1

IBL Integration & Testing activities

University of Geneva: G.Barbier, F.Cadoux, A.Clark, D.Ferrère, C.Husi, M. Weber

Preliminary definition of Integration & Testing sequences

IBL meeting, CERN, the 31th of August 10

2

Integration & Test sequences

Brainstorming this morning dedicated to the Integration & Testing sequences…very useful to kick off these activities (first priorities, constraint definitions, …)

IBL meeting, CERN, the 31th of August 10

Baseline defined as follows:-STAVE considered with the max length…7m long! Even if we keep some backup solutions such as “post loading” OWelding, different STAVE design (see next slide)-1 central Jig per STAVE (starting from the bare STAVE up to its final integration)…about 1 meter long.-20 STAVES to be considered for the full prod…so 20 “central Jigs”!-All the Integration activities in SR1

SR1 area

08/31/10

Temporary fittings for loading and QC and then welding before integration

Z=0

Stave length for loading: 1.3 m

Ti-bushin

Option 2:

TIGFitting

Manifold

Z=0

3203203330 3330

Fitting

No fitting inside the ID envelope

TIGZ=0

320320 3330

Fitting

Stave length for loading: ~ 4.5m

Fitting

Baseline: Manifold

Starting with the Stave envelopeStarting with the Stave envelope

Ti-bushin

TIG

~1200

No cooling pipe in the stave until the integration with the beam pipeZ=0

Stave length for loading: 0.64m + Type0 cable ends

Option 3:

Preferable, but…Needs much more time to validate the process!

Official baseline for tooling

Sort of back up in case… DPNC will investigate

4

Steps Requirements (Seen from loading side) Support & specs from

Stave reception tests Visual inspection , Tape electrical tests, Pressure/Leak tests, Mechanical references (3D metrology)

Stave fabrication experts

Module reception tests Visual inspection & Electrical tests Module experts

Module loading Stave support on 3 points (as on the structure) + strain relief for the pipe at the 2 sides

Module loading

Electrical tests Should be done in the same position as in the previous step. Requirements?

Module experts

Wire bonding Stave tooling jig move on the bonding machine. Module loading

Metrology Stave tooling jig move on the CMM Module loading

Thermal cycling & Cold tests

Stave tooling jig move on the test place inside an insulating box for the full stave envelope.

System test

Storage up to the integration

Dedicate a safe area to store up to 15 staves All

1 central jig following the STAVE throughout the whole sequences …to be interfaced / several stands

Integration & Test sequences

5

Central Jig definition (3 fixations over the length like connection / IST)

Flex not shown

STAVE will be fixed onto the jig from the bottom (be careful / Flex)

IBL meeting, CERN, the 31th of August 10

Integration & Test sequences

Clear access from the top…

IDEA: get this end part (x2) longer(in order to locate a threaded hole for fixation onto the jig)

6

Wire bonding & Metrology processing @ SR1

Wire bonding Machine…simplified!

Extensions to release the

stress thru the stave (STAVE Cradle)

7m long

IBL meeting, CERN, the 31th of August 10

Integration & Test sequences

08/31/10

Stave Envelope versus Wire Bonding Machine H&K 810Stave Envelope versus Wire Bonding Machine H&K 810(located today at UniGe)(located today at UniGe)

7 m

08/31/10

Wire bonding area on the machineWire bonding area on the machine

305 mm

180

mm

To cover the 640 mm stave length one need to move the stave 3 times

08/31/10

Base plate height Base plate height

~110 mm

Working height has to be set correctly within ~20mm

Height for cradle and stave jig

08/31/10

How to move in 7m stave jig for the fixation on the base plateHow to move in 7m stave jig for the fixation on the base plate

Vertical pillar for the binocular that could be dismounted but

preferable not!

Stave jig when setting it on the bonding space has to get around the pillar

08/31/10

Considering long stave envelope such has 7 m is possible with the H&K machineConsidering long stave envelope such has 7 m is possible with the H&K machine

BUT BUT a dedicated space only for wire bonding of ~20m a dedicated space only for wire bonding of ~20m22 has to be considered (8x2.5m has to be considered (8x2.5m22))

m

Dedicated space for wire bonding

8 m

2.5 m

1.1 m

1.7mH&K

Operator space

Somewhere in SR1

+ Metrology machine, and areas for :Loading, electrical Testing, Thermal cycling, Storage (x20), Final IntegrationOne should come up soon with a complete SR1 configuration, should be OK, but…

08/31/10

SR1 organizationSR1 organization

Wire bondingMetrology

??????

???

Loading

Something like that…

08/31/10

Integration & Test sequences

DPNC will focus soon on the “central jig” + Cradle design in order to:-Iterate / STAVE design-Flex design (accessibility issue)-Transfer tool onto the ITT