1 IBL Integration & Testing activities University of Geneva: G.Barbier, F.Cadoux, A.Clark, D.Ferrère, C.Husi, M. Weber  Preliminary definition of Integration & Testing sequences IBL meeting, CERN, the 31th of August 10

2 Integration & Test sequences Brainstorming this morning dedicated to the Integration & Testing sequences…very useful to kick off these activities (first priorities, constraint definitions, …) IBL meeting, CERN, the 31th of August 10 Baseline defined as follows: -STAVE considered with the max length…7m long! Even if we keep some backup solutions such as “post loading” OWelding, different STAVE design (see next slide) -1 central Jig per STAVE (starting from the bare STAVE up to its final integration)…about 1 meter long. -20 STAVES to be considered for the full prod…so 20 “central Jigs”! -All the Integration activities in SR1 SR1 area

08/31/10 Temporary fittings for loading and QC and then welding before integration Z=0 Stave length for loading: 1.3 m Ti-bushin Option 2: TIG Fitting Manifold Z= Fitting No fitting inside the ID envelope TIG Z= Fitting Stave length for loading: ~ 4.5m Fitting Baseline: Manifold Starting with the Stave envelope Ti-bushin TIG ~1200 No cooling pipe in the stave until the integration with the beam pipe Z=0 Stave length for loading: 0.64m + Type0 cable ends Option 3: Preferable, but… Needs much more time to validate the process! Official baseline for tooling Sort of back up in case… DPNC will investigate

4 StepsRequirements (Seen from loading side)Support & specs from Stave reception testsVisual inspection, Tape electrical tests, Pressure/Leak tests, Mechanical references (3D metrology) Stave fabrication experts Module reception testsVisual inspection & Electrical testsModule experts Module loadingStave support on 3 points (as on the structure) + strain relief for the pipe at the 2 sides Module loading Electrical testsShould be done in the same position as in the previous step. Requirements? Module experts Wire bondingStave tooling jig move on the bonding machine.Module loading MetrologyStave tooling jig move on the CMMModule loading Thermal cycling & Cold tests Stave tooling jig move on the test place inside an insulating box for the full stave envelope. System test Storage up to the integration Dedicate a safe area to store up to 15 stavesAll 1 central jig following the STAVE throughout the whole sequences … to be interfaced / several stands Integration & Test sequences

5 Central Jig definition (3 fixations over the length like connection / IST) Flex not shown STAVE will be fixed onto the jig from the bottom (be careful / Flex) IBL meeting, CERN, the 31th of August 10 Integration & Test sequences Clear access from the top… IDEA: get this end part (x2) longer (in order to locate a threaded hole for fixation onto the jig)

6 Wire bonding & Metrology SR1 Wire bonding Machine…simplified! Extensions to release the stress thru the stave (STAVE Cradle) 7m long IBL meeting, CERN, the 31th of August 10 Integration & Test sequences

08/31/10 Stave Envelope versus Wire Bonding Machine H&K 810 (located today at UniGe) 7 m

08/31/10 Wire bonding area on the machine 305 mm 180 mm  To cover the 640 mm stave length one need to move the stave 3 times

08/31/10 Base plate height ~110 mm Working height has to be set correctly within ~20mm Height for cradle and stave jig

08/31/10 How to move in 7m stave jig for the fixation on the base plate Vertical pillar for the binocular that could be dismounted but preferable not! Stave jig when setting it on the bonding space has to get around the pillar

08/31/10 Considering long stave envelope such has 7 m is possible with the H&K machine BUT a dedicated space only for wire bonding of ~20m 2 has to be considered (8x2.5m 2 ) m Dedicated space for wire bonding 8 m 2.5 m 1.1 m 1.7mH&K Operator space Somewhere in SR1 + Metrology machine, and areas for : Loading, electrical Testing, Thermal cycling, Storage (x20), Final Integration One should come up soon with a complete SR1 configuration, should be OK, but…

08/31/10 SR1 organization Wire bondingMetrology ??? Loading Something like that…

08/31/10 Integration & Test sequences DPNC will focus soon on the “central jig” + Cradle design in order to: -Iterate / STAVE design -Flex design (accessibility issue) -Transfer tool onto the ITT