost Part Cost (€) Cost/line OM support OM Link Sphère+Base LCM OMF SPM Buoy system BSS Release system IL+ Conn. +jumper EMC cable/line ANTARES cost/line: 530k€ Cost on defined perimeter

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Model Strategy Introduce sensitive parameters Parametric Models Fit these models with ANTARES cost

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Mechanical models C _x= M _x. c mat + C machiningM _xC machining Product cost Weight Machining cost Ti75€/kg Fe6€/kg PE10€/kg Material cost Possibility of several materials/Part

Beurthey Stéphan/CPPM/IN2P3 16/04/07Weight  : density (4500 Ti) P: Pressure (250b) R e : tensile strength (900MPa Ti) V elec : electronic volume (16l) H: high of storey (2m) F: line traction resistance (18T) F lot : line floatability (1800Kg) PartsFormula ANTARES (Kg) LCM ~ .V elec.P/R e 16 OMF ~ .F.H/R e 16 BSS Titanium 2525 BSS Steel ~(F lot +800) 2600 BSS PE (release system) 2525 OM support (Ti) 22 Cable fixation (Ti) Buoy fixation 1616

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Machining cost Part Machinning Cost (€) LCM400 OMF500 BSS15000 OM Support 70 Other 1/3.M _X.c mat

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Manufactured product models PM model PM parts € Base140 Base supports 20 Glass sphere 600 Magnetic shield 160 Gel80 OM Assembly / testing 70 Connector base €/PM PM is not included in this model

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Manufactured product models Data link model C _cable =L.c cable +N connec.c conne c c cablec conne c cablec conne c link cost link length Number of connexion Connection cost (connector or penetrator) cable cost (€/m) Possibility of different connections/Link

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Cable type €/m ANTARES EMC (21 fibers,2 power) 33 ANTARES IL (7 fibers,2 power) 20 ANTARES OM link twisted pairs 0.5mm twisted pairs 0.5mm twisted pairs 0.5mm power 1mm fibres 10 Cable cost

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Connection cost Connexion type € ANTARES EMC penetrator 1100 ANTARES EMC water block 2700 ANTARES IL link connector+base ANTARES OM link Titanium connector+base 700 ANTARES OM link Ti penetrator twisted pairs connector+base twisted pairs connector+base 200 (2 power + 2 fibers) connector+base 2000 Break out on twisted copper cable 100 *: Estimation Price of moulding is included

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Mechanics Cost Analysis and Optimization KM3 design to cost

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Simple Mechanical optmization Ti  Al: -15k€ Ti  Al: -15k€ LCM: LCM: OMF: OMF: Design improvement: -10k€ Design improvement: -10k€ -20% on OMF height: -20% on OMF height: -20% on flotability: -20% on flotability: -20% on BSS weight: -20% on BSS weight: Cost reduction/line: -25k€ Small cost reduction (<5%) on constant perimeter System Approach Cost on defined perimeter 30  22  23 K€ 2x if we use today Ti price

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Release system cost BSS release system: 5k€ BSS release system: 5k€ Release : 22K€ Release : 22K€ IL connexion: 49k€ IL connexion: 49k€ (Boat recuperation: 30k€) (Boat recuperation: 30k€) Needs of this system/Line cost Low cost system? Cost reduction/line: -76k€ (15%) (106k€ with boat) On defined perimeter

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Data link Data link Sphere+supports166 Sphere+supports166 LCM, SPM/SCM LCM, SPM/SCM OMF OMF BSS33 BSS33 Release system22 Release system22 Boy16 Boy16 IL+connexion108 IL+connexion108 PM repartition Influence 6 PM/storey 6 PM/storey 12 storeys 12 storeys 28m between storey 28m between storey 100m BSS/first storey 100m BSS/first storey IL 500m IL 500m Same BSS/ANTARES Same BSS/ANTARES LCM, OMF: x2 bigger LCM, OMF: x2 bigger 10 Water block 10 Water block Cost/line: 460k€ -65k€ (15%) /ANTARES Line with nearly the number of PM and length of ANTARES On defined perimeter

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Embedded OM 2 Embedded PM with LCM: 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 6 PM/storey 6 PM/storey 12 storeys 12 storeys -75k€/ligne (-15%) 6 PM/storey 6 PM/storey 12 storeys/line 12 storeys/line On defined perimeter

Beurthey Stéphan/CPPM/IN2P3 16/04/07 25MHz/storey  2 fibers/2 power :10k€ (4 cables: m) 8 Optical connections: 16k€ 7 pairs cable : 3k€ (30mx8 cables) 16 Connexions 3k€ (4 wires) 32k€/ligne (-38k€) Data link 6 PM/storey 6 PM/storey 12 storeys 12 storeys 28m between storey 28m between storey 100m BSS/first storey 100m BSS/first storey Cable type € ANTARES OM link Ti penetrator twisted pairs connector+base twisted pairs connector+base 200 (2 power + 2 fibers) connector+base 2000 Break out on twisted copper cable 100 Cable type €/m 21 twisted pairs 0.5mm twisted pairs 0.5mm twisted pairs 0.5mm power 1mm fibres 10 Connector  integration time reduce

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Coïncidence: 25kHz/storey 12 pairs cable 10k€ (500m) + 12 Breakout: 1,5k€ + 12 Connections 2,5k€ (4 wires) + 1 connection 0,5k€ (24 wires) 15k€/ligne (-55k€) Data link 6 PM/storey 6 PM/storey 12 storeys 12 storeys Twisted Copper 28m between storey 28m between storey 100m BSS/first storey 100m BSS/first storey Cable type € ANTARES OM link Ti penetrator twisted pairs connector+base twisted pairs connector+base 200 (2 power + 2 fibers) connector+base 2000 Break out on twisted copper cable 100 Cable type €/m 21 twisted pairs 0.5mm twisted pairs 0.5mm twisted pairs 0.5mm power 1mm fibres 10 Connector  integration time reduce

Beurthey Stéphan/CPPM/IN2P3 16/04/07 Optimized Line Ti  Al: 15k€ Design improvment:10k€ Release system:76k€ 6PM/storey:65k€ Embedded PM:75k€ Copper Data link:55k€ ~300k€ ANTARES line cost: 530k€ New line cost: 240k€ -55% 6 PM/storey 6 PM/storey 12 storeys 12 storeys 28m between storey 28m between storey 100m BSS/first storey 100m BSS/first storey On defined perimeter

Beurthey Stéphan/CPPM/IN2P3 16/04/07 One more step for optimization Cost deployment reduction Compact line  cable <30mm

Beurthey Stéphan/CPPM/IN2P3 16/04/07Conclusions: Optimization up to 50% with design to cost system approach Optimization up to 50% with design to cost system approach “Well known” proposed solutions but risk analysis should be done (in progress) “Well known” proposed solutions but risk analysis should be done (in progress) Iterations with physics, sea operation, data transmission and integration needed (in progress) Iterations with physics, sea operation, data transmission and integration needed (in progress) Development cost should be taken into account Development cost should be taken into account Others optimization should be studied: Others optimization should be studied:  Sea operation with compact line  Oil IL (cheap connectors), Jumper IL take away