July 2003SC Pixel Meeting N. Hartman LBNL 1

ATLAS Pixel Detector

Pixel Support TubeWBS 1.1.1.1.3.5

Santa Cruz Cost WorkshopJuly 9, 2003

July 2003SC Pixel Meeting N. Hartman LBNL 2

ATLAS Pixel Detector

Pixel Support Tube (PST) Overview

• PST Structure– 3 Independent composite tubes– Joined together with bonded flanges– Mounted on specially designed flexures– Support detector insertion rails– Laminated with heater/EMI foils

• Key Cost Points– Actual expenditures match ETC03 estimates very well– ETC03 to ETC04 costs show substantial decrease

• Assumptions– Prototyping finishes Q4 of FY03 (almost finished now)– Production begins simultaneously in Q4 of FY03– Remaining Prototype/Production time is staffed with MT

(1/2 FTE)– All costs in FY03 $K

July 2003SC Pixel Meeting N. Hartman LBNL 3

ATLAS Pixel Detector

PST Deliverables

• 3 Composite tubes• 6 Bonded composite flanges• Full Length insertion rails• Mount pads at forward and barrel (8 total)• PST Supports (8 flexures)• Pixel detector supports (kinematic, 4 total)• Heaters and EMI shielding (continuous over

length)

• All must be delivered by September - December ’04• SCT installation is ~Dec. ’04• Barrel mount pads are bonded using transfer jig

from SCT (must be done during initial barrel assembly – about September ‘04)

• Full PST must be present at LBL for dry-fit (summer ’04)

• Installation work costed in separate installation plan

July 2003SC Pixel Meeting N. Hartman LBNL 4

ATLAS Pixel Detector

PST Key Structures – Barrel Tube

Shell

Hoop Stiffeners

Mount Pads

Mount blocks

Insertion Rails

Flanges

July 2003SC Pixel Meeting N. Hartman LBNL 5

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Shell Laminate with New Heater Panels

July 2003SC Pixel Meeting N. Hartman LBNL 6

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Full length rails

July 2003SC Pixel Meeting N. Hartman LBNL 7

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Mount Pads

July 2003SC Pixel Meeting N. Hartman LBNL 8

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Flanges

Backing Ring

Flange face

Bonded andDrilled flangeOn PST shell

July 2003SC Pixel Meeting N. Hartman LBNL 9

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Bond Jig

Barrel Length Bond jig

Production jig setup for Prototype length PST shell

July 2003SC Pixel Meeting N. Hartman LBNL 10

ATLAS Pixel Detector

PST Production Mandrel

Rotation Head Detail

Autoclave Cart

Shop Cart

July 2003SC Pixel Meeting N. Hartman LBNL 11

ATLAS Pixel Detector

FY03 Cost Tracking

• Prototype Budget shows under-spending– Rail tooling (which was moved to prototyping

budget) completed at lower cost with simpler tools

• Production Budget shows over-spending– PST Mandrel costs increased to include additional

carts and handling hardware

• Overall FY03 Budget is “on-track” so far

Cost Comparisons Prototype Production TotalFY 03 - ETC 03 Estimate 53 69 122FY 03 Expenditures 24 79 104FY 03 Future Expenses 8 7 15Balance 21 (17) 4

July 2003SC Pixel Meeting N. Hartman LBNL 12

ATLAS Pixel Detector

FY04 CostsETC03 FY03 Q4 FY04 TotalPrototyping

Shop/Labor $0 $0 $0Materials $0 $0 $0

Tech Time 0 0Production

Shop/Labor $33 $50 $83Materials $36 $54 $90

Tech Time 313 938

Totals $69 $104 $174

ETC04 FY03 Q4 FY04 TotalPrototyping

Shop/Labor $6 $0 $6Materials $4 $0 $4

Tech Time 132 0Production

Shop/Labor $11 $33 $44Materials $13 $40 $53

Tech Time 344 1,032

Totals $35 $73 $108

July 2003SC Pixel Meeting N. Hartman LBNL 13

ATLAS Pixel DetectorKey Cost Points

• Substantial Savings in Tooling and Fabrication– Rail designs simplified and tooling fabricated for reduced

cost offsite (~20K savings)– Flange tooling simplified (26 parts reduced to 2) and

fabricated onsite (~40K savings)• Some budget “re-allocated”

– Insertion mechanism (see next talk) sub-task created– About 25K from PST budget “moved” to insertion

mechanism prototyping and production

July 2003SC Pixel Meeting N. Hartman LBNL 14

ATLAS Pixel Detector

Schedule Milestones - Slippage• Production Readiness Review

– February 18, 2003• Production Material Delivered

– April 14, 2003 -> May 25, 2003• Mandrel Delivered

– May 1, 2003 -> June 9, 2003• Production Begins

– May 1, 2003 -> August 1, 2003• Barrel PST Completed

– September 14, 2003 –> December 1, 2003• Forward PST’s Completed

– June 1, 2004• Pixel System Dry-fit (PST, BP Support,

service panels, pixel frame)– July, 2004 – August, 2004

• Fit-up with SCT (transfer jig bonded)– September, 2004

• SCT/PST Installed– December, 2004 – January, 2005

July 2003SC Pixel Meeting N. Hartman LBNL 15

ATLAS Pixel DetectorSummary

• Current Status– All tooling currently fabricated except for hoop stiffener tool and

rail bonding jig (hoop stiffener tool is in shop now)• Prototyping

– Must bond rails into prototype shell using rail bonding jig by end of FY03

• Production– Plan to begin barrel shell production by August 1 (3 months late)

• Personnel– FY03

• Require 1 FTE until FY04 (476 hours)– Research assistant (350 hours) and part of Mech Tech available

– FY04• Require ½ FTE for all of FY04 (1032 hours)

– Research assistant (550 hours) and part of Mech Tech available

• Budget– Current spending (FY03) is on-track with last cost estimate– Redesigns of fabrication tooling and processes have saved about

70K from budget – these can be used to offset increases in other mechanics areas (particularly insertion mechanism)