LHC-b Outer Tracker module production

LHC-b Outer Tracker module production
Jan Spelt 2/28/2019 OTR production / Jan Spelt / Nikhef

We should have a golden rule:
This presentation My idea of the LHC-b project from what I have learned last three weeks Most important is to get the mechanical assembly running Electronics is a more or less smooth running part of the project, we will incorporate this in a later stage into the main assembly schedule. We should have a golden rule: “No module will leave Nikhef before it is fully finished, tested and approved” 2/28/2019 OTR production / Jan Spelt / Nikhef

OTR production / Jan Spelt / Nikhef
Outline Objectives and requested milestones Process steps, problems and tooling Proto typing 1 and 5 meter Quality assurance Assembly schedule Some remarks on engineering and components Some remarks on personnel To conclude 2/28/2019 OTR production / Jan Spelt / Nikhef

Objectives Roughly 120 tracker modules to construct Plus ???? spare modules ?? Plus support frames No tracker module will leave Nikhef before total completion, with electronics and fully tested! As soon as possible from research to production !! 2/28/2019 OTR production / Jan Spelt / Nikhef

Project Milestones 11/06/2003: EDR 03/2005: 50% prod. 02/2004: 10% prod. 12/2005: 100% prod 2/28/2019 OTR production / Jan Spelt / Nikhef

Process steps Supplies and storage Straw preparation Straw to panel Panel wiring, HV test & wire tension test Module assembly Leak tests Performance tests Module packaging 2/28/2019 OTR production / Jan Spelt / Nikhef

Supplies and storage Components Straws Wire locators, end and middle plugs Wire PCB’s Panels (production site ready) Side strips Module box Glue, solder and other samll materials Delivery scheme not yet started Ordering not all done It is time to freeze spec’s ASAP Delivery running Jan 1st 2004 Tooling Straw quality control tools Panel quality control tools ?? PCB quality control performed by ET Transport tooling Module package tooling Stock location and tooling 2/28/2019 OTR production / Jan Spelt / Nikhef

Specifications and quality control supply and storage
Specifications to be defined Cleanliness of deliveries in general Quality control Storage manual, to be written Badge administration, to be defined Checks&limits, to be defined Data base tooling, to be defined 2/28/2019 OTR production / Jan Spelt / Nikhef

Straw preparation Preparation steps 256 Straws per module Straws from buffer in template Tong cutting/tromping Wire locator installation and crimping Tong soldering End block installation and bonding Length cutting/tromping Middle block installation Straw to (template tuned) container Crucial: Keep the straw cylindrical and as straight as possible !!!! Tooling Straw production frame Straw buffering Straw positioning an fixation Tong cutter/tromp tool Soldering/welding method&tool Locator positioning method/crimp tool End block installation/bonding tool Straw cutter/tromp tool Middle block installation tool Straw moving tool to temporary storage device Action: Final decisions/design lay out and tools before mid October 2/28/2019 OTR production / Jan Spelt / Nikhef

Specifications, components & quality control straw preparation
Specifications to be defined Tong length/width Straw length Locator position/orientation Quality control Assembly manual, to be written Data base administration, to be defined Data base tooling, to be defined Checks&limits, to be defined 2/28/2019 OTR production / Jan Spelt / Nikhef

Straws to panel Assembly steps Panel installation in handling device, adjust and parking PCB’s to template Straw to template Comb to straws (end & middle) Glue end block & solder tongs to PCB’s Middle block orientation (fixation ?) Glue to panel Panel to straws 16 hour curing Panel and handling device to wiring station Tooling Panel handling device Panel handling device spacers Compr. air/vacuum to handling device Panel handling hoisting bar/moving table Glue dispensers/combs PVC PCB spacers & dowel pins Straw to panel frame moving tool Templates, proto test still to be done !!!! Vacuum installation for template Template alignment checks, to be defined Straw positioning combs Glue mixing station and sample holders Temp/moisture/vacuum surveillance, to be defined if necessary 2/28/2019 OTR production / Jan Spelt / Nikhef

Specifications, components & quality control straw to panel
Specifications to be defined Straw position accuracy (at wire locator position) PCB tolerances Quality control Assembly manual, to be written Data base registration, to be defined Checks&limits, to be defined Data base tooling, to be defined 2/28/2019 OTR production / Jan Spelt / Nikhef

Panel wiring, HV test & wire tension test
Assembly steps Panel and handling device to wiring frame Wiring per two straws (long + short) Attach the wire in the mid area Stretch the wires at both ends Repair in case of defects High Voltage test Wire tension test Installation gas distribution details Panel to module assembly station Tooling Wiring frame (Bosch) Wire storage tool Wiring tooling ( table & sucking heads, tool to reel out the wire Tool to stretch the wire Solder tooling (standard stuff) Wire position check ?? High Voltage test in air combined with wire tension test instrumentation and computer in a movable unit. 2/28/2019 OTR production / Jan Spelt / Nikhef

Specifications, components & quality control panel wiring
Specifications to be defined Wire position accuracy Wire tension limits High Voltage leakage limits Quality control Assembly manual, to be written Data base registration, to be defined Checks & limits, to be defined Data base tooling, to be defined 2/28/2019 OTR production / Jan Spelt / Nikhef

Module assembly Assembly steps Panel A to module assembly station Panel A positioning Dry assembly check panel B to A Glue spacers to A Distribute glue on the end blocks Glue panel B to panel A Install side wall tooling and glue the side walls 16 hours curing Side walls and earth strip soldering Tooling Assembly frame (wiring) Compressed air/vacuum & controls Side wall tooling Positioning tooling Soldering method and tooling Glue mixing station and sample holders, glue dispensers Safety precautions for glass bubbles (20 Micron) 2/28/2019 OTR production / Jan Spelt / Nikhef

Specifications, components & quality control module assembly
Specifications to be defined Quality control Assembly manual, to be written Data base administration, to be defined Checks&limits, to be defined Data base tooling, to be defined 2/28/2019 OTR production / Jan Spelt / Nikhef

Leak tests Assembly steps Move module to test frame Install gas distribution system Install leak test instrumentation Fill the chamber with a mixture of ??? And flush for some time Find big leaks and repair Detect small leaks and repair Module to transport frame Tooling Test frame Completion of gas infrastructure Gas ventilation tooling in clean room Rough leak test detectors to buy Sensitive leak test method and instrumentation for small leaks including the computer read out on a movable unit Module transport frame and handling mechanism Leak test manual 2/28/2019 OTR production / Jan Spelt / Nikhef

Specifications, components & quality control leak tests
Specifications to be defined Leak limits Quality control Leak test manual, to be written Data base administration, to be defined Checks&limits, to be defined Data base tooling, to be defined 2/28/2019 OTR production / Jan Spelt / Nikhef

Performance tests Test steps Move module to test frame Connect gas distribution Connect current measurement instrumentation Measure dark current Measure current with Strontium source 1600 V & 1800 V versus straw and source position, upper en lower side Module to packaging Tooling Test frame Turn around mechanism and alignment Gas distribution and mixing station Strontium slit source & moving mechanism Module charge read out system Code for measuring sequence and data storage 2/28/2019 OTR production / Jan Spelt / Nikhef

Specifications, components & quality control Performance test
Specifications to be defined Dark current limits (5 nA over 10 sec) Process time before measuring Analyses to be defined concerning wire and locator position, mass distribution and corona problems Quality control Assembly manual, to be written Data base administration, to be defined Checks&limits, to be defined Data base tooling, to be defined 2/28/2019 OTR production / Jan Spelt / Nikhef

Infrastructure Clean room Gas supplies Vacuum system Environment Supply and module storage Cleaning OK October 2nd delivery distribution network Incorporate buffer vessel, tubing and pumps to be done ASAP Log temperatures, moisture levels ordered To be completed still Nikhef facility or external 2/28/2019 OTR production / Jan Spelt / Nikhef

Protoyping 1 Meter module To exercise the assembly process To find the obtainable accuracy To judge methods To evaluate the tooling Gas tightness and system separation Gas distribution To find out what time things take Aim is a fully operational module for performance tests 5 Meter module Same issues Application of what we learned Template behavior is crucial 2/28/2019 OTR production / Jan Spelt / Nikhef

1 Meter module progress Assembly in progress Panel A wired (two weeks work) Precision measurement and analyses is now starting Results (eye inspection) Straw straightness & roundness not good enough, better preparation Mould grove oversized, less precision? Tong soldering not correct, method ? Sucking the straw into the mould is difficult Glue distribution ? and diffusion End & middle block position distribution 2/28/2019 OTR production / Jan Spelt / Nikhef

Quality assurance To assure good quality, retracebility and production control and process registration is absolutely necessary Nomenclature, terminology (has to be fully formulated first and agreed) Component bulk and badge registration (OTRSTOCK) Process parameters registration Measurement data registration Written assembly procedures Quality limits Assembly Manager software (OTRAM) End product status Quality data base (OTRAD) and data base tooling File and data base structure (OTR) 2/28/2019 OTR production / Jan Spelt / Nikhef

File and directory structure
Quality Assurance File and directory structure //OTR on Ajax /Manuals /Photographs /Data /Log /OTRAD (Data base) /OTRStock /OTRassy /Environment /Module status /Quality /Program Files Mounted as “O-drive” on each process computer At Atlas proven to be convenient 2/28/2019 OTR production / Jan Spelt / Nikhef

Quality assurance Stock administration OTRSTOCK Bulk Batches Access data base In and output facilities Atlas MDT stock administration example 2/28/2019 OTR production / Jan Spelt / Nikhef

Quality Assurance Atlas MDT example quality data base structure 2/28/2019 OTR production / Jan Spelt / Nikhef

Quality Assurance Atlas MDT Example quality data base structure 2/28/2019 OTR production / Jan Spelt / Nikhef

Quality Assurance Atlas MDT example quality data base for one item 2/28/2019 OTR production / Jan Spelt / Nikhef

Quality Assurance Atlas MDT example quality assurance limits table 2/28/2019 OTR production / Jan Spelt / Nikhef

Quality Assurance Atlas MDT assembly manual example Template for LHC-b OTR 2/28/2019 OTR production / Jan Spelt / Nikhef

Software and registration
Software Remarks Stock administration (OTRSTOCK) - Component and badge wise, like Atlas MDT, frame work available Quality data base (OTRAD) - Atlas frame work, parameter definition, limit definition Assembly manager (OTRAM) - Atlas like File and directory structure (OTR) - Atlas like Environment logging - Atlas program and hardware Wire tension measurement - CVI program available, add OTRAD link HV isolation measurement - CVI program available, add OTRAD link Wire position measurement - Difficult, necessary ??, ideas available Gas leak rate measurement - Improve program, add OTRAD link Module scan measurement - CVI software partly available, add OTRAD link Gas distribution measurement - Time consuming, automation helps 2/28/2019 OTR production / Jan Spelt / Nikhef

Engineering & component production
First priority Completion of module engineering before 31/12/03 Completion of production drawings as soon as possible Start serial production such that delivery of first set module components is guaranteed in week Inventory and scheduling remaining engineering issues asap Draw up a comp. delivery schedule asap Delivery to and from other institutes Second priority Frame engineering Gas distribution Installation issues 2/28/2019 OTR production / Jan Spelt / Nikhef

A possible module production schedule
1 Meter proto type 5 Meter proto type Completion of engineering Component delivery Running up module production Module production cycle time Cycle time variation Manpower budget Module completion rate Beginning of last quarter of 2003 ASAP at least before the end November 03 Crucial work Jan. 1st 2004, remain. June 1st Start Jan. 1st 2004 During first quarter of 2004 Between 10 an 16 working days possible By parallel processing, decouple straw prep Linear with module cycle time Between 5 and 2 days possible 2/28/2019 OTR production / Jan Spelt / Nikhef

Module production schedule
Our choice M 1 to 10 every 5 days M 11 to 30 every 4 days M31 to 60 every 3 days M61 to 120 every 2 days Mid Sept 2005 2/28/2019 OTR production / Jan Spelt / Nikhef

Personnel budget to be defined
Supplies and storage Straw preparation Straw to template, panel to straws Panel wiring, HV test & wire tension test Module assembly Leak tests & repair Performance tests Module packaging QA and assembly control software Engineering Component production Frame production MT, t.b.d. (to be defined), 0.2 fte VUA, t.b.d., 1 or 2 fte?? MT/VUA & ext, t.b.d. MT, t.b.d. MT & physicists t.b.d. Physicists t.b.d. CT, t.b.d. 2 or 3 fte EA, 1 fte VUA, next year ?? MT & outsourcing, t.b.d. MT & outsourcing t.b.d. 2/28/2019 OTR production / Jan Spelt / Nikhef

To conclude Infrastructure is almost ready, lots of work to do concerning tooling Proto typing very important (straw connection method, template behavior etc.) Freezing of & decision making concerning specifications as soon as it is possible We think we have a manageable schedule which meets the requested milestones 4th quarter 2003 completion module engineering, tooling, prototyping, ordering 1st quarter 2004 assembly running up 2nd quarter 2004 start of a sliding schedule, mid Sept 2005 completion Manpower has to be filled in still We have good insight in the assembly process but it has to be organized still Coming six months are crucial 2/28/2019 OTR production / Jan Spelt / Nikhef

LHC-b Outer Tracker module production

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