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FE hybrid assembly and quality assurance

FE hybrid assembly and quality assurance. “...resistance of hybrids is not futile…”. The hybrid team: Alan Honma, Michael Poettgens, Gabriella Pasztor, Bernd Reinhold, G.S. Bruno Wittmer CERN –EP Division. Assembly procedure @ CERN. Hybrid assembly test Test during thermal cycle(s). 1. 2.

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FE hybrid assembly and quality assurance

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  1. FE hybrid assembly andquality assurance “...resistanceof hybridsisnotfutile…” The hybrid team: Alan Honma, Michael Poettgens, Gabriella Pasztor, Bernd Reinhold, G.S. Bruno Wittmer CERN –EP Division G.Sguazzoni

  2. Assembly procedure @ CERN • Hybrid assembly test • Test during thermal cycle(s) 1 2 • Bare Hybrid (no Pitch Adapter) • Reception test • Pitch Adapter (PA) gluing at the gantry • (PA bonding) 3 G.Sguazzoni

  3. Hybrid reception ‘fast’ test • Check that no damage occurred during shipping • Fast ARC test FHIT like • will be replaced by FHIT G.Sguazzoni

  4. Gantry PA assembly • First 50 TOB hybrids glued @ the gantry… all good!!! • Hyb+PA • TOB: 16/plate • Gantry time  1h • Curing  8h • Spacer+PA • TOB: 64/plate • Gantry  30min • Curing  8h • Typical requested throughput • 52 hyb/day • Handling and preparation is a limiting factor G.Sguazzoni

  5. Hybrid assembly results (Dx2, Dy2) • RMSs (in mm) indicate assembly precision within bonding requirements • All hybrids have been bonded successfully!!! • stability as the glue cures checked and fine!!! ~14 ~11 50 50 Dx1 Dx2 ~43 ~42 Dy2 Dy1 50 50 (Dx1, Dy1) G.Sguazzoni

  6. Post PA assembly tests • ...to insure that: • the hybrid is still alive after many operations • the PA bonds are OK • no opens, no shorts! • the hybrid+PA survives… • …a cooling cycle (TROOM –20oC TROOM) • …multiple (~10) thermal cycles (to emulate CMS shutdowns) • We need a nice test setup!!! Sample test!!! G.Sguazzoni

  7. The nice test setup • Located in the new CERN Gantry Clean ROOM Status screens TestBox Electronics Water leak detector Water/Gas management Chair G.Sguazzoni

  8. Test setup block diagram G.Sguazzoni

  9. Test Box • 4 hybrid slots • standard/stereo • N2/dry air flushed • temperature sensors • humidity sensors • Cooling/Heating: • 300W Peltier element (24V-14A) • TLOWEST ~ -25oC with max load (4 running hybrids) hybrid on the test plate G.Sguazzoni

  10. Readout & GUI • ARCbased readout • automatic cycling/testing of all loaded hybrids • TCP/UDPcommunication with slow control application • Ready soon: • DB compliant output • “One-button” test G.Sguazzoni

  11. Slow control: hardware • Aachen Cooli box • m-controller • RS232 interface • Peltier driving • Temperature/Humidity sensor readout • safety interlocks • ...custom patched for: • gas/water flow meter • NIM-TTL pulser driving G.Sguazzoni

  12. Safety Temperature monitor Temperature regulation Humidity monitor TCP UDP Peltier current Slow control: software Custom version of Aachen Cooli Devive Controller – ACDC (LabVIEW) Water & gas flow G.Sguazzoni

  13. Post PA assembly tests • Typical test sequence during a cooling cycle • Hybrid ON* • Ped, Noi • Pulser • Short Detection • Hybrid OFF* TROOM  –20oC ~25 min/4 hybrids *Added after problem with hybrid in cold (see later) G.Sguazzoni

  14. Long term cycles ~5 hours/4 hybrids • Sample test!!! • emulates ~10 CMS running-shutdown periods • Each cycle  same tests as the single cycle… TROOM  –20oC • last cycle: stronger! (TROOM –25oC  +35oC) G.Sguazzoni

  15. PA line ARC FE adaper Hybrid GND plane Hybrid Al support plate Hybrid • GND lines connected to the support plate by a wide copper strip ARC FE Noise issues for hybrid+PA • No reference plane below PA • PA is a weak point wrt noise injection ampli channel G.Sguazzoni

  16. Noise comparison • Grounding scheme comparison BAD grounding PA lines length structure NEW grounding G.Sguazzoni

  17. Short detection • 1 SHORT = 2 channels lost G.Sguazzoni

  18. Short detection principle • Calibration signal is sent every 4 channels • PIN HOLE like effect may also contribute IN OUT ch. #N CAL signal ch. #N+1 G.Sguazzoni

  19. Short detection • Simple and effective threshold criterium Pulse shape SHORTs Pulse heights G.Sguazzoni

  20. The first (detected) short! • Short = bonding problem PA APV G.Sguazzoni

  21. Open detection • OPEN = 1 channel lost G.Sguazzoni

  22. Pulser hardware NIM pulser NIM to TTL start trigger ARC 50W “antenna” very close (~1mm) to the bond pads out OPENS • Pulser ON • Peak Mode • Optimal latency Peak - InvOFF G.Sguazzoni

  23. Open detection: basics Removed Hybrid-PA bonds or scratch on PA lines*  Spikes in the pedestal profile!!! *even quite close to the bonding pads On-board CM subtraction  Pedestal ~unchanged G.Sguazzoni

  24. The open-detection criteria • Optimal to detect isolated opens Difference wrt neighbours OPENS in our test hybrid Mean Subtracted Pedestal G.Sguazzoni

  25. The TOB outcome so far… • 78 received • Reception TEST • 72/74 good; 2 not OK • 11  FNAL & 5  UCSB • 2  ‘ TEC1.1 ’  Aachen • Assembled • 48/48 good • Bonded • 45/45 good • Thermal cycle test • Standard: 20/20 good • 20  FNAL; • Long term: 8/9 good, 1 fails in cold • 14846/14848 good bonds; 1 short, no opens G.Sguazzoni

  26. Pedestal Pedestal <Pedestal> <Pedestal> Pedestal • Large non-uniformities Max-Min APV wise Max-Min Pedestal Preliminary!!! APV wise • Pedestal cuts in module-test draft procedure ~ too tight G.Sguazzoni

  27. Noise <Noise> Hybrid+PA Noise • Normalized Noise cuts (20%) in module test draft procedure ROOM • Noise increases in cold • Peltier current? Noise Preliminary!!! -20oC G.Sguazzoni

  28. The faulty hybrid:i.e. the kind of nasty problems we are supposed to discover • The hybrid fails only @–200C • No APVs output but answers to I2C commands • other strange behaviors (current, DCU readings) • only a certain command sequence induces the failure; otherwise the hybrid works perfectly • Test procedure modified to foresee hybrid OFF/ON & initialization before any group of tests • First crude investigation: • No visible defect • MUX chip??? • …further study needed G.Sguazzoni

  29. Test Station throughput • Target: • Nominal: 32 hybrids/day • UCSB will take over TOB bonding and testing – they are duplicating the setup • 4 hybrids  40 min (preparation+test) • Limiting factors • Cooling time • Loading/Unloading • (40min/4hyb) * 32hyb ~ 5h • Effective production request could be higher… • A second “CERN” teststation is in preparation • (Cooling cycle test could be done on sample basis or dropped in case no problems are found) G.Sguazzoni

  30. Conclusion Hey folks, is there someone willing to test hybrids on a large scale?!?!… G.Sguazzoni

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