MINERvA Mini-Review Debbie Harris Jeff Nelson Kevin McFarland Jeff’s slides version 1.

MINERvA Mini-ReviewDebbie Harris

Jeff NelsonKevin McFarland

Jeff’s slides version 1

MINERA DOE Mini-Review

Deborah HarrisFermilab

1/9/2009 2

Outline of talks

• Project Overview: Deborah Harris– MINERvA Physics– MINERvA Construction Paths

• Plane Assembly Technique: Jeff Nelson– Plane Ingredients and Outfitting Needs– Plane Assembly steps– Lessons Learned from Tracking Prototype Production

• Module Performance: Kevin McFarland– Module Definitions and Criteria– Module QC procedures and status report

• Schedule Acceleration Plan: Deborah Harris– Schedule – Costs– Conclusions



The goals in this task:from scintillator bars to assembled

detector elements

• Receive– Scintillator, mirrored fibers,

optical connectors• Produce

– Inner detector planes (ID)• 127 strips per plane• 2 planes per tracker module• 196 deployed in full detector

– Outer detector towers (OD)• 4 pairs of strips per tower• 6 towers per module• 648 deployed in full detector

• Ship to Fermilab for module assembly & detailed source scans



WBS 3: Scintillator assembly(Jeff Nelson, L2 manager)

• William & Mary, Hampton University & Rochester– Rochester and W&M led development of plane and tower design– Rochester led module integration– W&M lead the plane assembly prototyping and outfitting design– HU led development of on-site QA– HU and W&M prototyped plank and tower assembly

• Assembly 3 sites– William & Mary (Jeff Nelson, PI)

• 2 plane assembly stations• Tower assembly site• Machine parts• Supplies and parts procurement• Shipping crate procurement and warehouse

– Hampton (Eric Christy, PI)• 2 plane assembly stations• Tower assembly site• Coordinates skin material procurement

– Fermilab (Jim Kilmer site coordinator)• Shipping for all sites• Planks for all sites• 4 plane assembly stations• Fermilab and Rochester technical staffing


Deborah HarrisFermilab Life cycle of a plane

• Preassembly planks (at FNAL)– Cut scintillator– Glue planks – Trim planks (to move to FNAL)– Reflective paint on plank ends

• Plane assembly (1 or 2 days)– Glue lower skin, side & planks– 4hr cure time (optional)– Fill any gaps between planks– Clear fiber holes– Glue upper skin & upper combs– 4hr cure time

• Fibers & connectors (1 or 2 days)– Attach fiber baggies– Tread fibers– Pot connectors – Let cure

• Polish and Pot (1 or 2 days)– Polish connectors and mount– Optically couple fibers in scint– Glue lower combs– Let cure

• Seal and test (1 day)– Seal fiber baggies and edges– Light leak test top– Light leak test bottom– Load into shipping crate

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Dark Blue = on plane workstationLight Blue = on cartRed = at the Fermilab planking facility

Could be done in 4 workstation days with enough staffSchedule assume 8.75 days



Cutting scintillator and making planks

• For the tracking prototype this was done at W&M and HU• For MIE this is being done at Fermilab

– First deliveries this fall and now in routine production

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Plane assembly



The first 2 planes completed at Hampton (1st week of October)

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12/10/2008 10

Plane Workstation Staffing

• Based on Tracking Prototype experience, the days/plane/workstation has been around 7.5

• In full production mode, for VA factories, there will also be OD work, but no planking

• To get aggressive but achievable rates, assume 7.5*(1.15) or 8.75 days/plane/workstation

• Workstation model for FNAL: – 1 workstation on February 1, – 4 workstations starting March 1– Glue machine scheduled to arrive in early February

• Personnel requirements: 2.5 FTE’s for 1 or 2 workstations, 5 FTE’s for 4 workstations



1/9/2009 11

Conclusions

• Demonstrated the industrialization of MINERvA scintillator plane assembly– Due to design changes (esp. plank-based method) made

after the Full Module Prototype experience, the final assembly method is more intensive than originally envisioned but produced a better product

• The Fermilab planking site envisioned at the September Review is in full production– The first FNAL planks were used in planes in November

and December • Labor needs and production rates have been established

based on experience gained over assembly of the planes for the Tracking Prototype

• The Fermilab ramp up model is based on the experience of the successful Hampton University turn on

1/9/2009 12



Fermilab plane assembly site status

• Decision to go ahead with the Fermilab assembly site in late September

• Staffed by FNAL, Rochester, and collaborators (esp. during summer)– 4 workstations

• Outfitting in progress– Workstations in plane– Glue machine to be delivered in early February– Polisher ready to go– Most fixturing in place

• Rest is in the shop and slated to come out for a February phased start

– Staff being identified and/or hired• Being dovetailed with plank assembly (c.f. Debbie’s slide)

1/9/2009 13



Production status(TP = 45 planes)

1/6/2009 Planes Parts made 78.6 Parts machin'd 68.9 Cut 108.0 Planks 82.4 Plane 45.0 Baggies 45.0 Fiber+ferrule 45.0 Polish+mount 45.0 Couple+Bott comb 44.0 Seal 41.0 Leak test 41.0 Test 41.0

1/9/2009 14


Deborah HarrisFermilab 15 machined parts per plane

• Side rails (U/V or X)– Machined– Done in 3 steps

• 2 on Mill; 1 on table saw (slope)– Done using a vacuum chuck to

save a pass (true for lowers, side and tops)

– 2 per plane• Lower combs

– Machined– Done in 3 steps

• 2 on Mill; 1 on table saw (groove)– 2 per plane

• Center comb– Machined laminated small part

(5” x 11”)– 24 machined in a day

• Upper combs (x/HCAL)– Machined– Done in 3 steps

• 2 on Mill; 1 on table saw (slope)

• Upper combs (u/v)– Machined, laminated part– Done in 6 steps

• 2 on Mill; 4 on table saw (slope)

• Connector mount– Small machined part; mill, drill,

tap– 4 per plane

• Mount cover– Small machined part– Simple, same fixture as mounts– 4 per plane

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Deborah HarrisFermilab Part production data

# days #/day #/plane Days/plane center 40 2.0 20 1 0.05 upper u/v 8 2.0 4 1 0.25 upper x 40 8.0 5 1 0.20 side u/v 40 3.0 13.3 1 0.08 side x 40 3.0 13.3 1 0.08 lower 40 2.5 16 2 0.13 mounts 20 1.0 20 4 0.20 covers 105 1.0 105 4 0.04 Total 1.01

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As-realizedtime motion requirements

Time motion Notes Top down estimates FTE hours

skins cut and spliced Currently done at each site; propose to farm FNAL CDF techs1 person for a quarter day; 1 person for quarter day 4

parts fitted and adjusted Currently done by measuring & cutting planks; hope to speed by making a fixture; plan to farm to FNAL

lower skins & side rails Glue lower skin and side rails; 3 people 2 hours in the AM for 2 people; 1 person for an hour in the pm; 2 hrs for 2 people + 1 helper for 15 minutes

9.3post glue cleanup One person to put stuff away and clean up glue and putty from

the table; check holes; dam & backfill

top skin & upper combs Same basic task (but simpler) than bottom-skin gluing; 3 people

clear holes, foam & bags Clear holes; cut foam, cut and mount the bags

2 people for 8 hours 16baggie art Mark the connector mounts and stay outsfiber and tape Stuff fibers and put boxes away, tape and mark fiber connector glue Glue ferrules to the fibers and fixturemount connectors Tape boxes, attach, mount boxes

1 person for 5 hours; 2 people for 3 hours 11

fly cut Move the cutter down, set up, polish, check depth, put away optically couple Use the glue machine, includes set up, clean up, and spotterlower combs Glue lower combslight tighten Tape bags, lower combs, tape sides/lower combs, Al rails

2 people for 8 hours 16leak test PMT with lights on/of for each bundlesource test Guess based mostly on set up/take download Put it into the crate

Total Total 56.3 FTE-hours



FTEs for production (w/o planks)

• 7.5 days per plane– To get the FTEs– Use 85% efficiency to

get the schedule

• Fermilab uses only the top part

• HU and W&M do both

Labor (hr/pln or hr/frame)

Production rate FTE

ID plane 66.2 2/7.5 days 2.2 OD frame of towers 59.0 1.6/5 days 2.4 Total 4.6

MINERvA Mini-Review Debbie Harris Jeff Nelson Kevin McFarland Jeff’s slides version 1.

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