Status of the Tracker Outer Barrel Joe Incandela
Status of the Tracker Outer Barrel Joe Incandela University of California Santa Barbara for the US and CERN Tracker Groups Comprehensive Review June 28, 2005
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 2 Covered in this talk • Past year: • Overcame problems with hybrids and sensors • Adapted to a shorter production schedule • US production lines were reworked to be as robust as possible • Upgraded US production capacity by factor of 3 original plans • Recent Milestones • Good module components are flowing • Frames and sensors are well off critical path • Hybrids still pace production but rates will rise • US module production has ramped to ~65% of peak • Quality is close to what we anticipated and improving. • Mechanics and integration preparations proceeding well at CERN • Current issue: Rods • Rod component procurements and assembly nearing completion • Seeing potentially serious problems with rods (as we expected) that must be dealt with now despite potential schedule disruptions. • I will summarize US activity followed by CERN
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 3 US Tracker Group • Brown University • R. Hooper, G. Landsberg, H. D. Nguyen, C. Pehlevan, T. Hartman, H. Y. Jung • University of California, Riverside (UCR) • G. Hanson, H. Liu, G. Y. Jeng, G. Pasztor, A. Satpathy, R. Stringer • University of California, Santa Barbara (UCSB) • A. Affolder, S. Burke, C. Campagnari, F. Garberson, D. Hale, J. Incandela, Jaditz, P. Kalavase, S. Kyre, J. Lamb, D. Stuart, D. White + technicians S. • University of Illinois, Chicago (UIC) • E. Chabalina, C. Gerber, L. Nigra, T. Ten • Fermilab (FNAL) • S. Cihangir, M. Demarteau, D. Glenzinski, H. Jensen, A. Ronzhin, J. Spalding, Spiegel, S. Tkaczyk + technicians L. • University of Kansas (KU) • P. Baringer, A. Bean, L. Christofek, D. Coppage • Mexican Consortium: • Cinvestav: H. Castilla, R. Perez, A. Sanchez • Puebla: E. Medel, H. Salazar • San Luis Potosi: A. Morelos • University of Rochester (UR) • R. Demina, R. Eusebi, Yu. Gotra, E. Halkiadakis, S. Korjenevski, S. Lockwood Miner, P. Tipton + technicians D.
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 4 US Module Assembly Plates 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 5 15 7 3 3 5 3 If add R 7 at FNAL 15 7 3 3 5 8 5 36 41 We are now setup to process at most 20 plates (60 modules) per 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.
Wire bond 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, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 5 US Production Cycle
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 6 US Production Steps/Status 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
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 7 TE C S R 5 R 7 C TOB r-phi TEC R 6 R TEC 5 P TE Modules Assembled in the US TOB stereo
UCSB TEC Production Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 8 • Module Production • R 5 N, R 5 S, R 6 and R 7 • Designed built commissioned: Assembly plates, wirebond fixtures, carrier plates, shipping boxes • All TEC production equipment is commissioned except for R 7. • General capacity issues • Could saturate our production capacity with TEC production (30/d) • 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 capacity limit is ~100 per week but could eventually be mostly TEC if necessary (since TOB burn-in will be shifted to rods) or it will have to be sampled
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 9 US Components Inventory Hybrids FNAL ST HP Sensors UCSB IT ST HP FNAL IT ST HP Frames UCSB IT ST HP FNAL UCSB 247+ 249 759 IT 197 482 - 276 357 - 609+ 251 47 272 113 - 159 204 - 859 - 18 496 - 70 4 - 18 496 - 77 1 48 - 0 170 - 229 - 0 262 - 255 4 chip 56 0 - 85 9 L 56 pu 0 41 108 0 163 R 5 p 0 5 R 5 s 6 R 6 0 R 7 0 - As of 6/27/05: Plenty of sensors and frames on hand Hybrids are the critical path components
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 10 Quality assurance program at University of Rochester Ø Total number of sensors received 2351 since October 2004 (only OB 1 and OB 2 HPK silicon microstrip detectors) Ø Corresponds to 89 production batches Ø All batches are qualified for production 254 sensors(*) have been fully tested 4 Rejected – damaged during shipment * Last shipment of 532 sensors is being tested. As of 6/14/05
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 11 US Module Assembly
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 12 US Module Assembly Grade 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 A 11 0 0 0 484 1109 83 75 111 34 B 1 0 0 0 13 30 2 1 9 7 F 0 0 0 13 0 2 0 1 % Passing 100. 0% 0. 00% 100. 00% 98. 9% 100. 00% 97. 4% 100. 00% 97. 6% Total 1907 63 16 99. 2% (All quantities are up to June 24 th 2005)
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 13 Sensor-to-sensor-alignment Metrology
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 14 Sensor-to-sensor-alignment Metrology UCSB FNAL s ~ 7 -8 mm Specification is 30 m (i. e. range shown on x axis)
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 15 US Hybrid Testing
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 16 US Hybrid Testing Recovered 11 hybrids this week Approaching 99% yield
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 17 ARCS Testing Results
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 18 UCSB ARCS Testing Results • UCSB 1016 Tested • 1006 Grade A • 3 Grade B • 7 Grade F • Past 2 weeks: 17 bad out of 56, 196 channels (0. 030%) • Total UCSB Production: 322 bad strips in 698624 (0. 046%)
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 19 US ARCS Testing Status US capacity is 300 modules per week. Have slowed in most recent week due to shortage of hybrids at FNAL and commissioning of R 7 production at UCSB
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 20 US LT Testing Status
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 21 US LT Testing Status US Capacity is 200 per week
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 22 US module production (to June 10) US will build >8, 000 modules US peak Capacity ~250 -300 modules per week. One week peak so far = 185
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 23 Further Planning • US will help accelerate TEC schedule • R 7 production at FNAL in Autumn at 12 -15 modules per day. • Plate design were transferred from UCSB for FNAL modifications. FNAL will fabricate and commission the plates. • UCSB making additional wirebond fixtures, shipping boxes • UCSB will also transfer all programs related to testing. • FNAL will manufacture carrier plates, LT test plates etc. • Second hybrid line • UCSB overseeing hybrid assembly at Amtech (GS substrates) • Initial results are comparable to HSA. • New tooling has been ordered to improve bonding. • Expect to be ready for 200/wk production in mid-July • Riverside repair and diagnostics center • nearly online
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 24 Diagnostic Facility at UC Riverside • ARC Test • Test stand is operational • Able to reproduce problems found at production sites • Long Term Test • All hardware components (except TPO) are in hand • Debugging test stand • Will be operational shortly • Other capabilities • Optical inspection and probe station
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 25 Rods Overview • Basic components procured • Assembly of frames is nearing completion • Integration of modules on rods is understood • Rate of ≳ 8/d in the US should not be a problem … • Testing has been problematic • US rod production was halted • Persistent I 2 C communication errors seen on 30 -50% of rods • Recent and very substantial effort to understand remedy • Communication is marginal • Simple solutions exist but we are not sure how robust • A better solution probably requires some redesign • Secondary issues of header errors and failures in LT tests are also under study • Header errors were also observed at CERN recently while operating rods in the Cosmic Rack for long periods, but it may not be the same effect as seen in the US…
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 26 Tests of I 2 C errors • Guido Magazzu & Wim Beaumont • Visited FNAL then UCSB May 30 to June 7 • Many studies performed. Most, but not all, mysteries resolved. • Full Report is available http: //hep. ucsb. edu/cms/rod/I 2 c_230_investigation_v. 1. 2. doc • Problem: different RC time constants on the I 2 C clock lines (to hybrid and optohybrid) • Causes transitions to occur at non-ideal relative times • Margin we have to play with is less than ~7 ns • Can be made more robust by adding a rad-hard buffer on each hybrid line. • Work is underway
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 27 Tests at UCSB Most of the proposed solutions worked in Tests at UCSB Rod Mod Errors 192 jumper no i 2 c errors (warm, cold cycle) (some header errors) 361 R=820 ohm no errors (warm, cold cycle) 498 R=0 single PS no errors (warm, cold cycle) noise OK 20 R=3 k. Ohm error "23" in Wim's i 2 ctest. sh Situation at FNAL is less clear – under investigation
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 28 Current planning • Restarted rod production • Each of UCSB and FNAL will modify 6 Layer#6 rods by adding a jumper across optical and readout hybrid I 2 C lines. • Then they will go through an extended LT test. • We will follow with 4 more groups of 6 rods each site and ship 60 rods to CERN for integration exercises • In parallel: a redesign of ICC card • If the first 60 rods shipped to CERN are reasonably error free, we will continue rod production to complete one complete end of Layer 6 • Further rod production will await new ICC card • Will also refit the already completed Layer 6 rods when cards are available • This plan allows us to get more experience with large number of rods in various situations. Should help us uncover any further residual problems.
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 29 Frame production in Helsinki • Rod frame production in Helsinki complete. • 753 good frame produced compared to 760 possible and 688 needed in TOB (target was > 723, i. e. > 5% spares) • Geometry of each frame is checked • The positions and orientations of the 12 module positioning pins relative to the frame, as defined by the rod support spheres, are the most critical dimensions. • Data goes into the production database • Translated to precision in module positioning, RMS = 40 microns - excellent result
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 30 Rod cabling at CERN • Discovered end of March: Example of a dirty board • Microscopic solder residues on 2 (out of 3) types of PCBs • Potential source of corrosion in the presence of humidity • Restarted assembly after re-cleaning ~60% of rods are now cabled • Continuing smoothly • 100% yield with experienced technicians • Rate > 5 rods per day Before After
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 31 TOB wheel construction: complete • Mechanics complete and rotated into final position • Precision elements of disks and cylinders glued on a single jig yielding typically 30 m relative precision • Relative positioning of disks and cylinders limited only by measurement system precision ( 100 m) • A major achievement by Antti Onnela and the DT 2 technical crew!
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 32 Wheel ready Wheel on assembly chariot Wheel ready for insertion in the tracker support tube and… The tube with thermal screen are already in the assembly clean room. Thermal screen operational
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 33 Ongoing work on mechanics • Installation of TIB support rails now a high priority • Production of cooling manifolds • Production and installation of services support elements • (first on mock-up: a combined TOB/TIB cabling test next month)
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 34 Rod reception @ CERN • Box: 3 -rod capacity, dry air line • T/RH probes interlocked to PS • Mobile source + scintillator • DAQ (XDAQ + RCMS) ready • migrating to new OS • Scenario with automatic scan of all sensors finalized • 1/2 day @ room temperature • includes control of HV power supply • Scan of rod label DAQ configured from DB • Up-loading results to DB still to be defined “XY table” test setup Located in “rod clean tent” There is sufficient storage facilities available to house production rods before/after acceptance test source on moving arms Scintillator moving with source
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 35 TOB integration • TOB integration is done by cooling segments • One cooling segment = 8 to 22 rods fed by the same manifold, that serves as common ground (the TOB cooling system has soldered joints) • Several preparation tasks - on auxiliary workbenches • • clean rod cooling pipe and leak test prepare and register optical ribbons pre-cable rod with optical ribbons select, test and register power cable • In addition: • Production and testing of the 88 cooling manifolds • Production and validation of all Digital Optohybrid Modules (92 in the TOB)
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 36 Preparation work - status • DOHM production • 5 prototypes successfully produced • Assembly and testing procedure defined • Cleaning and leak-checking of pipes • Fixtures ready • Sophisticated He leak detection system commissioned • TK assembly room plumbing ready • Rod pre-cabling with optical ribbons • Fixtures ready • Connection scheme defined, ribbons prepared • Rod insertion • Sophisticated tool commissioned long ago
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 37 Preparation work - status • Cable production • Acceptance test and labeling scheme defined • Now finalizing all lengths (nearly done) • Manifold production • Procedure defined and tested • Connection points along manifolds finalized • Cooling loop integration procedure has been defined • Current plan relies upon ability to operate ctrl ring with FE off • May need to be modified depending on choice of solution to the I 2 C problem – but, hopefully not. • Test setup for cooling segment test • Power supplies received, cables being modified. • Still missing FEDs and trigger system.
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 38 Special case: layer TOB 6 • Due to small clearance to support tube • Layer 6 - integrated with wheel outside support tube • Test with incomplete plumbing and temporary power cables • Then, finally can Insert TOB in support tube • Then we will run at operating temperature • Complete and leak check all plumbing • Complete cabling and test functionality
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 39 Regarding Schedule • Priorities • It is of primary importance to install a tracker that will perform well for the duration that it is needed. “There is no reward for the on-time delivery of a detector that does not work” – H. Frisch • I 2 C problem and consequent delays • It is important to note that ALL integration and commissioning tasks are faster and more reliable if the problems that we encounter are immediately treated. • A well considered solution to the I 2 C problem will save more time than it costs in the long run. • Recovering lost time • We will likely have to revisit the planning and adapt somewhat to the situation at hand in order to recover delays where possible. • e. g. The US is preparing to build up a substantial, well experienced integration team that could complement the CERN team and help advance the schedule • In the past, we have run 24 hour shifts, 7 days per week for up to several months when necessary in the US…
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 40 Summary • US production lines have completed 25% of TOB • >99% yield and >99. 95% good channels • Production rates of 40 -50 modules/day and ≳ 8 rods/day can be achieved, provided that we have adequate parts flow and stable multi-rod qualification testing • Rod frames production in Helsinki is complete • I 2 C communication problem is understood • Rod integration and testing has restarted in the US • TOB Wheel is basically ready • Integration should start soon • Large capable team at CERN • US to send large team as soon as all production is stabilized
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 41 Conclusions • Excellent progress • In module production • Preparation of mechanics for final assembly • Excellent progress • In understanding the small residual problems we are now encountering • Not only will we solve them, but in doing a proper job of addressing them we will be able to install a better understood and more reliable detector. • We will recover schedule • We plan a substantial influx of experienced personnel to CERN • The new integration center will provide an excellent working environment and the 25% test system will provide a major step in preparing the tracker for physics as soon as possible after the LHC turns on. • We are very optimistic that the TOB will meet all requirements!
Additional Slides
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 43 Module Testing Flowchart Modules Enter Bonded, Untested Modules Shelf Repairs Bad Thermal Cycle, Needs Retest Shelf TEC Thermal Cycled Ready For Shipping Shelf If Failed TEC or TOB? LT Testing Needs Repair Shelf in Bonding Room Yes If Passed ARCS Testing Repaired Modules Shelf Chosen for LT Test? Can We Fix It? No If Failed No Yes Is the Problem Understood? Failed Modules Shelf TOB Yes Good ARCS Tested Modules Shelf No Undiagnosed Modules Shelf If Passed TOB Thermal Cycled Ready For Rod Assembly TEC or TOB? TEC Not Thermal Cycled Ready For Shipping Shelf TOB Not Thermal Cycled Ready For Rod Assembly
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 44 Present Electrical circuit FE-Hybrid 82 W Parasitic on FE Hybrid CH SCL SDA CH > C A AOH 82 W Parasitic on AOH CA
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 45 (Main) Solutions under investigation • R=82 Ohms R=0 Ohms • As implication for power-on sequence. • Would need to power-on control and F. E. at the same time • Most robust from I 2 C stand point • Tune of the R to equalize RC • R to AOH ~ 820 ohm • Jumper across resistance • Forces same RC
Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 46 Solution 6 FE-Hybrid 82 W Parasitic on FE Hybrid CH SCL SDA AOH 82 W PSU Control before FE Parasitic on AOH CA
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