1. DOE REVIEW 1/20/04 – Dean White 1 Gantry Module Assembly TOB & TEC Dean White University of California, Santa Barbara

2. DOE REVIEW 1/20/04 – Dean White 2 Talk Overview Gantry Personnel New 5 th floor clean room Gantry design Gantry module precision Gantry production capabilities Summary

3. DOE REVIEW 1/20/04 – Dean White 3 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.

4. DOE REVIEW 1/20/04 – Dean White 4 New 5 th Floor Clean Room Reasons for new 5 th 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

5. DOE REVIEW 1/20/04 – Dean White 5 New 5 th 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.

6. DOE REVIEW 1/20/04 – Dean White 6 Gantry Design BREIF DISCUSSION OF UCSB GANTRY AND MODUDE ASSEMBLY TOOLING Aerotech AGS 1000 gantry X,Y,Z & U (rotational) positioning system Gantry image recognition system and electronics. Vacuum/Pressure control values

7. DOE REVIEW 1/20/04 – Dean White 7 Gantry Design – Assembly Plates CERN style assembly plate Laminated assembly plate Vacuum chuck plate PVC support and vacuum posts

8. DOE REVIEW 1/20/04 – Dean White 8 Gantry Design – Assembly Plates Vacuum chucks and vacuum transfer lines on gantry base plate

9. DOE REVIEW 1/20/04 – Dean White 9 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

10. DOE REVIEW 1/20/04 – Dean White 10 Gantry Design – Assembly Plates Assembly plate feet that rest on vacuum chucks - precision machined flat and parallel Sensor vacuum Hybrid vacuum Hybrid supply vacuum

11. DOE REVIEW 1/20/04 – Dean White 11 Gantry Design – Assembly Tooling TOB / TEC HYBRID AND SENSOR PICK-UP TOOLS. TOB HYBRID BRIDGE

12. DOE REVIEW 1/20/04 – Dean White 12 Gantry Design – Assembled Modules 3 completed modules on the assembly plate.

13. DOE REVIEW 1/20/04 – Dean White 13 Gantry Precision - Sensors

14. DOE REVIEW 1/20/04 – Dean White 14 Gantry Precision - Hybrids

15. DOE REVIEW 1/20/04 – Dean White 15 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: 8-9:00Survey modules, install into carrier plates for 5 plates (50 min) 9-9:45Run 1 st assembly plate (45 min) Break 10-10:45 Run 2 nd assembly plate 11-11:45 Run 3 rd assembly plate 12-1:00Lunch 1-1:45Run 4 th assembly plate 2-2:45Run 5 th assembly plate Break 3-5:00Make-up time for assemblies with problems Technician Two: Load assembly plate, DB entry, glue prep (50min) Prepare 2 nd assembly plate Prepare 3 rd assembly plate Prepare 4 th assembly plate Prepare 5 th assembly plate Prepare parts for next day’s assembly plates Receive parts, DB transfers, maintenance, etc.

16. DOE REVIEW 1/20/04 – Dean White 16 Gantry Production Capabilities TOB 5 TOB R-phi assembly plates commissioned during 2003 1 TOB Stereo assembly plate commissioned during 2003

17. DOE REVIEW 1/20/04 – Dean White 17 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

18. DOE REVIEW 1/20/04 – Dean White 18 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.

19. DOE REVIEW 1/20/04 – Dean White 19 Summary During 2003: New 5 th 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.