Gantry Module Assembly
TOB & TEC
Dean White
University of California, Santa Barbara
DOE REVIEW 1/20/04 – Dean White
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Talk Overview
• Gantry Personnel
• New 5th floor clean room
• Gantry design
• Gantry module precision
• Gantry production capabilities
• Summary
DOE REVIEW 1/20/04 – Dean White
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Gantry Module Assembly Personnel
• Technicians: Andrea Allen
David Staszak
• Post-doc:
Russel Taylor
• Engineers:
David Hale
Dean White
 These are the key people in module assembly. They also
are involved to greater and lesser degrees in other areas of
module production.
DOE REVIEW 1/20/04 – Dean White
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New 5th Floor Clean Room
• Reasons for new 5th floor clean room:
• Temperature stability of +/- 1deg C needed for gantry.
• Availability of Emergency Power.
• Future need of high-bay clean room for Rod Production
DOE REVIEW 1/20/04 – Dean White
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New 5th Floor Clean Room
• Better than class 10,000 clean
room.
• Main production room (5324)
has new gasket sealed grid
ceiling and lighting.
• Hard wall anteroom entrance
added in room 5332.
• New compressed air drier, filters
and clean copper piping was
added in the building core to
deliver clean/dry air to clean
rooms.
• ~$45,000 of University funds
were used for these
improvements.
DOE REVIEW 1/20/04 – Dean White
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Gantry Design
BREIF DISCUSSION OF UCSB GANTRY AND MODUDE ASSEMBLY TOOLING
Gantry image recognition
system and electronics.
Aerotech AGS 1000 gantry
X,Y,Z & U (rotational)
positioning system
Vacuum/Pressure control
values
DOE REVIEW 1/20/04 – Dean White
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Gantry Design – Assembly Plates
• CERN style assembly plate
Laminated
assembly plate
Vacuum chuck
plate
PVC support and
vacuum posts
DOE REVIEW 1/20/04 – Dean White
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Gantry Design – Assembly Plates
Vacuum chucks and vacuum transfer lines on gantry base plate
DOE REVIEW 1/20/04 – Dean White
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Gantry Design – Assembly Plates
ASSEMBLY PLATE TEFLON PADS ARE MACHINED TO FINAL
HEIGHTS (+/- 25um) REFERENCED OFF OF FEET ON BOTTOM
Vacuum
channels and
o-ring grove
machined into
assembly plate
for each sensor
DOE REVIEW 1/20/04 – Dean White
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Gantry Design – Assembly Plates
Assembly plate feet that rest on vacuum chucks - precision machined flat and parallel
Sensor vacuum
Hybrid vacuum
Hybrid supply
vacuum
DOE REVIEW 1/20/04 – Dean White
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Gantry Design – Assembly Tooling
TOB / TEC HYBRID AND SENSOR PICK-UP TOOLS.
TOB HYBRID BRIDGE
DOE REVIEW 1/20/04 – Dean White
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Gantry Design – Assembled Modules
• 3 completed modules on the assembly plate.
DOE REVIEW 1/20/04 – Dean White
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Gantry Precision - Sensors
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Gantry Precision - Hybrids
DOE REVIEW 1/20/04 – Dean White
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Gantry Production – Assembly Time
• Rough module assembly timeline using two people for producing 15 modules / day.
(this probably could be increased for short periods, but over the long run it would be hard to
do more than this in an 8 hour day)
Technician One:
Technician Two:
8-9:00
Survey modules, install into carrier
plates for 5 plates (50 min)
Load assembly plate, DB entry, glue prep
(50min)
9-9:45
Run 1st assembly plate (45 min)
Prepare 2nd assembly plate
Break
10-10:45 Run 2nd assembly plate
Prepare 3rd assembly plate
11-11:45 Run 3rd assembly plate
Prepare 4th assembly plate
12-1:00
Lunch
1-1:45
Run 4th assembly plate
Prepare 5th assembly plate
2-2:45
Run 5th assembly plate
Prepare parts for next day’s assembly plates
Make-up time for assemblies with
problems
Receive parts, DB transfers, maintenance,
etc.
Break
3-5:00
DOE REVIEW 1/20/04 – Dean White
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Gantry Production Capabilities
TOB
• 5 TOB R-phi assembly plates
commissioned during 2003
• 1 TOB Stereo assembly plate
commissioned during 2003
DOE REVIEW 1/20/04 – Dean White
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Gantry Production Capabilities
TEC
• 1 TEC R6 assembly plate fully commissioned (designed and built over
the last 2 months of 2003).
• Part of new responsibilities for TEC module assembly at UCSB.
TEC hybrid tool
DOE REVIEW 1/20/04 – Dean White
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Gantry Production Capabilities
Additional Assembly Plates
• 10 more module assembly plates in different stages of design and
construction:
• 2 more TOB R-phi plates – dwgs are in the Physics machine shop
• 2 more TOB stereo plates – dwgs are in the Physics machine shop
• 2 more TEC R6 plates – dwgs are in the Physics machine shop
• 2 TEC R5N plates – design in progress
• 2 TEC R5S (stereo) – design in progress
• These 10 plates + the 7existing plates will give us the capability to build
2750 TOB and 1000-2000 TEC modules (R6, R5N & R5S) at UCSB.
• Switching between assembly plate types is easily, so modules can be built
from whatever parts that are available.
DOE REVIEW 1/20/04 – Dean White
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Summary
• During 2003:
• New 5th floor clean room installed
• Production of TOB and TEC modules, that are will within
specification, has been accomplished on the UCSB gantry.
• New assembly plate design developed here at UCSB.
• 79 modules assembled on gantry.
• Fabrication of multiple assembly plates of modules/day (4) has
been demonstrated.
• Gantry team is ready for 150 module production run over 2 weeks
that will begin the last week of January 2004.
DOE REVIEW 1/20/04 – Dean White
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