HFT PIXEL Mechanical Progress Strasbourg June-2009 Wieman 1

Topics Thin support beam ladder fabrication Air cooling analysis Air vibration tests Full scale cooling tests Spatial mapping 2

3 Development of sector beam and ladder fabrication Eric Anderssen and Tom Johnson have been working on fabrication methods for: –Sector Beam –and Ladders Produced sample beams, 244  m thick, 7 ply, 21 gm expected ladder mass 7.5 gm ladders sector beam

4 prototype design being built

5 PIXEL mass breakdown

Sector structures 6

ladder fabrication and tooling 7

8

9 finalizing mechanical designs and developing rapid production methods

ladder fabrication and tooling 10 ladder with silicon heater chips (50  m thick)

wire bonding 50  m silicon to flex PC 11 vacuum chuck to secure flex and silicon flat against solid surface to remove bounce Any bounce then no bond Good News after a couple of minor modifications to the vacuum chuck wire bonding works well

12 ladder to sector bond fixture ladder to out2 bond fixture.SLDASM (designed to allow ladder replacement)

ladder to sector tooling fixtures (4 stations) 13

Air cooling of silicon detectors – Computational Fluid Dynamics (CFD) analysis air flow path – flows along both inside and outside surface of the sector Silicon power: 100 mW/cm 2 (~ power of sunlight) 240 W total Si + drivers 14

Air cooling – CFD analysis air flow velocity 9-10 m/s maximum temperature rise above ambient: 12 deg C sector beam surface – important component to cooling dynamic pressure force 1.7 times gravity stream lines with velocity silicon surface temperature velocity contours mm ID

16 vibration modes – preliminary – better composite numbers available 229 Hz 316 Hz 224 Hz 473 Hz 348 Hz

17 vibration modes with reinforced end cap The message –Lots of complicated modes close in frequency –End cap raises frequencies a bit 259 Hz 397 Hz 276 Hz 441 Hz 497 Hz

18 air velocity probe two positions shown capacitance vibration probe two positions shown carbon fiber sector beam wind tunnel setup to test vibration and displacement adjustable wall for air turn around air in air out C:\Documents and Settings\Howard Wieman\My Documents\aps project\mechanical\PXL phase 1 sept 2008\sector ph1 wind tunnel.SLDASM

19 wind tunnel, rapid prototype parts from model air flow control parts built with 3D printer parts built with SLA, stereolithography apparatus

20 wind tunnel

21 capacitive probe vibration measurements air velocity 2.7 m/s position signal, 25  m/volt air velocity 9.5 m/s position signal, 25  m/volt log FFT, peak at 135 Hz

22 Ladder vibration induced by cooling air system resolution limit all errors desired vibration target required air velocity 18 mph

Full sized cooling tests Thermal camera window not shown > 300 CFPM air flow for verification of cooling capability Cooling tests will begin as soon as prototype sectors completed 9 inch diameter tube mocks up MSC 23 dust collector for air supply

24 development of spatial map procedure Bob Connors Spiros Margetis Yifei Zhang touch probe 2-3  m (xyz) and visual 2-3  m (xy) 50  m (z) active volume: huge 10 gm touch probe force (could deflect beam) MEMOSTAR3, 30  m pitch We need better fiducials on the main pad side that the coordinate machine can find automatically. The pads will be buried and not visible