23-Aug-2005 VELO Production UCD VELO Module Production at Liverpool T. Bowcock

23-Aug-2005 VELO Production UCD Overview Progress to Production Readiness –Status –Issues/Risks –Timeline Summary

23-Aug-2005 VELO Production UCD Production Readiness Engineering Review –Concept of the project Point at which we are ready and can be cleared to start production –All equipment in place and debugged –QA procedures –Techniques proven Specific for VELO –4 mechanical modules –4 physics grade modules – experiment standard

23-Aug-2005 VELO Production UCD Status Expected to be past PR(R) in July (or earlier) –Two major problems arose Pitch adaptor (connecting sensors to electronics)- contamination from production at CERN Hybrid twist Components and Procedures

23-Aug-2005 VELO Production UCD Schematic

23-Aug-2005 VELO Production UCD Sensors Remeasurement of current at Micron Excellent shape from Micron Laser Improved jigs manufactured (Liverpool and Syracuse) Mechanical tests on sensors –100 cycles on/off on jig does not make 200 micron mechanical snap –Pressure on edge up to 10kg/mm2 does not cause cracks in Si –Twist of up to 2mm does not significantly Mounting in jigs and handling –In production we have decided to move to 2 person mounting of sensors High current detectors seem to be isolated to one crystal, otherwise good. 21 day vacuum (10 -5 mb) test at high voltage

23-Aug-2005 VELO Production UCD Sensors

23-Aug-2005 VELO Production UCD Lots of data available from production process -Implants -Metal resistances etc.

23-Aug-2005 VELO Production UCD Yield

23-Aug-2005 VELO Production UCD Hybrid K-05 Industry was not able to reproduce flatness achieved in lab –6 months extra R&D (!) –£15K additional cost Move production to in-house –4 substrates per day –Bare substrate ~50 micron twist (10 times better than achieved externally) Twist on K-04 hybrids measured for effect on Si K-05 circuits have been fabricated at Stevenage Circuits PLC –Error found in testing system and corrected, this caused additional delay 7 K-05 have been laminated onto substrates at Stevenage 2K-05 (populated) posted yesterday to Liverpool, remainder at end of week. Check K-05 functioning by early next week

23-Aug-2005 VELO Production UCD Mechanics In full production, completion soon Bases in production (30 complete) Paddles mould tools –Paddle production will start in 2 weeks (3/day)

23-Aug-2005 VELO Production UCD Laser Rig – Hybrid holder (cooled) Modified Bonding Jig

23-Aug-2005 VELO Production UCD Bits Handling frames complete –Once the hybrid comes to Liverpool (Post population) it doesnt have to be touched Bonding jig modified(works) –Special backend bonding jig built for HK710 (no sensors – remove leaks) Table for Laser –Flat surface surveyable into 2stage x-y drive –Incorporation of bonding jig/w cooling Assembly System complete and programmed Gluing Robot Complete (programming underway) Equipment for vacuum thermographs –Dual arm vac vessel/flange being constructed –Allows up to 3 detectors to be tested simultaneously –Motion sensors tested on K-04 substrate (sensitive to ~5microns)

23-Aug-2005 VELO Production UCD

23-Aug-2005 VELO Production UCD

23-Aug-2005 VELO Production UCD LHCb Assembly System Programmed Alignment Plates

23-Aug-2005 VELO Production UCD More Bits Cable clamps –Designed – about to be submitted Short cables –Designed, awaiting production order

23-Aug-2005 VELO Production UCD 2-sided bonding Backends programmed –K-05 (twisted) Frontends –Chips programmed (BE!) –Completing programme to sensors this week Double sided bonding on our substrates is OK

23-Aug-2005 VELO Production UCD Major Issues Contamination of PAs at CERN still not resolved… another bad batch –Require 80% yield good testing K-05 yet to be electrically tested Assembly of hybrid to paddle –Assume non-twisted components –Final adjustment (tested) using W-sticks added to design – removeable for repair

23-Aug-2005 VELO Production UCD Minor Issues No such thing! –Transport boxes being designed and fabricated (gas tight, 3000m for aircraft, safe for insertion etc). Expensive –Handling and reception procedures to be finalized (Glasgow/Liverpool mtg before Sept 7) –Distortions –Outgassing tests

23-Aug-2005 VELO Production UCD Project Timeline to PRR Everyday planned … –Still not in production mode as fighting problems

23-Aug-2005 VELO Production UCD Project Gantt

23-Aug-2005 VELO Production UCD Current Completion for PRR About 1 week late on current schedule…. Catchup??? Hybrids delayed. Due to arrive today

23-Aug-2005 VELO Production UCD Realistic Start Schedule Oct 05 – approx 9 months late – last week Oct How many modules can we make per week? –Start at 1/week and build up –Maximum capacity 3 (or 4) but we will not be able to achieve this until Feb 2006

23-Aug-2005 VELO Production UCD Production at Liverpool Christmas & Startup No major failure

23-Aug-2005 VELO Production UCD Summary We should have full VELO complement at CERN by end of April 2006 –If testbeam in April 2006 this may be only 50% can be tested during system test Large amount of work left Two big risks remaining –Pitch adaptor contamination –Paddle-hybrid assembly (manageable)