QA/QCduringconstruc0on

FinalDesignReview9thNovember2015

FabienJeanneauonbehalfofMMcommunity

Preliminaryremarks•  CentralizedorderatCern:

–  Checkcomplianceofdelivery(exceptforFR4sheetsforinstance)

–  Dispatchinconstruc0onsitesandcompletechecklocally–  Timeneededtogaranteereplacementincaseofnon-conformity

•  Requirements:–  Expressedinabsolutetoleranceandnominalvalue–  Meanvalue,r.m.s.,minandmaxareneededtoevaluatethequalityofacomponentandforacceptance/rejec0ondecisioninnon-conformityprocedure

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Parameters

•  Geometrical– Thickness(boards,panels,frames,inserts)– Planarity(panels,quadruplets)– Posi0on,alignment(boards,strips,panel)

•  Opera0onal– Electrical(HV,grounding,insula0on)– Gas0ghtness– Modulevalida0on(seepresenta0onbyP.Iengo)

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FR4sheetsthickness

•  Nominalthickness–  Centraldri\andROboards:

•  coppercladononeside•  0.5mm+0.17µm

–  Outerskinofouterdri\:rawFR4sheet(0.5mm)

•  Tool:digitalthicknesscaliper

•  Method:Measurementson10pointsontheedgeofthesheet.

•  10%ofbatchformodule0havebeenmeasure:–  Thicknessvaria0onswithinasheetarebelow25µm,withanrmsof5–8µm

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Parameter Requirement #measurements

Thickness ±50µm ~10

Honeycombfoils

•  Tools–  Heightgauge–  Depthmicrometer–  CMM

•  Methods–  Foilss0ckedongranitetablewithweightorbyvacuum–  Beforecufng(delivery):

•  measurementsaredoneinindustry•  Preliminarycheckswithathicknesscaliper

Parameter Requirement #measurements

Thickness 10.1mm±60µm ~50

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HC1Entries 8Mean 10.13Std Dev 0.01602

10 10.05 10.1 10.15 10.2 10.25 10.30

0.2

0.4

0.6

0.8

1 HC1Entries 8Mean 10.13Std Dev 0.01602

HC2Entries 11Mean 10.16Std Dev 0.01384

10 10.05 10.1 10.15 10.2 10.25 10.300.5

11.5

22.5

3 HC2Entries 11Mean 10.16Std Dev 0.01384

HC3Entries 13Mean 10.16Std Dev 0.01646

10 10.05 10.1 10.15 10.2 10.25 10.300.5

11.5

22.5

3 HC3Entries 13Mean 10.16Std Dev 0.01646

HC4Entries 19Mean 10.13Std Dev 0.02938

10 10.05 10.1 10.15 10.2 10.25 10.300.20.40.60.8

11.21.41.61.8

2 HC4Entries 19Mean 10.13Std Dev 0.02938

HC5Entries 21Mean 10.13Std Dev 0.01995

10 10.05 10.1 10.15 10.2 10.25 10.300.20.40.60.8

11.21.41.61.8

2 HC5Entries 21Mean 10.13Std Dev 0.01995

HCAEntries 72Mean 10.14Std Dev 0.02552

10 10.05 10.1 10.15 10.2 10.25 10.3012345678 HCA

Entries 72Mean 10.14Std Dev 0.02552

HoneyComb Thickness (N33)

10

Thickness [mm]

Thickness [mm]

Thickness [mm]

Thickness [mm]

Thickness [mm]

Thickness [mm]

CELL: From Centralized order @CERN

@CELL 10.13mm

1 2

3 4

5 All

Frames

Tools–  CMM–  Ver0calgaugeorruler–  Limbo

Methods

–  Beforemachining:sampling10%–  A\ermachining:eachframe–  Pitchofmeasurement:5cm

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Parameter Requirements #Measurements

Type1,2.1,4,5 Type3(Mesh) Type6(Gasgap)

Thickness 10mm±60µm 5.06±25µm 5.17±30µm ~80for1mlong

9,9

9,92

9,94

9,96

9,98

10

10,02

10,04

10,06

0 200 400 600 800 1000 1200 1400

T2-005_2015-07-15_LP_SC.csv-Epaisseur

0,498 11,999 25 Limit_Min Limit_Max

Saclay

INFN-Roma1

Panelthicknessandplanarity

•  Tools–  CMM–  Laser-tracker–  Probe-ruler

•  Methods–  Panelaremeasuredonagranitetableevery10or20cm,onbothsides

–  Combinedmeasurement:•  Vacuumàthickness•  Free(underitsowweight)àplanarity(globalshape)

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Parameter Requirement #measurements

Thickness -  ROpanel:11.7mm-  Dri\panel(vacuumbag):11.1mm-  Dri\panel(s0jack):11.3mm

Planarity ±110µmw.r.t.nominalthickness ~2000/side

BMBF

Gas0ghtness

•  Tools:Localdetectororvesselbasedonadifferen0alpressuresensor

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Parameter Requirement

Gasleakrate <10-6barL/s(10-4vol/min)

Flowrateloss <10-5l/s

Local0ghtnesscheck(atthejunc0onbetween2boards)

Globalgas0ghtnesscheck(withavessel)

Dri\panelcomple0on

•  Mechanicalchecks–  Mesh-frameheighta\erfixa0on:5.06mm±45µm–  Dri\spacer(IC):5mm±45µm–  Tool/method:heightordepthcaliper

•  Electricalandgroundingtests

–  Meshframe:•  Shortcutswithcathode•  GroundingàR<0.1Ohm(tobecheckedalsoforHCandframes)

–  Cathode:•  HVcontact,con0nuity•  Insula0on:500V/<1nA

–  Tool/method:Ohmmeterandpowersupply

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Mesh

•  QCofmeshisdetailedinATL-M-CD-0001v.1•  Tool:commercialtensometer(e.g.SEFARtensocheck100)

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Parameter Requirement #measurements

Tension nominalbetween7and10N/cm 50-100

Quadruplets

•  Gas0ghtness:samerequirementthanforpanels–  Leakrate<10-6barL/s–  Flowrateloss<10-5l/s

•  Planarity:samerequirementthanforpanels–  ±110µmw.r.t.nominalthickness–  Nominalthicknessà77<T<77.6(s0jackvsvacuumbag)

•  HVtests:–  Resis0vestrips

•  At800Vinair,i<40nA/m2(affectedbyhumidity)•  At580Vinstandardgasmixture,i<1nA/m2

–  Cathode•  i=0nA@1000Vinair

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Alignmentchecks

Toolsforstrip-alignmentchecksarebasedon:-  Contact-CCD:CCD+fiberop0cs-  Codedmasks:rasmask

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Parameter Requirement

Stripsononeside ±40µm(withconstantalloweddisplacement±20µm)

Stripsrela0veposi0oningside-to-side ±60µm(withconstantalloweddisplacement±35µm)

Stripsrela0veposi0oningpanel-to-panel

±60µm(withconstantalloweddisplacement±35µm)

2ROpanelsrela0veposi0on ±20µm(perpendicularityofalignmentpin)

Strip-alignmentchecks:methodsandtools

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SpheressupportforC-CCDruler

Posi0onsofspheresaremeasuredwithaCMM

Sphere:!12mmCodedmask:7mm

Stripposi0onononesideischeckedusingacalibratedjigmadeofFR4‑Honeycombsandwichwithspherestoposi0ontheC-CCDruleronthecodedmasks

C-CCDrulerscanbemountedonaU-shapemechanics.Side-to-sidestripposiYoningcanbecheckedwitha“doubletclip”Adedicatedmechanicalsupportcanbeused0checkthealignmentofstripspanel-to-panel

Acceptancecriteria•  Non-conformityproceduresmustbedefinedcasebycasefor

–  Thickness:HC,perimeterframes(type2.1,4,5),panels,quadruplet–  Alignment:

•  Stripononeside•  Stripside-to-side•  2ROpanels

–  Gas0ghtness–  Meshtension–  Grounding

•  Followingrequirementsarevery0ghtandcomponentsoutofspecsmustberejected:

–  FR4thickness–  Frameswith0ghtthickness(type3and6,meshframeandgas-gapframe)–  Mesh-frameheighta\ergluinganddri\spacer(IC)–  Coolingleaks–  Electricaltests:

•  Cathodeinsula0on•  Resis0vestripscurrentconsump0on

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Conclusion

•  EachstepsofQCduringconstruc0oniswelliden0fied

•  Mostofthetoolingisready(s0llneedtofinalizeC-CCDtool)

•  Methods:–  Notallhavebeentested(willbeduringcomple0onofmodule-0)–  Someneedtoberefined(e.g.numberofmeasurementstoachievthe

requestedaccuracy)

•  Acceptancecriteriaares0llmainlybasedontolerance–  Casebycaseaceptance/rejec0oncriterias0llneedtobedefined(Non-

conformityprocedures)

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