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TS-DEM Development of Electronic Modules Group

TS-DEM Development of Electronic Modules Group. Erik van der Bij CERN. Agenda. Services and organisation of TS-DEM Organisation of files in EDMS (AB/PO) Reliability engineering. MANDATE Turn schematics into boards (standard + special). PCB design Manufacture of special circuits and PCBs

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TS-DEM Development of Electronic Modules Group

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  1. TS-DEMDevelopment of Electronic ModulesGroup Erik van der Bij CERN

  2. Agenda Services and organisation of TS-DEM • Organisation of files in EDMS (AB/PO) • Reliability engineering

  3. MANDATETurn schematics into boards (standard + special) • PCB design • Manufacture of special circuits and PCBs • Assembly

  4. Examples of ‘standard’ work

  5. Design Office DEM-BE TS-DEM Request Circuit or module Planning Office technological and commercial choices invoicing DEM-BE Subcontractingordering, collecting components, tracking DEM-BE Industry Circuit Manufacturing DEM-PMT Assembly Workshop DEM-WS

  6. BE – Design officeBetty Magnin • Layout of PCB, flexible circuit, hybrid or fine-pitch detectors • Design of associated small mechanics(front-panels, crates) • Creation of schematic and padstack symbols • Cadence and PCAD/Altium libraries • Storage of manufacturing files • PCB production, assembly, bill of material all in EDMS (EDA-xxxxx) • Organisation of production and assembly • prototype quantities: in-house or local industry • larger quantities: European industry • Component purchasing service (new!) • Technical advice on manufacturing Easy wayto savetime!

  7. Example of mechanics

  8. PMT – FabricationRui de Oliveira • Special circuits • flex-rigid boards • multi-layer boards with integrated metal or pyrolytic carbon • high-definition circuits (traces and isolation 5 to 10 μm) • Thick-film hybrids • seriegraphy of conducting paste on ceramic substrates (aluminium, aluminium nitride, berillyumoxide) • Chemical treatment • thin metal sheets (copper, inox, nickel, aluminium, titanium) • Standard printed circuit boards (halogen free!) • single side to multi-layer boards (upto 14 layers, class 6) • flexible circuits (kapton) • Technical advice on material selection and processes

  9. TransferImage

  10. Percage

  11. Electrical test

  12. WS – Assembly workshopBetty Magnin • Mounting of components • through-hole • BGA downto 0.8 mm pitch • resistors and capacitors downto 0201 size • Replacing of components, including BGA • Production of cables (coax, flatcables, twisted pair) • Wiring of crates • 30-minute express service for small interventions • Cleaning of boards • Technical advice • component selection and manufacturing

  13. Condensation oven

  14. Cleaning of circuits After cleaning Before cleaning

  15. Turn-around time Prototype electronics productionmulti-layer PCB, standard priority • This time can be reduced if necessary! • PCB fabrication can handle 2 urgencies per week • e.g. double sided PCB in 1 day, single sided 0.5 day • Replacement of component: 30 minute service

  16. PCB Delivery times • Fast track PCB layout (since July 2007): • Small jobs (estimated ≤ 2 days) will be started immediately or on next day

  17. Example:Urgent full project for PH • Layout and PCBs needed ASAP • Received request 7 March 2007 • Same day layout finished! • 4 PCBs ready on Friday 9 March,rest on Monday after • Assembled 1 PCB on Friday 9 in evening,second finished on the 12th.

  18. Example:Urgent project for AB/CO • Layout ready: three different PCBs needed ASAP • Needed really fast: • no solder maks or silkscreen finish needed • Design files given Friday 30 March 7:00 • PCBs ready same day at 15:00! • Could have assembled connectors if needed • Two weeks later tests finished, production of series requested

  19. Conclusions • DEM provides you a turn-key solution • from your schematics to assembled boards • all services close to the engineers • production in small to medium quantities • advice on manufacturing (material, components, processes) • DEM has contracts with industry • local industry for prototyping • in other CERN member states for medium scale production • The service can save you a lot of time and cost

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

  21. PCAD to Altium • PCAD stops support after 2006 • With ELEC committee IT decided to move to Altium • Altium can read PCAD schematics and PCB layout • Altium is a bit more difficult to use (notably PCB layout) • Presentation on Tuesday 10/7 (amphi bld. 30, 8:30-12:15) • Two day courses will be given from September on • Pilot course in July

  22. Storage of design filesin EDMS Files stored in EDMS since 2002 http://edms.cern.ch/nav/eda-xxxxx BE: Schematics, PCB design & production, BOM & assembly files, mechanics User: specification, images, supplier info • Handling of 'executions' since 2006project with AB/PO

  23. Enregistrement des cartes fabriquées par TS/DEM GEREG HCREHAR002 Selon convention signée par AB-PO et TS-DEM (Document EDMS 801714 v1) 1 carte: HCRBSxxxxx = EDA-yyyyy-Vx-x Un dossier de fabrication unique Code de fabrication TS-DEM: EDA-xxxxx-Vx-x Code d’exploitation AB-PO : HCRBSxxxxx Christophe Mugnier :Présentation du 16 Juin 2006

  24. Dossiers de fabrication TS/DEM Christophe Mugnier :Présentation du 16 Juin 2006

  25. Dossiers de fabrication TS/DEM - Identification d'une carte Etiquette apposée par l’assembleur sur le connecteur dans le cas d’une exécution. La sérigraphie du print: Elle comporte le code EDA+la version et la désignation de la carte. La sérigraphie de la face avant : Elle comporte le code EDA et la désignation de la carte.

  26. Dossiers de fabrication TS/DEM - Identification d'un chassis Etiquette apposée par l’assembleur pour spécifier la version. La sérigraphie de la face avant : Elle comporte le code EDA et la désignation du chassis.

  27. Dossiers de fabrication TS/DEM - Example en EDMS Example: http://edms.cern.ch/nav/eda-01586

  28. Reliabilityengineering In development phase: qualitative strategy • Find weak points fast -whatever it takes • Accelerated testing: quantative strategy • get idea of final reliability • concepts (without acceleration) also valid to get data for our installed base Ideas from Hobbs Engineering course "Demonstrating Reliability Requirements with Accelerated Testing" and book "Accelerated Reliability Engineering - HALT and HASS" http://hobbsengr.com, see alsohttp://weibull.com

  29. Stress-Strength "Non-interference"

  30. Qualitative strategy

  31. Effect of qualitative testing

  32. HALT

  33. PDF to CDF Unreliability Probability Unreliability Time Time Time

  34. Weibull function handles all shapes

  35. Paperclip example

  36. Calibrated Accelerated Lifetime Test

  37. Example of Voltage CALT Car electronics 12-15 Volt

  38. Example of Tcycle CALT

  39. Wiper graph

  40. A serious test flow

  41. Conclusions • Development • have fun with your cards and 'burn' a few. You learn a lot! • temperature, voltage, vibration, on/off cycles... • Know (measure) the environment of your cards • e.g. on-time, on/off cyles and temperature variations • is needed to calibrate acceleration factors • Measure precisely the on-time, on/off cycles etc of each card to know precisely when failed • allows Weibull plotting and gives invaluable reliability data

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