Pixel Demonstrator Programme

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Presentation transcript:

Pixel Demonstrator Programme D. Álvarez Feito1; M. Hamer2 ;S. Kuehn3; S. Michal4; 1CERN EP-DT; 2University of Bonn; 3CERN EP-ADE; 4Université de Genève; CERN, May 2017 15/05/2017

Why a Pixel Inclined Layout? Flat section + Tilted region: Reduction in silicon area for large η coverage Lower heat load Less services Cost reduction Joint effort over the last two and a half years to demonstrate physics advantages (LTF) and feasibility of mechanics/cooling (UniGe & CERN) Pixel Barrel

SLIM v1 Concept Support Structure: TRUSS Longeron Support modules from two adjacent layers Two types to couple 3 and 4 CLs Thermal management: Module Cells Cooling block (Al-Cf) + TPG Plate Two types: Flat (M4) and Tilted (M2) Alignment Pins TPG Plate Phase-change TIM Base Block Solder layer Cooling Block Titanium pipe

Modules and Module Cells Two types of modules and module cells: Tilted (or inclined) Cell: M2 or DUAL modules (~40x20mm) Flat (or barrel) Cell: M4 or QUAD modules (~40x40mm) ~40mm ~20mm Tilted cell ~40mm ~40mm Flat cell

SLIM v1 Pre-qualification Several longeron prototypes (~1m long) tested for FEA validation A number of single cells and “triplets” have been manufactured and tested, obtaining positive TFM results TRUSS Longeron (“hybrid” construction) See S.Michal talk at Valencia ITK Week: https://indico.cern.ch/event/562672/

Parallel R&D: SLIM v3 Concept Different cooling solution: the “curly” pipe Alternative to blocks to cool inclined QUADs (~40x40mm) J.BENDOTTI J.DEGRANGE F.PEREZ M.VERGAIN N.DIXON; R.GOMEZ In Construction Preliminary Results Global TFM (˚C∙cm2∙W-1) Inclined region (8 loops) Flat region Inclined region (8 loops)

Stave Demonstrator

2017 Demonstrator Programme: Objectives Build & test large scale, realistic prototypes (Aimed at Pixel TDR – End of 2017) Validate SLIM local support concept → Engineering Prototypes Thermo-Fluidic prototypes Thermal prototypes Thermo-mechanical prototypes Material qualification (i.e. irradiation campaign) Validate integration and electrical services schemes Short electrical prototypes FINAL STAVE DEMONSTRATOR Validate procedure for loading, re-workability and survey Loading prototypes

Final Stave Demonstrator (the final goal) Layer 2-3 Longeron, 4CLs (SLIM Layout) See EMDS (1758951) for envelope CAD model 1600mm 1 CL loaded with electrical modules 3 CLs loaded with silicon heaters with embedded RTDs Modules and heaters connected to real stave services (flexes) Local Support Length (m) Layer # Modules per CL Module Type Power Dissipation per CL (W) Cooling Power Required (W) L23 Rectangular Longeron (i.e. 4CLs) 1.6 2 Flat 12 M4 302.4 1276.8 Tilted 30 M2 3 14 336.0 32

Short Electrical Prototypes Needed by 4 institutes to perform further electrical tests in the future (Wuppertal, Bonn, UniGe, CERN) Each prototype comprises: Support structure with 1 CL (L3_C_X+) 7 flat cells loaded with electrical modules (QUADs, B1 to B7) Stave flex (L3_C_X+_BSF)

Engineering Prototypes

Demonstrator Programme: Engineering Prototypes Full length supports structures and prototypes to be tested Thermo-fluidic prototype (under construction) Thermal Prototype (single CL populated with cells and silicon heaters) Thermo-mechanical Prototype (1/2 longeron with 4CLs and base blocks) Simplified test to assess the variability of HTC along the pipe for different heat loads and phi orientations (heat applied locally using braced copper blocks and kapton heaters) Block geometry selected to replicate heat flux at the pipe surface Assess TFM changes along the pipe & qualify the production performance Dedicated thermal flexes Tested in a cold box to validate FEA (modules simulated with bare silicon) Services and cells added in steps End-of-longeron supports and End-flanges also to be prototyped

Demonstrator Programme: Thermo-Fluidic Prototype Simplified test to assess Variability of HTC along the pipe for different heat loads and phi orientations (& validate COBRA simulations) Realistic pipe length (1.6m) Heat load applied locally Braced cooper blocks with glued kapton heaters NTCs glued at each block To be tested in B186 (TIF Cooling Plant) Block geometry selected to replicate heat flux at the pipe surface

Thermal Prototypes Small scale thermal prototype (limited by available cooling power) 4 flat & 4 tilted cells loaded with silicon heaters and glued thermal sensors Heater powering and sensor RO via cables TFM measurements for different vapour qualities “Curly” pipe triplet with inclined QUADS Large scale thermal prototype 1 full CL or 2 x ½ CLs + U turn Cells loaded with silicon heaters with embedded RTDs (and heater flexes) Thermal flexes used to power the heaters and read the PTs Assess TFM changes along the pipe & qualify the production performance The support structure doesn’t need to be realistic Dedicated thermal flexes (produced before the real stave flexes)

Thermo-mechanical Prototypes Cold box testing (@ CPPM) to validate FEA models Modules simulate with bare silicon dummies (No CO2; No heaters!) Single cell testing → Assess deformation at the module level Large scale thermo-mechanical prototype tested in steps 1 or ½ longeron with 4CLs and base blocks Added 4 thermal flexes to simulate stave services Added a reduced number of cells loaded with silicon dummies and fake module flexes connected to the thermal flexes Short prototype of SLIM v3 Support structure (~400mm) + local supports + “curly” pipes Cells with silicon dummies (no flexes needed at first)

Material Characterisation & Irradiation Campaign Irradiation campaign to study various glues and resins Lap joint samples Material tests before and after irradiation to assess potential damage Apparent thermal conductivity (B154) Mechanical strength (tensile testing machine)

We are not alone… Up to 15 institutes take part in the demonstrator programme:

What are we (i.e. DT/CERN) supposed to do?

Proposed Integration Scheme Functional Longeron (including pipes and base blocks) Module (& Heater) Flexes Stave Services (i.e. stave flex) Bare Cells Modules (& Heaters) Off-stave services (e.g. powering, readout, cooling, DSC, cable saver board…) PSPP assembly & QA Bare cell QA (thermal performance) Flex Integration Module (& Heater) Assembly & QA Longeron ready to “receive” modules Module Loading Loaded Cells Electrical (& T) QA Longeron Integration (+ Module flex connection to stave flex) Demonstrator Connection to setup for system tests

Functional Longeron TRUSS longeron manufactured in several parts 2 x TRUSS + central sandwich step Local CFRP supports 2 x End-of-longeron supports Bonded on alignment jig Bending of the titanium pipes (ahead of Ni coating)

Functional Longeron UniGe to solder base blocks to Ti pipes Jig in production Once the solder is completed, the plan is to use the same jig to glue the pipes to the local CFRP supports and the TRUSS (DT & UniGe). Ideally, we would use the same jig to glue the end-of-longeron supports using the same jig (same reference used to position the blocks).

Module Cells Inclined Cells Flat Cells UniGe to design & produce tooling for assembly of module cells Not clear yet whether we need to help with the cell production (~350 cells to be produced) Inclined Cells Flat Cells

Silicon Heaters with Embedded RTDs CERN to produce silicon heaters with embedded RTDs Minimum of 5 PTs per heater Order placed with external supplier (VTT) M2 & M4 heater flexes compatible with the new silicon heaters to be designed and produced by CERN

Heaters (& Module) Assembly + Calibration Design and production of tooling for heater (and module) assembly Gluing of flex to heater + wire-bonding Initial design for M4s already prepared by C. Bault (needs to be adapted to new dimensions). Produced externally. Module Alignment Jig Vacuum Pickup Chuck Flex Alignment & Gluing Jig Heater Test Bench & Database Design & Production of PCB to calibrate several heaters simultaneously Setup and maintain database to store & trace calibration results (RTD’s curves and heater resistance) Tooling design (after debugging) to be shared with other institutes (LPHNE, Bonn, LPSC) so that they contribute to the heater assembly/calibration.

Heater Loading Loading of the heaters on the bare cells Bare Module Cells Loading Loaded Cell Heater Assembly Current idea is to incorporate the loading functionality to the cell assembly jigs so that multiple heaters can be loaded in a single step (Alignment based on silicon edges + pins)

Integration will be carried out at CERN (in B154) Longeron Integration Integrating the stave services inside the functional longeron (help from LAPP) Mount the functional longeron on the handling frame The attachment of the structure to the handling frame will mimic the support conditions in the real detector (i.e. replica of end-flanges at both ends) The demonstrator will remain on this frame for the entire lifecycle (integration, survey, transport and system testing) Gluing the cells (with heaters/modules) on the functional longeron and connection to the services Integration will be carried out at CERN (in B154) Handling frame to be designed and produced at CPPM (to match our end-of-longeron supports)

Testing under vacuum and with dry air flow Thermal Setup (B154) Update thermal setup in B154 to test Short thermal prototype Long thermal prototype Testing under vacuum and with dry air flow Required modifications: New flanges compatible with new PCB for thermal flexes Commissioning of the cartridge heater for control of vapour quality Currently discussing whether the vacuum vessel will be extended in length Updated TRACI to allow testing with higher mass flow rates New thermal readout for the new silicon heaters and CO2 pressure & temperature sensors Power supplies and control for the silicon heaters and cartridge heaters Power/Cooling interlock system

System Setup (SR1) New setup built in SR1 to perform system test with the demonstrator: Test chamber (light-tight) Feedthroughs Environmental control (e.g. humidity, dry air) Cooling (updated SR1 plant) + thermal readout (~1000 sensors) Support for the demonstrator handling frame and CSBs Source stage, linear movement and control Camera system ~4m

Proposed Organisation (Who is doing what?) Support Structures (TRUSS, local CFRP supports, end-of-longeron supports, pipe bending, gluing) Heater & Module Assembly (heater design, heater flexes, heater assembly including tooling, calibration and database) Loading & Integration (cell loading, assembly of long thermal prototype, thermo-mechanical prototype & demonstrator) Thermal Setup (Vessel + Flanges, piping, connection PCB, readout, commissioning) Thermal Testing (short and long prototypes) System Test Setup (design and construction of environmental chamber, control & interlock, source stage, cooling piping, thermal readout) Material testing (irradiation, thermal, mechanical) Valery Nicola Neil Francois Kari Francisco Ruben Xavier Maurice Jerome Jordan

First/Ongoing Activities Who Task Completion date Jordan Design of end-of-longeron supports. Design of pipe bending jig 24/05/2017 Edyta Final Design of moulds for local supports 19/05/2017 Ruben Testing lap joints for glue selection. Design of upgraded thermal setup. Kari Design of heater assembly tooling 02/06/2017 Neil Dismantle SR1 setup. Assemble thermo-fluidic prototype 30/05/2017 Francois Produce initial lap joints. Produce central sandwich. 26/05/2017 Francisco Design of end-of-longeron supports. Produce curly pipe triplet. Jerome Production of local support moulds Maurice Finish 3PB jig. Production of pipe bending jig Nicola Design of heater flexes (M2 & M4) Valery Produce first complete 0.8m long TRUSS. Xavier Develop readout and PCB for thermal setup 30/06/2017

Final Comments Detailed plan available Weekly progress meetings Please, could you let me know when you are planning to go on summer holidays to take it into account in the planning? Weekly progress meetings Mondays from 10.45-12.00 or Tuesdays from 10.45 to 12.00?

Questions?

Additional Material

Layer_Side_Flank_Item&Number Nomenclature Unified nomenclature (following ATLAS axis convention) now summarised in EDMS 1791997 / Sharepoint Numbering of the individual modules included Layer_Side_Flank_Item&Number S. Michal CL=cooling line BM=Barrel Module IC=Inclined Module BSF=Barrel Stave Flex ICF=Inclined Stave Flex ………. 2 3 A C X+X-

Numbering to be also used in DCS Nomenclature Unified nomenclature (following ATLAS axis convention) now summarised in EDMS 1791997 / Sharepoint Numbering of the individual modules included Numbering to be also used in DCS S. Michal

Loading Prototypes Small scale prototypes to validate cell loading and longeron integration procedures Module loading on SLIM cells (i.e. module/cell loading) Integration of cells on functional longeron (i.e. longeron integration) Re-work/Replace defective cells Survey of the final assembly Electrical and/or thermal tests to be performed between sub-steps to ensure that the procedures do not impact the performance.

Prototypes: Summary Thermal Thermo-mechanical Electrical #CL #Cells per CL Longeron (mm) Heaters Modules Flat Tilted Thermal Short 1 4 - Silicon heaters with glued RTDs Large Scale (or 2 x ½) 14 32 1600 (not required) Silicon heaters with embedded RTDs + heater flexes Thermo-mechanical Single cells Bare silicon dummies Large scale (v1) L2: 6 L3: 7 L2: 15 L3: 16 800 Bare silicon dummies with fake module flexes and connectors Medium scale (v3) 2 Electrical Short electrical 7 M4: 7 Final Demonstrator L2: 12 L3: 14 L2: 30 L3: 32 Silicon heaters with embedded RTDs + heater flexes in 3CLs M4: 14 M2: 32