1. Takashi Matsushita t.matsushita@imperial.ac.uk Imperial College T. Matsushita 1 Engineering (Mechanical) Geoff Barber

2. T. Matsushita 2 Contents Station assembly Tracker assembly Installation Patch-panel Installation procedure Infrastructure/Operation Gas system Helium/vacuum window Summary

3. T. Matsushita 3 Station assembly We already have built four stations for a prototype tracker module We learned a lot from this experience as well as from the KEK test beam results We will incorporate quality assurance steps to station assembly procedure to eliminate source of problems for light-loss and fibre mapping In the following slides, station assembly procedure for the production of stations is explained step by step

4. T. Matsushita 4 Station assembly - sequence Receive doublet-layers from FNAL Visual inspection of the doublet-layers for any damage caused in transit Align the doublet-layers on a vacuum chuck Bundle seven fibres with rubber sleeves (QA) Thread the bundle into a station connector (QA) Put the vacuum chuck on an assembly jig Fix a carbon-fibre station to the assembly jig Glue the doublet-layers to carbon-fibre station Attach doublet-layers connectors to the carbon-fibre station Cut the fibres Pot the fibres Polish the fibres

5. T. Matsushita 5 Station assembly - tools Station holder Bundling Comb Connectorisation bridge Vacuum chuck Alignment jig

6. T. Matsushita 6 Unique numbering scheme defined to make sure correct fibre mapping Start bundling from the “centre fibre”, marked during doublet-layer manufacturing QA procedure ensures correct bundling with “comb” Station assembly - numbering 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

7. T. Matsushita 7 Station assembly - bundling Align doublet-layer on vacuum chuck “comb” to help identify error during bundling is being manufactured at Liverpool with aluminium Bundling procedure with “comb” will be established with the existing fibre ribbon

8. T. Matsushita 8 View ‘W’ 20 Way Bundles 1 – 20 To Bulkhead Connectors 1, 6, 11, 16 & 21 1 5 3 7 4 6 2 8 9 10 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. Bundle is threaded into the correct hole in the connector on “bridge” QA ensures correct threading; procedure to be defined Station assembly - connector QA gauge

9. T. Matsushita 9 Put the vacuum chuck on an assembly jig Fix a carbon-fibre station to the assembly jig Glue doublet-layer to carbon- fibre station Connectors on “bridge” is attached to the correct position Cut fibres Pot fibres Polish fibres Station assembly – final steps View of the station onto the polished face of the connector

10. T. Matsushita 10 Station assembly - prototype

11. T. Matsushita 11 We have built four stations. The fourth station design was improved by the experience gained during the three stations assembly. We have identified the source of problems to be fixed by the KEK test beam; connector hole alignment, fibre bundling and fibre connectorisation QA procedures will rectify the problems during station assembly, see Paul’s talk We will build the fifth station with the improved assembly procedure which incorporates QA We will be ready to produce the stations soon. TODO: Establish QA procedures with “comb” and “bridge”, see Paul’s talk Station assembly - summary

12. T. Matsushita 12 We have built a tracker prototype with four stations Assembly scheme for the prototype will be used for the three production version of tracker modules with five stations Before starting assembly we need to fix the station spacing, see Malcolm’s talk Tracker assembly

13. T. Matsushita 13 Space frame between stations connects two stations together Barrel Gluing fillet Structural tube Locating foot Foot design improved from prototype Tracker assembly - space frame I

14. T. Matsushita 14 These are the parts used for the prototype Close up view of the space frame feet and structural tubes Tracker assembly - space frame II

15. T. Matsushita 15 These are jigs used for the prototype assembly Jigs to be made after fixing station spacing Could be outsourced, the possibility will be investigated Tracker assembly - jigs

16. T. Matsushita 16 Channel map for station 1 Length of the light-guide to be determined after fixing the station spacing 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 Station end Patch-panel end Tracker assembly - light-guide

17. T. Matsushita 17 Four stations prototype without light-guides Equipped with light-guides We will build three more trackers; one for spare Tracker assembly - prototype

18. T. Matsushita 18 Tracker assembly - summary We have built a tracker prototype with four stations Assembly tools and scheme for the prototype will be used for the production version TODO: fix the station spacing, see Malcolm’s talk

19. T. Matsushita 19 Installation We need to install the tracker module inside the bore of the solenoid module Damages to the tracker during the installation procedure should be prevented In the following slides, patch-panel and installation procedure is explained step by step

20. T. Matsushita 20 Works as a fan-out for light-guides Gas-tight with O-ring to contain He 25 holes for fibre connectors 1 hole for hall probe field monitoring service Installation – patch-panel

21. T. Matsushita 21 Installation – pp and diffuser 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 Responsibilities allocated Need to finalise detailed design Detail Drawing almost complete

22. T. Matsushita 22 External light-guide makes one to one connections between the patch-panel connector and the VLPC 128 way connectors. O-ring incorporated to ensure a gas seal Length of the external light-guide to be fixed with a full-size mock-up Installation – pp & ext. light-guide Patch-panel connector VLPC connector

23. T. Matsushita 23 Installation – Hall-probe mount Hall-probe 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 The position will be locked by means of a taper clamp to expand the collar Need to finalise detailed design

24. T. Matsushita 24 Installation - sequence The following slides shows a first attempt of installation stages of the tracker into the solenoid Serve as a basis for a debate/discussion The installation procedure will be evolved by all interested parties It should be noted that all of this work will need to take place in a “light- controlled” environment, no ultra-violet light to avoid damage on scintillating fibres

25. T. Matsushita 25 Installation - requirements To carry out the installation 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 beam line 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 We think this is better than having a lock mechanism for the lights in the MICE-hall, since other parties can work at the same time, less scheduling headache

26. T. Matsushita 26 Installation – stage 1 The patch-panel is fitted and sealed to the solenoid Hope to test the seals using cover plates at this stage

27. T. Matsushita 27 Installation – stage 2 1. Alignment jig is fitted into the bore of the solenoid 2. feet are adjusted to set the cross hairs on the same axis as the solenoid bore 3. azimuthal/z retaining bracket is fitted 4. whole assembly surveyed The alignment jig works as a ‘Go-gauge’ for the final installation

28. T. Matsushita 28 Installation – tracker adjustment PTFE foot, which rests on the bore of the solenoid, is eccentric PTFE foot 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 Views and sections of the adjustable PTFE foot and its adjusting/locking tool

29. T. Matsushita 29 Installation – tracker positioning The tracker module sits on 4 adjustable feet; two at the front, two at the rear The tracker module is held down by a sprint loaded foot at the 12 o’clock position These foot aligns the axis of both tracker and solenoid The tracker module is aligned in z and azimuth by pulling a locating block into a Vee, which is located using dowels to the patch panel

30. T. Matsushita 30 The alignment jig is mounted onto the CMM* in a jig that simulates the bore of the solenoid The alignment jig is surveyed CMM*: Computerised Measuring Machine Installation – stage 3

31. T. Matsushita 31 Installation – stage 4 The tracker module is mounted on the same jig With the survey from the alignment jig, adjust the 4 support feet till the same axis as the alignment jig

32. T. Matsushita 32 Installation – stage 5 The tracker module, 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

33. T. Matsushita 33 Installation – stage 6 The tracker module is slid into its pre-determined position inside the bore of the solenoid The position will already have been determined using the target module

34. T. Matsushita 34 Installation – stage 7 With the tracker in position and secured, the light guides can now be carefully re-routed to their final position in the patch panel. The gas-seal is fitted If the external light guides are not to be attached immediately then light tight/protection covers will remain fitted. The light-guides are secured. A shield will be fitted to stop any damage on light guides during diffuser installation When the diffuser is installed, the light guide support structure is removed If we are not ready to fit the diffuser mechanism then a cover plate will be attached

35. T. Matsushita 35 Installation – stage 8 The patch-panel cover is installed and sealed to the patch-panel We can repeat the gas seal test at this point Now, installation finished!! Sequence designed, need to elaborate with all interested parties

36. T. Matsushita 36 Infrastructure – Land grab We need space for; Cryocooler/Cryostat for VLPC read-out Two VME creates, local-DAQ computer, cabling He gas system for Cryo/Tracker; pipes/cylinders Tent for installation 4 x 3 x 3 m**3 (x, y, z); to be fixed with mock-up Because of the amount of equipment required to fit into the area and possible conflicts this may cause, it has been decided to ‘build’ a 3D virtual model of the region 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 build a full size mock-up 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

37. T. Matsushita 37 Infrastructure – layout 1 st attempt

38. T. Matsushita 38 Infrastructure – layout 2 nd attempt This was an attempt to achieve a shorter fibre run In 2D-model the longest run increased from 1884 mm to 2200 mm Need to elaborate in 3D-model and with a full size mock-up Activities initiated

39. T. Matsushita 39 Infrastructure/Operation - Gas Maximum volume to be filled per tracker; V(solenoid) = pi*0.4**2*2.735 = 1.38 m**3 (depends on window position) V(p-panel) = pi*0.855**2*0.1/2 = 0.12 m**3 (guess) V(total) = 1.5 m**3 = 1500L To fill a tracker, 5 hours with flow rate of 300L/hour In operation mode, 30L/hour?; 7000L (60kg) cylinder every 9.7 days Needs; - gas cylinder - pressure regulator - flowmeter - bubbler - supply/exhaust pipes - shutoff valve? - overpressure valve? He gas leaks from patch panel WILL NOT cause oxygen deficit. The MICE hall is ventilated Exhaust to high release or outside

40. T. Matsushita 40 Helium/vacuum window - study Chris Roger’s study on aperture measure acceptance of MICE cooling channel in 2D phase space The detector and diffuser apertures should be at least large enough to transport these muons Apertures [m] Small LH2 + RF Large LH2 + RF Large LH2 Only Diffuser z= -6.011 0.140.180.19 Window 1 z~-3.8 0.190.250.28 Window 2 Z~+3.8 0.240.29 Beam envelope

41. T. Matsushita 41 Helium/vacuum window - design Top Hat Top Hat cylindrical length machined to suit position of the window Radial distance of window curvature = 360mm Window to have 396mm OD Decoupled from solenoid z-position will be adjusted to have smaller beam envelope Make it thinner; 0.5mm Effects of window will be studied with G4MICE

42. T. Matsushita 42 Summary We will build fifth station to establish production line for the tracker As soon as doublet-layer becomes available, August Mechanical designs for station/tracker assembly almost complete Need to elaborate some details and require a final set of engineering drawings There is more work to be carried out on the installation/layout, helium/vacuum window, gas system Works initiated