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TS-DEM Development of Electronic Modules

TS-DEM Development of Electronic Modules. Erik van der Bij CERN. The role of DEM at CERN. CERN Bulletin 18 April 2005. “Industrial excellence is rewarded by CMS”. CMS TIB Barrel pitch adapter DEM has taught the company the tricks of the trade. Cover of Bulletin 4 April 2005.

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TS-DEM Development of Electronic Modules

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  1. TS-DEMDevelopment of Electronic Modules Erik van der Bij CERN The role of DEM at CERN

  2. CERN Bulletin 18 April 2005 “Industrial excellence is rewarded by CMS” CMS TIB Barrelpitch adapter DEM has taughtthe company thetricks of the trade

  3. Cover of Bulletin 4 April 2005 ATLAS TRT: “The detector with the golden wires!”

  4. Cover Bulletin 8 November 2004“Photons on many fronts” The hybrid photon detector group of PH-TA1, holding their detectors

  5. Urgency just before testbeam start Friday. Responsible engineer not present. Board does not work. “let’s just replace all chips!” DEM replaced 50 ICs in less than 2 hours.Testbeam a success!

  6. Crisis in CMS From: Marcello MannelliSent: Monday, May 03, 2004 12:19To : Erik Van Der BijCc : Rui De Oliveira; Gigi Rolandi Subject: Visit to company xxx with Rui De Oliveira, for CMS Tracker hybrids Dear Erik, We are having an important quality problem with hybrids being produced by xxxfor the CMS Tracker. We have organized an urgent technical discussion with xxx, for which I thinkthe presence of Rui would be a very important value added for us. I understand that this week there is a series of workshops which Rui should attend. I hope you will not find it too inconvenient if Rui is absent from the Thursday morning session of the workshop. Thanks and best regards, Marcello Mannelli

  7. The role of DEM at CERN Is it already clear?

  8. Contents • TS-DEM organisation • Design and assembly services • DEM core technology • Examples of raisons d’être • Conclusions

  9. Design office DEM-BE TS-DEM Request Circuit or module Planning office(DEM-BE) ‘commercial’ contact Ordering Tracking Invoicing Circuit manufacturing DEM-PMT Assembly DEM-WS Sub-contracting (overflow of CERN capacity) Prototypes, fast turn-aroundlocal industry Sub-contracting Large quantitiesmember states

  10. DEM – work done in 2004 • BE - Design office • 600 jobs, 150 clients • organised fabrication of over 800 designs • PMT - Production • 800 “standard” jobs • 100 jobs in cleanroom • WS - Workshop • 900 jobs, 200 clients Flying probe testerbought together with PH used on all boards

  11. Role of the design office DEM-BE • provide a local central service for PCB layout • grouping of professional draughtsmen lowers cost • to standardise design and production files • eases production, lowers cost, guarantees long term storage (EDMS) • maintain central electronics symbol libraries • symbols are re-used, feedback from assembly useful for all designs • centralise knowledge of subcontractors • reduces number of visits, makes experience available to all • provide a single interface to subcontractors • improves image of CERN and communication

  12. Role of the assembly workshop DEM-WS • provide a central facility for assembly of prototypes • immediately available for urgent work and repairs • grouping of assembly technicians improves quality • lowers cost as expensive machines (oven, placement and inspection machines) need to be bought only once • to centralise the knowledge of assembly processes • allows sharing of experience • available to asses quality of productions made by industry • functions as a local authority on issues as no-clean and lead-free

  13. Role of DEM Provide a fast service!

  14. CERN Technologies and developmentsCris Benvenuti (TS Workshop 2004) Raisons d’être: • 1. competencies not available in industry • 2. prototyping facilities • 3. flexibility as needed to face emergency situations All these aspects are essential and should be defined as CERN “musts”

  15. DEM-PMT: Photolithographic and Microconnectics Technologies Capability based around core technology developed by: skills to etch and process materials that are not commonly used in industry ... (aluminium, aluminium-nitride, berilliumoxide, beryllium-copper, gold, molybdenum, niobium, tantalum, titanium, tungsten) ... ... combined with production methods used in PCB manufacturing technologies (photo imaging, stacking of layers, metallization of holes and other surface treatments)

  16. 1. Competencies not available in industry • circuits with Aluminium layers and staircase sides • ALICE Pixel bus • flexible circuits with millions of hair-sized holes • GEM detectors, e.g. for TOTEM and LHCb • large circuits • COMPASS micromega 1.3 m, ALICE HMPID 1.7m2 • complex ceramic hybrids • ATHENA bus with Si carrier • circuits inside tubes • LHC kicker magnet: 3 meter circuit in silver inside tube

  17. ALICE PIXEL BUS & PILOT MCM MCM PIXEL BUS Signals2 Signals3 Signals1 Signals3 VDD Signals2 Signals1 GND VDD Pixel detector GND Pixel readout chip Difficult to work with Aluminum, needed long development. Industry cannot fabricate this!

  18. 2. Prototyping facilities to assist research • flex-rigid circuits with particularly shaped holes • ATLAS TRT • complex ceramic hybrids requiring integration • ALICE Pixel MCM • circuits using over a million via holes • MICE Readout circuit • circuits using special stackups and structures • LHC cryogenic thermometer

  19. TRT web developed by DEM, produced by industryStill some steps done at CERN

  20. Cryogenic thermometer (AT/ACR) 7000 being installed in LHC and experiments Prototypes developed with help of DEM

  21. 3. Flexibility as needed toface emergency situations • technical problems in industry that made that production had to be stopped • ATLAS TRT, CMS hybrids • industry that withdrew because of problems • LHC QRL heating elements, ALICE hybrids • urgent production for testbeams • COMPASS, TOTEM

  22. QRL Thermofoil Vaporises helium that is still in liquid form in return lines Etched stainless steel on Fr4 with Aluminium cover layer

  23. Crise pour ALICE From: societé industrielleSent: vendredi, 2. juillet 2004 10:28Subject: TR : cartes EDA 00638V1-EDA 00404-V2 Bonjour, Nous constatons des difficultés à stratifier les couches, qui se sont traduites par un décollement partiel de la dernière couche (révélé lors du choc thermique du NiAU). Le type de colle et à sa faible épaisseur peuvent être une cause racine mais notre analyse technique du dossier ne nous offre pas suffisamment de garanties de réussite sur une éventuelle relance. Etant donné l’ensemble des incertitudes et la volonté de notre nouvelle direction technique de maîtriser nos engagements, nous préférons aujourd’hui décliner ce projet. Nous sommes navré d’avoir à vous présenter cette décision et espérons que vous pourrez trouver une solution de remplacement. Meilleures salutations,

  24. Conclusions (1)Role of DEM at CERN • to assist engineers and physicists by offeringeasy access to competencies often not available from industry • to be always geared up to handle emergency situations with available expertise and production capacity

  25. Conclusions (2)Role of DEM at CERN • almost anywhere where you see electronics at CERN, DEM has played a role • (almost?) all of the experiments and accelerators could only work because of the competencies of DEM’s people

  26. http://cern.ch/dem DEM on the web DEMonthe web!

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