1. S.Movchan Straw manufacturing and QC
Dubna status
Straw machines
Assembly halls and tooling
Presented by S.Movchan
1-May-18
S.Movchan Straw manufacturing and QC

2. Continuous straw fabrication Straw fabrication one by one
Common view
NEW machine
Continuous straw fabrication
Machine in operation
Straw fabrication one by one
ready
1-May-18
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3. S.Movchan Straw manufacturing and QC
Sonotrode + anvil
1-May-18
S.Movchan Straw manufacturing and QC 3

4. S.Movchan Straw manufacturing and QC
Round shape formation
by 4 rollers
1-May-18
S.Movchan Straw manufacturing and QC 4

5. Straw seam quality control
1-May-18
S.Movchan Straw manufacturing and QC 5

6. O-ring sample tensile test
Seam quality control
O-ring sample tensile test
Visual check
1-May-18
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7. Straw bar code + DB NA62 straw label: NA62TASTDU003525
NA62 – NA62 experiment
TA – Tracker
ST - straw
DU– JINR, Dubna, Russia
СE – CERN, Sefar, Swiss
– straw serial # ( )
1-May-18
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8. S.Movchan Straw manufacturing and QC
Plans
“Old” straw machine – READY for straw manufacture
(needed tape from CERN)
“NEW” straw machine:
Tuning – September
Tests and improvements September
(add on-line monitoring)
Machine certification end of September
- pre-production series: N=100 pc, September (1-2 days)
- send to CERN – 3 weeks
- tests a lot of straws at CERN – 2 weeks
- approval
Start of straw manufacture – October
1-May-18
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9. S.Movchan Straw manufacturing and QC
Dubna 806 straws
1-May-18
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10. Mass-production of 806 straws
1-May-18
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11. Straw machine parameters after sonotrode reparation:
(for straws with serial # ≥180)
clean room: T=+(21±1) degree, H=(70±5)%
some straw machine parameters:
sonotrode angle: about 20 degree
anvil diameter: 9.73 mm
fixture diameter: 9.90 mm
rollers position: right roller – 42/5 mm, left roller – 45/4 mm, gap – 18 mm
dust removing from anvil: ON
straw welding parameters:
ultrasonic generator: clock F=(39750±50) Hz, P = (60÷100) a.u. => about 60%
sonotrode head temperature: (27±1) degree (cooling ON)
ultrasonic head pressure to tape: 210 g
spool pretension: ( ) g
tape friction: (300÷400) g
manufacture speed: 7 mm/sec
1-May-18
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12. S.Movchan Straw manufacturing and QC
806 straws
Tapes number
Straw tubes
A1-9 58
A1-11 73
A1-17 62
A1-10 84
A1-12 77
A1-8 93
A1-18 96
A1-4 (300 m) 98
A1-2 (300 m)
100
A1-7 (180 m) 65
806
~90 straws/spool
1-May-18
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13. S.Movchan Straw manufacturing and QC
BLUE – straw start
RED – straw end
806 straws
Diameter
Elongation
Min =
1 mm
Resistance
Seam width
1-May-18
S.Movchan Straw manufacturing and QC 13

14. Load max F vs elongation dL: 3-D presentation
Dubna 806 straws N
Cut:
F≤3.7 kG
F (kG)
dL(mm)
1-May-18
S.Movchan Straw manufacturing and QC
Cut:
dL≤1 mm 14

15. Zoom of BAD region near “0”
7 straws
F=(0÷3.7)
dL=(0÷1) mm
8 straws N
F (kG)
dL(mm)
F=(3.7÷8)
dL=(0÷1) mm
F (kG)
dL(mm)
1-May-18
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16. dL > 1 mm @ Load max > 3.7 kG (for Dubna 806 straws)
Blue – start straw
Red – end straw
dL=1 mm
GOOD straws
F=3.7 kG
Total rejected straws
N=28+7 = 35 straws
Dubna straw rejection criteria: elongation dL ≤ 1 L ≤ 3.7 kG
Total rejected straws: N = 35 straws (~ 4 %)
and all good straws have elongation more than dL > 1 L > 3.7 kG
1-May-18
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17. S.Movchan Straw manufacturing and QC
Conclusion
Both CERN and Dubna proposed criteria for straw rejection were tested on
Dubna straws. Was shown that:
- rejection criteria Load max F ≤ 3.7 kG (Strength=100 Mpa) is wrong:
~ 1 % of straws (7 straws out from 800) have elongation less
than dL=1 mm
- rejection criteria dL < 1 mm is correct. Number of
rejected straws are N = 15 straws ( ~ 2 %)
- combine criteria dL < 1 Load max F < 3.7 kG was tested too.
Number of rejected straws are N = 35 straws ( ~ 4 %)
2 criteria and are tested and acceptable
Sefar straws:
Straw sample elongation was not fixed during tensile test. So, straw
rejection criteria can not be correctly tested. Elongation must be measure too.
wrogn
“soft”
“hard”
“soft”
“hard”
1-May-18
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18. S.Movchan Straw manufacturing and QC
Conclusion
Dubna 806 straws were manufactured (February-April 2011):
~ 20 straws/shift
~ 100 straws per spool (L=300 m). Efficiency of mylar tape used is about %
Straw parameters:
- diameter Dav = 9.78 mm
- sample elongation dLav= 7.0 mm (o-ring 5 mm width tensile test)
- visible ultrasonic track width Wav=0.725 mm
- resistance Rav=61.8 Ohm (L=2600 mm)
Straws rejection:
- out of parameter specification ~ 0.7% ( 6 straws)
- dL < 1 Load max F < 3.7 kG ~ 4.3% (35 straws)
(and data lost for 34 straws)
Dubna straw quality is adequate to NA62 requirements
1-May-18
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19. S.Movchan Straw manufacturing and QC
NA62 straw modules assembly site
1-May-18
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20. S.Movchan Straw manufacturing and QC
Bld. 217: common view
Entrance
gate
1-May-18
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21. Straw module 3 assembly halls
Frame
assembly
Vacuum test
Wiring
Connectivity
Gas tightness
HV test
Assembly
Area
Cosmic test
1-May-18
S.Movchan Straw manufacturing and QC 21

22. S.Movchan Straw manufacturing and QC
3 halls
Crane: 1.0 tone
height ~ 4.5 m
S ~ 150 m2
( 9 x m)
Condition system
S ~ 50 m2
( 5.4 x 9 m)
1-May-18
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23. Module assembly tooling Support frame + scaffolding
Module tilter
Delivery - 20 September
1-May-18
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24. Vacuum pump and pressure sensors for module tests
1-May-18
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25. S.Movchan Straw manufacturing and QC
Conclusion
Dubna NA62 straw modules assembly halls (S ~ 250 m2) – ready
Module assembly tooling delivery - 20 September
Module assembly tooling installation at hall – Sept.-Oct. 2011
Vacuum pump and pressure sensors – ok!
Vacuum table – tender started
Due to Module-0 assembly is in progress:
Manufacture straw assembly tooling – postpone
1-May-18
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