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G.Sguazzoni 1Tracker Week April ‘03
FE hybrid assembly andFE hybrid assembly andquality assurancequality assurance
The hybrid team:Alan Honma, Michael Poettgens, Gabriella
Pasztor, Bernd Reinhold, G.S.
Bruno WittmerCERN –EP Division
““...resistance...resistanceof hybridsof hybrids
isisnotnot
futile…”futile…”
G.Sguazzoni 2Tracker Week April ‘03
Assembly procedure @ CERN Assembly procedure @ CERN
Hybrid assembly test Test during thermal cycle(s)
Pitch Adapter (PA) gluing at the gantry
(PA bonding)
Bare Hybrid (no Pitch Adapter) Reception test
1 2
3
G.Sguazzoni 3Tracker Week April ‘03
Hybrid reception ‘fast’ testHybrid reception ‘fast’ test
Check that no damage occurred during shipping
Fast ARC test FHIT like will be replaced by FHIT
G.Sguazzoni 4Tracker Week April ‘03
Gantry PA assemblyGantry PA assembly
First 50 TOB hybrids glued @ the gantry… all good!!!
Hyb+PA TOB: 16/plate
Gantry time 1h Curing 8h
Spacer+PA TOB: 64/plate
Gantry 30min Curing 8h
Typical requested throughput 52 hyb/day Handling and preparation
is a limiting factor
First 50 TOB hybrids glued @ the gantry… all good!!!
Hyb+PA TOB: 16/plate
Gantry time 1h Curing 8h
Spacer+PA TOB: 64/plate
Gantry 30min Curing 8h
Typical requested throughput 52 hyb/day Handling and preparation
is a limiting factor
G.Sguazzoni 5Tracker Week April ‘03
Hybrid assembly resultsHybrid assembly results
RMSs (in m) indicate assembly precision within bonding requirements
All hybrids have been bonded successfully!!! stability as the glue cures checked and fine!!!
RMSs (in m) indicate assembly precision within bonding requirements
All hybrids have been bonded successfully!!! stability as the glue cures checked and fine!!!
~14 ~11
~42~4350 50
50 50
(x1, y1)
(x2, y2)
x1
y1 y2
x2
G.Sguazzoni 6Tracker Week April ‘03
Post PA assembly testsPost PA assembly tests ...to insure that:
the hybrid is still alive after many operations
the PA bonds are OK no opens, no shorts!
the hybrid+PA survives… …a cooling cycle (TROOM –20oC TROOM) …multiple (~10) thermal cycles (to emulate
CMS shutdowns)
We need a nice test setup!!!
Sample test!!!
G.Sguazzoni 7Tracker Week April ‘03
The nice test setup
The nice test setup
Located in the new CERN Gantry Clean ROOM
Located in the new CERN Gantry Clean ROOM
TestBoxTestBox ElectronicsElectronics
Water/GasmanagementWater/GasmanagementChairChair
Status screensStatus screens
Water leak detectorWater leak detector
G.Sguazzoni 8Tracker Week April ‘03
Test setup block diagramTest setup block diagram
G.Sguazzoni 9Tracker Week April ‘03
Test BoxTest Box 4 hybrid slots
standard/stereo
N2/dry air flushed
temperature sensors humidity sensors Cooling/Heating:
300W Peltier element (24V-14A)
TLOWEST ~ -25oC with
max load (4 running hybrids)
hybrid on the test
plate
G.Sguazzoni 10Tracker Week April ‘03
Readout & GUIReadout & GUI
ARC based readout
automatic cycling/testing of all loaded hybrids
TCP/UDP communication with slow control application
Ready soon: DB compliant
output “One-button”
test
G.Sguazzoni 11Tracker Week April ‘03
Slow control: hardwareSlow control: hardware
Aachen Cooli box controller RS232 interface Peltier driving Temperature/
Humidity sensor readout
safety interlocks
...custom patched for: gas/water flow meter NIM-TTL pulser driving
G.Sguazzoni 12Tracker Week April ‘03
Slow control: softwareSlow control: software
Temperature monitor
Humidity monitor
Peltier current
Safety
TCPUDP
Temperature regulation
Water & gas flow
Custom version of Aachen Cooli Devive Controller – ACDC (LabVIEW)
G.Sguazzoni 13Tracker Week April ‘03
Post PA assembly testsPost PA assembly tests
Typical test sequence during a cooling cycle
Hybrid ON* Ped, Noi Pulser Short
Detection Hybrid OFF*
*Added after problem with hybrid in cold (see later)
TROOM
–20oC
~25 min/4 hybrids
G.Sguazzoni 14Tracker Week April ‘03
Long term cyclesLong term cycles Sample test!!! emulates ~10
CMS running-shutdown periods
Each cycle same tests as the single cycle…
TROOM
–20oC
~5 hours/4 hybrids
last cycle: stronger! (TROOM –25oC +35oC)
G.Sguazzoni 15Tracker Week April ‘03
Noise issues for hybrid+PANoise issues for hybrid+PA
No reference plane below PA PA is a weak point wrt noise injection
ampli channel
GND lines connected to the support plate by a wide copper strip
Hybrid
ARC FEARC FE
Hybrid GND plane
Hybrid Al support plate
PA line
ARC FEadaper
G.Sguazzoni 16Tracker Week April ‘03
Noise comparisonNoise comparison
Grounding scheme comparison
PA lines length
structure
BAD grounding
NEW grounding
G.Sguazzoni 17Tracker Week April ‘03
Short detectionShort detection
1 SHORT = 2 channels lost
G.Sguazzoni 18Tracker Week April ‘03
Short detection principleShort detection principle
Calibration signal is sent every 4 channels
PIN HOLE like effect may also contribute
IN OUT
ch. #N
ch. #N+1
CALsignal
G.Sguazzoni 19Tracker Week April ‘03
Short detectionShort detection Simple and effective threshold criterium
SHORTs
Pulse shape
Pulse heights
G.Sguazzoni 20Tracker Week April ‘03
The first (detected) short!The first (detected) short!
Short = bonding problem PA
APV
G.Sguazzoni 21Tracker Week April ‘03
Open detectionOpen detection
OPEN = 1 channel lost
G.Sguazzoni 22Tracker Week April ‘03
Pulser hardwarePulser hardwareA
RC
NIMpulsertr
igge
r NIMto
TTL
start
out
50“antenna” very close (~1mm) to the bond
pads
Peak - InvOFF Pulser ON Peak
Mode Optimal
latency
OPENS
G.Sguazzoni 23Tracker Week April ‘03
Open detection: basicsOpen detection: basics
Removed Hybrid-PA bonds or scratch on PA lines*
Spikes in the pedestal profile!!!
Removed Hybrid-PA bonds or scratch on PA lines*
Spikes in the pedestal profile!!!
On-board CM subtraction
Pedestal ~unchanged
On-board CM subtraction
Pedestal ~unchanged
*even quite close to the bonding pads
G.Sguazzoni 24Tracker Week April ‘03
The open-detection criteriaThe open-detection criteria
Optimal to detect isolated opens
Difference wrt neighbours
Mean Subtracted Pedestal
OPENSin our test
hybrid
G.Sguazzoni 25Tracker Week April ‘03
The TOB outcome so far…The TOB outcome so far… 78 received Reception TEST
72/74 good; 2 not OK 11 FNAL & 5 UCSB 2 ‘ TEC1.1 ’ Aachen
Assembled 48/48 good
Bonded 45/45 good
Thermal cycle test Standard: 20/20 good
20 FNAL;
Long term: 8/9 good, 1 fails in cold
14846/14848 good bonds; 1 short, no opens
G.Sguazzoni 26Tracker Week April ‘03
PedestalPedestal Large non-uniformities
Max-MinMax-MinAPV wise
Pedestal cuts in module-test draft procedure ~ too tight
Pedestal
Pedestal<Pedestal>
Pedestal<Pedestal>
APV wisePre
lim
inary
!!!
G.Sguazzoni 27Tracker Week April ‘03
Hybrid+PA NoiseHybrid+PA Noise
Normalized Noise cuts (20%) in module test draft procedure
-20oC
ROOM Noise increases in cold
Peltier current?
Prel
imin
ary!
!!
Noise<Noise>
Noise
G.Sguazzoni 28Tracker Week April ‘03
The faulty hybrid:i.e. the kind of nasty problems we are supposed to discover
The faulty hybrid:i.e. the kind of nasty problems we are supposed to discover
The hybrid fails only @–200C No APVs output but answers to I2C commands other strange behaviors (current, DCU readings) only a certain command sequence induces the failure;
otherwise the hybrid works perfectly Test procedure modified to foresee hybrid OFF/ON &
initialization before any group of tests
First crude investigation: No visible defect MUX chip???
…further study needed
G.Sguazzoni 29Tracker Week April ‘03
Test Station throughputTest Station throughput Target:
Nominal: 32 hybrids/day UCSB will take over TOB bonding and testing
– they are duplicating the setup 4 hybrids 40 min (preparation+test)
Limiting factors Cooling time Loading/Unloading
(40min/4hyb) * 32hyb ~ 5h Effective production request could be
higher… A second “CERN” teststation is in preparation (Cooling cycle test could be done on sample
basis or dropped in case no problems are found)
G.Sguazzoni 30Tracker Week April ‘03
ConclusionConclusionHey folks, is there
someone willing to test hybrids on a large
scale?!?!…
Hey folks, is there someone willing to test
hybrids on a large scale?!?!…