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BTOF demonstrator/mechanics meeting
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US/Pacific
Description
https://ucsc.zoom.us/j/98299273347?pwd=HHm9tGM6hD7aZaIVWWaF16ueAT3gVu.1
Quick recap
The meeting focused on the design and integration of the service hybrid for the detector stave, particularly its thickness and mechanical constraints. Wei presented the current design, which has a total thickness of 1.5 centimeters, dominated by the height of the inductors on the power board. The group discussed the challenge of fitting the service hybrid within the strict envelope constraints, especially with a proposed new layout involving three stave layers. Elke suggested creating a 3D step file of the service hybrid for better spatial integration and simulations. Rachid raised concerns about the thermal impact of the service hybrid on the stave and suggested exploring options to decouple them, possibly with independent cooling. The group also discussed alternative mounting and cooling solutions, but noted the need for more detailed design information and collaboration with the mechanical design team, including Andy from Purdue. The conversation ended with the agreement to find a better time for future discussions involving all relevant parties.
Next steps
- Wei: Create a rough 3D model and provide a STEP file of the service hybrid for integration into the 3D model.
- Wei: Look into the power dissipation of the service hybrid for FEA analysis.
- Simone Mazza: Send out a new poll to find a better meeting time for all participants, including those from Japan and Purdue.
- Group (led by Elke/Andy): Perform simulations to evaluate the impact of a two-stave solution versus the current three-stave design.
- Group (led by Andy/mechanics team): Study different mounting and cooling options for the service hybrid, considering maintenance and envelope constraints.
- Group: Discuss the size and mounting of the service hybrid with Andy and the mechanics team in a future meeting.
Summary
Service Hybrid Dimensions Discussion
The team discussed the dimensions of the service hybrid, which measures 1.5 centimeters thick, 160 millimeters long, and 60 millimeters wide. Wei explained that the thickness includes both the PCB board and the components mounted on it, primarily dominated by the height of the inductors. The discussion clarified that one service hybrid is needed for each stave (not stavelet), with one hybrid serving all components on one phase of the stave. The team also discussed the material composition, confirming the board is likely standard PCB material, though the exact type needs verification.
3D Model Design Integration Discussion
Elke suggested creating step files for the readout and power boards to integrate them into the 3D model and proposed simulating whether a three-stave design is necessary or if a two-stave design with reduced overlap would suffice. Wei acknowledged needing to catch up on the discussion and confirmed understanding of the layout proposal. The group discussed the constraints of the envelope, with Dan clarifying that the green boxes in the slide deck represent the service hybrid for the previous two-layer layout.
Service Hybrid Component Design Discussion
The team discussed the cooling requirements and spatial constraints for the service hybrid component. Rachid proposed alternative configurations including a ring-shaped service hybrid with independent cooling and flexible cables connecting to the stave, though Wei emphasized the need to stay within the existing envelope constraints. Elke noted that a detailed design of the service hybrid is needed to properly assess different layout options and their impact on physics performance, requiring both CAD modeling and physics simulations.
Service Hybrid System Implementation Discussion
The team discussed the implementation of a service hybrid system for detector maintenance, with Rachid emphasizing the need for mechanical flexibility and ease of replacement in case of problems. Wei confirmed they could create a rough 3D model of the service hybrid, though detailed specifications would require further design work. The discussion also covered mounting considerations, with Rachid suggesting a sliding and clamping mechanism instead of screws, and Wei noted that the service hybrids should maintain good thermal contact and would only need replacement in case of massive failures.
Service Hybrid Cooling Solutions Discussion
The team discussed cooling solutions for the service hybrid, with Simone Mazza explaining that carbon fiber would be sufficient for heat dissipation and that the main concern was the interface between the pipe and carbon foam. Rachid raised concerns about heat transfer from the service hybrid to the stave, emphasizing the need for independent cooling systems. Wei noted that the service hybrid would generate 25-30% of the total stave heat, and the team agreed that detailed power dissipation data and FEA analysis were needed before proceeding with the design. The discussion revealed uncertainty about the PC connection requirements and whether six bipole connections could fit within the 16-centimeter space, with Wei indicating this was unlikely.
DC-DC Converter Placement Discussion
The team discussed the placement of DC-DC converters in the service hybrid design. Satoshi proposed putting the converters outside the magnet system, but Wei and Elke explained this would require multiple power lines and create stability issues, making it a significantly different design approach. Simone Mazza suggested mounting the inductor upside down to reduce height, but Wei showed that the current design already uses a stacked configuration with power board at the bottom and radar board on top. Rachid emphasized the need to decouple the service hybrid from the stave for safety and stability reasons. The team agreed that maintenance considerations and the involvement of Purdue's mechanical design team, particularly Andy and Matthew, would be important for future discussions.
There are minutes attached to this event.
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