Status of the Tracker Outer Barrel J Incandela
Status of the Tracker Outer Barrel J. Incandela University of California Santa Barbara for the illustrious TOB Group Tracker General Meeting October 26, 2005 Slides courtesy of D. Abbaneo, A. Affolder, P. Baht, C. Campagnari, Y. Gotra, J. Lamb, S. Kyre, A. Onnela, A. Satpathy, L. Shabalina, J. Spalding, L. Spiegel, D. White, and others…
US Module Assembly Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 2 Past Week L 12 pu L 12 pd L 12 su L 12 sd L 34 p L 56 p R 5 N R 5 S R 6 R 7 Total A 23 0 31 0 0 15 0 0 39 45 153 B 1 0 0 0 0 2 Cumulative F 0 0 1 0 0 0 0 1 A 190 285 123 60 799 1367 177 195 297 162 3667 B 7 6 12 15 23 35 6 8 13 14 139 F 2 5 9 3 5 16 1 5 1 2 49 % A or B 99. 0% 98. 3% 93. 8% 96. 4% 99. 4% 98. 9% 99. 4% 97. 6% 99. 7% 98. 9% 98. 7% • Current inventory of components sufficient for > 2 -3 weeks production • 1. 3% F grade modules are mostly very near to spec. (usually the angle between sensors exceeds spec slightly)
Module Assembly Planning Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 3 • FNAL: • Last week increased to 15 TOB modules/day. • Storage capacity is very tight • Summary tables can be viewed at http: //cmsdb. fnal. gov. • November: ramp to 18 TOB modules/day. • Goal: Finish TOB modules end of January • Need to understand quantity of spares to be built. • Then: Transition to TEC R 7 • Rod assembly will continue through April. • UCSB • Last week 18 modules/day • This week 21 modules/day • Also to do: bias connections on some 1, 400 modules. • Wire bonding and ARCS operations (but not LT).
FNAL Plans for TEC Production Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 4 • FNAL preparing to build ~700 TEC R 7 modules • Beginning early next year. • The UCSB R 7 Gantry assembly plate design has been modified for use on the FNAL Gantry • expect first of 6 assembly plates by end of year. • Other fixtures and plates – for hybrid testing, hybrid and module bonding, storage and shipping – will be constructed from existing designs. • Once established, production will take about 10 weeks. • FNAL plans closer contact with the TEC community. • At some point it would be helpful to receive some non-qualified or spare sensors, hybrids, and frames for R 7 modules.
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 5 Module Bias Connections • Solder gold-kapton extension tabs to unused vias on TOB frames. • Glued down with TRD 1100 (Ag Epoxy following (during) Gantry assembly at FNAL (UCSB) • Then wirebond to backplanes (15 bonds per sensor) • Bonds encapsulated with Sylgard 186 • The application of silver epoxy (single drop) and scratching of sensor backplanes as part of the traditional Gantry assembly is unchanged.
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 6 Existing Module Bias Connections • Plan to use an insulated wire for some already fabricated modules. • Wire is connected to a gold-kapton tab that spans the two sensors. • Some 1400 modules may require this modification • FNAL expanding work force to retrofit 24 modules/day.
Bias bond encapsulation • For the detailed procedure see: Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 7 http: //hep. ucsb. edu/cms_procedures/tec-encapsulation-procedure. pdf • For the drawings of UCSB designed tools see: http: //hep. ucsb. edu/cms/mechanical. html • A talk describing the procedures is available from the bonding working group agenda this week, .
US Module Storage Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 8 • Delays in rod and pedal assembly have made module storage a critical issue and UCSB and FNAL. • TEC modules: • 4 more boxes are being built at UCSB to help alleviate the problem. (~20 are available for shipping currently) • It is critical that boxes received in Europe are unloaded and returned to UCSB. • TOB modules: ~2800 modules currently in storage at UCSB and FNAL • New storage capacity for roughly 1000 more by the end of the month. • This includes building module storage plates. (Recently built 1300). More may have to be fabricated.
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 9 US Hybrid Testing Status
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 10 Hybrid Testing • Both sites now have a fast PC working, run time is shortened by another 10 minutes. • FNAL Tested/Thermal cycled 171 hybrids this week…A US Record • With present conditions we can test 44 4 hybrids a day. • Best day was 10/21 with 48 hybrids tested.
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 11 US ARCS Testing Status
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 12 UCSB ARCS Testing Results
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 13 US ARCS Testing Status
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 14 US ARCS Testing Status
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 15 US ARCS Testing Status
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 16 US ARCS Backplane Testing
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 17 US LT Testing
Riverside Repair Center Work Done • Test modules with fully functional ARCS and LT test stand • Visually check modules with shorts / pinholes etc. Work in Progress • Sometimes I 2 C FEC error occurs during LT run - possibly due to inadequate shielding of the cables. To be sorted out soon • Developing a probe station that can troubleshoot bad hybrids at low Temps Future plans • Received some bad modules/hybrids from Fermilab & UCSB to test and understand problems. Troubleshooting them now.
Rod Status - UCSB and FNAL Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 19 • In the past couple of weeks, while waiting for ICC cards to start production, the two sites have focused on slightly different issues • FNAL: testing of new SW (FEC V 3, Scientific Linux, Lt V 30) • UCSB: production exercise to shake down remaining operational issues • Fine-tuned scenario to match 4 rods/day rate • Freezer takes max 8 SS 4, 6 SS 6, 4 DS need one day scenario (so much for long term ) • Only two thermal cycles W C W • Cal. Prof. Runs only with inverter-on to save time • Added HV cycling at each temperature • This is not working reliably, may have to ditch
General • 4 sets (2/site) of OFECs in transit from CERN Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 20 • FNAL will "commission" this system first; UCSB will follow when it works • First batch of ICC cards for 25 rods also in transit • ½ FNAL, ½ UCSB • Will mount on existing rods, then put modules on rods, then test, then ship. ASAP
FNAL Status (1) Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 21 • Over 30 production scenarios run on MRT since July 2005 • 50 SS 6 rods and four DS 4 rods were assembled (using jumpers on pre-production ICC cards), tested and burned-in • Migration of rod test software running on Red Hat Linux 7. 3 with FEC Software V 1 to Scientific Linux 3. 0. 5 with FEC software V 3 was successful • Long term testing with latest release of the FEC Software showed good stability of software and the control ring (1 upload/download error in 24 hours with 4 DS 4 rods) • Latest release of the Lt. Struct (v 30) was extensively tested with a number of production scenarios with Single Sided and Double Sided rods
FNAL Status (2) Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 22 • First batch of 12 new (production grade) ICC cards were shipped from CERN to FNAL and are expected to arrive this week • Plan for assembling of the first 12 production rods has been prepared • Optical FECs are expected to arrive this week. Test stands will be upgraded and tested with new hardware while the first production rods are assembled • We will need new rod frames to arrive not later than the second shipment of production ICC cards
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 23 UCSB Production Exercise: Mechanical • • Built 24 rods last week (22 SS 6, 2 DS) Warmup 1 st two days, then built 4 rods/day Bottom line: OK Some Issues: • Dirty rod boxes, Al dust • Will tape lips of boxes with kapton tape, avoid friction, dust • All boxes will be in plastic sleeve for shipping • Need to understand desiccants • Tail bending a la FNAL: OK. • ICC cards swap: adds 20 -30 minutes/rod • DS rods: worry about exposed non-encapsulated bonds • Now designing a cover with cutouts for ICC cards. Will enable handling of connectors and cables with minimal risk of smashing bonds
UCSB Production Exercise: Testing Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 24 • 20/24 rods through SRT • Mounted some modules with known pinholes • Flagged them without a problem • 1 st MRT scenario OK, 2 nd failed • Failure in newly introduced HV cycle. • CAEN got stuck. Not a new problem. • A couple of laser failures (? ) – Very worrisome… • Some noise oddities to be investigated • Some ICC/header errors. • Hopefully will be better with new SW, new OFEC • (Almost) successful 1 st upload of rod XML file to DB • Need some small name changes
UCSB Production Exercise: Short Term Plans Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 25 • Stop making rods • We learned what we needed to learn • Continue exercising testing cycle
TOB Integration Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 26 • Procedure being tested with pilot cooling segment • • Rod insertion: ~30 -60 min x N rods Functional test per control loop [could be dropped at some point? ] Solder cooling connections per rod: ~30 -60 min x N rods He leak test per cooling loop Dress cables, Dbase entries etc…: ~30 -60 min x N rods DAQ test per control loop Initially: N = 1 cooling segment. Once confident: N = 1 layer. • Organization • • Ramp up to 7 -day 24 -hour operation Two 3 -person tech shifts per day (3 crews of 3 for 7 -day coverage) Two testing crews covering night shifts 1 st Tech crew now in place, 2 nd one identified for Dec, will need 3 rd in Jan • Once operation is smooth may be able to add 1 tech per crew and work on both ends of TOB • Schedule: Ramp up Dec+Jan, complete by May • estimate should improve after experience with pilot segment
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 27 TOB Cooling Segments
Pilot Integration Test • Purpose Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 28 • Primary: Test the procedures and fixtures, and guide any improvements • Secondary: Confirm staffing plan and improve schedule estimate • Plan • Use Rods with old IC cards • Install and test 19 rods in the top segment of layer 6 • Remove them again (confirm our ability to replace rods after insertion) • Status • All 19 rods have been inserted (17 by technician crew) • A first round of tweaks were made to the fixturing, further improvements to aid efficiency are under discussion • A test of soldering the cooling line connections using a single rod was successful • Next steps are to connect and test the cooling for the 19 rods this week, and to start electrical testing next week • Expect to be ready to start integration with final rods by end Nov • Need to design/build the work platform for installation of layers 1 -5 inside TST – platform is not trivial, will be needed by January
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 29 Fixture Installing A Rod in Side Position
Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 30 Installing At the Top
Summary & Conclusions • Module production back to high levels. Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 31 • Should complete TOB by February • Rod Production a little dicey still • Have learned numerous critical lessons • Need more experience – will get it very soon • Integration studies underway • Again, many important lessons learned • Generally things appear to be in good shape • Establishing additional qualified manpower will be critical to schedule and quality • These are very critical times • Must maintain high standards and not drop our guards
Tracker Monitoring Workshop • Jointly @ Fermilab and CERN via video Ø Organizers: Lisa Shabalina (U. Illinois at Chicago), Pushpa Bhat (FNAL), Slawek Tkaczyk (currently at CERN) • Tentative Date/Time: Ø Tuesday, Nov. 15, 2005 Ø 8 AM – 12: 30 PM (Fermilab); 3 -7: 30 PM(CERN) • Venue@Fermilab: Sunrise room, WH 11 • Venue@CERN: 40 -5 -A 01 in Bldg. 40 • Preliminary Agenda: Ø Ø 2 -3 talks on CDF/DØ experience 1 talk on CMS Tracker integration/commissioning 2 Talks -- x. DAQ, DQM and visualization tools 1 talk on HCAL remote data analysis/monitoring US CMS Si. Tracker Meeting
Tracker Monitoring Workshop • Goals: Ø To find out what CDF and DØ learned during commissioning/tests of 800 k channel silicon detectors for Run 2; what tools worked, what wasn’t useful, what would have helped Ø What x. DAQ, DQM software and tools exist for CMS tracker monitoring? Ø The focus of this workshop is on tools for integration and commissioning of the tracker - to figure out how to help those efforts using existing tools and/or by developing dedicated tools and with remote monitoring/analysis. Pushpa and Lisa will produce a written summary/outcome of the workshop US CMS Si. Tracker Meeting
Additional Information
US Module Assembly Plates Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 35 Now in use Plate Types UCSB FNAL TOB R-phi TOB Stereo TEC R 5 R-phi R 5 Stereo TEC R 6 TEC R 7 7 3 3 3 5 3 8 4 Totals 24 12 proposed UCSB Totals FNAL Actual 6 15 7 3 3 5 3 If add R 7 at FNAL 15 7 3 3 5 9 6 36 42 We are now setup to process at most 15 plates (20 plates) per day (extended day). A much larger number of plates was prepared to allow us to adapt to whatever variations may occur in component deliveries and tracker needs.
US Production Cycle Quick test hybrids on ARC Final pinhole test on ARC Assemble rods from modules Thermal cycle hybrids Thermal cycled module Rod burn-in Gantry makes modules. Modules test on ARC Rods shipped to CERN Wire bond Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 36 Wire bond
US Production Steps/Status Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 37 Task Capacity Manpower issues Software Issues? Hardware Issues? Hybrid Bonding & 84/d Thermal Cycle Module Assembly 50/d Module Bonding >50/d None No No ARC Testing LT Testing ARC LED Reinforcing Rod Assembly Single rod test Multi rod test None None No No No Yes >50/d 200/wk >50/d 8/d >32/wk DAQ Component shortages and/or failures can limit production testing capacity in future
UCSB TEC Production Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 38 • Module Production • R 5 N, R 5 S, R 6 and R 7 • All TEC production equipment is commissioned • General capacity issues • Can (and likely will) saturate our capacity with TEC production • Actual rate depends on need and availability of parts as well as TOB production parts availability and schedule • Bonding and Testing capacity adequate • LT testing : eventually be mostly TEC if necessary (since TOB burn-in will be shifted to rods) AND sampled
Multi Rod Test-stand (MRT) Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 39 FNAL (Semi) long term test ~ 2 days 6 -8 SS rods/load Thermal cycle Full channel level characterization UCSB
Current MRT test cycle Tracker Outer Barrel- October 26, 2005 – Tracker General Meeting slide 40 Warm Test Warm Expected to evolve… Cold Test Cold Warm Test Cold Test Warm
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