3-D View of UIUC ATLAS TileCal Submodule <Heights>
Point-By-Point, After Tack Welding
291.7
291.6
291.5
291.6-291.7
291.4
291.5-291.6
mm
291.3
291.4-291.5
291.3-291.4
291.2-291.3
291.2
291.1-291.2
291-291.1
291.1
3
291.0
2
1
7:21:08
6:20:09
5:19:10
4:18:11
3:17:12
2:16:13
1:15:14
Point #
Figures 10 &11 – 3-D View of Average Submodule
Tack Weld (above)
Final Weld (below)
3D View of UIUC ATLAS TileCal Submodule <Heights>
Point-By-Point, After Final Welding
291.7
291.6
291.5
291.6-291.7
291.5-291.6
291.4-291.5
291.4
mm
291.3
291.3-291.4
291.2-291.3
291.1-291.2
291-291.1
291.2
291.1
1
291.0
2
3
7:21:08
6:20:09
5:19:10
4:18:11
Point #
3:17:12
2:16:13
1:15:14
If one wants a topography view of the two previous
graphs, they can be found below.
Note the same
conclusions can be drawn from them.
Topography of UIUC ATLAS TileCal Submodule <Heights>
Point-By-Point, After Tack Welding
3
291.6-291.7
2
291.5-291.6
291.4-291.5
291.3-291.4
291.2-291.3
7:21:08
6:20:09
5:19:10
4:18:11
Point #
3:17:12
2:16:13
1
1:15:14
Figures 12 & 13 – Topography of Average Submodule
Tack Weld (above)
Final Weld (below)
Topography of UIUC ATLAS TileCal Submodule <Heights>
Point-By-Point, After Final Welding
3
291.6-291.7
291.5-291.6
2
291.4-291.5
291.3-291.4
291.2-291.3
291.1-291.2
291-291.1
7:21:08
6:20:09
5:19:10
4:18:11
Point #
3:17:12
2:16:13
1
1:15:14
the top part. When the dial moves counter-clockwise the
perpendicularity is negative. This implies that at the
measurement point being examined the top part of the
submodule sticks out past the bottom part.
In order to see if UIUC was producing submodules
that tended to slanted one way or another, the measurement
points were split up and plotted using a histogram. This was
done for tack weld and final weld measurements. Appendix
B shows what points on the submodule correspond to the
measurement points. The graphs are color coded so that one
may quickly glance from a point’s graph that has been tack
welded to the corresponding graph for the final weld.
When analyzing the numbers that originate from
the measurement of the perpendicularity at each point along
the submodule, one must have some sort of frame of
reference so that the numbers will make sense. As stated
before if the dial moves clockwise as it is moved from the
inner part, closer to the submodule, of the cylinder to the
outer part, farther from the submodule, that means that
perpendicularity is positive. To say that perpendicularity is
positive means that at the measurement point being
examined the bottom part of the submodule sticks out past
Point B After Tack W eld
12
6
4
2
.0
3
.0
2
-0 5
.0
-0 2
.0
1
-0 5
.0
-0 1
.0
05
-0
0. 0
00
5
0.
01
0.
01
5
0.
0
0. 2
02
5
0.
03
M
or
e
1
05
.0
.0
-0
-0
2
15
25
20
20
Frequency
15
10
5
Perpendicularity (Actual - Nominal) (in)
03
0.
02
0.
0.
01
0
1
.0
2
.0
3
.0
2
Perpendicularity (Actual - Nominal) (in)
Po in t L After T ack W eld
Figure 4 – Tack Weld Perpendicularity Plots
03
0.
02
0.
01
0.
0
2
-0
.0
3
.0
F re q u e n c y
P e r p e n d ic u la r ity (A c tu a l - N o m in a l) (in )
16
14
12
10
8
6
4
2
0
-0
3
0
.0
2
0
.0
1
.0
0
0
0. 0
00
5
0.
01
0.
01
5
0.
0
0. 2
02
5
0.
03
M
or
e
.0
3
.0
25
-0
.0
-0 2
.0
15
-0
.0
-0 1
.0
05
-0
-0
03
0.
02
0.
01
0.
0
1
-0
1
-0
.0
2
-0
.0
3
03
0.
02
0.
01
0.
0
1
0
.0
5
.0
.0
2
.0
-0
.0
-0
Fre que nc y
10
-0
4
0
40
35
30
25
20
15
10
5
0
-0
15
2
6
P o in t K A fte r T a c k W e ld
20
.0
8
Perpendicularity (Actual - Nominal) (in)
25
-0
-0
Frequency
10
Point J After Tack Weld
3
Point I After Tack W eld
16
14
12
10
8
6
4
2
0
3
Frequency
0. 0
00
5
0.
0
0. 1
01
5
0.
02
0.
02
5
0.
03
M
or
e
3
.0
2
-0 5
.0
-0 2
.0
15
-0
.0
-0 1
.0
05
-0
.0
Perpendicularity (Actual - Nominal) (in)
Perpendicularity (Actual - Nominal) (in)
Perpendicularity (Actual - Nominal) (in)
.0
0. 0
00
5
0.
0
0. 1
01
5
0.
0
0. 2
02
5
0.
03
M
or
e
.0
3
.0
25
-0
.0
-0 2
.0
1
-0 5
.0
-0 1
.0
05
-0
-0
0. 0
00
5
0.
0
0. 1
01
5
0.
02
0.
02
5
0.
03
M
or
e
3
25
-0
.0
-0 2
.0
15
-0
.0
-0 1
.0
05
.0
-0
-0
5
Point H After Tack Weld
14
12
10
8
6
4
2
0
-0
10
0
Point G After Tack Weld
-0
15
-0
Frequency
25
0
.0
Frequency
Point F After Tack Weld
Point E After Tack Weld
16
14
12
10
8
6
4
2
0
Perpendicularity (Actual - Nominal) (in)
Frequency
Perpendicularity (Actual - Nominal) (in)
Perpendicularity (Actual - Nom inal) (in)
Point D After Tack Weld
Frequency
.0
.0
Perpendicularity (Actual - Nominal) (in)
-0
3
25
.0
.0
-0
-0
-0
0.
03
0.
02
0.
01
0
-0
.0
1
-0
.0
2
-0
.0
3
0
1
0
.0
5
8
-0
10
14
12
10
8
6
4
2
0
-0
15
10
Frequency
Frequency
20
Frequency
Point C After Tack Weld
-0
Point A After Tack Weld
0. 0
00
5
0.
01
0.
01
5
0.
0
0. 2
02
5
0.
03
M
or
e
VII. QUALITY CONTROL ANALYSIS PERPENDICULARITY
Pe rp e n d ic u la rity (Ac tu a l - N o m in a l) (in )
F re q u e n c y
12
10
5
P o in t G A f t e r F in a l W e ld
14
F re q u e n c y
12
10
8
6
4
Point J After Final Weld
Perpendicularity (Actual - Nominal) (in)
0 .0 3
M o re
0 .0 2
0 .0 2 5
0 .0 1
0 .0 1 5
0
0 .0 0 5
03
0.
02
0.
01
30
25
20
15
10
5
0
F re q u e n c y
30
25
20
15
10
Perpendicularity (Actual - Nominal) (in)
3
0
P e rp e n d ic u la rity (A c tu a l - N o m in a l) (in )
Figure 15 – Final Weld Perpendicularity Plots
When analyzing the measurements, one should be
aware that human error might affect the accuracy of the
measurements. When considering the measurements that
result from the use of the dial indicator, it must be noted that
one should allow +/-0.025 mm for error in each
measurement resulting from human error. After examining
these graphs, one can see that UIUC’s submodules are
typically perpendicular. Of course not all measurements
taken are perfect and human error that occurs while
measuring must be considered when looking at this data.
The majority of the measurements for almost all the points,
.0
2
0
.0
1
.0
0
0
1
.0
2
.0
-0
.0
3
0
-0
More
0.03
0.025
0.02
0.015
0.01
0.005
0
-0.005
-0.01
-0.015
-0.02
-0.025
5
after tack weld and after final weld, fall within the range of
being +/- 0.005 in. of perfect perpendicularity.
VIII. QUALITY CONTROL ANALYSIS – BOLT
HOLES
The measurements for the bolt holes are very
difficult to perform using the digital caliper. So when
analyzing the data for each measurement once must keep in
mind that human error when measuring will effect the data.
M o re
0 .0 3
0 .0 2
0 .0 2 5
0 .0 1 5
0 .0 1
0 .0 0 5
0
-0 .0 0 5
-0 .0 1
-0 .0 1 5
-0 .0 2
M o re
0 .0 3
0 .0 2 5
0 .0 2
0 .0 1 5
0 .0 1
0 .0 0 5
0
- 0 .0 0 5
- 0 .0 1
- 0 .0 1 5
- 0 .0 2
35
-0.03
Frequency
03
0.
02
0.
01
0.
0
1
-0
.0
2
.0
P o in t L A fte r F in a l W e ld
Point K After Final Weld
0
-0
P e rp e n d ic u la rity (Ac tu a l - N o m in a l) (in )
P e r p e n d ic u la r it y ( A c t u a l - N o m in a l) ( in )
P e r p e n d i c u l a r i ty (A c tu a l - N o m i n a l ) (i n )
3
- 0 .0 2 5
- 0 .0 3
3
0
.0
2
0
.0
1
0
.0
0
1
.0
-0
.0
-0
.0
2
0
3
2
-0 .0 2 5
4
0
5
0.
6
0
10
0
8
2
15
-0 . 0 1
10
2
20
-0 . 0 0 5
12
-0 .0 3
F re q u e n c y
16
16
14
4
1
P o int I Afte r F ina l W e ld
14
-0
-0 . 0 2
P o in t H A f t e r F in a l W e ld
18
8
6
.0
.0
-0
Perpendicularity (Actual - Nominal) (in)
Perpendicularity (Actual - Nominal) (in)
P e r p e n d ic u la r ity (A c tu a l - N o m in a l) (in )
12
10
-0 . 0 1 5
5
3
More
0.03
0.025
0.02
0.015
0.01
0.005
0
-0.005
-0.01
-0.015
-0.02
-0.025
-0.03
M o re
0 .0 3
0 .0 2 5
0 .0 2
0 .0 1 5
0 .0 1
0 .0 0 5
0
-0 .0 0 5
-0 .0 1
-0 .0 1 5
-0 .0 2
-0 .0 2 5
10
0
0
-0 .0 3
15
2
2
20
15
-0
4
25
20
-0
6
25
.0
8
Point F After Final Weld
-0
10
.0
-0 . 0 3
P e r p e n d ic u la r ity (A c tu a l - N o m in a l) (in )
Frequency
Frequency
12
-0
-0 . 0 2 5
03
0.
02
0.
0.
01
0
1
.0
2
-0
.0
3
.0
-0
0
Point E After Final Weld
14
F re q u e n c y
6
2
P o in t D A fte r F in a l W e ld
F re q u e n c y
8
P e rpe ndic ula rity (A c tua l - N om ina l) (in)
16
0
10
4
-0
Fre que nc y
03
0.
02
0.
14
16
14
12
10
8
6
4
2
0
P e rp e n d ic u la rity (Ac tu a l - N o m in a l) (in )
Frequency
P o in t C A f t e r F in a l W e ld
P o int B After F ina l W eld
0.
01
0
1
.0
2
-0
.0
-0
-0
.0
3
F re q u e n c y
Po in t A A fter F in al W eld
16
14
12
10
8
6
4
2
0
Again, when analyzing the measurements, human
error might affect the accuracy of the measurements. When
considering the measurements that result from the use of the
Mitutoyo digital caliper it must be noted that one should
allow +/-0.2 mm for error in each measurement resulting
from human error, as it is very difficult to use the caliper.
The bolt hole data will be analyzed in the same way that the
perpendicularities were analyzed.
Histograms of the
measurements were created, but first some calculations had
to be done so that the measured values could be compared to
the design values. The bolt hole separations that go across
from one weld bar to the other should be 325.00 +/- 0.2 mm.
However, when measuring the bolt hole separations, we
must take into account that the precision bolts have a head
diameter of 22.23 mm. So after the separations have been
measured, 22.23 mm must be subtracted in order to obtain
the actual measurement. Then take the actual measurement
and subtract from it the nominal separation of 325.00 mm.
The resulting value should be somewhere around zero and is
used to plot the graph.
When measuring the bolt hole heights on each
weld bar, more calculations must be done before they can be
compared with the nominal heights. One must know the
height of points 1 and 14, that is the height of the
submodule at both weld bars. Then one must take into
consideration that the top and middle bolt holes should be
separated by 110 +/-0.2 mm, same as the middle and bottom
T o p B H S e p a r a tio n A fte r T a c k W e ld in g
bolt holes. This separation is verified on every weld bar
before the weld bars are tack welded on using a specially
designed Go/No Go gauge. This ensures that both bolt hole
separations on each weld bar are 110 +/-0.2 mm. Early on
in the project many of the weld bars were machined
incorrectly and that is why each weld bar must now be
checked. Then in order to obtain the actual measurement of
the top bolt hole height from the raw measurement, one
must first subtract the height of the precision metal bar,
19.05 mm, and half the diameter of the precision bolt,
11.115 mm, from the raw measurement. This process will
result in the actual measurement for all bolt holes. In order
to tell if the weld bar is centered on the submodule, half the
height of either points 1 or 14, depending if the left or right
weld bar is being measured, must be subtracted from the
resulting value. Again this process may be performed for all
bolt holes. Now, for the top bolt holes on both weld bars
one must add 110 mm, since it is supposed to be 110 mm
above the center, in order to obtain the difference between
the actual and nominal heights. For the middle bolt holes on
both weld bars, one may stop at just subtracting half of point
1 or 14 in order to obtain the difference between the actual
and nominal heights. Finally, for the bottom bolt holes on
both weld bars one must subtract 110 mm in order to obtain
the difference between the actual and nominal heights. The
differences between the actual and nominal heights are used
to create the graphs.
B o t B H S e p a r a t io n A f t e r T a c k W e ld in g
Mid BH Separation After Tack Welding
16
18
Frequency
10
8
6
4
2
15
10
5
0
0
10
8
6
4
2
(Actual - Nominal) Deviation (mm)
F re q u e n c y
12
10
8
6
4
re
o
.5
.3
.4
M
0
0
.2
0
.1
0
0
B o t L e ft B H H e ig h t A fte r T a c k W e ld in g
12
16
10
14
F re q u e n c y
14
0
(A c tu a l - N o m in a l) D e v ia tio n (m m )
M id L e ft B H H e ig h t A fte r T a c k W e ld in g
T o p L e f t B H H e ig h t A f t e r T a c k W e ld in g
16
.1
.2
-0
5
.3
-0
4
0.
e
3
0.
or
2
0.
M
1
0.
0
0.
.2
.1
-0
.3
M
-0
-0
re
.5
o
.3
.4
0
0
.2
0
.1
0
0
0
.1
.2
-0
-0
-0
.3
0
(A c tu a l - N o m in a l) D e v ia tio n (m m )
8
6
4
12
10
8
6
T o p R ig h t B H H e ig h t A f t e r T a c k
W e ld in g
B o t R ig h t B H H e ig h t A f te r T a c k
W e ld in g
M id R ig ht BH H eig ht After T ack W eld ing
25
14
14
5
(Ac tu a l - N o m in a l) D e v ia tio n (m m )
Figure 16 – Tack Weld Bolt Hole Plots
4
.2
0
0
.2
-0
.4
-0
.6
-0
M o re
0 .2
0 .1
0
-0 .1
-0 .2
-0 .3
-0 .4
-0 .5
-0 .6
-0 .7
-0 .8
-0 .9
-1
M o re
0 .2
0 .1
0
- 0 .1
- 0 .2
- 0 .3
- 0 .4
- 0 .5
- 0 .6
- 0 .7
- 0 .8
- 0 .9
6
0
0
( A c t u a l - N o m in a l) D e v ia t io n ( m m )
8
2
2
0
10
.8
4
10
12
-0
6
15
-1
8
20
Fre que nc y
F re q u e n c y
10
-1
F re q u e n c y
12
(A c tu a l - N o m in a l) D e v ia tio n (m m )
0 .2
M o re
0 .1
0
-0 .1
-0 .2
-0 .3
-0 .4
-0 .5
-0 .6
-0 .7
(A c tu a l - N o m in a l) D e v ia tio n (m m )
( A c t u a l - N o m in a l) D e v ia t io n ( m m )
( A c t u a l - N o m in a l) D e v ia t io n ( m m )
-0 .8
-1
M o re
0 .2
0 .1
0
- 0 .1
- 0 .2
- 0 .3
- 0 .4
- 0 .5
- 0 .6
- 0 .7
- 0 .8
-1
re
.2
o
0
M
0
.1
0
.2
.1
-0
-0
.3
-0
.4
.5
-0
.6
-0
-0
-0
-0
-0
.7
0
.8
0
.9
2
0
-0 .9
4
2
2
- 0 .9
F re q u e n c y
16
14
12
-0
Fre que nc y
12
F re q u e n c y
20
14
M id B H S e p a r a tio n A fte r F in a l W e ld in g
12
Frequency
25
8
20
6
4
(Actual - Nominal) Deviation (mm)
e
5
or
3
4
M
0.
0.
2
0.
1
0.
2
0.
0
.2
-0
.4
-0
.6
-0
.8
-0
15
10
5
(Actual - Nominal) Deviation (mm)
Figure 17 – Final Weld Bolt Hole Plots
When examining the bolt hole separations that go
from one weld bar the other, it is easy to see the effect of the
final welding. While the tack weld separations tend to be
greater than the design separation, the final weld separations
are closer to the design height and may even be smaller than
the design separation. This happens because the final weld
pulls the weld bars in closer to one another. As expected,
the final weld does not appear to have a great of an effect on
the individual bolt hole heights on the different weld bars.
However, UIUC’s submodules tend to have weld bars that
are systematically shifted down 0.2 mm from the center of
the submodule. This conclusion can be drawn from the fact
that the majority of the bolt hole heights, both after tack and
final weld, are slightly below the design the height.
IX. FUTURE WORK
UIUC is well on the way to complete 192
submodules by the May 2002 deadline, as seen by the
production chart on the following page. Quality control
must be continued to ensure that UIUC’s submodules are
within the tolerances of the design specifications. Another
task that must be continued is to keep the quality control
analysis going.
UIUC just recently received the light box needed to
test the photomultiplier tubes and is awaiting the dark box
so that the process of testing the 3,000 photomultiplier tubes
may begin.
More
0.2
0.1
0
-0.1
-0.2
-0.3
-0.4
-0.5
-0.6
-0.7
-0.8
-0.9
2
0.
0
.2
-0
.4
-0
.6
-0
.8
-0
(A c tu a l - N o m in a l) D e v ia tio n (m m )
-1
0
0
-1
0.2
More
0.1
0
-0.1
0
-0.2
-1
10
2
-0.3
Bot Right BH Height After Final
Welding
Frequency
F re q u e n c y
5
-0.4
(Actual - Nominal) Deviation (mm)
12
10
-0.5
5
M id R ig h t B H H e ig h t A fte r F in a l W e ld in g
15
-0.6
10
(Actual - Nominal) Dev iation (mm)
Top Right BH Height After Final
Welding
-0.7
15
More
0.2
0.1
0
-0.1
-0.2
-0.3
-0.4
-0.5
-0.6
0
0.
1
0.
M 2
or
e
(Actual - Nominal) Deviation (mm)
-0.8
20
0
-1
0
-0.7
5
25
-0.8
10
-0.9
.3
Bot Left BH Height After Final Welding
14
12
10
8
6
4
2
0
-0.9
Frequency
15
-1
-0
re
.5
o
.3
.4
0
0
.2
0
.1
0
0
M
(Ac tu a l - N o m in a l) D e v ia tio n (m m )
M id Left BH Height After Final Welding
20
-1
-0
.9
-0
.8
-0
.7
-0
.6
-0
.5
-0
.4
-0
.3
-0
.2
-0
.1
0
.1
.3
-0
-0
.5
o
.2
0
re
2
0
(A c tu a l - N o m in a l) D e v ia tio n (m m )
Top Left BH Height After Final Welding
Frequency
4
2
(A c tu a l - N o m in a l) D e v ia tio n (m m )
Frequency
6
0
4
8
0.
6
10
.1
8
.2
10
-0
F re q u e n c y
14
12
M
0
.4
0
.3
0
.2
.1
0
0
0
.2
.1
-0
-0
-0
.3
2
0
14
-0
14
12
10
8
6
4
F re q u e n c y
F re q u e n c y
18
16
B o t B H S e p a r a tio n Afte r F ina l W e ld ing
-0
T o p B H S e p a r a t io n A f t e r F in a l W e ld in g
Cumulative # Submodules vs. Month
UIUC ATLAS TILECAL
70
Cumulative #
Submodules
60
50
40
30
20
10
0
Jun- Jul-99 Aug- Sep99
99
99
Oct99
Nov- Dec99
99
Jan- Feb00
00
Figure 18 – Production Status
Mar00
Apr00
May00
Jun- Jul-00 Aug00
00
15
14
1
13
16
2
12
17
3
11
18
4
10
19
5
ATLAS TileCal Submodule # ILL–______
Personnel:____________ Date:_________
Tacked:
Final:
9
20
6
Appendix A
8
7
J
L
K
I
A
H
B
ATLAS TileCal Submodule # ILL–______
Personnel:____________ Date:_________
Tacked:
Final:
G
C
Appendix B
F
E
D
Appendix C
This is file C:\ATLAS\TileCal Docs\Submodule_Weld_Bar_Posns.doc
UIUC ATLAS TileCal Submodule #_______
Personnel: _____________________
Date:
_____________________
Tacked:
Final:
Nominal/Design Bolt Hole Separation Distance = 325.00 mm
Diameter of M16 Bolts
= 0.875 inches = 22.23 mm
Thickness of Precision Flat = 0.750 inches = 19.05 mm
Actual Measurement (mm) = 25.4*(Raw Measurement (inch) – 0.875 inch)
=
Raw Measurement (mm) – 22.23 mm
Item
Top BH Separation
Mid BH Separation
Bot BH Separation
Raw Measurement (mm)
Actual Measurement (mm)
Nominal/Design Middle Bolt Hole Heights = ½ of <Submodule Height >
(<Submodule Height> = Average of Points 1 + 14 (@ outer radius of submodule))
Submodule Height (Point # 1): _____________________ (Left Weld Bar)
Submodule Height (Point # 14): _____________________ (Right Weld Bar)
<Submodule Height> :
_____________________
<Submodule Height> / 2:
_____________________
Actual Measurement (mm) = 25.4*(Raw Measurement (inch) – 1.1875 inch)
=
Raw Measurement (mm) – 30.1625 mm
Item
Top Left BH Height
Mid Left BH Height
Bot Left BH Height
Raw Measurement (mm)
Actual Measurement (mm)
Item
Top Right BH Height
Mid Right BH Height
Bot Right BH Height
Raw Measurement (mm)
Actual Measurement (mm)