1 / 27

Loading Tools Work Preparation / Discussion

Loading Tools Work Preparation / Discussion. UniBe-UniGe meeting of February 10 th , 2012. Maarten, Franck, Coralie , Didier. Overview and target. Experience so far 1 stave loading with digital modules – Stave-1: Jigs version -1 and CERN stave

saul
Download Presentation

Loading Tools Work Preparation / Discussion

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Loading Tools Work Preparation / Discussion UniBe-UniGe meeting of February 10th , 2012 Maarten, Franck, Coralie, Didier

  2. Overview and target • Experience so far • 1 stave loading with digital modules – Stave-1: Jigs version -1 and CERN stave • 2 stave loading with Si-heaters – Wuppertal stave (1 under test at CERN) • 1 stave loading with ceramic heaters • Handling frame with section 50x50 from Swiss Composit • Stave 0 – 1st target • 2 stave0 to be built from March 12 (sequentially) • Final handling frame from Composit Design (2 bare prototypes exist) to be machined and equipped • Loading tools to be design and produced for Production Readiness Review (PRR) • All the sequences loading and QA will have to be tested, qualified and OK • Make a PRR and a document to described all the working steps • Production target • 14 good staves + spares to be fabricated • 30 handling frame + extenders + cable-PCB saver sets will be targeted • All the tooling sets to be made according to the feed back from stave 0 pre-production • Production will start around July 12 2

  3. Recall - Stave-1 with 1st Loading Experience • 1st experience with the reception test and USBPix test bench • Module pigtail trimming and handling (special tooling under development by CPPM for the production) • Module loading practicing with jigs v-1 • Wing folding and gluing: simple holding jig but the adhesive is not suitable • Wire bonding went well except in the region where there was missing glue Module reception tests Wire bonding Electrical connection from flex to module Loaded module Digital modules Loading modules 3

  4. Loading experience with Ceramic and Si-heaters Under wire bonding • Stave with ceramic heaters – completed since end of last year •  Still need protection covers (from François-Xavier) Ceramic heaters – 7 types Thermal grease spreading with mask • 1st stave with 1.5mm pipe and Parylene coating •  Problem: Middle support pin 140m too high as compared to the 3D models!!! •  Loaded and equipped with soft braid cables and PT100 To survey!!! Parylen coating Half loaded stave Stave equipped with cables and PT100 4

  5. Production Flow Flex prod CERN Flex loading and QA Genova Stave-Flex Assembly CERN Stave-Flex QA CERN Bare stave prod Wuppertal Stave Metro + Fitting CPPM UniGE – Loading & QA UniGe Loading Wire bonding & QA Metrology Env. QA Planar Prod. CiS Reception QA Wing gluing Thermal Cycl. Readout QA Module assembly and QA Bonn 3D Prod. FBK/CNM Bump bonding UBM/IZM CERN SR1 Module assembly and QA Genova Stave burn-in & QA Pipe extension - Brazing Stave to beam pipe integration FEI4B IBM 5

  6. Activities at UniGe • Reception tests – QA • Module planar and 3D readout tests (Bump bonding check) + visual inspection • Stave-flex thermal cycling + metrology + visual inspection (Stave mounted onto endblock face plate side) • Loading • Quick inspection + module pigtail trimming + logistics • Placement of stave in the cradle + wing retract • 1st side loading: thermal grease + glue dots + module placement + load weight + inspection • 2nd side loading (same operations as for 1st side) • Wing attachment - By group of two wings and to be repeated 16 times • Module glue spreading • Wing release + guide placement + weight + insepction • Wire bonding and QA • Stave + handling frame placement in the cradle at 1 position then wire bonding • Repeat above at 2 other longitudinal positions • Placement of the stave on the pull tested cradle + pull tests of few wire bonds on test pads 6

  7. Activities at UniGe – Con’t • Thermal cycling • - Post polymerization of glue dots at +30°C during 1 hour • Thermal cycling of one or several staves from -40°C to + 40°C 10 times • NB: Release the PMMA cover screws • Metrology survey • Metrology survey of the 20 module versus stave location pins • NB: Fiducial marks to survey at the corners of the planar and 3D sensors • Stave functional tests and readout (side by side for stave 0) • - Stave to be inserted into a Styrofoam box and connected at the PCB savers for power, DCS and readout + fitting connection • - Flush the box with nitrogen. When dry enough cool down the stave • Make functional tests LV and HV + readout with RCE readout system • Stave envelop QA • Check the stave envelop: Wing + Omega-flex + module (to be defined properly the acceptance) 7

  8. Overview of the Loading Tools • Tooling under design and fab for stave0: • Handling Frame (UniGe): 2 pre-series soon release for machining • - Production to release with Composite Design • - Design and machining of the handling frame features + extenders (UniGe/UniBe) • Handling frame covers (UniGe): 2 prototypes produced but need updates • - Production to release with local company • Loading cradle (UniGe/UniBe):  Under design now • - Tooling consists of: Cradle, module location rules, shims blocks and locking system, 190 microns shims, grease mask, glue mask for wing, Intermediate foam feet and wing retract, module weight, wing weight • - Camera support with the common cradle socket – (UniBe) • Bonding cradle (UniBe):  Already made for stave -1 and ~OK for production • Pull test cradle (UniBe):  Design under study • HV insulation bars (UniBe):  Design and fabrication still to be made • Styrofoam box for stave readout test (UniGe): Design and fabrication to be made • Sucking tool (UniBe):  Design under study • Module pigtail guillotine (CPPM):  Done – To be shipped to UniGe • Stave envelope check (UniGe): Design and fabrication still to be made Goal is the validate the tooling with stave 0: - 2 handling frame + covers. Once validated 30 additional will be made - 1 set of loading tools will be made. Once validated 2 other sets to be made 8

  9. Handling Frame - From old to new version Motivation for a second version is the precision machining cost of the extenders • Handling frame features: • One dedicated handling frame per stave. Once the two side flexes are glued on the stave, it will never leave its support until it is integrated around the beam pipe • Its functions are: storage, handling, interface for loading, wire bonding, electrical tests, thermal cycling, metrology, cooling pipe extension and integration stand • It consists of 3 parts: a 1m central CRFP support structure plus 2 extenders of ~ 250mm on each side holding the PCB saver and pipe stress relieve blocks • Three protection covers made of transparent PMMA will be attached for transport and storage • Mechanical precision parts: • 1 central side location slot to reference the longitudinal loading and also for the integration stand • Precision machining of stave support blocks with respect to the above slot and stave surfaces • Surface precision obtained from the stave fabrication – no need of post machining 9

  10. Handling Frame - Few illustrations of the new version Side extender made of a CFRP plate Full length 1.m5 handling frame Half view with segmented covers for side connection access Protection covers made of transparent PMMA 10

  11. Handling Frame - Few illustrations of the new version Other side view with flex and PCB saver + PP0 region PCB saver with connector layout Side view with protection cover Prototype flex & PCB savers received and loaded but still to be tested Side covers must be removed for electrical and cooling connections 11

  12. CFRP prototype tube produced by Composite Design Handling frame – Con’t Central support Support - precision location Support foot for stave (Made by Uni. Berne) Support – Alignment slot Version 3 with latest feature End support on the face plate side 12

  13. Handling frame parts - Shopping list • 1m long CFRP tube (from Composit Design) to be machined by Programme SA  expected ~Feb 20th • Stave support block (UniBe)  Done (nice quality) • Other parts: Cable saver support, extender feet, right- and left-hand side PP0 support •  To be done by UniBe. Can this be confirmed? • PP0 holders in plastic 3D stereo-photolithography for stave 0  prod one to be made by molding • “U-shape” stave support – Design still to be made  Who will do it? • Extenders water jet cutting  Done • Final assembly  Can this be targeted for beginning of March • 2 sets of cable and PCB savers: Should be produced before validation/check (Yannick) • Pipe stress relieve (CPPM)  Followed by Eric. VCR fitting will have to be ordered! Target is to get 2 sets of fully equipped handling frame beginning to mid-March! 13

  14. Reception sequence – 3D views Reception of stave with covers to be removed Transfer of end-block fixations to the U-blocks 14

  15. Loading sequence – 3D views Insert the wing retract blocks Place stave handling frame into the cradle Place grease masks Grease spreading Mask removals Insert longitudinal rule Insert Z0 alignment 1st module placement Spacer + 2nd module 15

  16. 2nd spacer Loading sequence – 3D views ½ stave with module located Lateral rule envelope End side envelope 1st weight All weights Lateral rule removal End side ref rotation and 16

  17. Removal of guiding rule Loading sequence – 3D views 1 spacer fully removed Rotation/extraction of spacer rotation of central guide + removal of lateral guide 1st side completed and ready for loading the second side 17

  18. Wing attachment sequence – 3D views Stave in wing attachment cradle Rotation of mask on top of the module Block support mask located for 1st module 3 Glue spreading (Epoxy) Removal of the mask Wing retract block removed Wing jig block installed Wing clamped 18

  19. Wing attachment sequence – 3D views Back support stave slided Wing loaded with weight Next module and same sequences as described previously 19

  20. Wing attachment sequence – 3D views 19 20 21 20

  21. Agreed actions and plans • A little time remains for stave0 fabrication plan. Why? • FEI4B chips (production chips) are in production and they are performing well • FEI4A module for stave0 is progressing well at Bonn and Genova (we will learn more next week at IBL general meeting) • Stave flex are delivered and will be populated and tested in Genova • Tooling for flex to stave assembly is progressing • Stave fabrication is working fine and 1st real stave (final design) already loaded with Si-heaters • Target is to have tooling ready for beginning of April for 1st stave0: • It is only 6-7 weeks from now! • If we want to be efficient we have to make a part list (nomenclature) of all the tooling: handling frame + loading tool + wing gluing + other tools • Distribute the work amongst us: UniGe, UniBe, CPPM • Each will have to make the design fab and fabrication work based on a 3D model • Need to track the progress on weekly basis for each items of the part list for 3D, fabrication drawings, Machining/production, Assembly • Make a global stave loading and QA sequences to be reviewed 21

  22. Part List – Handling frame 22

  23. Part List – Loading tool 23

  24. Part List – Loading tool - Con’t 24

  25. Part List – Wing attachment 25

  26. Other tools 26

  27. Other tools – Con’t 27

More Related