1. G.Barber Mice Tracker Mechanical Progress 04 06 1 Tracker Update Contents:- Components Station Layout Light Guide Map QA Patch Panel Alignment of Tracker Installation Procedure 3D Virtual Model Conclusions

2. G.Barber Mice Tracker Mechanical Progress 04 06 2 Stations Modifications to the Carbon Fibre The New station has had its outer diameter reduced to 396 to take into account the fact that the bore of the solenoid is not machined but a rolled tube. The connector flange has been thickened to 3mm to allow machining. This is to ensure that there is a uniform thickness thus ensuring that the completed tracker is ‘of one axis’ and all planes are parallel. Also the face that seats the connectors has a completely machined face to allow all of the connectors to sit down flat thus keeping the axis of the fibres perpendicular to the plane

3. G.Barber Mice Tracker Mechanical Progress 04 06 3 Station 4 Fabrication (Finished)

4. G.Barber Mice Tracker Mechanical Progress 04 06 4 Space Frame Modifications The components that are used to construct the space frame are similar to before with the exception of the locating foot and the diameter change. The foot was changed because of problems during assembly, if the dowel location was pushed into the foot there was no way to extricate it. The new foot has 2 smaller dowels either side of the structural tube. Old Foot DesignNew Foot Design Gluing Fillet Design

5. G.Barber Mice Tracker Mechanical Progress 04 06 5 Space Frame Tooling The jigs that align the space frames will need to be modified/re-made To accommodate the new foot design and also to match the new station to station pitch. This has been identified as a work package that can be given out to contract people and will be investigated

6. G.Barber Mice Tracker Mechanical Progress 04 06 6 Station Layout/Pitch The final pitch has still to be decided but the two alternatives shown are Top:- 15cm, 23cm, 25cm and 47cm Bottom:- 15cm, 25cm, 23cm and 47cm If this is the case the only need for a decision is to accommodate the length of wave guide and I’m sure we can accommodate a 2cm change in the lengths by making them the longest required. Still to be decided

7. G.Barber Mice Tracker Mechanical Progress 04 06 7 C14 C2 C3 C4 C5 C6 C7 C1 C13 C12 C11 C10 C9 C8 C15 C17 C29 C28 C27 C26 C25 C24 C30 C18 C19 C20 C21 C22 C23 C16 1 To 20 21 To 42 43 To 64 65 To 86 87 To 108 109 To 128 129 To 148 149 To 170 171 To 192 215 To 236 193 To 214 621 To 640 599 To 620 577 To 598 555 To 576 533 To 554 513 To 532 493 To 512 471 To 492 449 To 470 405 To 426 427 To 448 299 To 320 277 To 298 257 To 276 237 To 256 321 To 342 343 To 364 365 To 384 385 To 404 22 20 22 20 22 20 22 20 22 20 22 20 22 20 22 View ‘X’ 212 Channels View ‘V’ 214 Channels View ‘W’ 214 Channels Bulkhead Connector 1 Bulkhead Connector 3 Bulkhead Connector 4 Bulkhead Connector 2 Bulkhead Connector 5 View of the station onto the polished face of the connector Light Guide Map This is the final version, assuming no one finds any glaring mistakes, of the connector map for the tracker it can be found in its full form at http://www.hep.ph.ic.ac.uk/CAD/mice/finalmice

8. G.Barber Mice Tracker Mechanical Progress 04 06 8 Definition of Channel Numbers Channel 214 Channel 1 Channel 107 Channel 108 Channel 212 Channel 1 Channel 106 Channel 107 View from end of chuck looking at the connector end of the fibre ribbon Chuck with numbering for planes ‘V’ & ‘W’ View from end of chuck looking at the connector end of the fibre ribbon Chuck with numbering for planes ‘X’ Mylar Centre Fibre

9. G.Barber Mice Tracker Mechanical Progress 04 06 9 Connector 1 View ‘W’ 20 Way Bundles 1 – 20 To Bulkhead Connectors 1, 6, 11, 16 & 21 1 5 3 7 4 6 2 8910 11 13 12141516 18 17 x x 20 19 Station connector Viewed from the polished face. Internal light guide connector viewed from rear or fibre entry side.

10. G.Barber Mice Tracker Mechanical Progress 04 06 10 Internal Lightguides Station 1 C1 1 to 20 C2 21 to 42 C3 43 to 64 C4 65 to 86 C5 87 to 108 C6 109 to 128 C7 129 to 148 C8 149 to 170 C9 171 to 192 C10 193 to 214 C11 215 to 236 C12 237 to 256 C13 257 to 276 C14 277 to 298 C15 299 to 320 C16 321 to 342 C17 343 to 364 C18 365 to 384 Bulkhead 1 1 to 128 Bulkhead 3 257 to 384 Bulkhead 2 129 to 256 Length = XXXmm

11. G.Barber Mice Tracker Mechanical Progress 04 06 11 External Lightguides These are one to one connections between the external tracker bulkhead connector and the VLPC 128 way connectors. Bulkhead connector VLPC connector

12. G.Barber Mice Tracker Mechanical Progress 04 06 12 QA Due to the problem that has been highlighted by the connectors, more thought is required for the QA. One of the things we will be doing is to manufacture a ‘GO gauge’. This would be a block of very accurately positioned pins that match the hole pattern on the connector. If the connector and the block fit together then the holes in the connector are acceptable, if not it is discarded. Such a gauge could be given to the manufacturer so as to ensure consistent quality.

13. G.Barber Mice Tracker Mechanical Progress 04 06 13 Assembly Comb This is being manufactured in Liverpool from aluminium and will be tried with the existing fibre ribbon (at Brunel).

14. G.Barber Mice Tracker Mechanical Progress 04 06 14 Assembly/QA The diagram shows a scheme for assembling the stations layer by layer. After the fibres are ‘bundled’ into groups of 7 they are put into the comb in the correct sequence. The ribbon can then be ‘excited’ using an LED on a linear stage and we can ensure that the bundles light up in the correct order. When we are happy we can put the bundles into the connectors and we can scan again to ensure the correct bundle corresponds to the correct channel in the connector. The connectors can then be transferred to the station once it has been glued to the layer.

15. G.Barber Mice Tracker Mechanical Progress 04 06 15 Patch Panel Hole Requirements Detail Drawing almost complete

16. G.Barber Mice Tracker Mechanical Progress 04 06 16 Positioning In The Solenoid The tracker sits on 4 adjustable feet two at the front two at the rear and is held down by a spring loaded foot at the 12 o’clock position. This aligns the axis of both tracker and solenoid The tracker is aligned in Z and Phi by pulling a locating block into a Vee which is located using dowels to the patch panel.

17. G.Barber Mice Tracker Mechanical Progress 04 06 17 Tracker Adjustment The Diagram shows views and sections of the adjustable PTFE foot and its adjusting/locking tool. The PTFE foot, which rests on the bore of the solenoid, is eccentric and can be rotated by turning the green outer case that has a locating dog. Once adjusted it can be locked by turning the blue internal hex key.

18. G.Barber Mice Tracker Mechanical Progress 04 06 18 The Diffuser In The Solenoid The new device to hold and change the lead diffuser in the solenoid will be partially mounted onto the cover of the patch panel. The cover will need to be stiffened and tied back to the ‘solid’ region where the patch panel is mounted to the solenoid. We have allowed a bore of 331Ø in the cover with a series of holes and a position for an O-ring. The final details to be worked out with Wing & Stephanie

19. G.Barber Mice Tracker Mechanical Progress 04 06 19 Installation ‘Cartoon’ The following sequence is a first attempt to show the stages of installation of the tracker into the solenoid. They are not definitive and are aimed to provoke a debate/discussion. I hope that the installation will then evolve with all interested parties contributing. It should be noted that all of this work will need to take place in a ‘light controlled’ environment (NO UV).

20. G.Barber Mice Tracker Mechanical Progress 04 06 20 Stage 1 of Installation The patch panel is fitted and sealed to the solenoid. Hopefully at this stage we can test the seals using cover plates.

21. G.Barber Mice Tracker Mechanical Progress 04 06 21 Stage 2 of Installation A target module is fitted into the bore of the solenoid and the feet adjusted to set the cross hairs on the same axis as the solenoid bore. Then the Phi/Z retaining bracket is fitted and the whole assembly surveyed it is carefully removed to the CMM for measurement. (As Mike pointed out, this makes a good ‘Go Gauge).

22. G.Barber Mice Tracker Mechanical Progress 04 06 22 Stage 3 of Installation The target module is mounted onto the CMM (Computerised Measuring Machine), in a jig that simulates the bore of the solenoid. It is then surveyed.

23. G.Barber Mice Tracker Mechanical Progress 04 06 23 Stage 4 of Installation The tracker module is then mounted into the same jig on the CMM. Using the survey from the target module we can adjust the 4 support feet until the tracker shares the same axis as the target module.

24. G.Barber Mice Tracker Mechanical Progress 04 06 24 Stage 5 of Installation The tracker, complete with the light guide support structure is lifted onto the installation cradle. The light guide support structure is to ensure that no damaging forces are exerted on the fibres. Covers will be fitted during transit.

25. G.Barber Mice Tracker Mechanical Progress 04 06 25 Stage 6 of Installation The tracker is then slide into its pre-determined position inside the bore of the solenoid. This position will already have been determined using the ‘tracker target’ in stage 2.

26. G.Barber Mice Tracker Mechanical Progress 04 06 26 Recap of Positioning In The Solenoid The tracker sits on 4 adjustable feet two at the front two at the rear and is held down by a spring loaded foot at the 12 o’clock position. This aligns the axis of both tracker and solenoid The tracker is aligned in Z and Phi by pulling a locating block into a Vee which is located using dowels to the patch panel.

27. G.Barber Mice Tracker Mechanical Progress 04 06 27 Stage 7 of Installation With the tracker in position and secure the light guides can now be carefully re-routed to their final position in the patch panel and the seals fitted. If the external light guides are not to be attached immediately then light tight/protection covers will remain fitted.

28. G.Barber Mice Tracker Mechanical Progress 04 06 28 Stage 8 of Installation The light guides can then be secured to stop any damage and a shield (not shown) fitted to stop any damage occurring when the diffuser is installed. The Light guide support structure is now removed.

29. G.Barber Mice Tracker Mechanical Progress 04 06 29 Stage 9 of Installation The patch panel cover is fitted and sealed to the patch panel. If we are not ready to fit the diffuser mechanism then a cover plate will be attached. We can repeat the gas seal test at this point.

30. G.Barber Mice Tracker Mechanical Progress 04 06 30 Requirements (those thought of at least) To carry out the work we will need at least 2M of clear working area in front of the solenoid. We hope that this is achievable either by removing equipment in front of the solenoid or as is more likely, by moving the solenoid sideways out of the beamline. The solenoid and its kit would sit on a plinth and it would move as one. As already stated we will need this area to be light controlled, this will probably be achieved by building a tent structure over the area.

31. G.Barber Mice Tracker Mechanical Progress 04 06 31 Hall Probes The magnetic sensors can be fixed to a collar that will be attached to the bore of the solenoid. Because we do not want to drill the bore we will fit the probes to an expanding collar that can be slid into the bore and then by means of a taper clamp, expanded to lock it into position. This can be both up and down stream of the tracker

32. G.Barber Mice Tracker Mechanical Progress 04 06 32 Overall Layout (Land Grab) Because of the amount of equipment required to fit into the area and possible conflicts that this may cause it has been decided to ‘build’ a 3D virtual model of the region. Also we need to be sure that all of our fibres can be accommodated in the fibre length allowed so this model will be the first step in this process. We plan to eventually build a full size model of this region to convince ourselves that what we have designed is feasible. The patch panel, fibre run, trellis and VLPC unit have been modelled and the idea is (we hope) to ask Stephanie to ‘assemble’ all of the 3D modelled items into a master model based on Tony’s floor layout.

33. G.Barber Mice Tracker Mechanical Progress 04 06 33 Layout 1 st Attempt

34. G.Barber Mice Tracker Mechanical Progress 04 06 34 Layout 2nd Attempt This was an attempt to achieve a shorter fibre run. In actual fact it increased the longest run from 1884mm to over 2200mm

35. G.Barber Mice Tracker Mechanical Progress 04 06 35 Conclusions We have the design completed but for a few details and require a final set of engineering drawings. There is more work to be carried out on the layout and we hope to build a physical model to help.