June 8-th 2004W.Baldini1 Ferrara production center Ferrara production center Production Readiness Review OverviewOfOperations P R R

June 8-th 2004W.Baldini2 1.WGS machine: Wiring, gluing, soldering, pitch measurement 2.WTM table: wire cutting, side bars gluing, wire tension measurement, open air HV test (single panel) 3.Assembling table: chamber assembling 4.Service table: HV connections, mylar tape on HV bar A, repairing/fixing problems Operations overview Clean room Outside the clean area 1.Gas leakage test 2.OPB mounting and soldering 3.Conditioning / HV test of the chamber 4.Uniformity test with source (?)

June 8-th 2004W.Baldini3 Clean room operations Preliminary operations Mounting the clamps to fix the panels on the frame (4 in the corners + 3 along each side of the panel) Positioning / alignment of panels on the frame Check of half gap height Protect the cathode with a Kapton foil Final cleaning of wire pads with Isopropyl alcohol Panels entering the clean room have been cleaned already (outside the clean area and in the grey room) and have been checked for geometry and general quality HV bar A HV bar B corners

June 8-th 2004W.Baldini4 We had problems with wires touching the HV bars, this was due to too high HV bars and to the presence of some tin in the points where the fixing clamps go The HV bars height has been reduced (in Potenza), the clamps have been slightly modified and the tin will be put only after the wiring Screwed to the frame Clamp for the panel Reference surface Clean room operations

June 8-th 2004W.Baldini5 1.Wiring 2.While wiring we prepare the guard wires and the glue dispensers (about 5 min before the end of the wiring process) 3.Put the guard wires 4.Gluing 5.Soldering 6.Measurement of the wire pitch (for the first chambers we plan to measure the pitch after each process ) 7.Turn the frame and repeat the operations 8.Rough cut of the wires Operations Operations on the WGS machine Clean room operations

June 8-th 2004W.Baldini6 M1R4 (min) M2R3 (min) M4R1 (min) M4R2 (min) M4R3 (min) M5R1 (min) M5R2 (min) Wiring (14 rpm) Wiring (10 rpm) Soldering Gluing Panels per frame Expected times Preliminary operations: right now it takes about min Clean room operations

June 8-th 2004W.Baldini7 Clean room operations Soldering of HV connections Gluing of the side bars Precise cut of the wires Wire tension measurement (for the moment 1 panel at a time). We plan to measure 2 panels at the same time, it needs about half a day of work. HV test in air of single panel Operations on the WTM table At this point, if all the quality tests are passed (conditions will be shown in the traveler), the panel is ready to be put on a chamber and will be stocked in the shelf: “ready to be assembled”

June 8-th 2004W.Baldini8 Clean room operations Assembling of the chamber We assemble the chamber using the same tooling used in Frascati We plan to distribute the glue automatically (not yet implemented). This allow a better control of the amount of glue The height of the chamber is measured (while assembling) in 14 points for each layer A B

June 8-th 2004W.Baldini9 Clean room operations Assembling of the chamber We observe some discrepancies form the expected heights, this could be due to: Too high pressure on the panel from the “forks” Some discrepancies in thickness and planarity of the panels The problem is still under investigation

June 8-th 2004W.Baldini10 Clean room operations Assembling of the chamber HV_side A B L1 = 9.50 L2 = L3 = L4 = L5 = The height of all the layers is measured with a micrometer while assembling the chamber. Exp. Values: L1 = 9.00 mm L2 = mm L3 = mm L4 = mm L5 = mm

June 8-th 2004W.Baldini11 Operations outside the clean area 1.Gas leakage test 2.OPB mounting 3.Conditioning/HV test of the chamber: It’s not clear yet how much time it will take the chamber conditioning. We have anyway space for 20 chambers (8 weeks production) in the rack for the conditioning. 4.Uniformity test with source (??) Once the chamber has been assembled it is moved outside for the following operations:

June 8-th 2004W.Baldini12 Operations outside the clean area Gas leakage test Flow in from the bottle Differential manometer Requirements:  5 mb overpressure The system has been tested with sealed volumes Chamber 1 is under test, at present it shows a very high gas leak

June 8-th 2004W.Baldini13 Quality control Wire pitch measurement Pitch distribution right after wiring Pitch distribution after the gluing of the wires Pitch distribution after the gluing and soldering processes Some fine tuning is still needed (optimize the contrast of the images) Side A Side B

June 8-th 2004W.Baldini14 Quality control Wire pitch measurement P428 (L4) P489 (L1) P535 (L2) P491 (L3) Chamber 1 Side A: 99.7% < ± 50µm 100% < ± 100 µm Side B: 95.9% < ± 50µm 99.5% < ± 100 µm Side A: 99.8% < ± 50µm 94.4% < ± 100 µm Side B: 99.7% < ± 50µm 99.8% < ± 100 µm Side A: 100% < ± 50µm 100% < ± 100 µm Side B: 99.7% < ± 50µm 99.8% < ± 100 µm Side A: 91.0% < ± 50µm 95.4% < ± 100 µm Side B: 91.0% < ± 50µm 91.4% < ± 100 µm Side A Side B

June 8-th 2004W.Baldini15 Quality control Wire tension measurement Laser Photodiode wire Machanical excitation Panel This simple and reliable method has been developed together with Firenze and Roma II

June 8-th 2004W.Baldini16 Quality control Wire tension measurement Laser Mechanical Excitation Photodiode At present it takes about 3.5 sec/wire (about 40 min/panel) With 2 panels it will take less that 2 sec/wire (40 min 2 panels) We are confident to setup the double panel measurement in about half a day of work

June 8-th 2004W.Baldini17 Quality control Wire tension measurement p173 Before the reinforcement of the frame After the reinforcement of the frame The wire tension is in average too high (> 75g) it will be reduced by 5 g

June 8-th 2004W.Baldini18 Quality control Wire tension measurement L1 L2 L3 L4 T = (76.4 ± 3.6) g T = ( 77.3 ± 4.0) g T = (76.3 ± 4.3) g T = (76.1 ± 4.6) g Chamber 1

June 8-th 2004W.Baldini19 Panel number Panel type ChamberComments 213L diplaced wire (by 1 mm) 175L Broken wire 161L10No WTM yet 221L20No WTM yet 208L30No WTM yet 178L40No WTM yet 173L4----Few wires with tension < 50 g 214L2----Bump on the cathode 489L11OK 535L21OK 491L31OK 428L41displaced wires 537L2OK 384L3Several broken wires 602L1Under test 437L3Wired and glued 494L4wired So far we have produced 15 M2R3 panels, the best 8 panels have been assembled in M2R3-CH0 and M2R3-CH1

June 8-th 2004W.Baldini20 Conclusions All the production and quality control processes are set and working. There are still some fine tuning needed (2 panels measurement with WTM, fine adjustment in the pitch measurement ) but they are essentially in their final version So far we have produced 15 M2R3 panels and we have assembled 2 chambers. The very first one (M2R3-CH0) was used essentially to exercise the assembling procedure, the second one (M2R3-CH1) is at present under leak test but it shows a high gas leak. We have to improve the chamber assembling The procedure to optimize all the production steps is almost in its final version The learning process of all the people involved is under way