Final APA Prototyping and Pre-Production Components

1. Final APA Prototyping and Pre-Production Components R. Paulos DUNE Collaboration Meeting September 26, 2019

2. Topics • Frame construction plans • Cryo testing integrated frame • Board construction • Winder modifications • Pre-production APA R. Paulos

3. Frame construction plans • Material is on order for 5 frames from Atlantic (material for 5 plus extra) • We are currently working with an industrial partner on the best method for machining features in the long tubes • Conventional long bed machining vs. laser machining • We will work with at least one other vendor on machining long tubes in order to have a backup – concerns with cost and quality • Plan to start assembly of first frame by mid-November

4. Frame construction plans cont. • Five frames planned: • 1) Pre Production APA (PP APA) • 2) Frame for cryo test of new PD cabling scheme and mesh • 3) Frame for U. Chicago; for factory floor planning and winder commissioning • 4) Frame for Yale; for factory floor planning and winder commissioning • 5) Frame parts for U. of Iowa assembly trials • This is a flexible plan, we may find that one or more of these frames may be better used elsewhere…. R. Paulos

5. An Assembled APA Frame ready to ship to Ash River

6. Cryo testing integrated frame • We plan to install a set of PD cables and connectors in a frame for cold testing • Need to develop a plan for simulating the actual PDs and allow for a simple electrical test • Will install a full complement of mesh frames (likely provided from the UK) and test R. Paulos

8. Board prototype construction • In the past six months we have procured multiple sets of boards • One full set will be required for construction of the PP APA • Other boards will be available for consortium groups that have signed up for board production • A primary goal of this procurement activity is to develop vendor relationships and determine their ability to meet specifications R. Paulos

9. Typical PCB Vendor Experiences

10. Third-Party Board Machining • Three vendors have shown interest; at least two will be given 10 to 20 boards; will add counter-bores and channels • Ridout, Franklin Fiber, and Upland Fab • Control of board thickness is still a challenge

11. Third-Party Board Machining Head boards can be made thicker, and then machined within desired thickness tolerance Thickness reduction by machining was done for two-thirds of the board area for ProtoDUNE X head boards (feasible) Reduction was needed for a different reason, to accommodate Mill-Max sockets that are no longer being used

12. Mill-Max Pin-Insertion Methods Pins and sockets have been manually loaded into holes using magnetic pick-up tools Automation of this task doesn’t look economical (parts are small with odd shapes) Pin loading is good work for students (impossible to do wrong and easy to verify) A manual arbor press was used to seat pins and sockets into head boards and CR boards

13. Mill-Max Pin-Insertion Methods DUNE production sites can use arbor presses for seating pins and sockets into head boards (an easy operation if a good press is used) CR boards have pins inserted as the last step in the manufacturing process; it’s easy to damage components at this point A CNC press was built at PSL for seating pins in CR boards; will be used for next builds

14. Board Inspection Methods For ProtoDUNE all boards were screened using digital calipers and an optical comparator Pre-production prototype boards were inspected using the same approach Inspection jigs are being developed to simplify measurements and reduce cumulative measurement errors Other tools are still being evaluated

15. Inspection Tools Evaluated • 3-D Structured Light Scanners and Software • Scanning and results are slow and software is costly • 2-D Cameras and Image-Analysis Software • Many features cannot be verified this way • 3-D Line-Scanning Surface Profilers • Can be fast but accuracy is probably inadequate • Automatic Coordinate Measurement Machine • High accuracywith proper teaching and maintenance

16. Soldering Developments Vapor-Phase soldering for CR, G-Bias, and Adapter Boards (heat transfer via condensate) The process is relatively slow and messy Temperature control is excellent Minimal heat stress on board and components Results are consistent Solder flux and vapor-phase fluid residues are easy to clean

17. Automated Testing of CR and G-Bias Boards will be powered while voltages are monitored on all bias channels (40 or 88 at time, depending on the board) Transient responses reliably indicate when a resistor or capacitor misbehaves electrically The system reduces CR board leakage tests from a difficult 10 minutes evaluating each channel individually to a simple Go/No-Go test that takes about ten seconds

18. Pictures

19. Arbor Press for Pins & Sockets

20. Difficult Work for CR Boards

21. Automated Press for CR Boards

22. Inspection Jig (preliminary)

23. Surface Profile Scanner

24. Automatic CMM

25. Winder modifications • This task is a very high priority! • PSL is working very closely with Daresbury Lab on design details • Mods: • Interface to winder – arms and gearbox/clutch • Safety system – light curtain, trip wire • New camera system – for calibration and inspection • New winding head – with servo tension control • Y axis stiffening • Work platforms and covers R. Paulos

26. Winder modifications cont. • Schedule: • Designs complete: Dec 1, 2019 • Material orders: Nov 1 – Jan 15, 2020 (some material has already been ordered) • Assembly: Dec 15 – Feb 15, 2020 • Commissioning: Feb 15 – March 1, 2020 R. Paulos

27. Winder with new interface arm design

28. New gear box and clutch arrangement; Clutch allows decoupling of the drive system which prevents loads from being imparted to the APA

29. Pre Production APA • Construction start ~March 1, 2020 • Opportunity to build “APA 0” of the new design and work out any issues with changes from ProtoDUNE • Routing PD cables and connectors • Installing mesh panels • Working with the updated winder especially the new technique of spending more time on the winder and fewer moves in and out of the process cart • Working through updated processes and tools • Cold testing this APA in the cryo box at PSL before shipping to CERN R. Paulos

30. Epoxy Dispensing – Process Improvement • Former use of stencils to apply 3M 2216 Gray to the back sides of the V, U, G and Cover Boards is deemed to be too cumbersome on the larger scale necessary for creating multiple APA assemblies at each facility. • (2) Industry versions of Epoxy Dispense Equipment have been investigated - • Machine Dispensing Offers – • Minimizes - Time required to set-up and dispense • machine reads QR code on board, loads correct pattern • Reduces Waste – (Both) systems Accept 2-Part Epoxy Cartridges • facilities will not have to re-package epoxy for use • epoxy is mixed as it is dispensed – no waste of unused pre-mix • Repeatability – minimizes operator dependency of the process • same pattern / amount dispensed per board at each facility

31. Epoxy Dispensing – Process Improvement • (2) Industry versions of Epoxy Dispense Equipment have been investigated - Scheugenpflug – Work Station (System may be different than Shown) Video Call completed, boards being sent for process set-up and testing Nordson – 3 axis system w Smart Vision Sample dispensing system at PSL, Quote being prepared