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US CMS Silicon Tracker Project
Joe Incandela
University of California Santa Barbara
Status and scheduleCMS Weekly Meeting
Fermilab
May 14, 2004
Tracker status - Fermilab - May 14, 2004 - J. Incandela 2
North American Group
• Fermilab (FNAL)• M. Demarteau, A. Ronzhin, K. Sogut, L. Spiegel, S. Tkaczyk + technicians
• Kansas State University (KSU):T.Bolton, W.Kahl, R.Sidwell, N.Stanton• University of California, Riverside (UCR)
• P. Gartung, G. Hanson, G. Pasztor• University of California, Santa Barbara (UCSB)
• A. Affolder, S. Burke, C.Campagnari, D. Hale, (C. Hill), J.Incandela, S. Kyre, J. Lamb, S. Stromberg, (D. Stuart), R. Taylor, D. White + technicians.
• University of Illinois, Chicago (UIC)• E. Chabalina, C. Gerber, T. Ten
• University of Kansas (KU)• P. Baringer, A. Bean, L. Christofek, D. Coppage
• University of Rochester (UR)• R.Demina, R. Eusebi, E. Groves, E. Halkiadakis, A. Hocker, S.Korjenevski,
P. Tipton• Mexico Consortium:
• Cinvestav: H. Castilla, R.Perez, A. Sanchez• Puebla: E. Medel, H. Salazar• San Luis Potosi: A. Morelos
• Brown University• R. Hooper, G. Landsberg, H. Nguyen, C. Nguyen
Tracker status - Fermilab - May 14, 2004 - J. Incandela 3
Tracking Requirements
• Efficient & robust• Fine granularity to resolve nearby tracks
• Fast response time to resolve bunch crossings
• Radiation resistant devices for 10y of LHC operation
• ~1-2% PT resolution at ~ 100 GeV
• Asymptotic impact parameter d ~ 20 m
• MOST IMPORTANTLY – We want it to be there and useable as early as possible!
Tracker status - Fermilab - May 14, 2004 - J. Incandela 4
US Responsibilities
5.4 m
2.4
m
Outer Barrel (TOB)
~105 m2
NEW:End Caps (TEC)
50% Modules for Rings 5 and 6 and
hybrid processing for Rings 2,5,6
Tracker status - Fermilab - May 14, 2004 - J. Incandela 5
Outer Barrel Production
• Outer Barrel • Modules
• 4128 Axial (Installed)
• 1080 Stereo (“ “)
• Rods
• 508 Single-sided (“ “)
• 180 Double-sided (“ “)
• US Tasks• All hybrid bonding & test
• All Module assembly & test
• All Rod assembly & test
• Joint Responsibilities with CERN• Installation & Commissioning
• Maintenance and Operation
~20 cm
Modules Built & Tested in US
Tracker status - Fermilab - May 14, 2004 - J. Incandela 6
End Cap Construction
• Central European Consortium requested US help
• We agreed to produce up to 2000 R5 and R6 modules
• After 10 weeks UCSB successfully built the R6 module seen above.
• UCSB has built 27 R6 and 3 R5 modules to date
First TEC Module Built at UCSB
Pisa
ROD INTEGRATION
AachenKarlsruheStrasbourgZurichWien
PETALS INTEGRATION Aachen
Brussels Karlsruhe
Louvain
Lyon Strasbourg
BrusselsWien Lyon
TEC AssemblyTEC Assembly
CERN
Frames:Brussels
Sensors:factories
Hybrids:Strasbourg
Pitch adapter:Brussels
Hybrid:CF carrier
TK ASSEMBLY
CERN
LouvainStrasbourg
Perugia Wien
BariPerugia
Bari FirenzeTorinoPisaPadova
TIB-TID INTEGRATION
FNAL
UCSB
TOB Assembly TIB-TID Assembly
CERN/USA Pisa Aachen Karlsruhe. --> Lyon
KarlsruheSensor QAC
Moduleassembly
Bonding& testing
Sub-assemblies
FNAL
Integrationinto mechanics
PisaRU
FNAL UCSB
UCSB
UCSB
UCSBCatania UCSB
US in the tracker
US carries almost half of the production load
Tracker status - Fermilab - May 14, 2004 - J. Incandela 8
Summary I
• Problems continued to plague components this past year• US contributions have been critical
• US played major role in finding and fixing a series of flaws• In some cases they would have been fatal
• Problems for module components have been addressed • Frames and hybrids:
• Yields and rates are high and rising• Sensors
• US identified CM Noise and other problems with STM sensors• US advocated shifting order to HPK:
• Provided funds for procuring the masks• Pressed for order to be placed with HPK in February –
beyond which we would have delayed HPK production• CMS is reviewing STM now
• Either STM quality reaches adequately high standards or the remainder of the order will be shifted to HPK
• Upshot: no matter what – we’ll have very high delivery rates by July
Tracker status - Fermilab - May 14, 2004 - J. Incandela 9
Summary II
• These issues have meant that the schedule has slipped• We have lost 6-8 months in FY04 due to this last round of problems
• We have responded• In parallel with work to resolve component problems we improved our
production capacity
• Major upgrade of US production lines to achieve significantly higher production capacity to recover lost schedule time.
• New and better methods
• More and better tooling and hardware
• Better software and Quality Control
• Both FNAL and UCSB production lines have since demonstrated more than 100% increases in stable, high quality module production
• Our production capacity is now extreme:• CDF or D0 Run 2 silicon detectors ~ 750k channels each:
• We can produce this many channels in 10, 40-hour weeks
• With overtime we’d need only 6 weeks
Tracker status - Fermilab - May 14, 2004 - J. Incandela 10
Hybrid Problems
• Serious problems were uncovered by US and CERN1. Flex cable fragility (US)
2. Weak wirebonds (CERN)
3. Power via opens (US)
• Found early, solved quickly• Excellent communication
between US and Europe
• Great relationships with vendors
• Problems typically have been diagnosed, understood, and removed in 1-4 weeks
These could have been fatal
Tracker status - Fermilab - May 14, 2004 - J. Incandela 11
Sensor Production
• Thin Sensors (320 m)• 6273 of 6877 (91%) delivered
• Yield > 99% at CMS QC
• Thick Sensors (500 m) • 7000 ordered from HPK
• Deliveries have begun
• HPK has capacity to make all CMS sensors on schedule
• Thick Sensors (500 m)• Initially ~87% yield at CMS QC
• Major efforts by the CMS tracker group and STM yield at CMS QC increased to ~ 98%
• Still concerns …
Hamamatsu Photonics (HPK) SGS Thomson (STM)
Tracker status - Fermilab - May 14, 2004 - J. Incandela 12
1. CMN Noise Issue
•Example: Sensors31215014 and 14308304
•Channels causing the problem• 203 at 70V
• 251 at 130V
30200020005110
100
1000
10000
100000
1000000
0 100 200 300 400 500
Voltage
Bia
s C
urr
en
t (n
A)
Current(DB)
Current(probing)
Current(Bonded)
CMN problem first reported by US in July 2003. Understood to be a pt. discharge/breakdown effect
Tracker status - Fermilab - May 14, 2004 - J. Incandela 13
First IV in standard Vienna qtc setup: sensor outside specifications (20µA)
Vacuum switched off: Sensor perfect 0.5 µA
Vacuum switched on again: Sensor again bad (20µA)
Sensor 30211431541220
2. Vacuum – effect (single strip!)
without vacuum
with vacuum
Tracker status - Fermilab - May 14, 2004 - J. Incandela 14
We identify some sensors with odd noise structure:
Good sensor
3. Time structure in leakage current
Tracker status - Fermilab - May 14, 2004 - J. Incandela 15
Deliveries as of mid February show a new class of sensors:All sensors have currents >1.5 µA : all grade B (have to be fully tested 100%)
IV curve in most cases flat, sensors good?
4. Large processing changes
Tracker status - Fermilab - May 14, 2004 - J. Incandela 16
Module Components Summary
• We exerted a major positive influence.
• Many problems (most found by US) led to delays
• Module breakage in transport → 2 months
• Hybrid Cable problem → +3 months
• ST Sensor issues → +5 months
• Hybrid via problem (found April 04) → no added delay
• ST sensors are the remaining concern
• Shifted order of 7000 (out of 18000 thick sensors) to HPK
• Re-qualifying STM final process now with decision in July
• Timing such that we can shift all production to HPK without impact on schedule if STM fails qualification
Tracker status - Fermilab - May 14, 2004 - J. Incandela 17
Hybrids Progress
Yield is stabilizing above 90%
Tracker status - Fermilab - May 14, 2004 - J. Incandela 18
Rods
• Component issues resolved• OptoHybrids
• Frames
• CCU modules were an issue last month.
• Now receiving good devices
• Mounting/cabling at CERN is underway• Can reach production rate of 50 rods/month
• One issue with potential damage in shipping• Several good solutions under study
Tracker status - Fermilab - May 14, 2004 - J. Incandela 19
US Productivity Enhancements
• Gantry (robotic) module assembly• Redesigned: more robust, flexible,
easily maintained
• Surveying and QA• Automated use of independent
system (OGP)
• More efficient, accurate, fail-safe
•Module Wirebonding• Fully automated wirebonding
• Faster and more reliable bonding
• Negligible damage or rework
•Taken together:• Major increase in US capabilities
• Higher quality
• Could build 750k channels (equal to CDF or D0 in Run 2) in 6 weeks!
Tracker status - Fermilab - May 14, 2004 - J. Incandela 20
Testing & QA
• US has led in many respects • US testing macros and test stand
configurations now used everywhere
• Critical contributions• Discovered and played lead role in
solution of potentially fatal problems
•Taken together• Averted disaster
• Higher quality
Tracker status - Fermilab - May 14, 2004 - J. Incandela 21
Module Mechanical Precision
• Tolerances are stringent
• x of sensors most critical
• 97% modules in specs
• Second order corrections:
• All new modules in specs!
x(Frame-Sensor) (m)
x(Sensor-Sensor) (m)
(Frame-Sensor) (mdeg)
(Sensor-Sensor) (mdeg)
Tracker status - Fermilab - May 14, 2004 - J. Incandela 22
Bonding
• All centers fully operational
• UCSB and FNAL both keep pace with 15/d rate with ease!
Tracker status - Fermilab - May 14, 2004 - J. Incandela 23
Hybrid & Module Electrical Testing
• Specification < 2% faulty channels per module
• Module testing has matured significantly• Minimum set of tests is now defined
• Fault finding algorithms:
• >99% faults found & correctly identified >90% of time
• Less than 0.1% of good channels are flagged faulty
• Performance standardization• Easy comparison of results at different sites
Tracker status - Fermilab - May 14, 2004 - J. Incandela 24
Module Fault Finding
Noisy
1 sensor open
2 sensor open
Pinholes
Bad Channel Flags
Noise Measurement Pulse Height Measurement (Using Calibration Pulse)
Bad Channel Flags
Shorts
Pinhole
Opens
Tracker status - Fermilab - May 14, 2004 - J. Incandela 25
Module Quality
• Goal of less than 1% faulty channels per module• Single Sensor Modules
• 0.20% Faulty Channels Per Module
• Production introduced faults at less than 0.1% rate!
• Two Sensor Modules
• 0.55% Faulty Channels Per Module
• Production introduced faults at less than 0.1% rate!
• Unprecedented low rate of faulty channels
Tracker status - Fermilab - May 14, 2004 - J. Incandela 26
Substructure Integration
•Shells, petals, rods underway
•Systems tests helping to finalize components and procedures
Tracker status - Fermilab - May 14, 2004 - J. Incandela 27
Rod Assembly, Test, Transport
• US contributions• Module installation
• Single rod test stands
• Multi-rod burn-in stands
• Definition of tests & methods
• Transportation
Tracker status - Fermilab - May 14, 2004 - J. Incandela 30
US Module Production(as determined by A. Cattai, J. Incandela, S. Schael)
• This is our current module production schedule:• USA module final production
• TOB modules: Early June 2004 to May 2005
• TEC modules: Late June 2004 to mid-April 2005
• Paced by sensors & hybrids
• Currently it appears they will arrive simultaneously
Tracker status - Fermilab - May 14, 2004 - J. Incandela 31
Other Considerations
• Rods are expected to keep pace with module assembly• Most system integration will now occur in FY06
• Meanwhile, we analyzed all systems for potential sources of downtime in production
• Stocked critical spares of fabrication tooling and equipment
• Cross-training fabrication personnel
• Developed satellite hybrid processing capacity in Mexico
• Specialized testing and diagnostics facility at UC Riverside
Tracker status - Fermilab - May 14, 2004 - J. Incandela 32
Summary
• The tracker is one of the main strengths of CMS
• The US tracker group is making critical contributions
• Module component problems have been solved
• We’ve accumulated more delays …
• … But we’re on much more solid ground
• Consequence for schedule: • Final assembly of the wheels at CERN slips into FY06.