Takashi Matsushita Imperial College T. Matsushita 1 Station5 Assembly/QA status, schedule

T. Matsushita 2 Assembly/QA sequence Station five assembly/QA sequence 1. Visual inspection of doublet-layers - check any damage caused during transit 2. Pre-processing; trim fibres, mark top layers, mark centre fibre 3. Bundling/QA 4. Connectorisation/QA 5. Vacuum-chuck alignment 6. Glue doublet-layer to carbon-fibre station 7. Attach connectors to carbon-fibre station 8. Cut fibres 9. Pot fibres 10. Polish fibres 11. CMM of station five

T. Matsushita 3 Visual inspection/pre-processing Inspection at IC Extra piece of fibre (~2cm) on one ribbon [no harm] Prominent round ridge of glue; might be a problem when we glue it on carbon fibre station; we use less prominent ones for station 5 Two bent fibres on ribbon 5; during transit? Fibre end trimmed evenly at FNAL. But not good enough for QA procedures Before After trimming Fibre end Ridge of glue Bent fibre

T. Matsushita 4 Quality assuarance Purpose Ensure each bundle has correct seven fibres No more/no less fibres in a bundle No swap of fibres across bundles and no skip Ensure each bundle goes to correct hole of optical connector No more nightmare of channel decoding Methods Visual scan of skipped fibre in the middle of bundles Take picture of fibre bundle to count number of fibres in a bundle Take movie of fibre scan with UV LED to check sequence of fibres

T. Matsushita 5 Quality assurance Setup LED: 20 mW, peak = 405nm 86 hours illumination shows no noticeable damage on fibre ~20 minutes 100W Mercury arc illumination did damage fibre; yellow fluorescence instead of green Spectrophotometer shows a major increase in absorption in the blue region (~400 – 450nm) LED/optics attached to translation stage Doublet layer CCD Beam spot image by CCD50 micron x ~4mm(not this size on fibres) Side view Front view

T. Matsushita 6 Quality assurance Figure shows change of fibres’ absorbance caused by exposure to mercury arc. The insets a) and b) show colours emitted by the fibres before and after the exposure. The inset c) shows emission colour of the fibres after some recovery time. a)b)c)

T. Matsushita 7 Bundling/QA First we make bundle of seven fibres; single read-out channel Seven fibres held together with heat-shrink tube “comb” [version 3] is used for bundling and QA procedure bundles of four columns ( ) for one connector (22 way) comb Comb with bunldes in grooves

T. Matsushita 8 View from end of chuck looking at the connector end of the fibre ribbon Channel mapping to comb for view x Bundling/QA – mapping to comb

T. Matsushita 9 QA – software check; counting After making 22/20 bundles, we perform QA Software check of ccd image of one connector worth bundles Chcek number of bundles according to view and connector number Check number of fibres in each bundles It works.

T. Matsushita 10 QA – software check; scanning Software check of scanning movie of one connector worth bundles (20 or 22) Check bundle sequence Bundle sequence check works. x y

T. Matsushita 11 QA – software check; scanning Define fibre centre as centre of ‘cluster’ found in counting QA Trace intensity of 9 pixels around the centre pixel in terms of time Then we get intensity of fibres in terms of ‘time’ Detect leading/trailing edges of intensity distribution at 50% of peak height Peak time of a fibre is (lead. time + trail. time)/2

T. Matsushita 12 QA – software check; scanning Fibre sequence check Peak time position of fibres in bundles as a function of time Bundle # is arbitrary No collision between bundles is ok Sequence check suffers from rough cut surface of fibres, glue on doublet-layer, etc.

T. Matsushita 13 QA – software check; scanning Top/bottom sequence check Intensity of fibres at peak time Sequence check suffers from rough cut surface of fibres, glue on doublet-layer, etc.

T. Matsushita 14 Connectorisation/QA After bundling we thread bundle through each hole of connector Fibre radius guide is used for connectorisation “bridge” is used for QA bridge Fibre radius guide Bridge with connectors

T. Matsushita 15 Connectorisation/QA– mapping Comb to bridge mapping for view X

T. Matsushita 16 Connectorisation/QA We perform counting/scanning QA for bridge as well. x y

T. Matsushita 17 Mirror check Picture of fibres taken with and without covering mirrored end with black sheet under ambient light. Connector 3 seems to have one fibre with poor mirroring. Mirrored end coveredMirrored end NOT covered

T. Matsushita 18 Vacuum chuck alignment Align the centre fibre to the centre of the vacuum chuck

T. Matsushita 19 Gluing Fix vacuum chuck, carbon-fibre station frame to gluing jig Apply glue with grin, then glue them together

T. Matsushita 20 Attach connectors to cf-station

T. Matsushita 21 Status View X [mold4#? – 22aug06] bundling/connectorisation/QA finished, glued to carbon-fibre station frame Every single bundle has seven fibres Connectorisation is all OK Fibre sequence is most likely OK. One fibre seems to have poor mirror We have record of manufacturing process We made two kinks during manufacturing process. We made one fibre bent during manufacturing process. Try to avoid these errors next time View W [mold?#? – 17aug06] Bundling/QA for connector 1-6 finished Have dim fibres; due to glue, cut surface, fibre damaged???

T. Matsushita 22 Dim fibres for view W C1 C5 c6 Fibre end damaged

T. Matsushita 23 Schedule Station 5 will be at Fermilab … beginning of December