PH-DT Engineering Office - Indico - Cern

PH-DT Engineering Office

Section Meeting February 27th , 2014.

A. Catinaccio.

https://indico.cern.ch/event/304960/

Outline

EO Introduction

Tour de table

General news

Main EO tools and Activities today

Tour de table

Conclusions

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New section meetings organized every 4th Thursday of month.

◦ Number of participants: 18

◦ Typical agenda for the meetings:

◦ General information coming from the group and DTCM (Andrea)

◦ A presentation made by one designer/engineer about one or two projects.

◦ No tour de table . Too many participants to make it in a reasonable time. Before the meeting, we send to all participants a request for specific topics they want to discuss.

An exception for this1st meeting: many newcomers, part of the section in bat.70. A quick tour de table foreseen, to introduce each section member (name, office location, functions, and main projects he works on).

Specific project meetings will be organized regularly (i.e. microEO monthly) or called ad hoc.

EO Designer meetings to be called by Christophe.

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EO Meetings

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PH-DT-EO

The section is in charge of mechanical design activities required for

CERN detector-related projects.

Competencies include:

◦ Detailed Design, Drafting

◦ Integration studies,

◦ Structural, Thermal, Fluid-dynamics, Coupled-Field Analyses

◦ Verifications of compliance with relevant Standards and Codes,

◦ Manufacturing Support and Follow-up, Relations with External

Suppliers

Activities are carried out relying on a large range of CAD, FEM and

Analytical tools

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Mandate (EO)

Engineering Office

• 18 members (plus Thomas, Julien)

• 12 staff

• 2 Fellows

• 2 DOCT Students

• 2 Users

ALICE

ALICE

New arrivals

• 4 Designers (plus 2)

• 13 Engineers

• 1 Physicist

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• Neutrino project:

• 1 PJAS (Francesco NOTO) feb.2014

• 1 new Engineer expected (TBC)

New staff

New arrival

EO Personnel and New Projects

Gen. FEA Support, MicroSystems fracture mechanics, Alfa thermal

studies, Atlas ITk Upgrade phase II, Composite Lab and materials

DT Composite lab

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LHCb and NA62 engineering, Micromegas, EO calculations, CFD.

CLIC project

CFD detectors – Composite lab

NOTO Francesco Neutrino

Tour de Table:

Introduction

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One new master student with EPFL (Clement Gabry) in EO from 17.02 to work with Diego and continue studies on fracture mechanics silicon cooling devices

Three new master students (Wiese Cindy, Brouzet Davy, Asiatici Mikail) starting on microscint for 6 months with Alessandro.

There is a new stager coming 11 weeks (Thomas Lejeune, IUT Génie Mécanique Productique) (14.04-21.06): on two projects:

◦ NA62 microscint (not micro-cool)

◦ AIDA testbeam calorimeter phase II

Mars exercise started: 4 left (Alessandro, Olivier, Joao, Fernando)

New EO web site:

https://new-ph-dep-dt-test.web.cern.ch/sections/engineering-office

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EO News

Space

There is a project to convert the mechanical workshop in building 25 into an open office space for 14-18 people.

MARS 2014:

HR deadlines for the MARS exercise 2014. As soon as the PH internal deadlines will be available, Mar will distribute them:

◦ Interviews to be completed by 15th March

◦ MARS forms to be signed by Group leader on 25th April at the latest

◦ Promotions proposals deadline 21st March

General news:

No salary increase

+ 0.84% for material, mostly due to energy cost increase

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DTCM News

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Barrack 70

PH-DT Offices

(~18 people)

B166

PH-DT Mechanical WS

(Conventional & CNC)

B25

PH-DT Engineering Office

Open space (~10 staff + students)

B25 Mechanical

WS

Converted to

open office

space for 14

people

Clean room

Engineering Office

KOTTELAT Luc-Joseph KRISTIC Robert LOOS Robert CANTIN Bernard PIEDIGROSSI Didier ANSTETT Didier Henri BOUVIER Philippe Jacques DENARIE Charles-Henri IJZERMANS Pieter LESENECHAL Yannick VAN BEELEN Jacob Bastiaan DZIURDZIA Piotr (TECH) LIMA DA COSTA E SILVA Pedro Miguel (FELL – TES)

Engineering & Mechanics 1 (DT-EM1)

Antti ONNELA/ deputy Raphael DUMPS

BAULT Christophe

DEGRANGE Jordan

JAMET Olivier

LENOIR Philippe

MAPELLI Alessandro

WERTELAERS Piet

NUIRY Francois-Xavier (FELL)

MAODDI Pietro (DOCT)

GARGIULO Corrado

ESPOSITO Marco (FELL)

BERRUTI Gaia Maria (DOCT)

MIGNE Julien (detached)

Engineering Office (DT-EO)

Andrea CATINACCIO

Core of design office in 25-R-028 (6 posts used permanently out of 8)

With a new engineer arriving, only 1 spare post left for students / users

Other offices in 25-R-020, 25-R-018, 20 and 70.

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Proposal for moving machines and material storage from WS 25 to WS155

Engineering Office & Composite Lab (Francois Boyer, Francois Xavier)

KOTTELAT Luc-Joseph KRISTIC Robert LOOS Robert CANTIN Bernard PIEDIGROSSI Didier ANSTETT Didier Henri BOUVIER Philippe Jacques DENARIE Charles-Henri IJZERMANS Pieter LESENECHAL Yannick VAN BEELEN Jacob Bastiaan DZIURDZIA Piotr (TECH) LIMA DA COSTA E SILVA Pedro Miguel (FELL – TES)

Engineering & Mechanics 1 (DT-EM1)

Antti ONNELA/ deputy Raphael DUMPS

BAULT Christophe

DEGRANGE Jordan

JAMET Olivier

LENOIR Philippe

MAPELLI Alessandro

WERTELAERS Piet

NUIRY Francois-Xavier (FELL)

MAODDI Pietro (DOCT)

GARGIULO Corrado

ESPOSITO Marco (FELL)

BERRUTI Gaia Maria (DOCT)

MIGNE Julien (detached)

Engineering Office (DT-EO)

Andrea CATINACCIO

New project managed by our two Francois’s to re-boost activities on

composites in the group: inventory of available machines ready.

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Bat 153

Composite laboratory location

DT plan Car SHARING! (to reduce)

PH-DT Car keys in TRAKA boxes (B166, B108, B162)

◦ Except cars for piquet services (Gas, Cooling, Magnets)

Real time info on car availability (key in/out and person) in the new PH-DT Web (access granted to DT members)

Timescale for new DT cars policy: After LS1

Main Engineering Tools (EO)

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ANSYS Classic and APDL programming

ANSYS Workbench

Scia Engineer Structures

Composites EsaComp

EXAGON assemblies

Analytical Mathcad library

Vibration SRS software

Main Design Tools (EO)

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Catalsyt for 3D printer Dimension Elite

CATIA V5 - 3D modeling and Smarteam

Autodesk Inventor - 3D modeling

Geomagic – laser scan reconstruction

EDMS and \dfs EO libraries and docs

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https://edms.cern.ch/nav/P:CERN-0000089058:V0/P:CERN-0000089058:V0/TAB3

EDMS and \dfs EO libraries and docs

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\\cern.ch\dfs\Departments\PH\Groups\DT\PO

https://edms.cern.ch/nav/P:CERN-

0000089058:V0/P:CERN-0000089058:V0/TAB3

Mathcad section library

ANSYS APDL

scripts library

Example Activity Planning

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G:\D

epar

tments

\PH

\Gro

ups\

DT

\Act

ivitie

s_Pla

nners

\EO

-Act

ivitie

sPla

nner-

S37-2

013.x

lsx

Overview of current activities

in EO (not exhaustive list of contributions)

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Atlas Tracker Upgrade phase II

The ITk global engineering effort, coordinated by two convenors (A. Catinaccio, G.

Wiehhauser) – Andrea, Christophe, Diego (and Piet).

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Integrated model and envelopes

Overall ITk support structure

Pixel global support

Barrel strips global support

Endcap strips global support

Thermal enclosure design

Surface assembly and installation

Access scenarios

Failure management

Material for Simulation

Positioning Requirements

Common standards

Internal services

PP1 and TE feed-troughs

CMS Tracker upgrade phase II (Jordan, Philippe)

Efforts coordinated by Antti

◦ 3D modeling of the tracker Outer Barrel.

◦ Cooling inside the rods to improve performances and envelopes

◦ New studies starting in EO for the TIB upgrade

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NA62 Rich and Straw links (Piet, Olivier)

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Link between STRAW4 and RICH of NA62.

Reception of Rich Vessels from Cadinox.

Assembly with aluminium membrane.

Forming and leak-testing of that assembly.

Luc Kottelat, Jerome Noel, Tonio

NA62 integration ECN3 area and Straw link (Olivier)

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Olivier:

detectors and services integration,

installation scenarios,

supports structure,

access structures

NA62 ECN3 AREA

Dump platform –NA62 (Olivier, Joao)

Purpose

- Access to people;

- Support of equipment (racks and beam pipe)

Structural assessment

- Compliance with Eurocode 3;

- Actions: dead load; imposed load, seismic

- Software: SCIA

Figure 1 - Unity check: cross- section & stability

Figure 2 - Design of joints

(O. Jamet, 2013)

NA62 Straw Tracker (Jordan)

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Design of new support plates

for services

Design of cover partitions

Integration design work still

ongoing

Micro-megas (Jordan, Joao)

ZEBRA connector integration (512 Channels PCB).

Design of the vacuum table 500mm x 500mm for the precise assembly of the

sandwich panels

(J. Degrange, 2013)

Micromegas vacuum table – prototype (Joao, Jordan)

Purpose

- To assemble micromegas for ATLAS

Thermal analysis

- Actions: gravity; uniform temp:8c; surface

temp: 2c

- Software: ANSYS

8c +gravity

1c top surface +gravity

Completion of stave / flex assemblies.

IBL services integration (Both type 0 and type 1).

Procedure & integration of 28 harnesses around the IBL detector.

Design of tooling for gluing rings and clips on IPT

First stave mounted !

IBL Integration (Francois)

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Second IBL thermo-

mechanical mock up

4m long, all IBL

services mounted

AIDA test-beam calorimeter (Francois,

Christophe, Jordan)

FCAL collaboration for ILC and Clic

PH/DT/EO has designed, and built a calorimeter infrastructure able to support

25 tungsten plates. Each plate has a flatness of 10 microns. The distance between

two plates is better than 1mm, +/-50 microns.

PH/DT/EO will supervise all the mechanical aspects of this infrastructure during

the next test beam at DESY (Hamburg).

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CLIC vertex detector (Francois at all.)

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Development, optimization and prototyping of

lightweight carbon fibre structures for the future

Design (procurement and assembly) of a test

bench to measure the heat dissipation on

staves, and the vibrations induced by the air

flow (cooling).

CLIC vertex detector simulation (Fernando)

Image showing the temperature distribution on a dummy stave obtained by simulation. A similar image taken with a thermal camera and a graph showing how both simulations and measurements compare for different scenarios.

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Micro-systems Engineering (Ale, Giulia, Pietro,

Jordan and all.)

microScint

Development and study of microfluidic

scintillation detectors (for single particle

tracking or beam monitoring)

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microCool

Support to Cooling project for the

fabrication of silicon microfluidic devices

used as active cooling plates. Selected by

NA62 for the GTK and by LHCb for the

VeLo upgrade. Under study as alternative

for ALICE ITS

Micro-systems Engineering (cont.)

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Support for design and fabrication follow up:

◦ Tooling(s) for handling and accurate positioning for bonding sensor / cooling system / PCB

◦ Tooling(s) for Wire Bonding PCB by PH-DT bond-lab.

◦ GTK Integration

Next:

Implementation infrastructure for conversion of Mechanical Drawings (e.g. CATIA) to Photolithography Masks Layers (e.g. CleWin) to be used for micro-fabrication in cleanrooms (e.g. EPFL and external partners)

Implement the EDMS repository a database in DT-EO of the microfabrication process-flows, wafer runcards and photolithography masks

2 microchannels

Baseline Device #031 + Si Heater #31112

CFD simulations for micro-channels GTk (Cecilia)

Micro-Cooling Devices: Fracture Analysis (Diego)

Thermal Analysis Fracture Analysis (CZM)

Development of methodology to predict

fracture in silicon devices used for micro-

cooling applications

ALFA Stations: Ring Ferrites (Diego)

Steady-State

Thermal Analysis

LHCb consolidation LSI (Olivier)

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CONSOLIDATION MAGNET

Interface between clamps and coils to be

exchanged

-> Qualification of the material ,study for

this new part and tooling needed for

Insertion of this new component.

VISIT PLATFORM :Study and installation of this new structure for LHCb experiment.

RICH ACCESS STRUCTURE MODIFICATION

Extension of the platform to the HCAL-ECAL for calorimeter upgrade.

• TRT repair interventions

• ID mass finding

• nIDEP upgrade with BNL (specification and engineering

support)

Atlas consolidation LSI (Christophe, Andrea)

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Support to DT-Cooling team (Philippe)

Design support for versatile transceiver latches for the single mode version

design and FEA calculations

Several validation prototypes built (3D printing and stereolitography):

Fabrication by moulding on-going

Design support to ESE for DCDC converter integration

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Design support to Cooling team:

parametric 3D model for the construction of 2 new cooling plants based on the existing prototype for P5 CO2 cooling

Support to PH-ESE (Philippe, Jordan, Christ.)

1- development and production support structure for clean

room @ building 182

2- development transportation tool for t600 detector at

CERN to LNGS (building 185)

Neutrino activities (Francesco)

Alice Technical Coordination and ITS upgrade

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(Corrado, Thomas) Design, integration, installation, maintenance and consolidation during LS1 of the Alice

Detectors and infrastructure: EMCal, TRD, PHOS, DCal (new detector).

Design, prototyping and test of the Mechanics and Cooling for the new Silicon Tracker

to be installed during LS2.

Supervision of the ALICE team of designers and technicians.

ALICE Inner Tracker Silicon Upgrade

Mechanics and Cooling New design and prototype

Carbon Fibre reinforced structure

with embedded polyimide cooling pipes (OD=1mm)

Outer layer stave 1500mm length, 80 gram weight

ITS design and integration of the new detectors DCAL et PHOS d’ALICE.

Different installation tooling and tests for LSI (with mainly Yannick et Corrado)

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Alice Technical Coordination and ITS upgrade (Thomas)

Conclusions

Next meeting on March 27th

Tank you for sending proposals and feedback for

any ad hoc discussion / material you might need

Proposal: presentation on status of the activities by

Diego, Fernando, Francois B. - 20 min. each

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Material

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Skills and Capabilities (EO)

3D modeling and drafting

Advanced FEA: structural mechanics, thermal, fluid, coupled-analyses

◦ Static structural

◦ Modal analysis, pre-stressed modal

◦ Harmonic analysis (steady state response)

◦ Transient dynamic (implicit transient response)

◦ Vibrations & shocks: spectrum analysis, random vibration analysis, SRS.

◦ Buckling analysis: linear (eigen-buckling) and non-linear methods

◦ Non-linearities: changing status (ie contacts), plasticity,

creep, large strain, stress stiffening …)

◦ Fracture mechanics (Cohesive Zone Model)

◦ Composite analysis (micromechanics, lamination properties, some failure criteria …)

◦ APDL routines

Knowledge of materials metals, polymers, composites

Standards and calculations for: metallic frames, pressure equipment, lifting equipment …

Connections: bolted, welded, bonded

Analytical methods and Mathcad library

Testing and metrology

Production follow up, QA

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