1. Hybrid & Module Electrical Testing
Outline
Overview of Current Testing At UCSB
Estimates of time/manpower/equipment needed
How we can shorten times
Reductions of tests
Improvements in automation

2. Hybrid Testing Cycle 28 hybrids per day expected rate per site
Wirebond PA (28)
Mount/Inspect Hybrids (28)
Quick Test Hybrids (28)
Thermal Cycle Hybrid (28)
Assemble into Modules (15)
28 hybrids per day expected rate per site
Ship to TEC/FNAL(13)

3. Module Testing Cycle Repair (If necessary) Repair (If necessary)
Gantry makes modules (15)
Quick test unbonded modules (15)
Wirebond (15)
Repair
(If necessary)
Bonded module tests (15)
Thermal cycle modules (15)
Repair
(If necessary)
Final pinhole tests (15)
Storage/Mount on Rods

4. Mount/Inspect Hybrid
Upon receiving hybrid, must attach test tail and mount onto hybrid plate
After mounting, hybrid wire bonds inspected quickly for damage
~ 5 minutes need in total per hybrid
~2 ½ man hours

5. Quick Test Hybrid
Hybrids are tested on ARCS stand prior to PA wire bonding
Ensure no damage has occurred during shipment
No/little faults found
No repair
Test takes minutes per hybrid
4 ½ - 7 hours ARCS stand time
Takes ~5 minutes manpower per hybrid
~ 2 ½ man-hours
Includes mounting/unmounting, determining test result and local database entry
During production, we should drop this test. We would find all these problem in 4-hybrid test or visual inspection
If problem is found in 4-hybrid test, then we quick test rest of shipment

6. Hybrid Thermal Cycler-Pulser
4 hybrids are taken to operating temperature (-20 C) and charge injecting into chip through capacitive coupling of pulser to PA
Checks wirebond quality and first “long” test of hybrid
~45 minutes to thermal cycle 4 hybrids
~9 cycles per day possible
~20 minutes of manpower needed per cycle
Includes data analysis, mounting/unmounting and database
~3 man hours
No opens or shorts caused by bonding so far

7. ARCS Module Test Before Bonding
Checks if assembly damaged sensors/hybrid
Quick hybrid Test + IV test
Test takes ~20-25 minutes per module
~5-6 hours of ARCS stand needed
About ~20-25 minutes of man-power per module needed
~5-6 man-hours needed per day
Includes data analysis, loading/unloading, and local database entry
Test only for first few modules of each type (will NOT be performed during full production)

8. ARCS Module Test After Bonding
Main tests to find faults introduced during assembly
Full set of test run
Test takes ~20-25 minutes per module
TIB/TEC also report minute test time
~5-6 hours of ARCS stand needed
Includes tests performed at multiple bias voltages
About ~10 minutes of man-power per module needed
~2 ½ man-hours needed per day
Includes data analysis, loading/unloading, and database entry

9. Wien Cold Box/Burn-in
Wien cold box cycles modules from –20 C to 20 C while reading out up to 10 modules
Module burn-in/tests modules at operating temperature
Modules cycled ½ day with ~2 thermal cycles per load
2 loads/unloads needed
About 1 hour to unload/load box
Assume another 1 hour per load for data analysis, database, etc.
~ 4 man-hours per day
This time could be shrunk considerably if we make two set of cold plates per site
Load one as we test bonded modules, unload other set as post-cycle LED test proceeds

10. ARCS Pinhole Test
After thermal-cycling, module retested on ARCS with noise and LED pinhole test
Ensures no new faults from thermal cycle/burn-in
Test takes about ~10 minutes per module
~2 ½ hours of ARCS stand time
~2 ½ man-hours per day

11. Man-Hours/ARCS Stand Time
Man-hours Needed
ARCS Stand Time Needed
Mount/inspect hybrids
~2 ½ hours
N/A
Quick Test Hybrids
~4 ½ -7 hours
Thermal Cycle Hybrids
~3 hours
Mount Module Cables
~ ½ hours
Unbonded Module Test
~5-6 hours
Bonded Module Test
Wien Box Test
~4 hours
Pinhole Test
TOTAL
~22 ½ - 23 ½ hours (3 techs)
~17-21 ½ hours (3 stands)

12. How we shorten times necessary
Reduction of tests taken
Removal of hybrid quick test and unbonded module tests
Test bonded modules at only one voltage
Improved automation of testing
“One button” testing (for ARC hybrid/module tests and Vienna box)
Man-hours per test dominated from starting/stopping test, changing test settings, etc.
Clear progress is being made with both ARCS and LT software
Improve creation of local/global database entry
Database group and Derek providing more/faster tools
Multi-tasking
Mount/inspect hybrids while hybrid quick test and 4 hybrid test are running
Mount modules onto cold plates during bonded modules test
Unmount modules onto cold plates as post-thermal cycle testing
Database entry during tests
Construction of second set of cold plates

13. Man-Hours/ARCS Stand Time (Shortened)
Assumes only reduction of time due to removed tests
Man-hours Needed
ARCS Stand Time Needed
Mount/inspect hybrids
~2 ½ hours
N/A
Quick Test Hybrids
~4 ½ -7 hours
Thermal Cycle Hybrids
~3 hours
Mount Module Cables
~ ½ hours
Bonded Module Test
~5-6 hours
Wien Box Test
~4 hours
Pinhole Test
TOTAL
~ hours (2 1/2 techs)
~7 ½ -8 ½ hours (2 stands)
Would prefer 1 additional tech and ARCS stand for stand down time, vacations, etc.
So I guess 3 ½ techs and 3 ARCS stands necessary for testing

14. Conclusions
With reduction of testing and some multi-tasking, current ARCS equipment should satisfy needs
With the reduction of testing and some more automation of testing, I believe 4 techs/grad students/post-docs could perform module test
At least 1 experienced physicists should be in room at all times
If necessary, other tests could be removed if no additional problems found with tests
Post-thermal cycling module testing