23-Aug-2005 VELO Production UCD VELO Module Production at Liverpool T. Bowcock.

23-Aug-2005 VELO Production UCD

VELO Module Production at Liverpool

T. Bowcock


Overview• Progress to

Production Readiness– Status– Issues/Risks– Timeline

• Summary


Production Readiness• Engineering Review

– Concept of the project

• Point at which we are ready and can be “cleared” to start production– All equipment in place and debugged– QA procedures– Techniques proven

• Specific for VELO– 4 “mechanical” modules– 4 “physics grade” modules – experiment standard


Status• Expected to be past PR(R) in July (or

earlier)– Two major problems arose

• Pitch adaptor (connecting sensors to electronics)- contamination from production at CERN

• Hybrid “twist”

• Components and Procedures


Schematic


Sensors• Remeasurement of current at Micron• Excellent shape from Micron Laser • Improved jigs manufactured (Liverpool and Syracuse) • Mechanical tests on sensors

– 100 cycles on/off on jig does not make 200 micron mechanical snap

– Pressure on edge up to 10kg/mm2 does not cause cracks in Si– Twist of up to 2mm does not significantly

• Mounting in jigs and handling– In production we have decided to move to 2 person mounting of

sensors• High current detectors seem to be isolated to one

crystal, otherwise good.• 21 day vacuum (10-5 mb) test at high voltage


Sensors


Lots of data available from production process

-Implants

-Metal resistances etc.


Yield


Hybrid K-05• Industry was not able to reproduce

flatness achieved in lab– 6 months extra R&D (!)– £15K additional cost

• Move production to “in-house”– 4 substrates per day– Bare substrate ~50 micron twist (10

times better than achieved externally)• Twist on K-04 hybrids measured for

effect on Si • K-05 circuits have been fabricated at

Stevenage Circuits PLC– Error found in testing system and

corrected, this caused additional delay• 7 K-05 have been laminated onto

substrates at Stevenage• 2K-05 (populated) posted yesterday to

Liverpool, remainder at end of week.• Check K-05 functioning by early next

week


Mechanics• In full production, completion soon

• Bases in production (30 complete)

• Paddles mould tools– Paddle production will start in 2 weeks (3/day)


Laser Rig – Hybrid holder (cooled)

Modified Bonding Jig


Bits• Handling frames complete

– Once the hybrid comes to Liverpool (Post population) it doesn’t have to be touched

• Bonding jig modified(works)– Special backend bonding jig built for HK710 (no sensors – remove

leaks)• Table for Laser

– Flat surface surveyable into 2stage x-y drive– Incorporation of bonding jig/w cooling

• Assembly System complete and programmed• Gluing Robot Complete (programming underway)• Equipment for vacuum thermographs

– Dual arm vac vessel/flange being constructed– Allows up to 3 detectors to be tested simultaneously– Motion sensors tested on K-04 substrate (sensitive to ~5microns)




LHCb Assembly System

Programmed

Alignment Plates


More Bits• Cable clamps

– Designed – about to be submitted

• Short cables– Designed, awaiting production order


2-sided bonding• Backends programmed

– K-05 (twisted)

• Frontends– Chips programmed (BE!)– Completing programme to sensors this week

• Double sided bonding on our substrates is OK


Major Issues• Contamination of PA’s at

CERN still not resolved… another bad batch– Require 80% yield good

testing• K-05 yet to be electrically

tested• Assembly of hybrid to

paddle– Assume non-twisted

components– Final adjustment (tested)

using “W-sticks” added to design – removeable for repair


“Minor” Issues• No such thing!

– Transport boxes being designed and fabricated (gas tight, 3000m for aircraft, safe for insertion etc).

• Expensive

– Handling and reception procedures to be finalized (Glasgow/Liverpool mtg before Sept 7)

– Distortions– Outgassing tests


Project Timeline to PRR• Everyday planned …

– Still not in production mode as “fighting problems”


Project Gantt


Current Completion for PRR

0

50

100

150

200

250

18/0

7/2

005

25/0

7/2

005

01/0

8/2

005

08/0

8/2

005

15/0

8/2

005

22/0

8/2

005

29/0

8/2

005

05/0

9/2

005

12/0

9/2

005

19/0

9/2

005

26/0

9/2

005

03/1

0/2

005

10/1

0/2

005

17/1

0/2

005

Tasks

Done

17/08/2005

About 1 week late on current schedule…. Catchup???

Hybrids delayed. Due to arrive today


Realistic Start Schedule• Oct ‘05

– approx 9 months late– last week Oct

• How many modules can we make per week?– Start at 1/week and build up– Maximum capacity 3 (or 4) but we will not be

able to achieve this until Feb 2006


Production at Liverpool

0

5

10

15

20

25

30

35

40

05/09/2005

25/10/2005

14/12/2005

02/02/2006

24/03/2006

13/05/2006

Weekly

CumulativeChristmas & Startup

No major failure


Summary• We should have full VELO complement at

CERN by end of April 2006– If testbeam in April 2006 this may be only

50% can be tested during system test

• Large amount of work left

• Two big “risks” remaining– Pitch adaptor contamination– Paddle-hybrid assembly (manageable)

23-Aug-2005 VELO Production UCD VELO Module Production at Liverpool T. Bowcock.

Documents

velo production ucd

velo production ucd

velo production ucd

velo production ucd

velo production ucd

velo production ucd

production order slide

production mode