CMS Tracker Week, CERN, 19-23 Apr 2004 22 Apr 2004CMS Tracker Week - Module ProductionSalvatore Costa - Catania Module Production ___________ Report on

CMS Tracker Week, CERN, 19-23 Apr 2004

22 Apr 2004CMS Tracker Week - Module ProductionSalvatore Costa - Catania

Module Production___________

Report on the

Catania Status

Salvatore CostaUniversità di Catania and INFN – Sezione di Catania

22 Apr 2004CMS Tracker Week - Module Production 2 Salvatore Costa - Catania

Outline

1. Module accounting

2. Bonding:1. Production rate

2. Bonding experience

3. Pull Test results

4. Failure analysis

3. ARCS & LT Tests1. ARCS test analysis

2. LT test analysis

4. Usage of central DB

5. Logistics & transportation of modules


Module Accounting

Module Type Total IB34 IB12phi

Received from Bari Gantry

61 28 33

Bonded 58 (51 in DB) 27 30

ARCS tested 56 (47 in DB) 27 29

OK 53 26 27

bad 3 1 2

LT tested 49 (0 in DB) 27 22

OK 49 27 22

bad 0 0 0


Production Rate

• Initially slow due to bonding commissioning (we lacked long-standing experience with previous bonding jobs), but now on schedule. To illustrate our progress…:– First box received, with 8 Modules, was completed

(bonded + ARCS tested) 23 days after arrival– Last 2 boxes, with 9 Modules each, have both been

completed within 2 working days after arrival

• Current bonding capability is 4-5 Modules/day• Long Term keeps up with no difficulty with current

incoming flux of ~1 9-Module box / week


Bonding Experience• Became full-blown Bonding Center on 5 Dec 2003

– Previously designated Bond Repair Center• Had passed official CMS Qualification Tests (“bond test # 1 & 2”)

• Bonding experience with previous experiments: none• Equipment:

– 2 Hughes 2470-II bonders • 1991, 1987• automatic but no Pattern Recognition or bond foot deformation feedback

– 1 ATV GM-100 pull tester• manual

Machine downtimes: each time a new machine fault occurred that we had not seen before.

Time spent to learn to locate the source of the fault, what action to take and with what procedures.

Higher probability of bond

failures or accidents


Bond Pull Tests Results

0

2

4

6

8

10

12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Module vs time

PA Test Area50th PA-Sen

5g

IB34 IB12phi sampling


Bond Failure Analysis 53 Modules

34048

bonds

repaired unrepairable

# modules affected

% # strips affected

% # modules affected

% # channels affected

%

Totals 44 84 563 1.65 10 19 29 0.08Machine failures

42 80 506 1.48 7 13.2 14 0.04

Bond foot misplacement

2 3.8 9 0.026

to stick 42 80 506 4 7.6 4 0.012

Pinholes (caused by bonding?)

1 1.9 1 0.003

Operator mistakes

2 3.8 57 0.17 3 5.7 15 0.04

Mishandling 1 1.9 7 0.02 2 3.8 7 0.02

Wrong ref 1 1.9 50 0.15

Wrong par

(lifts, pinholes)(1) (1.9) (384) (1.11) 1 1.9 8 0.02


Bond PA-Sen in TIB L1&2

correct

misplaced


ARCS Test Analysis• All tests performed following the official TIB procedure • ARCS 7.0 used for long time (7.1 installed & operational but not yet fully tested)• Tony’s macro used initially, starting mid March Riccardo’s update (now v3.1.0)• Flagging efficiency with Riccardo’s macro: ~ 100%

• Out of 53 good modules, 51 are grade A, only 2 are grade B– No IV problems– A total of 55 defective “strips” found over 34048 bonded strips

• 29 caused during bonding• 26 pre-existing: Sen pinholes + APV-PA bond opens + Hyb faulty chan

open

chan


ARCS Analysis: IVWe wrote a script which queries DB to compare measured IV with the Sensor one. We also implemented Temperature correction.

NO IV problems up to now

IV data not available for all the sensors


Long Term Test Analysis49 modules tested with TIB Official Scenario (about 72 h)

– Some modules retested with a 1-night scenario due to failure on the last record

– First, cold & last records always recorded

• Some failures of the sw before Marco’s patch on I2C• 1 failure due to DAQ problems with Lt_1.22• No failures since Lt_1.24 was installed• Riccardo’s macro used for the analysis (now v3.1.0)• No new defective strips appeared after LT test

– From time to time some noisy strips appear and disappear


3 Bad Modules In 3 Modules, all from the very last group of Modules received, we have

observed plain failure of the ARCS Test after bonding (they had passed with flying marks the test upon arrival):

• 2 Modules (30200020035289, 303) fail Fast Tests’ Low Voltage test: I(V2.50) = ~850 mA (max 750 mA)– Bonds are among the best we’ve made, both mechanically and aesthetically– No visually evident damage from possible mishandling– ESD?

• 1 Module (30200020035305) fails to power up the Hybrid– Damage to connector?

Has something changed in our working environment or procedures? All these modules’ Hybrids are marked with Alan’s blue dot Deep investigation needed to understand these problems


Usage of central DB

• Bonding data always timely uploaded to TrackerDB since the beginning

• for all ARCS & LT data, xFLAG 1.4.3 has been used to produce XML files: 53 ARCS + 49 LT – XML files checked for consistency with root files and macro’s

output• No serious problems reported• Only few root files need to be redone due to old ARCS bug in the header

– 86% of ARCS XML files already uploaded– LT XML files not yet uploaded


Logistics & Transportation

• No major problems with modules received from Bari– In first 2 boxes only the styrofoam blocks on the sides

were too far apart, so Modules (on transport cradles) slipped out of their slots, but no damage to the modules resulted. Problem was quickly corrected in newer boxes

– Some dirt (mainly small [fabric?] fibers)• We blow a 1.5 atm air jet on Module before starting visual

inspection

• Our storage space in clean room can hold ~8 more boxes (72 Modules), – After, better to start shipping to Pisa– or we will have to figure out how to carve out more

storage space

CMS Tracker Week, CERN, 19-23 Apr 2004

22 Apr 2004CMS Tracker Week - Module ProductionSalvatore Costa - Catania

ARCS & LT Test

The Catania CMS Module Production Crew

S. Costa, N.Giudice, F.Noto, F.Raimondo, C.Sutera, C.Tuve

Inspection, Test on arrival, Bonding

S. Albergo, M. Chiorboli, M. Galanti,

G. Gatto, A.Tricomi

Documents

CMS Tracker Week, CERN, 19-23 Apr 2004 22 Apr 2004CMS Tracker Week - Module ProductionSalvatore Costa - Catania Module Production ___________ Report on