1. J A Hill – EID RAL 1-2 September 2005 1 EE End Cap Mechanical Design ECAL EE End Cap Engineering CMS-UK Collaboration Meeting Brunel University September 1-2 2005

2. J A Hill – EID RAL 1-2 September 2005 2 ECAL EE End Cap components BACKPLATE SUPPORT RING SUPERCRYSTALS THIS FACE PATCH PANELS ENVIRONMENTAL SHIELD

3. J A Hill – EID RAL 1-2 September 2005 3 EE End Cap Mechanics 2005 Highlights End Cap Dee's have now been successfully fitted to both YE+ (Sept 04) and YE- (Feb 05) ends of CMS detector. New contract agreement for the supply of four ‘new’ support rings signed agreed in May 2005. Production of Environmental Screen in Russia. Progress in the layout and design of major End Cap components, Electronics units and related service support systems. End Cap services have been fitted to both YE+ and YE- using the final design of the End Cap Patch Panels.

4. J A Hill – EID RAL 1-2 September 2005 4 ECAL End Cap – at CERN during 2005 End Cap Major components trial fitted to YE- in February 2005. Like the YE+ fitting the assembly was successful with all EE/HE fixtures holes (bar one) being clear to fit. Major dimensional gaps between HE/EE/ES checked manually, clearance as expected. The final design layout of the End Cap Patch Panels was presented to CERN in early 2005, have now been used on the dummy End Caps for the service routing of all cables. ‘Dummy’ End Caps have been fitted to both YE+/YE- ends to allow the routing and laying out of End Cap and Preshower services. A decision has been made to introduce a flexible link between the End Cap cooling connections on the Patch Panels to the ECAL service trays, RAL has provided a specification for this requirement.

5. J A Hill – EID RAL 1-2 September 2005 5 ECAL EE Endcap Support Rings Production All four rings ‘cold rolled’ at Barnshaws, July 2005. ‘Rough’ machining of ring section at TM Engineers, August 2005. A new contract was placed with TM Engineers in May 2005, delivery at CERN for first pair expected October 2005, second pair December 2005. Base material supplied by ALCOA in 4 sections 350mm x 200mm x 7.7metres lengths. Sections ultrasonically inspected for flaws, none found. Each section cold rolled to correct internal radii (tolerance within 5mm of 1.65m rad). All rolled section have been stress relieved by heat treatment. Sections are currently undergoing rough machining, a further heat treatment may follow prior to final machining (note that 82% of material is machined away!). RAL staff to witness final load test….

6. J A Hill – EID RAL 1-2 September 2005 6 ECAL EE End Cap component Production EE End Cap Environmental screen under construction at Energia, Moscow. Environmental screen produced as single circular component before ‘splitting’. Procurement and engineering dealt with by IHEP Protvino, RAL engineers provide support. Delivery of both End Cap shields due at CERN October/November 2005. Castings of 100ch and 75ch cooling bars produced. Machining of all cooling bars in progress, delivery to CERN believed to be 2006... Open section of outer shield showing the cooling circuit. ‘Complete’ section of outer shield. Arrangement of prototype 100ch cooling bars.

7. J A Hill – EID RAL 1-2 September 2005 7 ECAL EE End Cap Build – Layout BACKPLATE SUPPORT RING VFE ELECTRONICS MODERATOR END CAP DEESIDE VIEW ~3.6m

8. J A Hill – EID RAL 1-2 September 2005 8 ECAL End Cap Build - Layers Arrangement at the Rear of the End Cap Backplate Backplate Cooling, fitting of patch panels, FOM Protection plates, HV support End Cap inner Shielding, Front Moderator Protection plates, LV support Mechatronics Support plates Umbilical connection, VFE Mothercards/support frames, LV distribution Mechtronics cooling system, internal flow and return manifolds VFE, LV and FE cards attachment, Inner Moderator Data/trigger fibre boxes plus support Rear Moderator, closure of End Cap

9. J A Hill – EID RAL 1-2 September 2005 9 ECAL End Cap Build - Progress Detailed drawings of End Cap Moderator system complete. Tender to be dealt with by IHEP Protvino, production in Russia late 2005/early 2006. Development of internal manifold systems approaching prototype stage however progress now on hold due to problems encountered on ECAL Barrel cooling. Drawings of current Mechatronics scheme, approaching prototype stage. Development model being produced with machined components from Bristol and Imperial.

10. J A Hill – EID RAL 1-2 September 2005 10 ECAL End Cap - 2006 Schedule 1.Production Drawings – Work continues, where possible, towards producing detailed drawings for the manufacture of End Cap components in the region behind the Backplate. The final design of many items are still on hold pending decisions on umbilical design, Mechatronics cooling, HV and LV service routing and LED pulsing system. The current plan is to release all major production drawings by summer 2006. 2. 2006 Test Beam – The announcement of this will allow the many of the working components to be manufactured to a level between prototype and final production. This includes the electronics cooling system and manifolds, various support plates as well as its supporting structure. Drawings for the 2006 test beam components must be completed by April 2006 as the components will be required for the November 2006 test run. 3.During 2006 it is hoped to use the existing backplates and support ring in the Crystal Palace to further develop the routing and final loom schemes for HV, LV and fibre routing. Procedures for the use of the Super Crystal assembly manipulator to be understood and documented.

11. J A Hill – EID RAL 1-2 September 2005 11 ECAL End Cap - Summary Good Progress to date New contract for End Cap Support Rings, completion by December 2005 Dry fitting of End Cap Major Mechanics to both ends of CMS a success End Cap Services have been fitted on both YE- an YE+ End Cap Environmental shields to be delivered Autumn 2005 Drawings available for End Cap Moderator system, manufacture to begin Winter 2005 Order placed for VFE cooling bars Further progress required Design of region behind the backplate progressing but requires input and assistance from other ECAL members Attention essential…. Decisions and direction required on engineering for Mechatronics cooling