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Apr 21, 2023 S.Movchan Straw manufacturing and QC 1
Straw manufacturing procedure and QC
• tape and straw parameters specification• conditions of straw production: • “clean room” status• seam QC by microscope
• plans
Presented by S.Movchan
Apr 21, 2023 S.Movchan Straw manufacturing and QC 2
Tape specification
spool # (001-999)batch # (01-99)roll and tape visual inspection ok! or commentsmylar type homogeneousmylar thickness (36.0+/-0.075) µmelastic elongation limit > 2 kg (H=80%, T=23 degree)damage limit > 5 kg (H=80%, T=23 degree) tape width (31.6+/-0.1) mmtape length (100 – 300) m(Cu+Au) thickness of coating (750+/-50) Aresistance (35+/-5) Ohm/m
oil on surface exist? No or comments shipment list scan of list
Apr 21, 2023 S.Movchan Straw manufacturing and QC 3
Straw specification
Straw dimensions and properties: (D0) - (9.770.05) mm elliptic shape - 0.1 mm (diff. D1 and D2 from D0)seam width - (0.6 0.2) mmseam shape - “good” (visual inspection)length - 2100 mm active area (total-(2400 1) mm at dP=0 Bar) non straightness - 0.2 mm (dP=1 Bar) increasing - (0.04 0.01) mm per dP=1 Bar overpressuregas leakage - < 0.003 cc/min (N2 at dP=1.5 Bar for repair straw) skin resistance R - (35 5) Ohm/m
elongation 1 - 1 mm at dP=1 Bar overpressureelongation 2 - 4 mm at F=1 kg overpressure test - dP=3 Bar @ 10 mincyclic test - N=10 cycles (dP: 0->3Bar->0)long term test - > 3 months at dP=1.2 Bar seam tensile test - > 5 kg (t.b.d.)
Production technology and rate: ultrasonic welding20 straws per shift
Apr 21, 2023 S.Movchan Straw manufacturing and QC 4
Conditions of straw manufacturing
• “clean room” with control T=(23+/-1) degree, humidity H=(65+/-5)%, clean (dust control) and atmospheric P+10 mbar
• control the set up of the machine (each day):• ultrasonic generator amplitude and clock • ultrasonic head pressure to Al tape • tape friction • tension and speed of transport mechanics
• flush inert gas of welding region (by ionization gun, clean anvil and tape from dust)
• automatically check seam quality by microscope with video camera (simultaneously with
welding)• for each straw cut 2 samples (start and end) and to do seam test by
tensile test machine • using box for straw transportation and storage
Apr 21, 2023 S.Movchan Straw manufacturing and QC 5
“Clean room”
S is about: S=(3.5x6)=21 m2Dust – class (6-7) ISOOverpressure inside – few mbarTemperature and humidity will be stable and record to DB
Special shoes, clothes, glovesAntistatic floor rug
Apr 21, 2023 S.Movchan Straw manufacturing and QC 6
Equipment and tools inside “Clean room”
Equipment:• temperature sensor• humidity sensor• atmospheric pressure sensor• counter of a number of dust particles in air• air flow meter • straw manufacturing machine based on ultrasonic welding • oscilloscope (amplitude measurement)• frequency meter (check ultrasonic generator freq.)• sensor for measurement pressure of ultrasonic head to tape• sensor for measurement tape friction• sensor for measurement temperature inside of seam• “ionization” gun (clear anvil from dust)
• tensile machine for seams quality control• microscope with video camera -> on-line QC -> “seams photos -> DB*”• computer• optical microscope -> for visual seam quality check -> DB• bar code generator (for straw labeling)
* DB – data base
Tools:• ultrasonic head clean tools• set of calibers for straw diameter measurement-> DB• tool for straw length calibration (based on scissors)
box for straw transportation1 or 2 boxes for straws mass storage
Apr 21, 2023 S.Movchan Straw manufacturing and QC 7Apr 21, 2023 7
Straw welding machine, heard and anvil
Apr 21, 2023 S.Movchan Straw manufacturing and QC 8
Straw machine with microscope + oscilloscope
Apr 21, 2023 S.Movchan Straw manufacturing and QC 9
Ultrasonic generator control
• frequency: F=38 kHz• amplitude: U=40 V
Apr 21, 2023 S.Movchan Straw manufacturing and QC 10
Seam shape QC by microscope
“Good” seam shape “Bad” seam shape
Apr 21, 2023 S.Movchan Straw manufacturing and QC 11
Gun with ionization air: for clean of anvil and tape from dust
Apr 21, 2023 S.Movchan Straw manufacturing and QC 12
Weld seam visual QC
for DB
Apr 21, 2023 S.Movchan Straw manufacturing and QC 13Apr 21, 2023 13
“go - no go” gauge for straw diameter check
Apr 21, 2023 S.Movchan Straw manufacturing and QC 14
Tool for straw length calibration (based on scissors)
L=(2400+/- 1) mm
Apr 21, 2023 S.Movchan Straw manufacturing and QC 15
Tools for straws QC (continue)
Outside of “Clean room”:• stand “overpressure test” (dP=3 bar) -> DB• tool for assembly straw with end plugs• tool for straw non straightness measurement (based on video camera)• tool for nipples installation• tool for straw filling with Nitrogen before storage • long term test with dP=(1.5-2) bar (inside storage boxes)• stand “straw gas leak measurement” -> DB• tools for straw reparation • etalon/reference metal “straw” (no gas leak)• set of etalon straws (for straw gas leak measurements)
Apr 21, 2023 S.Movchan Straw manufacturing and QC 16
Overpressure QC
Apr 21, 2023 S.Movchan Straw manufacturing and QC 17
Straw assembly with end plugs
Option 1:Straw assembly based
on optical bench(L.Glonty design)
Option 2:Machine for straw assembly
(Yu.Fedotov design)
Apr 21, 2023 S.Movchan Straw manufacturing and QC 18
Straw (with end plugs) non straightness QC
Method:- straw is rotate on flat table- visual control of straw deformations- preliminary straws sorting
Method:- straightness calibration by wire- video camera + data processing
Apr 21, 2023 S.Movchan Straw status 19
Straw diameter and non straightness measurement
Apr 21, 2023 S.Movchan Straw manufacturing and QC 20
Straw long term test (1-3 months) = damage + gas leak
Used nipple from bake well
dP=1.5 Bar at (1-3) months
Apr 21, 2023 S.Movchan Straw manufacturing and QC 21
Straw gas leak value measurement (if needed)
Reference straw
Tested straw
Diff.manometer
Ch1
Ch2
Straw gas leakage measurement stand
based on diff. manometer
Apr 21, 2023 S.Movchan Straw manufacturing and QC 22
Plans
Straws:
• QC of straw production (Dubna) – Sep -Feb 2010
• mylar order (CERN) – Aug-Sept 2009
• mylar (Cu+Au) coating (CERN) - Oct - Dec 2009
• mylar cutting on rolls (CERN) – Jan - Feb 2010
• straw end plug production (4000 sets – CERN) – Jan-May 2010 • 1600 straws manufacture and QC tests (4 months)– start July 2010 (Dubna)• storage 4x400 straws under pressure (Dubna) - start Aug. 2010
Apr 21, 2023 S.Movchan Straw manufacturing and QC 23
Conclusion
Tape and straw specifications – fixed
Preparation of “Clean room” with temp., hum. and dust control - in progress
Straw QC procedures – well defined
Part of tools – already exist
Additional tools for straw production, assembly and QC - in design
Order of needed sensors, tensile machine, “ionization” gun … – in progress
Plans: certification straw manufacturing procedure – June 2010 start straw mass-production – July 2010