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TOB Status
Joe IncandelaUniversity of California, Santa Barbara
For the TOB Group Tracker General Meeting
Sep. 21, 2001at CERN
Slides courtesy of: A. Affolder, C. Bloch, C. Campagnari, A. Dierlamm, E. Shabalina, A. Onnela, D. White… and others for sure.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 2
Module Assembly Issues
• TOB module production was slowed due to concerns about HV Bias• Long term performance instability of the conductive epoxy led us to
backside wirebonding for each sensor on all modules.
• Treatment of new TEC and TOB modules underway
• Procedure for previously completed TOB modules understood.
• Retrofit of all stored modules to start next week
• complete before rod production starts again in November
• No impact on TEC schedule is expected.
• TOB module production now back up to high rates
• Rod assembly on hold awaiting for replacement Inter-connect Cards. • Must now store a much larger than planned number of modules.
• Preparations for TEC at FNAL• UCSB R7 plate designs have been adapted to FNAL gantry
• Manufacture of parts to start soon
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 3
Production so far…
US Modules
0
500
1000
1500
2000
2500
3000
3500
Jan
-05
Jan
-05
Fe
b-0
5
Ma
r-05
Ma
r-05
Ap
r-05
Ma
y-05
Ma
y-05
Jun
-05
Jul-0
5
Au
g-0
5
Au
g-0
5
Se
p-0
5
Grade AGrade BGrade FTotal
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 4
US ARCS Testing Results
•2675 Total Tested
•2945 Grade A
•11 Grade B
•26 Grade F
•This week:
•111 of 78592 channels bad (0.14%)
UCSB
1
10
100
1000
10000
100000
1000000
10000000
Ja
n-0
5
Fe
b-0
5
Ma
r-05
Ap
r-05
Ma
y-0
5
Ju
n-0
5
Au
g-0
5
Se
p-0
5
Ch
an
ne
ls B
on
de
d
0.000%
0.020%
0.040%
0.060%
0.080%
0.100%
0.120%
Pe
rce
nta
ge
Ba
d C
ha
nn
els
Total Bad Channels
Total Channels Bonded
% Bad Channels
FNAL
1
10
100
1000
10000
100000
1000000
10000000
Ja
n-0
5
Fe
b-0
5
Ma
r-05
Ap
r-05
Ma
y-0
5
Ju
n-0
5
Au
g-0
5
Se
p-0
5
Ch
an
ne
ls B
on
de
d
0.000%
0.010%
0.020%
0.030%
0.040%
0.050%
0.060%
0.070%
0.080%
0.090%
0.100%
Pe
rce
nta
ge
Ba
d C
ha
nn
els
Total Bad Channels
Total Channels Bonded
% Bad Channels
WIEN BOX:3 modules have
failed in LT
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 5
All Modules
•Total Production:
•1248 of 1922296 channels bad (0.065%)
Good and Bad Channels
1
10
100
1000
10000
100000
1000000
10000000
Ja
n-0
5
Fe
b-0
5
Ma
r-05
Ap
r-05
Ma
y-0
5
Ju
n-0
5
Au
g-0
5
Se
p-0
5
Ch
an
ne
ls B
on
de
d
0.000%
0.010%
0.020%
0.030%
0.040%
0.050%
0.060%
0.070%
0.080%
Pe
rce
nta
ge
Ba
d C
ha
nn
els
Total Bad Channels
Total Channel Tested
% Bad Total
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 6
Completed fractions
0
200
400
600
800
1000
1200
1400
1600
1800
2000
L12p
u
L12p
d
L12su
L12sd
L34p
L56p
R5N
R5S
R6
R7
US Module Producton
Total Needed
Total Good
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 7
Backplane bias issues
•UCSB study showed evidence for decreasing conductivity with time in sensors with backside scratching and extra Ag epoxy points.
• FNAL Confirmed with lower stats
•From previous measurements the problem was understood to be the contact between the Ag epoxy and the aluminized sensor backside (and not the Ag-Au connections).
Delta Sensor Resistance (316 sensors) After LT Testing - After Assembly
1
10
100
1000
-10
-8 -6 -4 -2 0 2 4 6 8 10
ohms
Fre
quen
cy
Delta Sensor Resistance (144 sensors) July 2005 - May 2005
1
10
100
-250
-150
-50
-30
-10
-8 -6 -4 -2 0 2 4 6 8 10 30 50 150
250
ohms
Fre
que
ncy
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 8
U.S. Module Production
•For new modules we solder gold-Kapton tabs to the gold rings on the unused vias and wirebond to sensor backplanes.
• Still apply Ag epoxy to standard pads. And also use it to adhere extension pads to the backplane.
• 15 wirebonds per sensor
• Encapsulate with Sylgard 186
•Extension pads don’t affect sensor positioning during module assembly.
•UCSB has bonded to an existing pad on the frames of over 200 TEC modules and has ARCS tested these.
• No evidence of any damage.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 9
Backside Bonding – TEC Modules
•Bonds height average 0.30 mm.
•20 modules wirebonded < 1h
•Bond pull strengths have all been over 7 grams.
•The encapsulant height can be close to the frame thickness.
• To make sure we do not go outside this envelope, we will squeegee off any excess to constrain to 0.80 mm height.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 10
UCSB Existing Module Modifications
This Week A B F
Cumulative A B F A or B
L12pu 0 0 0 0 0 0 0.00%
L12pd 0 0 0 0 0 0 0.00%
L12su 0 0 0 0 0 0 0.00%
L12sd 0 0 0 0 0 0 0.00%
L34p 0 0 0 0 0 0 0.00%
L56p 0 0 0 2 0 0 100.00%
R5N 40 0 0 80 0 0 100.00%
R5S 20 0 0 38 0 0 100.00%
R6 19 0 0 19 0 0 100.00%
R7 24 0 0 24 0 0 100.00%
Total 103 0 0 163 0 0 100.00%
No evidence for additional noisy channels or pinholes.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 11
Existing Module Modifications (FNAL)
•At FNAL we are planning on soldering an insulated wire from the HV point on the top side to a pad bridging the two sensors on the backside.
• Situation different due to extra silver epoxy point and Gantry assembly plate style.
• Does avoid the use of silver epoxy in the electrical connection.
• Needs to be checked that rods built with such modules do not have additional noise.
• UCSB will use this in cases where silver epoxy has completely covered the via ring.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 12
Module Storage
•Modules are stored on aluminum plates in commercial cabinets.
• ESD shelving
• Dry air circulation
•200 modules per cabinet
•We are currently storing 2400 modules !
•We will need to add storage for >600 modules while waiting for rod assembly to restart
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 13
Rod Production
• Mostly on hold awaiting new I2C cards • Building DS rods now for CRACK • Start sustained production exercise (40 rods per site) very soon
• Internal workshop in August to converge on remaining loose ends• Minutes http://hep.ucsb.edu/cms/rod/workshopAug2005.html
• Some of the issues discussed• Agree on default long term standard scenario: 2 day, go cold 4 times• "Finalize" cuts to flag bad channels• Module grading: Same as ARCS• Rod grading - Pass if:
• Only A or B modules• ≥ 1 out of 3 non-DCU thermistors OK• I(leak) for all groups < 20 A
• XML file for DB• Went over it line-by-line
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 14
I2C Errors
• All indications are that the problem is completely solved with the new IC cards. However…
• In US test stands, we still have some occasional ones (64,68,72…)• Do not really affect testing
• Much progress done at CERN – Now believed to be completely understood and will be eliminated.
We agreed to stop I2C studies in US.
Concentrate on production readiness.
• New ICC Cards• About to have enough in hand for 20+ rods to start final rod installation
in early November!
• Focus now on preparation for high rate Rod production in US. Need:
• Shake out last kinks in production cycle (40 rod exercise).
• Definition of Digital tests.
• Some DB details to be sorted out.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 15
Developments at CERN
• Tests performed on rods at CERN indicate that residual I2C problems are negligible.
• Another change with the IC card is the potential to change the rod grounding.
• The new design of the Interconnect-Cards allows an additional ground connection (power return to cooling pipe).
• Tests performed with Cosmic Rack were performed to understand if the additional ground connection is to be implemented or not.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 16
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 17
Rods Acceptance at CERN
• Number of tested rods: 25
• Rod types:• SS4_H: 6 x Type 3
• SS6_L: 4 x Type 3
• SS6_H: 2 x Type 1, 2 x Type 2, 11 x Type 3
• NO rod rejected !
• Test of 3 rods takes ~ 6h
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 18
TST-TOB integration test, July 2005
The TOB fits!
… even if clearances reduced from nominal 10 mm to 2-3 mm at thermal screen connections.
Further clearance losses must not happen.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 19
TST-TOB integration test, July 2005
A perfect match inside the TST!
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 20
TST-TOB integration test, July 2005
Final TIB layer 4 backward + mock-up TID inside the TOB. Inner Rails function as required, clearances ok.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 21
Rod to Wheel insertion
Selecting the Rod.
Helium leak test of the Rod cooling pipe and Connection of the optical ribbon
Optical ribbon attached to installation fork.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 22
Rod to Wheel assembly
Rod installation tool aligned with a “Pre-Rod”
Rod attached to the installation tool at comfortable height and orientation.
Installation tool supported from the Wheel
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 23
Alignment tube prototype
Alignment tubes supplied by Aachen.
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 24
To do
• Test insertion and pipe soldering of a Double-Sided rod
• Prepare of lab 186 (upstairs) for present integration work• He, dry air, C6F14 lines, He leak detector
• Assembly of the Cooling segment 2.6.2 with 19 FNAL “Pre-Rods”• Pipe soldering, Cabling, Functional tests (power, ctrl, read-out)
• Development and testing of work platforms, tooling, etc.
• Get ready (by end of October) to start final Rod assembly• Dismount pre-assembled Cooling segment 2.6.2,
• Production and testing of all cooling manifolds (88-2)
• Cable supports for the Wheel and for the Thermal Screen
• Prepare equipment for Wheel transport to downstairs 186
• Solve all unforeseen…
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 25
Schedule
•FIRST RODS FOR FINAL INTEGRATION AT CERN:
• 11+11 rods finished and shipped to CERN by Oct. 14
• SS6-H type 1,2,3: 1,1,15+1
• US to study ICC swap in-line with production
•US Rod production ramp and rates
• Agreed today on ramping up to 4 rods per day at each site starting in November
• With 20% contingency, the rate is 130 rods per month delivered to CERN.
Month TOB+ TOB-
Buffer or Deficit at 3/d/site
Buffer or Deficit at 4/d/site
Oct 0 20
Nov 0 60 40 70
Dec 80 0 20 50
Jan 70 0 30 60
Feb 120 70 -90 -60
Mar 100 120 -120 -90
Apr 0 100 0 30
Totals 370 370 -120 60
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 26
In summary, things are going well
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 27
Backup slides
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 28
Hybrid Testing (as of Sep. 10)
Weekly Cumulative
Pass Fail Pass Fail % Pass
L12su 0 0 38 0 0.00%
L12sd 0 0 40 0 0.00%
L12pd 60 1 226 1 0.00%
L34p+L12pu 38 0 1084 15 98.64%
L56p 0 0 1635 22 98.67%
R2N 6 0 99 2 98.02%
R2S 0 0 78 1 98.73%
R5N 7 -1 295 2 99.33%
R5S 47 -3 325 2 99.39%
R6 9 0 334 6 98.24%
R7 0 0 158 1 0.00%
Total 167 -3 4312 52 98.81%
September 21, 2005 - J. Incandela- TOB Status – CERN, CMS Week 29
US Module Assembly (as of 9/16)
Weekly CumulativeA B F A B F % A or B
L12pu 12 0 0 12 0 0 0.00%L12pd 57 0 0 117 0 0 0.00%L12su 17 0 0 29 1 0 0.00%L12sd 15 0 0 36 0 0 0.00%L34p 0 0 0 788 4 10 98.75%L56p 27 0 0 1349 5 11 99.19%R5N 0 0 0 144 1 2 98.64%R5S 8 0 1 122 0 2 98.39%R6 0 0 0 215 0 0 100.00%R7 0 0 0 133 0 1 0.00%Total 136 0 1 2945 11 26 99.13%
TOB TOB 45% 45%
completecomplete
Will be Will be 48% by 48% by end of end of
this weekthis week
~650 TEC ~650 TEC completecomplete
TOB TOB 45% 45%
completecomplete
Will be Will be 48% by 48% by end of end of
this weekthis week
~650 TEC ~650 TEC completecomplete