DESY Industrialization models for XFEL / ILC industrialization model...Consumables Storage Cavity...

ILC_snowmass05, D.Proch, DESY

DESY Industrialization models for XFEL / ILC

• TESLA activities ( model I):– Contracts to industry for costing of components– Planning, layout & operation of fabrication facilities for major linac

components (“study by industry”)– Detailed report about costs of a new fabrication facility (investment and

operation)– Style of report is finances oriented– Financial informations are confidential

• XFEL activities ( model II)– Contracts to industy, similar to type I, but– In preparation for the start of X-FEL production– Also includes proposal for modifications of design / procedure– One report about findings for cost reduction / performance improvements;

will be published– One report about costs; is confidential


Contracts to industry for evaluation of fabrication (“industrial study I”)

• Analyze present production of TTF components– Describe present fabrication process– Determine cost drivers, critical procedures– Define core technology, outsourcing possibility

• Implementation of mass production methods– Evaluate investment of machinery, tooling, roboting– Cost optimize flow of fabrication– Describe layout for “core tech” factory


Contracts to industry in cost evaluation, (“industrial study I”),cont.• Complete planning of new “core tech” factory

– Determine costs for buildings, investment, man power, ramp up & production & ramp down, overhead, consumables, QC,…

– Get bits for outsourced parts– Sum up total cost of component fabrication


Industrial studies type I

• Cavity fabrication (welding) for TESLA– Noell (Dornier- Astrium),

• Cavity preparation and module assembly– Noell, – ACCEL

• Niobium production for TESLA– Noell (W.C.Heraeus)– H.C.Stark (under test sheets production)


Standard Cavity Production, welding

Cavity Prototype production cost

35%

49%

4%6% 3% 2% 1%

Machining

Welding

QA

Chemistry

Administration

Consumables

Storage



Reduction of fabrication cost

• 3 chamber welding machine:– Pump down and cool down in separate chamber– Welding in middle chamber

• Tooling for welding many parts in one cycle• Outsource machining of parts


Production facility


Cavity mass production cost breakdown

77%

10%4% 4% 2%1%2%

MachiningWeldingQAChemistryAdministrationConsumablesStorrage


Cavity Prototype production cost

35%

49%

4%6% 3% 2% 1%

Machining

Welding

QA

Chemistry

Administration

Consumables

Storage

Cavity mass production cost breakdown

77%

10%4% 4% 2%1%2%

MachiningWeldingQAChemistryAdministrationConsumablesStorrage


Industrial Studies type I:Cavity preparation, Cryostat and Assembly

• X-FEL cryo-modules are based on the 12 m TTF modules

• Two industrial investigations– Cavity preparation and module assembly by

• Babcock Noell Nuclear

– Vacuum vessel and cold mass by• ZANON


Cavity Preparation; String and Module Assembly


Cavity preparation, Cryostat and Assembly, cont.

• Major cost drivers are– Cavity heat treatment (1400°C) :

investment and operation costs

– Module assembly:man power

→ New study under preparation to optimize the cryostat assembly procedure


Industrial Study type II:XFEL-Cryomodule Design&Assembly

Bernd Petersen DESY –MKS- (technical coordinator)phone: +49 40 8998 [email protected]

Part of EUROFEL Design Study Workpackage DS6Part of EUROFEL Design Study Workpackage DS6

BESSY and DESY areBESSY and DESY are partners in DS6partners in DS6


MotivationPreparation of the European XFEL-Project and othersuperconducting linac based FEL-light sources like the BESSY FEL

In particular, preparation of the serial production of about 120 XFEL-cryomodules for the European XFEL-Project

Input for the final design and assembly procedures for theXFEL-cryomodules

Each cryomodule consist of:

8 1.3 GHz 9-cell Nb cavities

1 magnet package

2 thermal shields

8 main RF couplers

8 cold tuners


ScopeIndustrial XFEL-cryomodule design and assembly study

The present cryomodule assembly procedures and some aspects of the present design shall be analyzed and questioned with respect to the most cost effective serial production.

The key aspects of the study are as follows:1.2.1 Define the assembly procedure1.2.1 Analyze cost-reduction and production efficiency measures1.2.3 Analyze performance improvement measures1.2.4 Supply a cost estimate for the module production

A substantial part of the IS shall be the presence of CONTRACTOR’sexperts during the assembly of two prototype cryomodules at DESY.

SupportedSupported byby the EUROFEL designthe EUROFEL design studystudy


Cryomodule Assemblythe study shall cover clean room assembly and the assemblyoutside cleanroom

Startpoint: string assembly in cleanroom

(all parts are tested and ready for assembly)

Clean room assembly Assembly outside cleanroom


Procurement Procedures

EU callfor tender

Selection of suitedcontractorsfor bidding

Auditing of suitedcontractors

Specification (framework of studies)

biddingSelection of suitedoffers & contracting

Module assembly

Reports on assemblystudies

Supervising contractorsSpecification

of criteria

21.01.2005

22.04.2005

Industrial XFEL-cryomodule design and assembly study


DeliverablesFour reports on the specified issues:

1) Report on assembly of module 6

2) Report on assembly of module 8

3) Report on BESSY-FEL cryomodule special issues (cw-operation)

4) Final reportThe reports shall cover also specialissues, as specified

These reports will be published as part of theEUROFEL-Study

Cost issues shall be covered in separated attachments to the reports. These attachments are confidential and will not be published.


Industrialization process

Power couplers for XFEL projectas an example

------------


Industrialization: Topics of development -1-

Design for « manufacturability »

• Review existing design

• Identify the necessary functions

• Determine maximum acceptable tolerances

• Identify possible options for design

• Seek functional simplicity :

• to minimise the number of parts

• use standard products whenever possible

• design for ease of assembly: several assembly solutions are possible, investigate and optimise

• design for ease of control and test

• design in view of packing and transport


Industrialization: Topics of development -2-

• Risk mitigation:

• Assessment and re-design of areas af technical and process risk

• Generation of product and process specifications

• Update design

• Validation phase:

• Modelling of component and process

• Testing

• Prototypes

• Update design

• Other design topics to be considered:

• reliability (of components, welds, coatings)

• other risks (of procurement, logistics, financial)

• MTBF, failure analysis (welds, windows, motions)

• maintainability (easiness of replacement)

• ergonomy (handling, assembly)


For the XFEL power couplers, industrialization studies will be performed through “Definition contracts” :

• Essentially intellectual work (in dialog between the industry and our Lab) :

Define all manufacturing processes (analysis and validation models)

Risk analysis (process, logistics)

Determine cost in series and justify

• Produce 2 prototypes (to be tested at LAL – Orsay)

• (Reports about technology and costs (confidential))

Particularities

• 3 contracts will be awarded on the same subject: « Industrial studies »

• 2 teams will be selected after final evaluation

• contracts for manufacturing 2 series of 500 XFEL couplers will be awardedwithout a new call for tenders

• the 2 contracts may be awarded to a single company


Keypoints of the definition contracts

Contract Award: T0

Kickoff meeting: soon after T0

System Design Review: T0 + 3 months- functional analysis- identification of processes and proposal for models- preliminary development plan, management plan

Preliminary Design Review: T0 + 8 months- models for welding, brazing, specific materials, Cu coating- Quality assurance plan- development plan, management plan- Technical design review- preliminary risk analysis

Critical Design Review: T0 + 14 months- final models for validation of Cu coating

- final justification design file

- final risk analysis

- preliminary cost analysis

Final Review: T0 + 21 months- delivery of 2 prototypes

- plan for logistics of manufacturing and conditioning

- final cost report

DESY Industrialization models for XFEL / ILC industrialization model...Consumables Storage Cavity...

Documents

Transcript of DESY Industrialization models for XFEL / ILC industrialization model...Consumables Storage Cavity...