ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 1 Pixel Support Tube WBS Santa Cruz Cost Workshop July 9, 2003

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 2 Pixel Support Tube (PST) Overview PST Structure –3 Independent composite tubes –Joined together with bonded flanges –Mounted on specially designed flexures –Support detector insertion rails –Laminated with heater/EMI foils Key Cost Points –Actual expenditures match ETC03 estimates very well –ETC03 to ETC04 costs show substantial decrease Assumptions –Prototyping finishes Q4 of FY03 (almost finished now) –Production begins simultaneously in Q4 of FY03 –Remaining Prototype/Production time is staffed with MT (1/2 FTE) –All costs in FY03 $K

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 3 PST Deliverables 3 Composite tubes 6 Bonded composite flanges Full Length insertion rails Mount pads at forward and barrel (8 total) PST Supports (8 flexures) Pixel detector supports (kinematic, 4 total) Heaters and EMI shielding (continuous over length) All must be delivered by September - December ’04 SCT installation is ~Dec. ’04 Barrel mount pads are bonded using transfer jig from SCT (must be done during initial barrel assembly – about September ‘04) Full PST must be present at LBL for dry-fit (summer ’04) Installation work costed in separate installation plan

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 4 PST Key Structures – Barrel Tube Shell Hoop Stiffeners Mount Pads Mount blocks Insertion Rails Flanges

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 5 Shell Laminate with New Heater Panels

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 6 Full length rails

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 7 Mount Pads

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 8 Flanges Backing Ring Flange face Bonded and Drilled flange On PST shell

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 9 Bond Jig Barrel Length Bond jig Production jig setup for Prototype length PST shell

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 10 PST Production Mandrel Rotation Head Detail Autoclave Cart Shop Cart

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 11 FY03 Cost Tracking Prototype Budget shows under-spending –Rail tooling (which was moved to prototyping budget) completed at lower cost with simpler tools Production Budget shows over-spending –PST Mandrel costs increased to include additional carts and handling hardware Overall FY03 Budget is “on-track” so far

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 12 FY04 Costs

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 13 Key Cost Points Substantial Savings in Tooling and Fabrication –Rail designs simplified and tooling fabricated for reduced cost offsite (~20K savings) –Flange tooling simplified (26 parts reduced to 2) and fabricated onsite (~40K savings) Some budget “re-allocated” –Insertion mechanism (see next talk) sub-task created –About 25K from PST budget “moved” to insertion mechanism prototyping and production

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 14 Schedule Milestones - Slippage Production Readiness Review –February 18, 2003 Production Material Delivered –April 14, > May 25, 2003 Mandrel Delivered –May 1, > June 9, 2003 Production Begins –May 1, > August 1, 2003 Barrel PST Completed –September 14, 2003 –> December 1, 2003 Forward PST’s Completed –June 1, 2004 Pixel System Dry-fit (PST, BP Support, service panels, pixel frame) –July, 2004 – August, 2004 Fit-up with SCT (transfer jig bonded) –September, 2004 SCT/PST Installed –December, 2004 – January, 2005

ATLAS Pixel Detector July 2003 SC Pixel Meeting N. Hartman LBNL 15 Summary Current Status –All tooling currently fabricated except for hoop stiffener tool and rail bonding jig (hoop stiffener tool is in shop now) Prototyping –Must bond rails into prototype shell using rail bonding jig by end of FY03 Production –Plan to begin barrel shell production by August 1 (3 months late) Personnel –FY03 Require 1 FTE until FY04 (476 hours) –Research assistant (350 hours) and part of Mech Tech available –FY04 Require ½ FTE for all of FY04 (1032 hours) –Research assistant (550 hours) and part of Mech Tech available Budget –Current spending (FY03) is on-track with last cost estimate –Redesigns of fabrication tooling and processes have saved about 70K from budget – these can be used to offset increases in other mechanics areas (particularly insertion mechanism)