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IBL Loading Activity Overview

IBL Loading Activity Overview. Franck, Maarten, Coralie , Didier. Loading tool workshop. University of Geneva, Aug 31 st 2011. Design and production flow towards the detector commissioning . Design. Design check with FEA. Thermal stave today. Prototyping.

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IBL Loading Activity Overview

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  1. IBL Loading Activity Overview Franck, Maarten, Coralie, Didier Loading tool workshop University of Geneva, Aug 31st 2011

  2. Design and production flow towards the detector commissioning Design Design check with FEA Thermal stave today Prototyping Thermal stave – Thermo-mechanical Stave -1 – System tests Validation of the design Pre-series production & QA Stave 0 (January 2012) Production readiness April 2012 (originally Feb) Production & QA Integration Commissioning 2

  3. Simplified skeleton of the production workflow up the IBL commissioning Flex prod & QA Stave prod & QA Module prod & QA Pigtail prod & QA Wing folding/gluing & QA Stave + flex gluing & QA Module frame prod & QA Loading + wing gluing + wire bonding & QA Targeting activities @ UniGe Need to define the requirements and specs for each of the working steps & Need to define the QA tests Extensive loaded stave QA Pipe extension & QA Activities @ SR1 Integration of the stave to the beam pipe Essential to have a good communication for the work preparation & during production Commissioning tests 3

  4. Loading and QA activities during/after Loading Module assembly site(s) Stave & flex circuit assembly site(s) QA done QA done Shipment Transport Shipment Transport Visual inspection, electrical tests Visual inspection, leak tests, metrology of references Reception tests Loading Electrical test?  Wing gluing Rework? What type?  Wire bonding Rework? Pull test?  Baseline: 1.3m long stave for loading and QA at UniGe Rework? Electrical integrity at PP0 Is it required? Thermal cycling  Metrology survey Rework? Electrical tests and QA Storage Shipping to SR1 4

  5. What tests for the various staves and what QA for the production? - Wuppertal stave loaded with Si-heaters: Two are targeted Test to be performed: Thermal tests, Thermo-mechanical tests, Thermal shocks Steered by the Stave WG by Eric and Ole Design validation - CERN stave loaded with Si-heaters: Max 7 are targeted Test to be performed: Thermal tests  integration to mock-up and full thermal tests Steered by Andrea and Francois-Xavier • Wuppertal stave with Cu-flex loaded with digital modules: Stave-1 targeted • Will there be mix with real modules? 3D modules? Design validation Test to be performed: Mainly electrical tests Steered by Tobias, CERN, UniGe, all • Wuppertal stave with final flex loaded with real modules: 1 targeted before the production starts • This is called stave0 Leaning for production • This stave should allow us to tune-up the production workflow and all the QA tests • If the stave survive all this leaning curve it could even be used • Steered by UniGe for Loading and QA related activities 5

  6. Urgent for stave -1 with digital modules • Sliding rule to open the wings and to be interfaced with the cradle jig v-1 • Stress relieve for wing opening to retract during loading • Interface for wire bonding • PP0 support to be interfaced to the handling frame v-1 • Handling frame cover to be interfaced and stopped with the 1m long frame • Handling frame extender with strain relieve for pipe and cables connected at PP0 • NB: • Urgent to define what is stave -1 (how many modules and which flex?) • Stress relieve to be defined according to cable to be used…

  7. Handling Frame v0

  8. Cable Saver HV Peek Insulation T bar

  9. Loading Jigs

  10. Guillotine Metrology Wire bonding Pull Tester Envelope checking jig

  11. Other tooling not directly related to Loading

  12. Time estimation during production Total time (Serial): 9 – 12 working days Reasonable to assume 10 wd or 2weeks but when parallelizing can we target 1w/stave?

  13. Projection during Loading Production Proposal for the loading program : 1) A Minimum of 1 stave 0 with tooling v0 is an absolute requirement for: - Validating all the loading jigs - Validating all the QA procedures - Allow to spare some time for tuning-up and improve stave loading quality The first ~4 real staves will be produced serially. Only when the previous is fully QA and OK that the next can start If no problem with this pre-series the next ~15 staves will be done with optimal speed which is targeted to 1 stave/week Very preliminary • NB: • Stave0: Final stave (only FE will be different from the final design) • At step 2) only module with FEI4b will be used. Start date will depend upon the 1st module delivery from module production sites: Bonn & Genova

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