3. Production and control of Bakelite 3.1 Definition and standards

28
RPC Barrel EDR 3. Production and control of Bakelite 3.1 Definition and standards Standard bakelite electrodes are composed by • a bulk made of phenolic resin • a surface made of melaminic/phenolic resin In the following: Melaminic = bulk phenolic and surface melaminic Phenolic = bulk and surface phenolic BULK SURFACE

description

3. Production and control of Bakelite 3.1 Definition and standards. Standard bakelite electrodes are composed by a bulk made of phenolic resin a surface made of melaminic/phenolic resin In the following: Melaminic = bulk phenolic and surface melaminic - PowerPoint PPT Presentation

Transcript of 3. Production and control of Bakelite 3.1 Definition and standards

Page 1: 3. Production and control of  Bakelite 3.1 Definition and standards

RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.1 Definition and standards

3. Production and control of Bakelite3.1 Definition and standards

Standard bakelite electrodes are composed by • a bulk made of phenolic resin • a surface made of melaminic/phenolic resin

In the following:Melaminic = bulk phenolic and surface melaminicPhenolic = bulk and surface phenolic

Standard bakelite electrodes are composed by • a bulk made of phenolic resin • a surface made of melaminic/phenolic resin

In the following:Melaminic = bulk phenolic and surface melaminicPhenolic = bulk and surface phenolic

BULK

SURFACE

Page 2: 3. Production and control of  Bakelite 3.1 Definition and standards

RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.2 Quality control data flow

3. Production and control of Bakelite3.2 Quality control data flow

Bulk resistivity Determines the time constant of an elementary RPC cell, = 0 (r + 2 )

Average roughness Ra

It is related to the quality of the surface. A small Ra reduces spontaneous discharges which might affect the RPC rate capability

Dielectric constant r

It is related to and to the averagefast charge qe of a single avalanche

Bulk resistivity Determines the time constant of an elementary RPC cell, = 0 (r + 2 )

Average roughness Ra

It is related to the quality of the surface. A small Ra reduces spontaneous discharges which might affect the RPC rate capability

Dielectric constant r

It is related to and to the averagefast charge qe of a single avalanche

Protocol

Production

Measurement

Storage

Data acquisition

Out of range

Decide limits for accepting a given bakelite sheet on the basis of measurements

Decide limits for accepting a given bakelite sheet on the basis of measurements

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3. Production and control of Bakelite3.3 Production requirements

3. Production and control of Bakelite3.3 Production requirements

Resistivity range :• 2/3 of production in the range = 2-5 1010 cm• 100% of production in the range = 1-6 1010 cm

Resistivity range :• 2/3 of production in the range = 2-5 1010 cm• 100% of production in the range = 1-6 1010 cm

Average Roughness range :

• Ra = < 0.2 m

Average Roughness range :

• Ra = < 0.2 m

Size (thickness = 2 mm): • 1.3 m x 2.8 m “small” slabs• 1.3 m x 3.2 m “large” slabs

Needs:• 3000 (+150) “small” slabs (11466 m2)• 500 (+ 25) “large” slabs (2184 m2)

Total 3675 Slabs (13650 m2)

Size (thickness = 2 mm): • 1.3 m x 2.8 m “small” slabs• 1.3 m x 3.2 m “large” slabs

Needs:• 3000 (+150) “small” slabs (11466 m2)• 500 (+ 25) “large” slabs (2184 m2)

Total 3675 Slabs (13650 m2)

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3. Production and control of Bakelite3.4 Resistivity control

3. Production and control of Bakelite3.4 Resistivity control

Factory Main Parameters:

How muchthe resin spreads

out on the paper foil

Percentage of resin

in the paper

Relate the factory parametersto the bulk resistivity

• Type of Paper• Flow• Resin• Volatile• Heating Temperature• Pressing Temperature• Resin Reactivity

Percentage of additives Volatile

GOES

GOES

Up

Up

Up

Down

Resin

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RPC Barrel EDR Chapter 3

A measured value has to bemultiplied for a multiplicativefactor (20/ to obtain ( i.e. at T=20 C )

A measured value has to bemultiplied for a multiplicativefactor (20/ to obtain ( i.e. at T=20 C )

T (0C)

3. Production and control of Bakelite3.5.1 Temperature dependence

3. Production and control of Bakelite3.5.1 Temperature dependence

The resistivity depends on the temperature T

20/= exp( (20-T) )

The resistivity depends on the temperature T

20/= exp( (20-T) )

To define a common production protocol we usually quote a resistivity value at T = 20 0C using as normalisation the following experimental curve.

To define a common production protocol we usually quote a resistivity value at T = 20 0C using as normalisation the following experimental curve.

20/

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RPC Barrel EDR Chapter 3

Resistivity and Temperature

1,45

1,50

1,55

1,60

1,65

1,70

1,75

1 5 9 13 17 21 25 29 33 37 41 45 49 53

N. of measures (1 pt /15 minutes)

21,0

21,2

21,4

21,6

21,8

22,0

22,2

22,4

22,6Here temp starts to decrease

while

Then also startsto increase

3. Production and control of Bakelite3.5.2 Resistivity and Temperature

3. Production and control of Bakelite3.5.2 Resistivity and Temperature

Note also the ``inertia” of the bakelite in following the temperature change

(

x 10

11)

cm T (C)

is stillconstant

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.6 Resisitivity range

3. Production and control of Bakelite3.6 Resisitivity range

Bulk resistivity measurements - melaminic: production is able to reproduce the useful resistivity range

0,00

1,00

2,00

3,00

4,00

5,00

6,00

7,00

0 5 10 15 20

Slabs

(

x 10

10)

c

m

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3. Production and control of Bakelite3.7.1 Roughness range

3. Production and control of Bakelite3.7.1 Roughness range

Roughness QualityRoughness Quality

Qualitative view of the surface improved bakelite. Pixel matrix greyscale of a micro-picture of the surface

Pix

e l G

reys

cal e

Val

ue

X (Pixels)Y (Pixels)

X 600magnification

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3. Production and control of Bakelite3.7.2 Roughness range

3. Production and control of Bakelite3.7.2 Roughness range

Ra (

m)

Vertical deviation of the surface from its average profile

Ra

Measurements points on the surface

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3. Production and control of Bakelite3.8.1 Resistivity measurement

3. Production and control of Bakelite3.8.1 Resistivity measurement

Needs good electrical contact between electrodes and bakeliteNeeds good electrical contact

between electrodes and bakelite

We tried several options for the contact - among others:

• sponge with water

• antistatic foam (with and without water)

• conductive gel

• conductive rubber

We tried several options for the contact - among others:

• sponge with water

• antistatic foam (with and without water)

• conductive gel

• conductive rubber

• Brass Electrodes• Upper 5 cm • Lower 10 cm for guard ring option

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3. Production and control of Bakelite3.8.2 Resistivity measurement

3. Production and control of Bakelite3.8.2 Resistivity measurement

Constant pressure (3 atm) on the electrodes

How to measure ~ 1010 - 1011 cm

R = 10 ,100 k

= k V0/(V/R)

k = geometrical factor

V0 = 500 Volts

V0

VR

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3. Production and control of Bakelite 3.8.3 Resistivity measurement

3. Production and control of Bakelite 3.8.3 Resistivity measurement

Upper electrode

Lower electrode

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.9.1 Systematic

3. Production and control of Bakelite3.9.1 Systematic

A piston with conductive rubber is continuously measuring the resistivity of a bakelite sample; after a predetermined set of measurements the piston moves up for a fixed time and back down on the sample for the next cycle of measures.

Number of cycles, number of

measurements within a cycle,

time between cycles and time

between measurements are

supplied by the user. Automatic

reading of Temperature and Humidity is provided.

A piston with conductive rubber is continuously measuring the resistivity of a bakelite sample; after a predetermined set of measurements the piston moves up for a fixed time and back down on the sample for the next cycle of measures.

Number of cycles, number of

measurements within a cycle,

time between cycles and time

between measurements are

supplied by the user. Automatic

reading of Temperature and Humidity is provided.

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RPC Barrel EDR Chapter 3

0,9

1,0

1,1

1,2

1,3

1,4

1,5

1,6

1 23 45 67 89 111133 155177 199 221243 265287 309331 353 375397Time (A.U.)

20

(x 1

011)

cm

47

47,5

48

48,5

49

49,5

50

50,5

51

Hu

mid

ity

(%)

3. Production and control of Bakelite3.9.2 Systematic

3. Production and control of Bakelite3.9.2 Systematic

400 cycles of measurements, 10 meas./cycle, 10 sec after each measurements (~13 hours).

The resistivity (at T= 20 °C) of a melaminic sample as a function of time is plotted (left hand scale- purple). The recorded value of the Humidity is also shown (right hand scale - blue)

13 hours

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.9.3 Systematic

3. Production and control of Bakelite3.9.3 Systematic

0

0,05

0,1

0,15

0,2

0,25

0,3

0,35

0,4

0,7 0,9 1,1 1,3 1,5

Frequency distribution of 20/<20>

= 5,2 %

We can measure at a level of 5 %

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3. Production and control of Bakelite3.10.1 Station for resistivity measurement

3. Production and control of Bakelite3.10.1 Station for resistivity measurement

Lifting belt- conveyors bed

Fixed frame Transverse beams supporting the upperelectrodes system

Pistons

BAKELITE

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite 3.10.2 Station for resistivity measurement

Upper position of the belt conveyors bedfor bakelite loading and unloading

Pistons integral to the upper beam of the fixed frame

Fixed frame

Mobile frame integral to the belt conveyors bed

Position of the lower electrodes integral to the lower beam of the fixed frame

Rectified cylinder

Pneumatic piston for belt conveyors lifting

Adjustable feet

Conveyors belts

Lateral guide

Lower position of the belt conveyors bedfor measurements

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.10.3 Station for resistivity measurement

3. Production and control of Bakelite3.10.3 Station for resistivity measurement

567.5 1135.0 1135.0 567.5

1384

.813

16.0

1042

.0

position A position

B

Side view lengths in mm

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.10.4 Station for resistivity measurement

3. Production and control of Bakelite3.10.4 Station for resistivity measurement

520.0 505.0 505.0 520.02050.0

position A

position B

Front view(lengths in mm) Bakelite

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.10.5 Station for resistivity measurement

3. Production and control of Bakelite3.10.5 Station for resistivity measurement

Top view(lengths in mm)

2050

.018

40.0

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.10.6 Station for resistivity measurement

3. Production and control of Bakelite3.10.6 Station for resistivity measurement

Setup for DAQ and measurements bench-tests

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.10.7 Station for resistivity measurement

3. Production and control of Bakelite3.10.7 Station for resistivity measurement

RS-232 Network Module

8 Ch, SPST Relays Module

8 Ch, 12 Bit Analog Input Modules

8 ch Universal Discrete Input Module

Electronics: modular distributed I/O architecture FIELDPOINT (Nat. Instr.) with analog and discrete I/O modules, terminal bases and network communication module (RS232)DAQ: Labview 5.0x

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.10.8 Station for resistivity measurement

3. Production and control of Bakelite3.10.8 Station for resistivity measurement

Pre-production Resistivity measurements at the factory

Man

ual M

easu

rem

ents

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.10.9 Station for resistivity measurement

3. Production and control of Bakelite3.10.9 Station for resistivity measurement

Pre-production Resistivity measurements at the factory

Man

ual P

roto

type

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.11.1 Quality control time schedule 3. Production and control of Bakelite3.11.1 Quality control time schedule

production

Slabs at rest for a week

measurementsloading unloading stacking

Manual Automatic Manual

15 sec 4 min 15 sec

•Slab in position •Pistons down•Measurements•Pistons up•Slab is moving out

6 hours / (4 min/slab) ~90 slabs/day ~ 1800 slabs/month

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RPC Barrel EDR Chapter 3

3. Production and control of Bakelite3.11.2 Quality control time schedule 3. Production and control of Bakelite3.11.2 Quality control time schedule

1/10 4/10

1999 2000

TASK Jul Aug Sept Oct Nov DecJan Feb Mar Apr May Jun

Tabledelivery

Setup

Ready tomeasure atfirm

BakeliteProduction

Measurement

5/10

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3. Production and control of Bakelite3.12.1 Ageing

3. Production and control of Bakelite3.12.1 Ageing

Gamma (137Cs) Irradiation Facility

Gamma (137Cs) Irradiation Facility

vs Temp. (0 C)

(B) vs Integrated Dose (Gy)

A

BSource ON

Source OFF

Melaminic sample

10 y LHC

Page 28: 3. Production and control of  Bakelite 3.1 Definition and standards

RPC Barrel EDR Chapter 3

10 y LHC

Gamma (137Cs) Irradiation Facility

Gamma (137Cs) Irradiation Facility

vs Temp. (0 C)

(B) vs Integrated Dose (Gy)

A

BSource ON

Source OFF

Phenolic sample

3. Production and control of Bakelite3.12.2 Ageing

3. Production and control of Bakelite3.12.2 Ageing