1. IBL Loading Activity Overview Franck, Maarten, Coralie, Didier Loading tool workshop University of Geneva, Aug 31 st 2011

2. 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 (January 2012) April 2012 (originally Feb)

3. 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 Activities @ SR1 Targeting activities @ UniGe Simplified skeleton of the production workflow up the IBL commissioning Essential to have a good communication for the work preparation & during production 3

4. 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

5. 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: Max 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

6. Urgent for stave -1 with digital modules Sliding rule to open the wings and to be interfaced with the cradle jig v-1 Stress relieve for wing opening to retract during loading Interface for wire bonding PP0 support to be interfaced to the handling frame v-1 Handling frame cover to be interfaced and stopped with the 1m long frame Handling frame extender with strain relieve for pipe and cables connected at PP0 NB: Urgent to define what is stave -1 (how many modules and which flex?) Stress relieve to be defined according to cable to be used…

7. IDTask type# of setsDesignFabricationAssembly 1.0Handling frames (1m)> 25?UniGeUniGe + OutsourceUniGe 1.1 Feet (end block and middle support) > 25 sets?UniGeUniGe + OutsourceUniGe 1.2 PP0 support (left and right) > 25 sets?UniGeUniGe + OutsourceUniGe 1.3Pipe stress relieve> 50 sets?UniGeUniGe + OutsourceUniGe 2.0 Handling covers (Alu and or option PMMA) > 25?UniGe 2.1 Mechanical stops and cover fixations > 25 sets?UniGeUniGe + OutsourceUniGe 3.0 Extenders 25cm (left and right) > 25 sets?UniGeUniGe + OutsourceUniGe 3.1 PCB saver support and pipe stress relieve > 50 sets?UniGeUniGe + OutsourceUniGe 3.2 Extender cover > 50 sets?UniGeUniGe + OutsourceUniGe 4.0Extenders for Pipe (3m)> 50 sets?UniGeUniGe + OutsourceUniGe 4.1 Pipe stress relieve (3 sets/side) > 150 sets?UniGeUniGe + OutsourceUniGe 4.2Protection cover???? Handling Frame v0

8. IDTask type# of setsDesignFabricationAssembly 5.0 Flex savers (6 types) > 50?UniGeUniGe + OutsourceUniGe 5.1 PCB saver (Left and right) > 50?UniGeUniGe + OutsourceUniGe Cable Saver IDTask type# of setsDesignFabricationAssembly 6.0Peek “T” Bars~200UniBe?UniBe? + Outsource- HV Peek Insulation T bar

9. IDTask type# of setsDesignFabricationAssembly 7.0Cradle (3 parts)> 3 setsUniGeUniGe + outsourceUniGe 7.1 Centering dowel pin + lateral clamping > 3 setsUniGeUniGe + outsourceUniGe 7.2 Grease mask (Planar and 3D TBD) > 3 setsUniGeUniGe + outsourceUniGe 7.3 Module positioning (Planar and 3D TBD) > 3 setsUniGeUniGe + outsourceUniGe 7.4 Positioning counter pieces to define module envelope (Planar and 3D TBD) > 3 setsUniGeUniGe + outsourceUniGe 7.5 Shims for module gaps (3 types) > 3 setsUniGeUniGe + outsourceUniGe 7.6 Loading weight (Planar and 3D TBD) > 3 setsUniBe? + UniGeUniBe?UniGe 7.7 Module sucking tools (Planar and 3D TBD) > 3 setsUniBe? UniGe 7.8 Support for camera > 3 setsLPNHE/UniBe?UniBe?UniGe 7.9 Wing retracting bar > 3 sets??UniGe 7.10 Wing pressing tool for adhesion > 3 setsUniGeUniGe + outsourceUniGe Loading Jigs

10. IDTask type# of setsDesignFabricationAssembly 8.0 Guillotine set reference to the module frame > 3CPPMCPPM + ?CPPM Guillotine IDTask type# of setsDesignFabricationAssembly 9.0 Interface to handling frame? 1UniGe Metrology IDTask type# of setsDesignFabricationAssembly 10.0Interface guide to the table1UniBeUniBe + ?UniGe Wire bonding IDTask type# of setsDesignFabricationAssembly 11.0Interface guide to the table1UniBeUniBe + ?UniGe Pull Tester IDTask type# of setsDesignFabricationAssembly 12.0Interface to handling frame?1UniGeUniGe (Stereo + …)UniGe Envelope checking jig

11. IDTask type# of setsDesignFabricationAssembly A.0Wing folding and gluing jig1 or 2Genova? A.1 Hot pliers connected to soldering iron Few setsGenova? Other tooling not directly related to Loading IDTask type# of setsDesignFabricationAssembly B.0 Ti-pipe brazing work bench to be locked with the vacuum chamber 1LAPPP/CPPM B.1 Mechanism to level the stave handling frame 1LAPPP/CPPM B.2 Sliding mechanism to extract the stave once brazed 1LAPPP/CPPM B.3 Vacuum chamber and other bits for brazing 1LAPPP/CPPM

12. Time estimation during production IDOperationTotal/staveMin – Max [d] 1.0Module acceptance test 2h/module/set-up: If 2 set-up: 4d 2d 2 -4  TBC! 1.1Stave metrology2h 1.2Stave electrical integrity check2h 2.0Stave loading 1 st group of 6 planar modules3h 2 - 3 (1d if fast Araldit is used) 2.1Stave loading 2 nd group of 6 planar modules Leading time: curing 3h 1d 2.1Stave loading 2 groups of 8 planar modules Leading time: curing 4h 1d 3.0Wing attachment (32 operations: 5-10 min/wing)4h 1/2 4.0Wire bonding6h 1 5.0Pull test2h 6.0Metrology3h 1/2 7.0Connectivity test acceptance tests using RCE system4h 1/2 8.0Thermal cycling 10 cycles from 30 to -40°C1d 1 9.0Acceptance tests using RCE system4h 1/2 10Metrology survey3h 1/2 11Finallizing: HV insulator, Glue drops to wings, Module glue4h 1/2 Total time (Serial): 9 – 12 working days Reasonable to assume 10 wd or 2weeks but when parallelizing can we target 1w/stave?

13. Projection during Loading Production Proposal for the loading program : 1) A Minimum of 1 stave 0 with tooling v0 is an absolute requirement for: - Validating all the loading jigs - Validating all the QA procedures - Allow to spare some time for tuning-up and improve stave loading quality 2)The first ~4 real staves will be produced serially. Only when the previous is fully QA and OK that the next can start 3)If no problem with this pre-series the next ~15 staves will be done with optimal speed which is targeted to 1 stave/week Step #Start dateDurationComments 1)Mid-Jan 12~2 monthsTime should be left for needed improvements 2)Mar-Apr 122 months1 stave every 2 weeks 3)May-June 124 months1 stave per week Very preliminary NB: - Stave0: Final stave (only FE will be different from the final design) - At step 2) only module with FEI4b will be used. Start date will depend upon the 1 st module delivery from module production sites: Bonn & Genova