1. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20041 Mechanical Update for Tracker workshop Contents:- New Station Layout Light Guide Map Station Connectors Patch Panel Connectors Progress at Liverpool Assembly Area Fabrication Plan Minimum Pitch

2. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20042 New Station Layout The new station layout has a total of 30 connectors, 10 per view. Each connector has 22 holes instead of the previous 18 but all of these are not used in every connector (this is shown in the light guide map).

3. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20043 Light Guide Map View ‘X’ 213 Channels View ‘W’ 213 ChannelsView ‘V’ 213 Channels 0-21 22-42 43-62 85-106 63-84 107-128 191-212 129-150 151-170 171-190 20 22 2120 22 0-21 22 22-43 44-65 66-85 22 19 86-104 105-126 127-148 149-170 171-192 193-212 20 22 20 22 20 22 19 20 22 0-19 20-41 42-63 64-85 86-107 108-127 128-146 147-168 169-190 191-212

4. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20044 Station Connectors This is the new Station connector. The re-design will allow for easier assembly of the detector. We still need to carry out light transmission tests on this connector but cannot see any reason why it should perform less efficiently than the previous square connectors

5. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20045 Patch Panel Connectors This is the 128 way patch panel connector. It is designed to maintain a vacuum in the bore of the cryostat The 128 channels make it a match for the VLPC cassette. All the routing of the fibres takes place inside the chamber.

6. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20046 Patch Panel This is the the patch panel model. It is not the definitive model as detailed drawings will be required to mate it to the magnet. This model gives space for 26 connectors, as only 25 are needed the 26 th opening can be used for field monitoring services.

7. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20047 Progress at Liverpool This sequence shows the station mould being produced in the Liverpool workshop

8. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20048 Assembly Area The area has now been painted and the majority of the assembly equipment moved in. The lighting has been improved and we now need to re- connect the stages and the microscope. It is compared to our old assembly area, ‘quite roomy’, although non of the QA stations are set up yet.

9. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 20049 Fabrication Plan This is an outline of the tasks required to assemble the stations. It needs to be expanded and QA systems put in place. When all is agreed an assembly document can be compiled. Receive the planes from Fermilab Inspect the planes to ensure that they have not been damaged in transit The fibres are then grouped into ‘sevens’ and rubber sleeves fitted The plane is then fitted onto the vacuum chuck and aligned The vacuum chuck is transferred onto the assembly jig The first plane is glued onto the station and allowed to cure The second plane is then aligned on the vacuum chuck The vacuum chuck is transferred onto the assembly jig The second plane is glued onto the station and allowed to cure The third plane is then aligned on the vacuum chuck The vacuum chuck is transferred onto the assembly jig The third plane is glued onto the station and allowed to cure

10. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 200410 Fabrication Plan pt2 The station will now need the connectors fitted The centre fibre (this should be marked) is fitted in the correct position The fibre bunches are then fitted sequentially into the connectors When a complete plane is ‘threaded’ the fibres are ‘tidied up’ This plane is then potted using vacuum to pull epoxy through the holes This procedure is repeated for the other 2 planes When the epoxy has cured the station is taken to be diamond polished It should now be possible to conduct a series of tests to ascertain its final quality This is not exhaustive and will be added to during the coming weeks

11. G.Barber/Peter Cooke: Mechanical Design Update Imperial 22 July 200411 Minimum Pitch These two views show adjacent stations with a pitch of 100mm. It is difficult to assess the bend radius required on the fibres from this model therefore we will need to make a model using the carbon fibre stations and simulating an appropriate thickness where the fibre planes pass over the radius of the station. What the model shows is that it will be very tight