KM3 design to cost

Beurthey Stéphan/CPPM/IN2P3Beurthey Stéphan/CPPM/IN2P316/04/0716/04/07

KM3 design to costKM3 design to costMechanic optimization Mechanic optimization


Design to costDesign to cost

•What is it and Why? What is it and Why? •Cost Models ApproachCost Models Approach•Cost Analysis and OptimizationCost Analysis and Optimization

•Simple Mechanical OptimizationSimple Mechanical Optimization•Recovery System Recovery System •PM repartition (hypothesis)PM repartition (hypothesis)•Embedded PMEmbedded PM•Data linkData link


KM3 Design to costKM3 Design to costWhat and Why?What and Why?


What is it? (design to cost)What is it? (design to cost)• Industrial approachIndustrial approach::

•Design is driven by the cost;Design is driven by the cost;•Design respect only Design respect only requirements.requirements.

New

Con

cept

New

Arc

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RequirementAnalysis

Risk Analysis

Interesting concept?

no

Conceptrejected

Cost Analysis

yes


Why?Why?The biggest detector The biggest detector

Cost reductionCost reductionOn known concept (ANTARES)On known concept (ANTARES)

The cheapest detectorThe cheapest detector


KM3 Design to costKM3 Design to costCost Models ApproachCost Models Approach

From the buoy to the Junction BoxFrom the buoy to the Junction Box


Container(LCM,SPM)

CableConnectors

Structure(OMF)

BSS

Buoy

Releasesystem

Sphere (OM)

Sea operationsystem

Inter link

Field of workField of work30% of the global ANTARES costcost reduction potentialcost reduction potential


Cost dependencesCost dependences• Detector ArchitectureDetector Architecture

• PM repartition: 3, 6 PM/storey?PM repartition: 3, 6 PM/storey?• Distance between storey: 12, 30m?Distance between storey: 12, 30m?• Concept (Antares, Nemo, Nestor, …)Concept (Antares, Nemo, Nestor, …)

• Sea operation constraints: Sea operation constraints: • DeploymentDeployment• ConnectionConnection• Structure and Cable strength, …Structure and Cable strength, …

• Sea constraints:Sea constraints:• Corrosion: Aluminium, Titanium, …Corrosion: Aluminium, Titanium, …• Pressure, …Pressure, …

• Data transmission Data transmission • Copper, fibre, …Copper, fibre, …

• Integration:Integration:• connectors, penetrators, …?connectors, penetrators, …?

• …… Cost

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ApproachApproach• System approach: System approach:

• Cost reduction have impact on others productsCost reduction have impact on others products

• Cost models:Cost models:• Fast cost evaluation in function of the concept/designFast cost evaluation in function of the concept/design• Iterate with data transmission, physics, sea operations, Iterate with data transmission, physics, sea operations,

integration, …integration, …• Cost model sensitive to:Cost model sensitive to:

MaterialMaterial DesignDesign Spatial PM repartitionSpatial PM repartition Connectors/penetratorsConnectors/penetrators Data transmissionsData transmissions Electronics compacityElectronics compacity Sea operation constraintsSea operation constraints Recovery Recovery Flotability …Flotability …


ANTARES costANTARES costPart Cost (€) Cost/line OM support 220 16500

OM Link 600 45000

Sphère+Base+.. 1100 82000

LCM 1200 30000

OMF 1200 30000

SPM 4500 4500

Buoy system 16500 16500

BSS 51000 51000

Release system 22000 22000

IL+ Conn. +jumper 108000 108000

EMC cable/line 116000 116000

ANTARES ANTARES cost/line: cost/line: 530k€530k€

Cost on Cost on defined defined

perimeterperimeter


Model StrategyModel StrategyIntroduce sensitive Introduce sensitive

parametersparameters

Parametric Parametric ModelsModels

Fit these models with ANTARES Fit these models with ANTARES costcost


Mechanical modelsMechanical models

C_x= M_x. cmat + Cmachining

Product cost

Weight Machining cost

Ti 75€/kg

Fe 6€/kgPE 10€/kg

Material cost

Possibility of several materials/PartPossibility of several materials/Part


WeightWeight

: density (4500 Ti)P: Pressure (250b)Re: tensile strength (900MPa Ti)Velec: electronic volume (16l)

H: high of storey (2m)F: line traction resistance (18T)Flot: line floatability (1800Kg)

Parts Formula ANTARES (Kg)

LCM ~ .Velec .P/Re 16

OMF ~.F.H/Re 16

BSS Titanium 25 25BSS Steel ~(Flot+800) 2600

BSS PE (release system)

25 25

OM support (Ti) 2 2Cable fixation (Ti) 2.5 2.5Buoy fixation 16 16


Machining costMachining cost

Part Machinning Cost (€)

LCM 400

OMF 500

BSS 15000

OM Support 70

Other 1/3.M_X.cmat


Manufactured product modelsManufactured product models

PM modelPM modelPM parts €

Base 140

Base supports 20

Glass sphere 600

Magnetic shield 160

Gel 80

OM Assembly / testing 70

Connector base 20

1100€/PM

PM is not included in this modelPM is not included in this model


Manufactured product modelsManufactured product models

Data link modelData link model

CC_cable_cable=L.=L.cccablecable+N+Nconnecconnec..ccconnecconnec

link cost link length

Number of connexion

Connection cost(connector or penetrator)

cable cost (€/m)

Possibility of different Possibility of different connections/Linkconnections/Link


Cable type €/m

ANTARES EMC (21 fibers,2 power) 33

ANTARES IL (7 fibers,2 power) 20

ANTARES OM link 10

21 twisted pairs 0.5mm2 30



2 power 1mm2 + 2 fibres 10

Cable costCable cost


Connection costConnection costConnexion type €

ANTARES EMC penetrator 1100

ANTARES EMC water block 2700

ANTARES IL link connector+base 49000

ANTARES OM link Titanium connector+base 700

ANTARES OM link Ti penetrator 300

7 twisted pairs connector+base 400


(2 power + 2 fibers) connector+base 2000

Break out on twisted copper cable 100

*: EstimationPrice of moulding is includedPrice of moulding is included


Mechanics Mechanics Cost Analysis and Cost Analysis and

OptimizationOptimization

KM3 design to costKM3 design to cost


Simple Mechanical optmizationSimple Mechanical optmization• Ti Ti Al: -15k€ Al: -15k€

• LCM:LCM:• OMF:OMF:

• Design improvement: -10k€Design improvement: -10k€• -20% on OMF height:-20% on OMF height:• -20% on flotability:-20% on flotability:• -20% on BSS weight:-20% on BSS weight:

Cost reduction/line: -25k€Cost reduction/line: -25k€

Small cost reduction (<5%) on constant perimeter

System Approach Cost on Cost on defined defined

perimeterperimeter

3030

2223 K€

K€ 2x if we use 2x if we use today Ti pricetoday Ti price


Release system costRelease system cost• BSS release system: 5k€BSS release system: 5k€• Release : 22K€Release : 22K€• IL connexion: 49k€IL connexion: 49k€• (Boat recuperation: 30k€)(Boat recuperation: 30k€)

Needs of this system/Line cost

Low cost system?

Cost reduction/line: -76k€ Cost reduction/line: -76k€ (15%) (106k€ with boat)(15%) (106k€ with boat)

On defined On defined perimeterperimeter


• Data linkData link• Sphere+supportsSphere+supports 166166• LCM, SPM/SCMLCM, SPM/SCM• OMFOMF• BSSBSS 3333• Release systemRelease system 2222• BoyBoy 1616• IL+connexionIL+connexion 108108

PM repartition InfluencePM repartition Influence• 6 PM/storey6 PM/storey• 12 storeys12 storeys• 28m between storey28m between storey• 100m BSS/first storey100m BSS/first storey• IL 500mIL 500m• Same BSS/ANTARESSame BSS/ANTARES• LCM, OMF: x2 biggerLCM, OMF: x2 bigger• 10 Water block10 Water block

Cost/line: Cost/line: 460k€460k€-65k€ (15%)-65k€ (15%)/ANTARES/ANTARES

Line with nearly Line with nearly the number of PM the number of PM and length of and length of ANTARESANTARES

11667

353023

25



Embedded OMEmbedded OM

• 2 Embedded PM with LCM:2 Embedded PM with LCM: OM link: -1800€/storeyOM link: -1800€/storey sphere: -1800€/storeysphere: -1800€/storey OM Support: -1500€/storeyOM Support: -1500€/storey Sphere machining: -?Sphere machining: -? LCM: -2000€/storeyLCM: -2000€/storey Add Al torus of 20kg:+1000€/storeyAdd Al torus of 20kg:+1000€/storey

• 6 PM/storey6 PM/storey• 12 storeys12 storeys -75k€/ligne (-15%)

• 6 PM/storey6 PM/storey• 12 storeys/line12 storeys/line



25MHz/storey 25MHz/storey

2 fibers/2 power :2 fibers/2 power : 10k€10k€(4 cables:130+210+300+390 m)(4 cables:130+210+300+390 m)

8 Optical connections: 8 Optical connections: 16k€16k€

7 pairs cable : 7 pairs cable : 3k€3k€(30mx8 cables)(30mx8 cables)

16 Connexions 16 Connexions 3k€3k€(4 wires)(4 wires)

32k€/ligne (-38k€)

Data linkData link • 6 PM/storey6 PM/storey• 12 storeys12 storeys

• 28m between storey28m between storey• 100m BSS/first storey100m BSS/first storey

Cable type €






Cable type €/m





Connector Connector integration time integration time

reducereduce


Coïncidence: 25kHz/storeyCoïncidence: 25kHz/storey

12 pairs cable 12 pairs cable 10k€10k€(500m) (500m) ++12 Breakout: 12 Breakout: 1,5k€1,5k€

++12 Connections 12 Connections 2,5k€2,5k€(4 (4 wireswires))

++1 connection 1 connection 0,5k€0,5k€(24 wires)(24 wires)

15k€/ligne (-55k€)

Data linkData link • 6 PM/storey6 PM/storey• 12 storeys12 storeys

Twisted Copper


Cable type €






Cable type €/m





Connector Connector integration time integration time

reducereduce


Optimized Optimized LineLine

• TiAl: 15k€• Design improvment: 10k€• Release system: 76k€• 6PM/storey: 65k€• Embedded PM: 75k€• Copper Data link: 55k€

~300k€

ANTARES line ANTARES line cost: 530k€cost: 530k€

New line New line cost: 240k€cost: 240k€ -55%-55%

• 6 PM/storey6 PM/storey• 12 storeys12 storeys




One more step for One more step for optimizationoptimization

Cost deployment reduction

Compact line

cable <30mm


Conclusions:Conclusions:• Optimization up to 50% with design to cost system Optimization up to 50% with design to cost system

approachapproach

• ““Well known” proposed solutions but risk analysis should be Well known” proposed solutions but risk analysis should be done (in progress)done (in progress)

• Iterations with physics, sea operation, data transmission Iterations with physics, sea operation, data transmission and integration needed (in progress)and integration needed (in progress)

• Development cost should be taken into accountDevelopment cost should be taken into account

• Others optimization should be studied:Others optimization should be studied: Sea operation with compact lineSea operation with compact line Oil IL (cheap connectors), Jumper IL take awayOil IL (cheap connectors), Jumper IL take away

KM3 design to cost

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