1. Recent updates to the 2S module geometry Towards first dummy modules
Upgrade Phase II Plenary, Tracker week, 20 July 2012 News on the 2S module design Refers to work and inputs by Tristan Falcy, Antonio Conde Garcia, Luc Kottelat, Stefano Mersi, Giovanni Bianchi, Alan Honma, Duccio Abbaneo, Andreas Mussgiller, Nick Lumb, Riikka Häsä, Aleksis Chávez Niemelä, Antti Onnela
Introduction
Recent updates to the 2S module geometry
Towards first dummy modules
Rod adaptors and positioning tests
On-going + Next tasks
Summary
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2. Introduction Upgrade Phase II Plenary, 20 July 2012, indico: 197208
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3. 2S modules in the Tracker layout study
Stefano Mersi et al.
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4. 2S modules, different sensor spacings
“End-cap” 2S module with 4 mm sensor mid-plane to mid-plane distance (3.8 mm air gap).
4 mm is the thickest module in the present tracker layout study
“Barrel” 2S module with 1.4 mm sensor mid-plane to mid-plane distance (1.2 mm air gap).
1.4 mm is the thinnest module in the present tracker layout study
There are also other sensor spacings, between 1.4 mm and 4 mm, in the current layout study.
The sensor gaps can/will evolve in future following tracker layout optimisation.
Reference data on the 2S modules in the Upgrade website:
Silicon sensor
Base-line sensor spacing, used in the module design:
4 mm “End-cap” modules
1.4 mm “Barrel” modules
Silicon sensor
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5. Recent updates to the 2S module geometry
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6. Old version: Position of hybrid vs. sensors
Aleksis Chávez Niemelä, Alan Honma
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7. New version Aleksis Chávez Niemelä, Alan Honma
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8. Additional Kaptons against discharges
Aleksis Chávez Niemelä, Alan Honma
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9. Additional Kaptons against discharges
Aleksis Chávez Niemelä, Alan Honma
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10. 3D data of the 2S modules
Current 3D models of the 2S modules are available in
4.0 mm module:
1.4 mm module:
Available 3D data formats: 3DVIA: Visualisation format. Requires installation of a free viewer available from the above addresses. Allows taking measures of the 3D models, producing cut views, etc. Runs only on Windows. PDF: 3D PDF visualisation format. Runs on web browsers. More limited functionality than 3DVIA. STEP: suited for reading 3D geometry to CAD or FEA systems.
The module geometries will continue evolving. The latest versions will be made available in the Upgrade website:
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11. Towards first 2S (dummy) modules
In order to study the thermo-mechanical properties, assembly, handling, etc. we plan to start the prototyping of the 2S modules with simplified, dummy modules.
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12. Towards first 2S (dummy) modules
Components for first dummy modules
Dummy sensors are in production (Alexander Dierlamm / KIT, Hamamatsu)
Include heating, temp measurement, bond pads, positioning targets
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13. Towards first 2S (dummy) modules
Components for first dummy modules
Proto / dummy versions of other module components need to be procured / made.
Carbon-fibre support frame
Precise material choice still to be made
Pieces can be done in-house, when material available
Thermally conductive layers (TPG, PGS, ?)
Material choice not made, yet.
First material samples obtained, now ordering more
Mock-ups of the hybrids + components
Which materials to use? How to simulate heat production?
Kapton
Ok, can be prepared in-house
Aluminium contact pads
Rapid prototyping is one solution to make components, or even full module geometries
Limitations in material choice, dimensional tolerances, thicknesses (< 1mm is difficult), surface finishes.
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14. Towards first 2S (dummy) modules
How to test first dummy modules?
One option is to use our ~30 existing spare TOB Rod frames
Carbon fibre structure
Cooling is included
Setups for supporting and cooling rods exist
But, module supports in wrong places for 2S modules
 Adaptors needed.
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15. TOB Rod with 2S modules
2S module
Adaptor
Existing TOB rods (tens available) can be used for first module tests
E.g. cooling tests
But, new module dimensions do not directly match the rod
Need adaptors
TOB Rod frame
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16. TOB Rod with 2S modules Tristan Falcy, Luc Kottelat
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17. Adaptor design Tristan Falcy, Luc Kottelat
3 connection bars in carbon-fibre composite
Support and alignment of the 2S module
Support and alignment on the rod
4 support/cooling contacts in aluminium
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18. Adaptor production 2 adaptors have been produced
Completed adaptor
3 connection bars in carbon-fibre composite
4 support/cooling contacts in aluminium
2 adaptors have been produced
More adaptors can now easily be made, if/when needed.
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19. Rod + Adaptor + 2S module mock-up
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20. Module positioning studies
Tristan Falcy, Luc Kottelat
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21. Barrel rod with 2S modules
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22. Studies on module positioning
Study on combining module positioning inserts and captive screws (for improved module handling)
Module placed on supports
Module
Positioning
Screws tightened
Support structure
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23. Study on module positioning
Aluminium dummy module placed on a support plate
Small brass positioning inserts and captive screws
Optical measurement of module positioning
Positioning inserts + captive attachment screws and nearby optical targets
“Module” in aluminium
Support plate in aluminium
Attachment screws
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24. H7 tolerance on Ø2.5 and Ø3 holes: 0 - +10 μm
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25. Study on module positioning
Module positioning insert (brass) and captive M1.6 screw with a spring
h8 tolerance on Ø2.5 and Ø3 axis: -14 – 0 μm
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26. Precision (repeatability) of the positioning
σ = 10 μm
Dummy module installed and removed 8 times, with its position measured after each installation.
Optical measurement accuracy: +/- 2µm
Mean value of results normalized to zero
σ = 17 μm
σ = 11 μm
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27. Conclusions from these positioning studies
Precision of ~ μm (1 sigma) in module positioning can be rather easily obtained even with such small 2 mm high positioning inserts.
If necessary, the precision can be increased by tighter manufacturing tolerances on the components
Precise ‘slot’ hole is more difficult to produce than a precise round hole.
Note: For sufficient cooling contact the module attachment screws must be well tightened. Therefore, the long-term stability is better than the initial precision of such module positioning system.
Captive screws work nicely, but they are space-consuming, need a ‘high’ support insert
Problems with available space and added mass on the final rod assembly
Simple screws are now considered
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28. On-going + next tasks
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29. Module support design Used as base-line: Rod with modules upside up.
Space for module supports, positioning and screws?
Combine support of two modules?
Modules upside up
+ Radial distance between adjacent sensors is minimized
+ Connectors are well exposed
Total thickness is potentially rather big (here 24 mm). Thickness depends directly on the biggest components
Tight space for module supports and thermal contacts
Modules upside down
+ Total thickness minimized (here 15 mm), allowing compact barrel layers
+ Components are not exposed (= better protected) in the final assembly
+ Good space for module supports and thermal contacts
Radial distance between adjacent sensors is big.
Difficult access to connectors on the module
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30. Thermal design of the module supports
According to preliminary calculations ΔT of 5-7 ˚C expected in the module
Allowing total of 10 ˚C ΔT from silicon to coolant leaves ΔT max 3-5 ˚C for the module support – cooling pipe – fluid (CO2)
Analysis and preliminary optimisation on module supports on-going
Optimisation between mass and thermal performance of the module support insert
ΔT: 5-7 ºC
Module analysis (Andreas Mussgiller)
Support insert analysis (Riikka Häsä)
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31. Module and rod overlaps
Aleksis Chávez Niemelä
Module supports and Cooling contacts at the rod overlap area?
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32. Module holders
Module holders to allow safe access to module front and back sides.
During module assembly work
During bonding
During testing
During transports
Can one single holder do all, or are different holders for different steps necessary?
Images of preliminary concept studies
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33. Summary 1.4 and 4 mm 2S module geometries updated.
3D data available.
Components for first proto modules available in autumn 2012
Dummy sensors (heating, temperature measurements, bonding tests, positioning and assembly studies) available ~Oct 2012
Other components to be made / ordered.
Adaptors for mounting 2S modules on TOB rods have been designed and 2 first adaptors made.
Can be used in the first thermo-mechanical tests of the 2S test modules
Module positioning studies done with very dummy modules.
Reasonable positioning precision achieved with small positioning inserts.
Captive screw system works, but requires space (not easily available).
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34. Summary Work on-going with module supports for full rods.
The support need to be small, for mass and also for limited space available.
Thermal performance needs to be sufficient.
Particular challenges in the rod-to-rod overlap area
First concepts of module holders for assembly, tests, transports
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35. Thanks for your attention
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