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QA and Process Control

QA and Process Control. G. D. Patel. QA. There exist various QA criteria for the different components that go into the manufacture of a VELO module plus a well defined procedure for the manufacture process.

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QA and Process Control

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  1. QA and Process Control G. D. Patel LHCb PRR - Girish D. Patel

  2. QA • There exist various QA criteria for the different components that go into the manufacture of a VELO module plus a well defined procedure for the manufacture process. • My role is to ensure that the selection criteria are correctly applied and the procedures followed. To aid in this process I have designed, written and implemented a web based database system that holds all the information relating to all the components and the status of every item. LHCb PRR - Girish D. Patel

  3. Database & Components The database is designed to store all relevant information on the LHCb Velo detector in a central, web accessible location. It is implemented with an Apache web server running with a php interface to a MySQL database. Data input is restricted by password protection, but information retrieval is unrestricted. Information is stored on cables, chips, pitch adaptors, sensors, pedestals, substrates, hybrids and modules. All changes made to the database are logged and can be traced back to a specific user. All test data are stored and online analysis is possible. LHCb PRR - Girish D. Patel

  4. Cables • Visual inspection and log in database. • Send for population. • Electrical tests. • PASS/FAIL logged in database. LHCb PRR - Girish D. Patel

  5. Chips • Arrive in 11x11 waffle boxes, position in box identifies chip. • Maximum of 120 chips, but gaps indicate rejected chips. • Used chips have a link to the module on which they reside. • Link to original chip test data at MPI Heidelberg web site is automatically generated for every chip in the DB. LHCb PRR - Girish D. Patel

  6. Pitch Adaptor • Pre-selection at CERN. • Visual inspection and log in database. • Must be no breaks or shorts in any of the 512 strips. • Detected by a capacitance measurement of every strip. • Data logged in the database. • Algorithmic code implemented via the web server informs the operator if the pitch adaptor meets the QA requirements. LHCb PRR - Girish D. Patel

  7. Web based code can be run, on the probe station data file, before the data is logged in the database. This allows for re-measurements on the probe station before logging the final data. Problem channels identified and classified as shorts or breaks. PASS/FAIL indicated Data presented graphically LHCb PRR - Girish D. Patel

  8. Pitch Adaptor DB Summary LHCb PRR - Girish D. Patel

  9. Sensor • Metrology • Must be no damage and shape must be with-in limits of nominal. • Shape metrology measurements from the Smartscope are logged in the database. • Algorithmic code implemented via the web server informs the operator if the sensor shape meets the QA requirements. LHCb PRR - Girish D. Patel

  10. 5000 (x,y) coordinate measurements of contour analysed and compared with nominal shape. Any edges oversize or undersize outside of the specified tolerance are flagged and a software PASS or FAIL issued. Software decision Oversize Undersize LHCb PRR - Girish D. Patel

  11. Sensor • IV Currents • Total current at maximum volts • Must be < 100 μA. • Data logged in database in text format. • Code displays maximum current in red on summary page if over limit. LHCb PRR - Girish D. Patel

  12. Sensor • Bad strips • Measure capacitance per strip, must be within 20% of expected value. • Measure current per strip, must be less than 1 μA. • Algorithmic code implemented via the web server analyses the raw data from the probe-station and informs the operator of the numbers of strips which fail the capacitance and current criteria. • Must be < 20 bad strips • Average 6 bad strips/sensor LHCb PRR - Girish D. Patel

  13. Summary of numbers of channels that failed (capacitance or current tolerance) • Problem channels identified. • Failed channels in red • Warnings in green. • This analysis available before • the data is logged in the database Graphical presentations of data LHCb PRR - Girish D. Patel

  14. Sensor • CV measurements • Measure sensor capacitance as function of voltage up to 160 volts. • Online software displays data and calculates depletion voltage displayed on the summary page. • Must be < 150 volts LHCb PRR - Girish D. Patel

  15. Sensor • All the test information is displayed on the sensor summary page. • Physicist must look at the sensor summary page and the data and make a QA decision on the final status of the detector. • Final decision on accept or reject a sensor is taken after discussions andI inform Micron if a sensor is to be rejected. (3 rejections so far.) • Acceptable sensors are categorised as OK, GOOD or VERY GOOD. LHCb PRR - Girish D. Patel

  16. Sensor DB Display LHCb PRR - Girish D. Patel

  17. Sensor DB Summary Micron bad channels Liverpool bad channels LHCb PRR - Girish D. Patel

  18. Substrate • TPG and CF laminated in-house. • Metrology data logged in database • Sent to Stevenage for circuits to be laminated on the two side. • Logged in the database on return LHCb PRR - Girish D. Patel

  19. HybridStages 1-4 • Metrology measurements to determine curvature and bowing. • Those out of tolerance are heat treated between metal plates. • Additional metrology measurements on the heat treated hybrids. • Hybrids with acceptable QA are sent out for population. • Rest are rejected LHCb PRR - Girish D. Patel

  20. HybridStages 5-7 • Populated hybrids are electrically tested to ensure specified functionality. • Electrical test failures are rejected if they cannot be repaired. • The rest are cleaned and inspected. • Additional metrology measurements on those that pass electrical tests. • Those that are too far from the flatness required are rejected. LHCb PRR - Girish D. Patel

  21. HybridStage 8 The hybrid is now ready for the gluing of pitch adaptors and chips. The database has a hold at this point and no further work is allowed unless specifically cleared to proceed by Tony Smith or Themis Bowcock. LHCb PRR - Girish D. Patel

  22. HybridStages 8-9 • Batches of pitch adaptors and chips to be used taken from store. • Glue pitch adaptors to R side. • Visual inspection and fix problems. • Glue chips to R side. • Visual inspection and fix problems. • All pitch adaptors and chips used are logged in the database LHCb PRR - Girish D. Patel

  23. HybridStages 10-11 • Glue pitch adaptors to P side. • Visual inspection and fix problems. • Glue chips to P side. • Visual inspection and fix problems. • All pitch adaptors and chips used are logged in the database LHCb PRR - Girish D. Patel

  24. HybridStages 12-16 • Bond back ends of R side chips. • Visual inspection, repair problem bonds and log them in DB. • Bond back ends of Phi side chips. • Visual inspection, repair problem bonds and log them in DB. • Bare chip test data to electrically test that all chips are working. Results via web database interface. • Replace any problem chips and repeat the cycle till all chips OK. LHCb PRR - Girish D. Patel

  25. LHCb PRR - Girish D. Patel

  26. HybridStages 17-19 • Front end bond R side chips to pitch adaptors. • Visual inspection, repair problem bonds and log every bond in DB. • Front end bond Phi side chips to pitch adaptors. • Visual inspection, repair problem bonds and log every bond in DB. • Bare chip test data to electrically test that all chips are still functioning. LHCb PRR - Girish D. Patel

  27. HybridStage 20 The hybrid is now ready for the gluing of sensors. The database has a hold at this point and no further work is allowed unless specifically cleared to proceed by Tony Smith or Themis Bowcock. LHCb PRR - Girish D. Patel

  28. HybridStages 20-25 • Glue R and Phi sensors to hybrid. Log sensors used in the database. • Metrology measurements to confirm the alignment of the sensors. • Make bias bonds and check IV for the sensors. • Bond R and Phi sensors to pitch adaptors. • Quality of EVERY bond is logged and database informs operator of known problem channels on the sensors which are NOT to be bonded in terms of the bond numbers programmed in the bonding machine . LHCb PRR - Girish D. Patel

  29. Information on known problem channels on the sensor are presented to the bonding machine operator. The bonds which are NOT to be made in the current pass are shown in RED Rest of this page allows status of every bond in this current pass to be entered and logged in the database. LHCb PRR - Girish D. Patel

  30. HybridStages 20-25 • Laser tests on all 4096 channels of R and Phi sensors. • Correlate problem channels detected by laser scan with known bad channels and problem bonds. • Investigate anomalies and resolve. LHCb PRR - Girish D. Patel

  31. HybridStages 26-32 • Glue complete hybrid to pedestal. • The final module number is defined by the number engraved on the invar feet of the pedestal base. • Full module metrology on CMM. • Plug and clamp cables. • Burn-in and thermographs • Final metrology on CMM. • Package for shipping. LHCb PRR - Girish D. Patel

  32. OutstandingTasks • A further selection of chips within the ones we receive may be required. Plan to implement web input so that Aldo Saavedra can input this rejection information directly into the database to be displayed to the operator when selecting chips for gluing. • Front end bonding has recently been implemented on the 710 as a backup to the 8090. The bonding sequence and bond wire numbering is different and a separate input page for bonding problems has to be implemented and both machines supported. • Algorithmic analysis of laser test data and cross correlation with known problem channels is still to be implemented. • Analysis of burn-in data still to be implemented. • Database software and data store to be transferred to a more powerful server machine. LHCb PRR - Girish D. Patel

  33. Conclusion The web based database system has proved invaluable for the logging and tracking of all the many components and their QA test data and results which are required for the VELO project. I am sure that the inbuilt process control will be an essential tool for the management of the production phase giving a constantly updated overview of the status of every module. Additional features will be added that give numerical summaries of the module production process. Lists of known bad channels for every module for input to the conditions database will be made available from the DB. LHCb PRR - Girish D. Patel

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