Loading Tools Work Preparation / Discussion

Loading Tools Work Preparation / Discussion

Maarten, Franck, Coralie, Didier

UniBe-UniGe meeting of February 10th , 2012

Overview and target

• Experience so far- 1 stave loading with digital modules – Stave-1: Jigs version -1 and CERN stave- 2 stave loading with Si-heaters – Wuppertal stave (1 under test at CERN)- 1 stave loading with ceramic heaters- Handling frame with section 50x50 from Swiss Composit

• Stave 0 – 1st target- 2 stave0 to be built from March 12 (sequentially)- Final handling frame from Composit Design (2 bare prototypes exist) to be

machined and equipped- Loading tools to be design and produced for Production Readiness Review (PRR)- All the sequences loading and QA will have to be tested, qualified and OK- Make a PRR and a document to described all the working steps

• Production target- 14 good staves + spares to be fabricated- 30 handling frame + extenders + cable-PCB saver sets will be targeted- All the tooling sets to be made according to the feed back from stave 0 pre-

production- Production will start around July 12

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Recall - Stave-1 with 1st Loading Experience

-1st experience with the reception test and USBPix test bench- Module pigtail trimming and handling (special tooling under development by CPPM for the production) - Module loading practicing with jigs v-1- Wing folding and gluing: simple holding jig but the adhesive is not suitable- Wire bonding went well except in the region where there was missing glue

Loading modules

Wire bonding Electrical connection from flex to module

Module reception te

sts

Loaded module

Digital modules

3

Loading experience with Ceramic and Si-heaters•Stave with ceramic heaters – completed since end of last year

Still need protection covers (from François-Xavier)

• 1st stave with 1.5mm pipe and Parylene coating Problem: Middle support pin 140m too high as compared to the 3D models!!! Loaded and equipped with soft braid cables and PT100

Parylen coating

Thermal grease spreading with maskCeramic heaters – 7 types

Under wire bonding

To survey!!!

Half loaded stave

Stave equipped with cables and PT100

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Production Flow

Loading

Wing gluing

Wire bonding & QA

Readout QA

Metrology

Thermal Cycl.

Bare stave prodWuppertal

Stave Metro + FittingCPPM

Stave-Flex AssemblyCERN

Flex prodCERN

Flex loading and QAGenova Stave-Flex QA

CERN

Stave burn-in & QA Pipe extension - Brazing Stave to beam pipe integration

3D Prod.FBK/CNM

Planar Prod.CiS

FEI4BIBM

Bump bondingUBM/IZM

Module assembly and QABonn

Module assembly and QAGenova

Uni

GE –

Loa

ding

& Q

A

Env. QAUniGe

CERN SR1

Reception QA

5

Activities at UniGe

• Reception tests – QA- Module planar and 3D readout tests (Bump bonding check) + visual inspection- Stave-flex thermal cycling + metrology + visual inspection (Stave mounted onto

endblock face plate side)

• Loading- Quick inspection + module pigtail trimming + logistics- Placement of stave in the cradle + wing retract- 1st side loading: thermal grease + glue dots + module placement + load weight +

inspection- 2nd side loading (same operations as for 1st side)

• Wing attachment - By group of two wings and to be repeated 16 times- Module glue spreading - Wing release + guide placement + weight + insepction

• Wire bonding and QA- Stave + handling frame placement in the cradle at 1 position then wire bonding- Repeat above at 2 other longitudinal positions- Placement of the stave on the pull tested cradle + pull tests of few wire bonds on test

pads

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Activities at UniGe – Con’t

• Thermal cycling- Post polymerization of glue dots at +30°C during 1 hour

- Thermal cycling of one or several staves from -40°C to + 40°C 10 timesNB: Release the PMMA cover screws

• Metrology survey- Metrology survey of the 20 module versus stave location pins

NB: Fiducial marks to survey at the corners of the planar and 3D sensors

• Stave functional tests and readout (side by side for stave 0)- Stave to be inserted into a Styrofoam box and connected at the PCB savers for power, DCS and readout + fitting connection- Flush the box with nitrogen. When dry enough cool down the stave

- Make functional tests LV and HV + readout with RCE readout system

• Stave envelop QA- Check the stave envelop: Wing + Omega-flex + module (to be defined properly the

acceptance)

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Overview of the Loading Tools

Tooling under design and fab for stave0: Handling Frame (UniGe): 2 pre-series soon release for machining

- Production to release with Composite Design- Design and machining of the handling frame features + extenders (UniGe/UniBe)

Handling frame covers (UniGe): 2 prototypes produced but need updates- Production to release with local company

Loading cradle (UniGe/UniBe): Under design now- Tooling consists of: Cradle, module location rules, shims blocks and locking system, 190 microns shims, grease mask, glue mask for wing, Intermediate foam feet and wing retract, module weight, wing weight- Camera support with the common cradle socket – (UniBe)

Bonding cradle (UniBe): Already made for stave -1 and ~OK for production Pull test cradle (UniBe): Design under study HV insulation bars (UniBe): Design and fabrication still to be made Styrofoam box for stave readout test (UniGe): Design and fabrication to be made Sucking tool (UniBe): Design under study Module pigtail guillotine (CPPM): Done – To be shipped to UniGe Stave envelope check (UniGe): Design and fabrication still to be made

Goal is the validate the tooling with stave 0:- 2 handling frame + covers. Once validated 30 additional will be made- 1 set of loading tools will be made. Once validated 2 other sets to be made

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Handling Frame - From old to new version

Handling frame features:• One dedicated handling frame per stave. Once the two side flexes are glued on the stave, it will never leave its support until it is integrated around the beam pipe• Its functions are: storage, handling, interface for loading, wire bonding, electrical tests, thermal cycling, metrology, cooling pipe extension and integration stand• It consists of 3 parts: a 1m central CRFP support structure plus 2 extenders of ~ 250mm on each side holding the PCB saver and pipe stress relieve blocks• Three protection covers made of transparent PMMA will be attached for transport and storage• Mechanical precision parts:

- 1 central side location slot to reference the longitudinal loading and also for the integration stand

- Precision machining of stave support blocks with respect to the above slot and stave surfaces

- Surface precision obtained from the stave fabrication – no need of post machining

Motivation for a second version is the precision machining cost of the extenders

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Handling Frame - Few illustrations of the new version

Full length 1.m5 handling fra

me

Side extender made of a CFRP plate

Half view with segmented covers for side connection access

Protection covers made of transparent PMMA10

Handling Frame - Few illustrations of the new version

PCB saver with connector layout

Other side view with flex and PCB saver + PP0 region

Side view with protection cover

Side covers must be removed for electrical and

cooling connections

Prototype flex & PCB savers received and loaded but still to be tested

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Handling frame – Con’tCFRP prototype tube produced by Composite Design

Support foot for stave(Made by Uni. Berne)

Central support

Support - precision location

Support – Alignment slot

Version 3 with latest feature

End support on the face plate side

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Handling frame parts - Shopping list

• 1m long CFRP tube (from Composit Design) to be machined by Programme SA expected ~Feb 20th

• Stave support block (UniBe) Done (nice quality)• Other parts: Cable saver support, extender feet, right- and left-hand side PP0 support

To be done by UniBe. Can this be confirmed?• PP0 holders in plastic 3D stereo-photolithography for stave 0 prod one to be made by molding• “U-shape” stave support – Design still to be made Who will do it?• Extenders water jet cutting Done• Final assembly Can this be targeted for beginning of March• 2 sets of cable and PCB savers: Should be produced before validation/check (Yannick)• Pipe stress relieve (CPPM) Followed by Eric. VCR fitting will have to be ordered!

Target is to get 2 sets of fully equipped handling frame beginning to mid-March!

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Reception sequence – 3D views

Reception of stave with covers to be removed

Transfer of end-block fixations to the U-blocks

14

Loading sequence – 3D views

Insert the wing retract blocks Place stave handling frame into the cradlePlace grease masks

Grease spreading

Mask removalsInsert longitudinal rule

Insert Z0 alignment

1st module placement

Spacer + 2nd module

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Loading sequence – 3D views2nd spacer

½ stave with module located Lateral rule envelope

End side envelope

1st weight

All weightsLateral rule removal

End side ref rotation and

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Loading sequence – 3D viewsRemoval of guiding rule

Rotation/extraction of spacer 1 spacer fully removed

rotation of central guide + removal of lateral guide1st side completed and ready for loading

the second side

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Wing attachment sequence – 3D viewsStave in wing attachment cradleBlock support mask located for 1st module

3Rotation of mask on top of the module

Glue spreading (Epoxy) Removal of the mask

Wing retract block removed Wing jig block installed Wing clamped

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Wing attachment sequence – 3D viewsWing loaded with weight Back support stave slided

Next module and same sequences as described previously

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Wing attachment sequence – 3D views

19 20

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Agreed actions and plans

A little time remains for stave0 fabrication plan. Why?- FEI4B chips (production chips) are in production and they are performing well- FEI4A module for stave0 is progressing well at Bonn and Genova (we will learn more next week at IBL general meeting) - Stave flex are delivered and will be populated and tested in Genova- Tooling for flex to stave assembly is progressing- Stave fabrication is working fine and 1st real stave (final design) already loaded with Si-heaters

Target is to have tooling ready for beginning of April for 1st stave0:- It is only 6-7 weeks from now!- If we want to be efficient we have to make a part list (nomenclature) of all the tooling: handling frame + loading tool + wing gluing + other tools- Distribute the work amongst us: UniGe, UniBe, CPPM- Each will have to make the design fab and fabrication work based on a 3D model- Need to track the progress on weekly basis for each items of the part list for 3D, fabrication drawings, Machining/production, Assembly- Make a global stave loading and QA sequences to be reviewed

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ID Tooling Item Number Institute Delivery

1.1

Hand. frame

1m central part machining 2 UniGe + company Feb 20th

1.2 Sup. Block loc. 32 UniBe done

1.3 Sup. Block align. 32 UniBe done

1.4 Central block 32 UniBe done

1.5 PP0 support 4 UniGe done

1.6 PP0 leg left 2 UniBe End of Feb

1.7 PP0 leg right 2 UniBe End of Feb

1.8 PP0 comb (3D ABS) 8 UniGe To be validated

1.9 U-block support left & right 4 UniBe End of feb

1.10

Extender

CFRP plane 4 UniGe done

1.11 PCB saver support 8 UniBe End of Feb

1.12 Extender feet 4 UniBe End of Feb

1.13 Pipe stress relieve 4 CPPM Beginning of March

1.14

Cover

Central cover 2 UniGe (Franck) tbd

1.15 Side cover left 2 UniGe (Franck) tbd

1.16 Side cover right 2 UniGe (Franck) tbd

Part List – Handling frame

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2.1

Cradle

Base plate 1 UniGe + company tbd

2.2 Front wall 1 UniGe + company tbd

2.3 Rear wall 1 UniGe + company tbd

2.4 Locking system 2-3 UniBe Done

2.5Camera support

Sliding bars 3 UniBe tbd

2.6 Interlink to baseplate 3 UniBe tbd

2.7 Camera holder block 3 UniBe tbd

2.8

Grease mask

Grease mask type 1 1 or 2 UniGe tbd

2.9 Grease mask type 2 1 or 2 UniGe tbd

2.10 Grease mask type 3 1 or 2 UniGe tbd

2.11

Rules

Alignment rule left 1 UniGe tbd

2.12 Alignment rule right 1 UniGe tbd

2.13 Dowel pins align. (Delerin) 100 UniGe tbd

2.14 Rule for lateral envelope 2 UniGe tbd

2.15 End stop envelope 1 UniGe tbd

2.16 Start loading location 1 UniGe tbd

Part List – Loading tool

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2.17

Spacer

Spacer – kapton 190m 30 UniGe + Rui tbd

2.18 Spacer holder 10 CPPM? tbd

2.19 Rod for spacer support 2 CPPM? tbd

2.20 Block rod support 10 CPPM? tbd

2.21

Weight

Load weight planar (brass) 8 UniBe tbd

2.22 Load weight 3D (brass) 4 UniBe tbd

2.23 Handling rod 10 UniBe tbd

2.24 Delerin spacers 40 UniBe tbd

2.25

Wing retract

Wing retract block 14 CPPM? tbd

2.26 Special central support left 1 CPPM? tbd

2.27 Special central support right 1 CPPM? tbd

Part List – Loading tool - Con’t

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3.1

cradle

Base plate 1 UniGe + company tbd

3.2 Front wall 1 UniGe + company tbd

3.3 Rear wall 1 UniGe + company tbd

3.4 Locking system 2-3 UniBe Done

3.5

Wing positioning

Wing jig block 16 CPPM tbd

3.6 Wing holder tongue 32 CPPM tbd

3.7 Loading weight (brass) 16 CPPM tbd

3.8 Handling rod 16 CPPM tbd

3.9 Weight bracket plates 32 CPPM tbd

3.10 (Axial screws for rotation) 64 CPPM To be agreed

3.11aMask setOption 1

Mask position block 4 UniGe To be tested

3.12a Mask holder 4 UniGe To be tested

3.13a Mask SS (50 or 70 m) 4 UniGe To be tested

3.11b Guide setOption 2

Guide block 16 UniGe To be tested

3.12b Glue stamping bar 40 UniGe To be tested

Part List – Wing attachment

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Other tools


4.1

Bonding cradle

Base plate 1 UniBe Done

4.2 Walls 4 UniBe Done

4.3 Locking system 2 UniBe Done

4.4 Index for long. location 1 UniBe Done


5.1

Pull test cradle

Base plate 1 UniBe tbd

5.2 Rear wall 1 or 2? UniBe tbd

5.3 Removable front wall 1? UniBe tbd

5.4 Index for long. location 1 UniBe tbd

5.5 Locking system 2 UniBe tbd


6.1 Guillotine Guillotine 3D modules 1 CPPM Done to be tested

6.2 Guillotine Guillotine planar modules 1 CPPM Done to be tested

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Other tools – Con’t


7.1 Module sucking tool

Sucking fork and vacuum cups 2 UniBe tbd


8.1Envelope QA

Jig envelope block 1 or 2? ? tbd

8.2 Sliding block 1 or 2? ? tbd


6.1 HV insulation HV insulation bar (Peek) 200 UniBe tbd (expected from July)

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Documents

Loading Tools Work Preparation / Discussion