Optical Instrumentation Tasks

Quality Control  tasks are indicated in red

Work Crew: t- senior technician; g- general technician or (2) students; QC- engineer or physicist

 

Task/sub tasks

Work

Crew

Duration

(hours)

Manpower

(manhrs)

 

      

1) Prepare module:

  

15-21

22-34

Secure module on assembly stand

1t + 1g

1

2

Setup work platforms, light tent, supplies tables

2g

1

2

QC0: Module inspection

QC

2

2

Fix as necessary:

 		     
Epoxy in slots

2g

0-4

0-8
Spacer rings in slots 

2g

0-1

0-2
Burrs on weld bars

2g

0-1

0-2

Clean module surfaces

1g

2

2

Insert shims in slots between sub modules

1t + 1g

3

6

Fix the rails that will hold the WLS/laser fibres

1g

2

2

Insert "aspirin" tubes

1g

2

2

Mark cell boundaries/numbers and label PMTs

1t + 1g

2

4

 

      

2) Install tiles:

  

9-13

17-21

Insert tiles into slots

1t + 1g

8

16

QC1: Inspect tile installation

QC

1

1

Fix any displaced tiles or wrappers

1g

0-4

0-4

 

      

3) Install tubes and rods:

  

2

4

Install clamp rods

1t + 1g

1

2

Install temporary source tubes (for the EBs)

1t + 1g

1

2

 

      

4) Routing preparations:

  

3

7

Install routing QC devices (light source)

1t

1

1

Install fiber separator wires

1g

1

1

Install ITC fiber assemblies (EB)

1g

1

1

Install the laser fibre bundles

1t + 1g

2

4

 

      

5) Insert profiles/fibers:

  

29

60

Insert ITC fibers into profiles (EB)

1t

2

2

Insert profiles into slots and sort fibres into depth segments

2g

22

44

QC2: Verify fiber lengths and sorting

QC+ 1g

4

8

Secure profiles with tape

1t + 1g

3

6

 

      

6) Route fibers:

  

30

60

Make fiber sub-bundles

1t + 1g

6

12

Route sub- bundles to aspirin tubes

2g

18

36

QC3: Verify routing with a light source

QC+1g

6

12

 

 		     

 7) Insert and glue sourcs tubes:

NA

Barrel

Only

Insert straight tube sections 

 		     

Insert and glue curved tube sections

 		     

 

      

8) Make fiber bundles:

  

19

38

Fill aspirin tubes with dummy fibers 

2g

2

4

Adjust fiber ends in the aspirin tubes

1t + 1g

6

12

Secure the fibers at the aspirin tubes with ties

2g

5

10

Secure the sub-bundles along the girder

2g

6

12

 

 		     

9) Glue fiber bundles:

  

6-54

12

Glue the fiber bundles into the tube

1t + 1g

6

12

Wait for the glue to cure

 

48

0

 

 		     

 10) Secure fiber bundles:

  

3

5

Cut dummy fibre ends

1g

1

1

Tie fibre bundles inside the girder

1t + 1g

2

4

 

      

11) Polish the fiber ends:

  

13

15

Setup the polishing machine in the girder

1t + 1g

2

4

Polish the fiber ends

1t

6

6

Remove the polishing machine

1g

2

2

QC4: Inspect the fiber ends

QC

2

2

Clean out the girder

1g

1

1

 

      

12) Check/fix broken fibres:

  

12-18

24-36

QC5: Check for damaged fibres

QC + 1g

12

24

Repair damaged fibres

1t + 1g

0-6

0-12

 

      

13) Close up the module:

  

6

10

Remove the fiber separator wires and trays

1g

1

1

Cover the module with Aluminum sheet

1t + 1g

4

8

Attach girder end plates

1g

1

1

 

 		     

14) Cleanup

  

3

5

Remove assembly fixtures and tables

2g

2

4

Remove empty boxes and tools

1g

1

1
       

15) Management

  

0

45

Materials and supplies

1t

  

10

Scheduals and training

1t

  

20

Record keeping

1t

  

10

QC documentation

QC

  

5

 

      

Total

t: 96-102

g:196-218

QC:32

150-214

324-352