Transcript SLAC - B (Waveguide Assembly) Eric Coblin Clay Fenstermaker

SLAC - B
(Waveguide Assembly)
Final Project Report
Eric Coblin
Clay Fenstermaker
Greg McCandless
Eric Schmidt
Coach: Vikash Goyal
Liaison: Jeff Rifkin
Agenda
•
•
•
•
•
•
•
•
217A-Product Definition
217B-Product Specification
Concept Development
Design Recommendations
Scorecard
Implementation Process
Competitive Analysis
Questions
217A-Product Definition
–Understand the project
•CVCA
•Value Graph
•Function-Structure Mapping
•Product Definition Assessment Checklist
–Quantify the Understanding
•QFD
•Cost-Worth
•Design for Assembly
•Design for Variety
•Design for Environment
•FMEA
Customer Value Chain Analysis
Copper Raw
Material Supplier
10101
$!
Supplier of
Copper Tubing
$!
Supplier of
Conflat Flanges
10101
Physicists and
Other Users
10101
10101
$!
SLAC NLC
Waveguide Team
10101
$!
Taxpayers
NLC Project
Team
10101
10101
10101
10101
$!
Supplier of
Cleaning Equipment
-Physicists
-Engineers
-Technicians
$ ! 10101
$!
10101
$!
Department of
Energy
10101
$!
$!
10101
Supplier of
Other
Installation
Hardware
10101
Construction
Contractors
Congress
Legend
Hardware/Mat’l
Service
Power
10101
Information
$
Money
!
Complaints
Waveguide Value Graph
Run Computer
Model
Learn about the
components of atoms
Have Fun?
Run Physics Experiments
WHY
Manufacture
Electronics
components
Accelerate Particles
Guide Waves
Waveguide
WHAT
Efficient
HOW
Hold Vacuum
Transfer Energy
Surface
Roughness/
Conductivity
Joints
Safe
Reliable
Wall Thickness
Vacuum
Capacity
Tubing
Serviceable
Cleanliness
(particulate levels)
Pumps
Easy to
Install
Length
Hardware
Weight
Function-Structure Map
Structure
Function
Material
Con ductivity
Tub es
Geometry
Cle an of Gas
Transfer
Power
Provide
Vac uum
Environme nt
Cle an of Solid
Joints
No Leaks
Straigh t
Provide
Geometry
Con centric
Strong
Smooth
Sup por t
Stru cture
Waveguide
Assembly
PHASE I QFD
NLC Waveguide
Tube and Joint Roundness
Tube and Joint Concentricity
Tube Straightness
Tube Interior Surface Finish
Tube Conductivity
Wall Thickness
Joint Vacuum Limit
Tubing Material Outgassing
Tube Weight
Mean Time to Remove Joint
Mean Time to Remove Tube
Tube Length
Mean Time Assemble Joint
Exterior Surface Oxidation
+
+
+
+
++
+
+
-
+
++
+
+
9
3
Exterior Surface Oxidation
Mean Time Assemble Joint
Tube Length
Mean Time to Remove Tube
Mean Time to Remove Joint
1
9
9
3
< 25% after 1 yr
18
1%
< 10 minutes
63
< 2 hr.
< 2 hr.
102 20'<length<40'
9
5%
3
3
3
9
3
8%
1
9
36
1
1
9
3%
3
9
3
9
45
117 0.125" +/- .010"
9%
1
4%
81
6%
>ASTM F68-93, 1
108 <32 microinches
9%
<.010" per 24"
81
6%
<0.005"
90
7%
< 0.01"
3
117 <300 lbs
3
3
3
Tube Weight
3
9
9
9%
3
1
9
1
Tubing Material Outgassing
9
117 >ASTM F68-93, 1
Tube Conductivity
9
9%
Tube Interior Surface Finish
9
Joint Vacuum Limit
Tube Straightness
9
16% 198 < 10^-9 Torr
Tube and Joint Concentricity
9
Wall Thickness
Tube and Joint Roundness
dwn dwn dwn dwn up nom dwn dwn dwn dwn dwn nom dwn dwn
Engineering Metrics
Technical Targets
Raw score
Relative
Weight
+
81
9
9
9
9
3
3
1
++
6%
Customer Weights
Preferred
Customer Requirements
Able to Transfer Power
Reliability
Able to hold Vacuum
Safety
Serviceability
Installability
Cosmetics
++
++
+
-
PHASE II QFD
NLC Waveguide
Bolts (20/flange)
Nuts (20/flang)
3
1
1
3
1
9
3
3
3
3
3
1
9
9
3
9
1
9
9
3
9
1
13% 1.8
13% 1.8
Conflat Flange- Stainles Steel
3
Tube
Conflat Flange- Cu Ring
Relative Weight
9
13% 1.8
Raw score
3
17% 2.4
6%
7%
6%
9%
6%
9%
16%
9%
9%
4%
3%
8%
5%
1%
44% 6.0
Engineering Metrics
Tube and Joint Roundness
Tube and Joint Concentricity
Tube Straightness
Tube Interior Surface Finish
Tube Conductivity
Wall Thickness
Joint Vacuum Limit
Tubing Material Diffusion Rate
Tube Weight
Mean Time to Remove Joint
Mean Time to Remove Tube
Tube Length
Mean Time Assemble Joint
Exterior Surface Oxidation
Phase I Relative Weights
Part Characteristics
9
3
9
9
9
9
9
9
9
3
9
3
QFD Cost - Worth Diagram
(based on 5 meter tube sections)
80%
70%
Tube
Relative Cost
60%
50%
40%
30%
Flange - Stainless Steel
20%
10%
Bolts
Flange - Copper
0%
0%
10%
Nuts
20%
30%
Relative Worth
40%
50%
Fish Bone Diagram
Tube Section ~(20-40 ft)
F
Cusil Weld Conflat Flange (x2)
Legend
Screw Down/Rotate
Weld
Braze Conflat Flange (x2)
F
Emulsion & Water Rinse
F
Alcohol Dip & Water Rinse
F
Bright Dip & Water Rinse
F
50% Hydrochloric Acid & Water Rinse
F
Cyanide Dip & Water Rinse
F
High Temperature, High Purity Water Rinse
F
Blow with Nitrogen
F
Dry @ 150 degrees C
F
Transport to Site
Insert Copper Ring
Insert bolts (x20)
Assemble 20 nuts
Finished Assembly
Braze
Insert Down
Insert Side
F Fixture
Conductive
Local Effects
End Effects on
Product, User,
Other Systems
Detection Method/
Current Controls
Detection
Potential Failure Potential Causes
Modes
of Failure
FMEA Number:
Page:
Date:
Severity
Function or
Requirement
System Name: NLC Waveguide
Major Function: Transport Microwave Power
Prepared By: SLAC-B Team
Occurrence
Failure Modes &
Effects Analysis
R
P
N
Responsibility and
Actions Recommended
Target Completion
to Reduce RPN
Date
3 Power Loss
Increased Power
Requirements
Monitoring System
3 Outputs
1
9
1 Power Loss
Increased Power
Requirements
Monitor System
3 Outputs
1
3
System
Shutdown
3 Pressure Gauges
1
9
Delay in start-up
3 Pressure Gauges
1
27
Project Failure
9 Pressure Gauges
1
9
Delay in start-up
3 Pressure Gauges
1
9
Di-electric
3 break down
System damage
Monitoring System
9 Outputs
1
27
Di-electric
9 break down
System damage
Monitoring System
9 Outputs
1
81
Mfg. Process
1 Power Loss
Increased Power
Requirements
Supplier quality
3 control
3
9
Joining
3 Power Loss
Increased Power
Requirements
3 Visual Inspection
9
81
Low Conductivity Impure Material
Poor Material
Selection
Provide
Vacuum
Clean of Gases
Oxides Present
System Opens to
Air
Slow Installation
Process
Bad Material
Selection
Clean of Solid
Dust / Particles
Present
Virtual Leak
Bad Cleaning or
Installation
Process
Dirty
Manufacturing
Process
Pressure too
3 high
Extended time
to form
9 vacuum
Vacuum won't
1 form
Extended time
to form
3 vacuum
Geometry
Straight
Not Straight
1
7
2/27/00
Concentric
Strong
Not Concentric
Not Strong
Installation
3 Power Loss
Increased Power
Requirements
Laser levels during
3 installation
1
9
Transit
3 Power Loss
Increased Power
Requirements
Checked during
3 installation
1
9
Support Structure
1 Power Loss
Increased Power
Requirements
Monitor System
3 Outputs
3
9
Processing
1 Power Loss
Increased Power
Requirements
Supplier Quality
3 Control
3
9
Joining
3 Power Loss
Increased Power
Requirements
Monitor System
3 Outputs
9
81
Transportation
Increased Power
Requirements
Monitor System
3 Outputs
9
27
Increased Power
Requirements
3 none
9
27
Increased Power
Requirements
3 none
9
27
Weak Joints
1 Power Loss
Increased
chance of
local
1 deformation
Increased
chance of
local
1 deformation
Increased
chance of
local
1 deformation
Increased Power
Requirements
3 none
9
27
Processing
3 Power Loss
Increased Power
Requirements
Supplier Quality
3 Control
3
27
Joints
3 Power Loss
Increased Power
Requirements
Monitor System
3 Outputs
9
81
Transportation
1 Power Loss
Increased Power
Requirements
Monitor System
3 Outputs
9
27
Material Choice
Thickness of Pipe
Smooth I.D.
Not Smooth
M
an
uf
RPN
Tr
an
si
Pr
t
Ex
oc
pe
e
ss
ns
in
iv
g
e
M
at
er
ia
Ex
ls
te
rio
M
rD
es
irt
sy
Lo
ok
in
g
ac
tu
rin
g
Pr
Co
oc
nc
Sl
es
ow
en
s
t
ric
In
st
J
al
oi
la
ni
tio
ng
n
Pr
oc
Tr
es
an
s
sp
Th
or
ta
ic
kn
tio
es
n
s
of
Pi
pe
Pr
oc
Ex
es
pe
si
ng
ns
Di
i
ve
ff
ic
Jo
ul
tt
in
o
ts
Tr
an
Pe
sp
rm
or
an
t
en
tJ
Im
oi
nt
pu
Ba
s
r
d
e
M
M
at
at
er
er
ia
ia
lS
l
el
ec
tio
M
fg
n
.P
ro
ce
ss
Di
rty
Cause
90
60
80%
50
60%
40
30
40%
20
10
20%
0
0%
Cummulative %
1.5 Pareto Chart
120%
80
70
100%
RPN
Cum Tot.
217B-Product Specification
–Generate Concepts
•Morphological Analysis
•Brainstorm
•Pugh Analysis
–Evaluate Options
•Design of Experiments
•Poka Yoke-Mistake proofing
•Motorola Six Sigma
•Design for Ergonomics
•Scorecarding
•Cost Modeling (competitive analysis)
Morphological Analysis
Design Recommendations
• Tube Material
– Alternatives
– Selection
•
•
•
•
Tube Geometry/Parameters
Joint Design
Tube Segment Length
Cleaning
Tube Material Alternatives
• Copper
–
–
–
–
Low Electrical Resistivity (1.7 x10-6Ohm-cm)
Good Outgassing Properties (1 x 10-13 Torr-l/s/cm2)
Can be Cusil-welded to Stainless Steel
Traditional Choice (Class 1 Used for NLCTA)
• Class 1 used; could consider Class 2 because no oven braze)
– Dense & Expensive
Copper Wire Inside (+)
Steel Tube (-)
Sealed ends
• Composite Coated Steel
– Steel is cheap (but not stainless)
– Coating is expensive & not 100% coverage.
FLOW
Pump
Chemical Tank
Tube Material Selected
• 6061-T6 Aluminum
– Good Electrical Conductivity (~51% less than Cu)
• Can be made up for with larger diameter
– Comparable Outgassing to Cu. (1 x 10-13 Torr-l/s/cm2)
– Slightly more strength, less than 1/3 density of Cu
• Aids in Handling
– Approximately ½ cost per lb. than Cu
– Cannot be easily joined to Stainless Steel Flanges, but
Stainless Steel Flanges no longer required due to less
stringent vacuum requirement. (10-7 Torr)
Tube Geometry/Parameters
• Nominal Thickness: 0.125”
–
–
–
–
Patm=101.3 KPa
Wrench Drop Test
Pressure Deformation (.0002”)
Electrical Conductivity
Stiffness
Pinternal=~0 KPa
D
• Nominal ID: 5.1” (vs. 4.75” Cu)
– Matches power loss of baseline Cu
tube.
– Improves fluidic conductivity, C
( D3), which offsets increased
outgassing surface area, B ( D2),
so reduces spacing required
between pumps.

t
LP
L
2
PL


qB 1  1 
2C 
 Sp
LP
L
P0
Vacuum
Pump
LP
L
PL
L
P0
Vacuum
Pump
L
PL
P0
Vacuum
Pump
Tube Geometry/Parameters (cont.)
• Other Tolerances: Taguchi! (at NLCTA)
– Also gives opportunity to try Al.
Dimensions for 5.1" ID tubing1
SLAC NLCTA Spec Standard Extrusion Standard Drawn
Circularity (Deviation
from mean diameter)
Surface Finish
Straightness
Thickness
+/- 0.005"
32 microinch RMS
.010" per 24"
+/- 0.010"
+/- 0.050"
0.003" max
.010" per 24"
+/- 0.0125"
+/- 0.016"
0.005" max
.010" per 24"
+/- 0.006"
Taguchi L4 Array
Trial Number
Vacuum
Circularity
Surface Finish
1
10-6 Torr
0.005”
32 -inches RMS
2
10-6 Torr
.016”
125 -inches RMS
3
10-8 Torr
0.005”
125 -inches RMS
4
10-8 Torr
.016”
32 -inches RMS
1Standards
per the Aluminum Association, Inc.
Joint Design
• “Quick Flange” w/o-ring
– Off the shelf
– Precisely Locates
– Rated to 10-7 Torr vacuum
• Up to 10-9 w/viton & bake-out
or perhaps metal o-rings
– One Fastener
– Tolerates Radiation
• 1 x 105 rad/10 yr = ~800 yr. life
• Form Flange ends into Al tube
– Minimize risk w/proven geometry
– Minimize cost w/integration
Tubes: Make vs. Buy
• If made on-sight, could enable “infinite” length,
but distance between pumps & handling reasons
make this impractical.
• Want to outsource1 when
– There is a resource limitation.
– The requirements are temporary.
– There is a push to adopt the best practices from experts
in the given field.
– There is a drive to reduce time to market.
– There is a drive to improve financial performance.
• Nearly all apply!
1Per
Carol Nast, outsourcing expert in medical devices
Tube Segment Length
• 40 ft. long sections
–
–
–
–
Max Shippable by standard means
Manufacturable
96.2 lb. per segment- easy to handle
Strength: 1.5 g bump = ~26% of yield- OK!
Cleaning
• Flow Cleaning Agents through ID rather
than bathe tubes.
– Only uses expensive cleaning agents on ID
where needed.
– Minimizes Evaporative Losses
– Ensures even cleaning
Sealed ends
FLOW
Pump
Chemical Tank
Scorecard
• Project Objective: Project Approval
• Objective Measures:
– Cost
– Performance (Efficiency, Reliability)
• Control Factors:
– Tube specifications
– Joint type
• Noise Factors:
– Variability in manufacturing process
– Interaction with other components (radiation, heat)
• Transfer Function:
– To be determined by Taguchi DOE & cost models
Implementation Process
Aluminum
Plug
Drill hole
Extrude
Post-Draw
Form & Machine
Ends
12.2 meters
Ship segments
Clean Segments
12.2 meters
Fill w/Nitrogen & plug ends,
Transport to tunnel
Join segments in tunnel,
Perform QA
Implementation Process
• Extrusion
• Drawing
Competitive Analysis
• Alternatives designed for same performance
• Main differentiator is Cost
NLCTA
Cu Tube w/
Al Tube w/
Steel Tube w/ Cu
Quickflange
Quickflange
& Quickflange
(incorporating (incorporating (incorporating
endform)
endforming)
endforming)
Material
Cost
$7,701,987
Tube Mfg.
Costs
$1,955,307
Joint
Component
Costs
$6,834,467
Joint
Assembly
Costs
$243,936
Plating
$
Costs
$
Cleaning
Costs
$8,784,800
Total Cost: $25,520,497
$7,701,987
$2,860,489
$5,861,055
$1,955,307
$1,955,307
$1,955,307
$2,323,162
$2,323,162
$2,323,162
$7,519
$7,519
$7,519
$6,839,098
$18,827,073
$
$6,839,098
$13,985,575
$10,372,951
$6,840,060
$27,360,054
Cost Differentiators
• Material Choice
2' X 5"
Material Round
Copper
$456
Aluminum $158
Stainless $347
Cost/
cu.in.
$0.97
$0.34
$0.74
Expected Mat'l
Tube Waveguide Total Mat'l Cost (at 40%
I.D. Vol. (cu.in.) Cost
discount)
4.75" 13,265,107 $12,836,644
$7,701,987
5.1" 14,218,554 $4,767,481
$2,860,489
4.75" 13,265,107 $9,768,425
$5,861,055
• Joint Choice
# of Joints with 40' Al
sections or 5-meter Cu
sections & pumps every 160' Total Flange Costs
Quick Flange Costs $129.16
18,045
$2,330,632
Conflat Costs $182.81
38,720
$7,078,403
Cost Differentiators
• Plating and Cleaning
Cleaning Cleaning
Chemicals Labor
Copper w/
Conflat
Copper w/
Quick
Flange
Aluminum
Steel
Cleaning Plating
Hardware Material
$42,736 $7,742,064 $1,000,000 $
-
Plating
Labor
$
-
Plating
Hardware
$
-
Total Cost
$8,784,800
$32,060 $5,808,000 $1,000,000 $
- $
- $
$6,840,060
$31,098 $5,808,000 $1,000,000 $
- $
- $
$6,839,098
$32,060 $5,808,000 $1,000,000 $80,151 $9,292,800 $1,000,000 $17,213,011
Summary of Cost Improvements
• 45% Savings!
Cost Breakdown: Baseline NLCTA vs.
Proposed Design
25
20
Labor
Hardware/Raw Material
15
10
Tube
NLCTA
Aluminum
NLCTA
Aluminum
NLCTA
Aluminum
0
NLCTA
5
Aluminum
Cost ($ Millions)
30
Joint Cleaning Total
Risks
•
•
•
•
•
True Vacuum Requirements
Reliability of Aluminum
Packaging Requirements of Aluminum
Pump Cost vs. Seal Savings
Waveguide Assembly and Service
Questions?