1. Chamber construction Construction Tools Production sites Assembly Sequence (“travelers”) Manpower P. Campana LNF – LHCb Muon EDR Cern April 16 th, 2003

2. Construction tools Several steps in the chamber construction have been automated to speed up production, reduce the needed manpower and increase precision and reliability of the MPWC. Tools are used to glue the frames to the panel wire the panels solder the wires control the wire pitch control the wire tension assembly the layers close the chambers Each production site will have a set of tools.

3. Among the various sites, tooling has small differences (mainly due to characteristics of the different regions) : anode readout (R4) cathode readout (R3 and inner M4-M5) anode-cathode high density readout (inner M2-M3) These “theme variations” do not change the main conceptual design of the chambers that remains uniform in the whole detector These differences in the tools explain the small variations in the procedures for chamber assembly in the various sites Some of these procedures have still to be validated with the experience we will accumulate in the first months of the production

4. Glueing the frames to the panel Technique : perform a precise glueing of the frames (HV bars, lateral and side bars) onto the panels at the quote of 2.5 mm (to set the anode plane at the right level) with +- 50 micron precision PANEL GLUEING TOOL HV BAR GLUE 2.5 mm 2 panels can be glued per day on one glueing frame This procedure is the same in all sites

5. Status : 1 table ready for PNPI1 (4 needed), 1 table ready for CERN (1 needed) 1 table under construction in Potenza/Ferrara and 1 (simplified version) in Florence (6 needed in the INFN sites) CERN/PNPI Glueing table with vacuum system for the frame and the panel positioning The material is glued with structural epoxy and left under vacuum for several hours Very good precision achieved

6. Wiring methods COMBS CERN (2 pairs) PNPI (6 pairs needed !) INFN (3 pairs) 1 panel = 2 anode planes 1 panel = 1 anode plane WIRE

7. The different wiring methods do not affect the layout of the chambers The time needed for the cure of the glue is a limiting aspect of chambers production (for PNPI site in particular, a large number of combs is needed) Winding is performed at a speed of 6 -10 turns/min The largest chamber is wired in about 2 h (positioning included) Status : CERN, PNPI and Ferrara, ready LNF under setup (control of the uniformity of the wire tension)

8. Wiring Machines

9. Automated soldering (laser)

10. Status : LNF (2 laser heads + cameras for wire pitch control) ready; mechanical settings to be adapted to the final chamber dimensions Ferrara (2 laser heads + cameras for wire pitch control, integrated in the wiring machine) under setup CERN, PNPI (iron head) device under procurement and setup Ferrara

11. Laser 25 W 805 nm working at 60% nominal power Soldering pads adapted for a continous soldering and for eye-guiding wire positioning Tin-plates traces shows better results (true also for iron soldering) at lower power Low flux, low T, soldering wire (same of CSC-CMS) Solder velocity : 5 cm/min (largest chamber done in 30 min with two- heads setup) Two small cameras control the process Afterwards, visual, detailed control of the soldering quality

12. Production sites (clean rooms) CERN, PNPI, LNF ready; Ferrara, Florence under setup

13. Travelers : material preparation & construction procedures 1)Preparation, cleaning and controls of panels and of side material (HV, side and closing bars; wire, etc...) >> check of wire quality : visual inspection + stress test? >> dimensional controls 2)Glueing of bars on panels >> dimensional controls 3)Wiring, glueing of wires 4)Wire soldering

14. 5) QC on wire pitch and tension 6) Cutting wires’ end, cleaning of anode panels (for R4, mounting of R and C on anode bars) 7) HV test of single anode panels

15. 8)Preliminary assembly of WPC, test with HV and dry gas >> the 4 anode layers are assembled without glue for dimensional control and undergo preliminary tests with HV in dry gas environment 9)Final glueing/closing >> two lines pursued: in the high density region (all the boundary is filled with HV connections and FEE pins), the baseline is the use of O-ring the rest would be closed permanently with glue ( this decision has to be validated also with the yield in the chamber construction)

16. 10)Gas leak test >> in case of closing with glue, a supplemental peripheral glueing has to be applied 11)HV training with final gas mixture 12)Chamber uniformity control 13)Final assembly of Faraday cage and FEE - Cosmic Ray test >> this step is largely linked to the availability of the final electronics (only in July 2004). One part of the production will be equipped only afterwards. Tests on full preproduction and after on a small sample of chambers will be done with ASDQ

17. Manpower needed Evaluation from “Travellers” SiteChambers/ week Manpower (fte) Notes Ferrara2.55Panels glued in Potenza, chamber assembled and tested in Rome2 PNPI 1514 CERN12 LNF2.56+1 person from Rome1 for chamber assembly

19. Conclusions (open points) Final choice of glue Validation and commissioning of tooling Validation of closing methods HV training procedures