Recent updates to the 2S module geometry Towards first dummy modules Upgrade Phase II Plenary, Tracker week, 20 July 2012 News on the 2S module design Refers to work and inputs by Tristan Falcy, Antonio Conde Garcia, Luc Kottelat, Stefano Mersi, Giovanni Bianchi, Alan Honma, Duccio Abbaneo, Andreas Mussgiller, Nick Lumb, Riikka Häsä, Aleksis Chávez Niemelä, Antti Onnela Introduction Recent updates to the 2S module geometry Towards first dummy modules Rod adaptors and positioning tests On-going + Next tasks Summary Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Introduction Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

2S modules in the Tracker layout study Stefano Mersi et al. Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

2S modules, different sensor spacings “End-cap” 2S module with 4 mm sensor mid-plane to mid-plane distance (3.8 mm air gap). 4 mm is the thickest module in the present tracker layout study “Barrel” 2S module with 1.4 mm sensor mid-plane to mid-plane distance (1.2 mm air gap). 1.4 mm is the thinnest module in the present tracker layout study There are also other sensor spacings, between 1.4 mm and 4 mm, in the current layout study. The sensor gaps can/will evolve in future following tracker layout optimisation. Reference data on the 2S modules in the Upgrade website: https://espace.cern.ch/Tracker-Upgrade/2S-Module/SitePages/Home.aspx Silicon sensor Base-line sensor spacing, used in the module design: 4 mm “End-cap” modules 1.4 mm “Barrel” modules Silicon sensor Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Recent updates to the 2S module geometry Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Old version: Position of hybrid vs. sensors Aleksis Chávez Niemelä, Alan Honma Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

New version Aleksis Chávez Niemelä, Alan Honma Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Additional Kaptons against discharges Aleksis Chávez Niemelä, Alan Honma Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Additional Kaptons against discharges Aleksis Chávez Niemelä, Alan Honma Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

3D data of the 2S modules Current 3D models of the 2S modules are available in 4.0 mm module: https://edms.cern.ch/nav/SMTP141:PRJ00055343/SMTI137:ST0431040 1.4 mm module: https://edms.cern.ch/nav/SMTP141:PRJ00055343/SMTI137:ST0432049 Available 3D data formats: 3DVIA: Visualisation format. Requires installation of a free viewer available from the above addresses. Allows taking measures of the 3D models, producing cut views, etc. Runs only on Windows. PDF: 3D PDF visualisation format. Runs on web browsers. More limited functionality than 3DVIA. STEP: suited for reading 3D geometry to CAD or FEA systems. The module geometries will continue evolving. The latest versions will be made available in the Upgrade website: https://espace.cern.ch/Tracker-Upgrade/2S-Module/SitePages/Home.aspx Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Towards first 2S (dummy) modules In order to study the thermo-mechanical properties, assembly, handling, etc. we plan to start the prototyping of the 2S modules with simplified, dummy modules. Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Towards first 2S (dummy) modules Components for first dummy modules Dummy sensors are in production (Alexander Dierlamm / KIT, Hamamatsu) Include heating, temp measurement, bond pads, positioning targets Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Towards first 2S (dummy) modules Components for first dummy modules Proto / dummy versions of other module components need to be procured / made. Carbon-fibre support frame Precise material choice still to be made Pieces can be done in-house, when material available Thermally conductive layers (TPG, PGS, ?) Material choice not made, yet. First material samples obtained, now ordering more Mock-ups of the hybrids + components Which materials to use? How to simulate heat production? Kapton Ok, can be prepared in-house Aluminium contact pads Rapid prototyping is one solution to make components, or even full module geometries Limitations in material choice, dimensional tolerances, thicknesses (< 1mm is difficult), surface finishes. Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Towards first 2S (dummy) modules How to test first dummy modules? One option is to use our ~30 existing spare TOB Rod frames Carbon fibre structure Cooling is included Setups for supporting and cooling rods exist But, module supports in wrong places for 2S modules  Adaptors needed. Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

TOB Rod with 2S modules 2S module Adaptor Existing TOB rods (tens available) can be used for first module tests E.g. cooling tests But, new module dimensions do not directly match the rod Need adaptors TOB Rod frame Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

TOB Rod with 2S modules Tristan Falcy, Luc Kottelat Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Adaptor design Tristan Falcy, Luc Kottelat 3 connection bars in carbon-fibre composite Support and alignment of the 2S module Support and alignment on the rod 4 support/cooling contacts in aluminium Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Adaptor production 2 adaptors have been produced Completed adaptor 3 connection bars in carbon-fibre composite 4 support/cooling contacts in aluminium 2 adaptors have been produced More adaptors can now easily be made, if/when needed. Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Rod + Adaptor + 2S module mock-up Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Module positioning studies Tristan Falcy, Luc Kottelat Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Barrel rod with 2S modules Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Studies on module positioning Study on combining module positioning inserts and captive screws (for improved module handling) Module placed on supports Module Positioning Screws tightened Support structure Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Study on module positioning Aluminium dummy module placed on a support plate Small brass positioning inserts and captive screws Optical measurement of module positioning Positioning inserts + captive attachment screws and nearby optical targets “Module” in aluminium Support plate in aluminium Attachment screws Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

H7 tolerance on Ø2.5 and Ø3 holes: 0 - +10 μm Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Study on module positioning Module positioning insert (brass) and captive M1.6 screw with a spring h8 tolerance on Ø2.5 and Ø3 axis: -14 – 0 μm Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Precision (repeatability) of the positioning σ = 10 μm Dummy module installed and removed 8 times, with its position measured after each installation. Optical measurement accuracy: +/- 2µm Mean value of results normalized to zero σ = 17 μm σ = 11 μm Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Conclusions from these positioning studies Precision of ~ 10-20 μm (1 sigma) in module positioning can be rather easily obtained even with such small 2 mm high positioning inserts. If necessary, the precision can be increased by tighter manufacturing tolerances on the components Precise ‘slot’ hole is more difficult to produce than a precise round hole. Note: For sufficient cooling contact the module attachment screws must be well tightened. Therefore, the long-term stability is better than the initial precision of such module positioning system. Captive screws work nicely, but they are space-consuming, need a ‘high’ support insert Problems with available space and added mass on the final rod assembly Simple screws are now considered Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

On-going + next tasks Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Module support design Used as base-line: Rod with modules upside up. Space for module supports, positioning and screws? Combine support of two modules? Modules upside up + Radial distance between adjacent sensors is minimized + Connectors are well exposed Total thickness is potentially rather big (here 24 mm). Thickness depends directly on the biggest components Tight space for module supports and thermal contacts Modules upside down + Total thickness minimized (here 15 mm), allowing compact barrel layers + Components are not exposed (= better protected) in the final assembly + Good space for module supports and thermal contacts Radial distance between adjacent sensors is big. Difficult access to connectors on the module Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Thermal design of the module supports According to preliminary calculations ΔT of 5-7 ˚C expected in the module Allowing total of 10 ˚C ΔT from silicon to coolant leaves ΔT max 3-5 ˚C for the module support – cooling pipe – fluid (CO2) Analysis and preliminary optimisation on module supports on-going Optimisation between mass and thermal performance of the module support insert ΔT: 5-7 ºC Module analysis (Andreas Mussgiller) Support insert analysis (Riikka Häsä) Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Module and rod overlaps Aleksis Chávez Niemelä Module supports and Cooling contacts at the rod overlap area? Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Module holders Module holders to allow safe access to module front and back sides. During module assembly work During bonding During testing During transports Can one single holder do all, or are different holders for different steps necessary? Images of preliminary concept studies Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Summary 1.4 and 4 mm 2S module geometries updated. 3D data available. Components for first proto modules available in autumn 2012 Dummy sensors (heating, temperature measurements, bonding tests, positioning and assembly studies) available ~Oct 2012 Other components to be made / ordered. Adaptors for mounting 2S modules on TOB rods have been designed and 2 first adaptors made. Can be used in the first thermo-mechanical tests of the 2S test modules Module positioning studies done with very dummy modules. Reasonable positioning precision achieved with small positioning inserts. Captive screw system works, but requires space (not easily available). Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Summary Work on-going with module supports for full rods. The support need to be small, for mass and also for limited space available. Thermal performance needs to be sufficient. Particular challenges in the rod-to-rod overlap area First concepts of module holders for assembly, tests, transports Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN

Thanks for your attention Upgrade Phase II Plenary, 20 July 2012, indico: 197208 Antti Onnela, CERN