PartTec, Ltd. - Fiber Neutron Detector Description

Environment
The fiber neutron detector is the primary component of the Spallation Neutron Source’s POWGEN3 Powder Diffractometer and its VULCAN Engineering Diffractometer. PartTec easily and efficiently manufactures these detectors for the Spallation Neutron Source using its unique design, manufacturing and quality improvement methods.

The SNS-designed detector is the premier detector of its type in the world.  It is the best blend of resolution, energy sensitivity and area coverage for laboratories around the world.  Years of design and prototyping were devoted to it.

Challenge
The scientists, engineers and technicians at SNS are devoted to detector innovation and installation, with a goal of providing the Users at SNS the highest quality research results.  Translating those designs into manufactured detectors which meet the functional and cost requirements of the Laboratory was the challenge.  SNS opted to permit PartTec to embed a manufacturing professional into its detector group during the final generation prototyping and testing phase.  PartTec then provided guidance for the final design that allowed low-cost high quality manufacturing of the detectors

Design for Manufacturability
PartTec created the documentation, procedures, manufacturing tools and the test equipment for the manufacture of these high-precision detectors. PartTec’s considerable experience with wavelength-shifting, crossed fiber detectors was increased through a 2004 SBIR grant from the Department of Energy and was the project which brought PartTec to the attention of the SNS.  Leveraging its considerable knowledge of wavelength-shifting, crossed fiber detectors and its core competency, manufacturing, PartTec developed processes and tools specifically designed to enhance the manufacturability of the detectors.

Manufacturing
SNS had developed several tools for the manufacture of the loom.  From the basic weaving jig to the fiber end positioning instrument, to the final test of the fibers’ optics, all tools were modified by PartTec to allow the manufacture of multiple units simultaneously while improving and controlling quality.  Two of the tools that were developed are unique in the industry:  The fiber-end positioning camera and the Fiber ARRay Optical Testing (FARROT).

Delivery
PartTec’s Quality Control policy requires that every component and every service provided in the manufacture of any of its products be documented in a manufacturing database.  Upon delivery, every completed product or service is accompanied by a detailed Conformance Document, prepared from the database, which lists the parts that were used, the vendors that supplied them and their lot numbers.  It also lists all the tasks that were performed and which PartTec staff member performed them, all the quality testing procedures and their results and all re-work and repair tasks.

PartTec designed and manufactured shipping containers for the Fiber Detectors that are being delivered to SNS.   The shipping containers are mounted to air shock absorbers on a pallet and transported by PartTec.