14-Dec-15S.Movchan Straw manufacturing and QC1 Straw manufacturing procedure and QC tape and straw...

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Jun 14, 2022 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.Movcha

Transcript of 14-Dec-15S.Movchan Straw manufacturing and QC1 Straw manufacturing procedure and QC tape and straw...

Page 1: 14-Dec-15S.Movchan Straw manufacturing and QC1 Straw manufacturing procedure and QC tape and straw parameters specification conditions of straw production:

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

Page 2: 14-Dec-15S.Movchan Straw manufacturing and QC1 Straw manufacturing procedure and QC tape and straw parameters specification conditions of straw production:

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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

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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

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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

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“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

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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

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Straw welding machine, heard and anvil

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Straw machine with microscope + oscilloscope

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Ultrasonic generator control

• frequency: F=38 kHz• amplitude: U=40 V

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Seam shape QC by microscope

“Good” seam shape “Bad” seam shape

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Gun with ionization air: for clean of anvil and tape from dust

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Weld seam visual QC

for DB

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“go - no go” gauge for straw diameter check

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Tool for straw length calibration (based on scissors)

L=(2400+/- 1) mm

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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)

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Overpressure QC

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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)

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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

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Straw diameter and non straightness measurement

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Straw long term test (1-3 months) = damage + gas leak

Used nipple from bake well

dP=1.5 Bar at (1-3) months

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Straw gas leak value measurement (if needed)

Reference straw

Tested straw

Diff.manometer

Ch1

Ch2

Straw gas leakage measurement stand

based on diff. manometer

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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

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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