Loading and QA activities Introduction, Workflow, Tooling, Tasks UniBe – UniGe regular IBL-Upgrade meeting D. Ferrère Aug, 11 th 2011

Design Validation of the design Prototyping Design check with FEA Pre-series production & QA Production readiness Production & QA Integration Commissioning Design and production flow towards the detector commissioning 2 Thermal stave today Thermal stave – Thermo-mechanical Stave -1 – System tests Stave 0 February 2012

Stave prod & QA Module prod & QA Flex prod & QA Pigtail prod & QA Stave + flex gluing & QA Wing folding/gluing & QA Module frame prod & QA Loading + wing gluing + wire bonding & QA Extensive loaded stave QA Pipe extension & QA Integration of the stave to the beam pipe Commissioning tests Need to define the requirements and specs for each of the working steps & Need to define the QA tests SR1 Targeting UniGe Simplified skeleton of the production workflow up the IBL commissioning Essential to have a good communication for the work preparation & during production 3

Baseline: 1.3m long stave for loading and QA at UniGe Module assembly site(s)Stave & flex circuit assembly site(s) QA done Shipping to SR1 Reception tests Visual inspection, electrical tests Visual inspection, leak tests, metrology of references Loading Electrical tests and QA Wire bonding Electrical integrity at PP0 Thermal cycling Metrology survey Rework? Storage Rework?    Wing gluing Rework?  QA done Electrical test? Pull test? Shipment Transport What type? Is it required? Loading and QA activities during/after Loading 4

What tests for the various staves and what QA for the production? - Wuppertal stave loaded with Si-heaters: Two are targeted - CERN stave loaded with Si-heaters: ~7 are targeted - Wuppertal stave with Cu-flex loaded with digital modules: Stave-1 targeted Will there be mix with real modules? 3D modules? - Wuppertal stave with final flex loaded with real modules: 1 targeted before the production starts This is called stave0 Test to be performed: Thermal tests, Thermo-mechanical tests, Thermal shocks Steered by the Stave WG by Eric and Ole Test to be performed: Thermal tests  integration to mock-up and full thermal tests Steered by Andrea and Francois-Xavier Test to be performed: Mainly electrical tests Steered by Tobias, CERN, UniGe, all This stave should allow us to tune-up the production workflow and all the QA tests  If the stave survive all this leaning curve it could even be used Steered by UniGe for Loading and QA related activities Design validation Leaning for production Design validation 5

What do the Loading and QA sites need? 1.All the design info 2.All the relevant jigs for handling, loading, wire bonding, … 3.Test bench for the different QA: Connectivity tests  Connector saver to be defined Module reception tests (USBPix) Metrology system – Mitutoyo Wire pull test – Royce Thermal cycling  BIA Climatic chamber under investigation Module reception test – USBPix (under delivery from Bonn) Stave electrical test – Require to define a readout system with lab equipment (Need to have clearer view of which system to be used) 4.A database to handle all the production data – MTF (Daniel Muenstermann, Attilio Picazio) Finally one need to agree: - On all the work to be done at each of the workflow steps - The resources to help and allow the work preparation to be efficient - The resources to help during the production and QA 6

Listing the work and possible items/jigs to be designed and fabricated NB: Work has been investigated so far at UniGe but help from UniBe and CPPM are more than welcome 1m long handling frame made of carbon fiber square tube to be designed, fabricated and compatible with loading cradle, wire bonding process and other required features.  Now done at UniGe by Maarten – Urgent to freeze the size for interface definition End-block middle supports to be attached to the handling frame. Designed and fabricated at UniGe. Handling frame extenders are not designed yet but need to decide how to do it for 1.4m or 1.5m long stave and for 7m long staves.  To be done in phase with cable saver design (UniGe) Stave handling frame cover to be made with U-shape Aluminum profile (UniGe started) Pipe strain relieve at handling frame extremities (possibly made in Peek). (Design started at UniGe by Maarten) Support of the cable saver at the PP0 side to be hold by the handling frame extenders (connected to the above) Interface tool for the handling to do the wire bonding on the H&K and allowing a sliding movement along the stave by 3 incremental positions Interface tool for the pull test with also increments in Z T-shape Peek pieces to be designed and fabricated for the HV isolation between module groups (very precise piece could be done by UniBe or CPPM) Testing box and interface for cooling, services and dry gas: It will mainly depends of the cooling system we will use… To which extend we want to test the stave cold with CO2 evaporative system! (could be done by UniBe or CPPM in connection with CERN) See continuation next slide…

Listing the work and possible items/jigs to be designed and fabricated – Con’t Loading cradle to be designed according to what will be learned with the current jigs: 1 st prototype version engineered and compatible with Si-heaters loading and also with aluminum handling frame that already exist Future version should be designed by considering compatibility with CFRP handling frame and with final loading scenario (to be revisited to mix planar and 3D to be frozen) Spacer investigation to be made: 3 thicknesses if 3D and planar are mixed to comply with the wing pitch (Who do it and which technique to control the shim thickness) Wing folding during loading will have to be integrated properly and according to the experience Wing attachment pressing tool and jigs will have to be designed and made to control the force applied to the module Guiding and support jig for the camera that must be coupled to the cradle (Could be done by UniBe or CPPM) Grease mask has to be made and located properly on the cradle( grease size: 18x16mm2). (Already started by UniGe) Loading weights for planar and 3D (Could be done by UniBe or CPPM) Handling-sucking tool for 3D and planar modules (Could be done by UniBe or CPPM) To be discussed and agreed who and when we start to design versus the schedule… Design of the mockup plus fabrication drawings: ~2 ½ months Fabrication and assembly of the all the tooling: ~1 ½ months Validation and tests of the loading tools: ~ 2 to 3 weeks In total one need to count 4 to 5 months to have the production tools as soon as we start the final loading tools designs and freeze what we are going to use in term of 3D and planar! See continuation next slide…

Listing the work and possible items/jigs to be designed and fabricated – Con’t Guillotine tool to precisely cut the module pigtail at less than 1mm from the sensor edge.  Can this be done by CPPM (under agreement) Tooling for the flex folding and gluing. This require locating the flex inside a reference tool and allow each stave to be precisely folded and glue with adhesive that polymerized at 230°C. Pliers heating tool has been tested at UniGe but someone need to investigate this more precisely.  Can this be taken by CERN to be sorted at the management board Need urgently a 3D model of the stave + flex + handling frame + extender + short flex savers + PCB saver to allow the electrical design progress on this part.  To be maintained centrally at UniGe Do we need a tool to check the stave envelope once the stave if fully loaded and the wings are attached to every module? If yes someone will have to design and fabricate something. One think it should be linked to the loading cradle to check the wing and stave envelope. (UniGe since it is linked to the integration and loading)

Work preparation List for QA and Test Equipment QA taskWork preparation Flex to stave reception testsTo be done with CERN & Genova Stave envelope metrology surveyNeed Mitutoyo training of Coralie +? Module reception testsUnder investigation by Alessandro with CERN support Pull testNeed more training and with real tool Thermal cyclingNeed to buy the climate chamber + installation for chilled water secondary unit Stave XYZ metrology surveyNeed Mitutoyo training and program to be made Stave connectivity testsWhich equipment? USBPix or others? Envelope testNeed to validate the concept + training Stave electrical integrity testNeed to validate with a multi-module readout test. Work with CERN and SLAC DB entries for loading and QA workflowUnder preparation by Attilio. To be worked out together with Daniel Muenstermann. Stave storageNeed to buy a dry keeper cabinet for 1.5 m staves NB: All the QA work preparation and validation will require that the tooling, hardware, software is ready. The sooner the better BUT need to link things for scheduling

Loading and QA - Organization 11 Task type# of setsDesign & FabWork preparationProduction Loading tool3 Min Handling frames25 Min Handling covers25 Min Extenders 20-25cm50 Min Flex savers50 Min PCB savers (2 types)25 Min Pipe strain relieve50 Min Bonding jig1 Pull test jig1 Guillotine for pigtail1 Module handling tool2 Min Support for camera2 Jig for envelope check2 Flex reception test1- Mod reception test1- Stave electrical tests1Box & interfaces To be filled and kept updated…

Critical Issues Qualification of the brazing for the Ti-pipe extension after loading  If failing there is no loading solution yet. Even if a solution is found a significant delay is expected (6 to 12 months)  The missing equipment at UniGe could cost up to 100kCHF and that could not serve if we have to load 7m long staves. Do we have to wait and until when? Number of planar versus 3D sensors  Impact the loading tool design  Once frozen final loading jigs design and fab can start Flex version to be used: AlCu multilayer versus Al multi-stack layers  Impact the design of cable-PCB savers and also of the handling frame and extension  The wing type is not identical for the solution – The envelope could be an issue for one and the wing folding for the other  No design yet for Al flex! The overall schedule is tight: Loading production phase is targeted for Feb 2012  Need to list all the needed work preparation for stave 0 and assign the task with a schedule