ferrara 8 june 2004m.savrié1 production readiness review ferrara mwpc production site

Ferrara 8 june 2004 M.Savrié 1

Production Readiness Review Ferrara

MWPC Production Site


Agenda

09:30 Introduction: Mauro Savrié 30’10:00 panel preparation G.Auriemma 30’10:30 Clean room operations: W. Baldini 30’11:00 Measurements on panels & D.B.: S.Germani 30’11:30 radioactive source test tooling G.Carboni 30’12:00 Discussion: 30’

lunch

02:00 we move to the new labs (Polo TecnologicSaragat,1 tel. 0532 974704) and start the visit to the production center

17:00 referees private meeting referees -----

In the old Physics Department: via Paradiso,12 Ferrara


The PRR has to verify/assess:

• Readiness of the tooling and of the production site

• Quality controls and assurance tests

• Material procurement and its flow

• Manpower availability

• Production ( and installation ) schedule


Production goal:

• 72 M1R4 (+4)• 12 M4R1 (+4)• 24 M4R2 (+4)• 48 M4R3 (+4)• 12 M5R1 (+4)• 24 M5R2 (+4)• 48 M2R3 (+4)

Total chambers: 240 (268)

Production foreseen in Ferrara


EDR recommendations

1. A small ‘pre-production’ series should be constructed and tested for each chamber type ………the goal was to build and test 3 final M2R3 chambers and to test at least one in LNF with the radioactive source: we succeeded in building 2 of them, but due to time shortage, and many other commitments (…and a small accident…), only 2 were (nearly) built

2. At least one of these pre-production chambers of each type should have undergone a successful ageing test ………actually we have never tested our prototypes for ageing. We could perform a test in the near future at the GIF on the first chambers

3. The opening of the chambers should be exercised. In fact, the reviewers are mostly worried about the proposal to close two of the three chamber types by gluing…This has been already discussed in past


4. A wire replacement procedure should be defined and tested for each chamber type.

….we exercised the procedure several times on a M4R1 prototype and with a M2R3 “like” prototype. The tooling is already “designed”: it has just to be implemented (adapted) to the new site.

5. At nominal gas flow rate, the eventual formation of ‘pockets’ should be checked by efficiency mapping, especially in the case of the longest chamber type.……the general design of the chambers is the same as for LNF where this problem was already discussed and “understood”.

6. As the gap size is probably the most critical parameter for pulse height uniformity, an effort should be made to produce panels of best possible flatness.……..in fact we still see some problems but in a very small percentage of the panels ( see Stefano presentation)


7. The sagitta of the panels due to wire tension should be measured, for those panels carrying wires only on one side. ……it was already discussed and understood at LNF PRR but…… (see wander presentation)

8. The precision of the wiring should be checked on all pre-production chambers…… we do already for all the wired planes

9. Gluing should be handled with the utmost attention, with well tested, constant procedures, in particular under <50% humidity ……… the humidity control is very effective and the gluing procedures are already automatic and controlled by PC apart for the closing bars ( we are finalizing the code for the assembling table). Side bar gluing will be manual for all chanbers

10. Chamber materials and components (panels, bars, wires, glue, resistors and capacities…) should be identical as much as possible for all chamber types. ……largely achieved (already discussed at CERN and LNF PRR)


11. A well-defined testing procedure during production should be established with the pre-series, including some final two weeks of operation at nominal voltage with final gas mixture and flow. ….. It is in our program. For the first chamber we have still a big gas leak to be understood. HV test on each wire plane was successfully done ; HV test foreseen.

12. On the basis of the experience gained with the pre-production series, the production schedule should be re-evaluated ....we still have to experience the “real pre-production”, but we are quite confident in the proposed production schedule


Operations to be performedIn

Ferrara Production Center(1/2)

A. Outside the clean areas

1. Measurement of the height of the HV bars with respect to the cathode surface:

• On all the “pre-prduction” panels,• On 10% of the production panels ( if pre-production is O.K.),

2. Cleaning of the panels, visual check,check of the gas connections and the good geometry of the corners;

B. Inside the grey room1. Soldering of ground copper tapes on panels (in future it

will be done in Potenza);2. Final cleaning with isopropyl alcohol;


Operations to be performedIn

Ferrara Production Center(2/2)C. In the clean room

1. Wiring, gluing and soldering of wires 2. Pitch measurement3. Side bars gluing4. Wire cutting5. W.T.M. & HV test in open air on sigle panels6. Chamber assembling

D. Outside the clean areas1. Gas leak test2. Mounting and soldering OPB cards3. H.V. Test and conditioning

The chambers will be sent in Roma2 for the final assembly (electronics and Faraday cage) and test with cosmic rays ( X%?)

A test with a radioactive source is foreseen in the near(??)future on all chambers ( see Carboni presentation )


10.5 m

9 m

Class100.000

Class10.000

Class100.000

Grey room

Clean room

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elec

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Gas

Co

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rack

tab

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shel

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10 m

12.5 m


PeoplePeople

1. Staff physicists• Mauro Savrié • Wander Baldini• Ferruccio Petrucci• Alberto Gianoli

2. Staff technicians• Federico Evangelisti • Luca Landi• Claudio Pennini• Claudio Padoan

3. Non staff technicians• Stefano Squerzanti

4. Levan Glonti ( Dubna)

5. Phd & others• Stefano Germani• New Post doc ( 2+1 years)• Student ...soon


Material flow to Material flow to Ferrara Ferrara

Production center(1/3Production center(1/3))

1. From Potenza• Panels ready for wiring with:

• HV bars with components and anti-corona coating• Signal/gnd connectors• Gnd copper tape already soldered on both side of

the panel2. From LNF

• Side bars• Closing bars• Spacers and plastic rings• Gas connectors• HV distribution plastic bars• OPB cards• HV wire with pins• Chamber labels



Production center(2/3)Production center(2/3)

3. From CERN• 30 microns wire• 100 microns wire• Adekit 145/400 with mixers ( black )• Adekit 140/50 with needles (clear)

4. We buy by ourselves:

• Tin• Adekit 145/400 with mixers• Adekit 145/50 with mixers• Mylar adhesive tape• Any other stuff ( syringes, needles…)


item amount/ch. amount needed received rejected used remaining enough for # ch. still missingpanels (top cover) 1.00 48.0 9.0 1.0 2.0 6.0 6.0 40.0panels to be wired 4.00 192.0 20.0 4.0 4.0 12.0 3.0 176.030 microns wire(m) 1458.00 70000.0 76050.0 0.0 5832.0 70218.0 48.2 -6050.0100 microns wire(m) 8.30 400.0 100.0 0.0 8.3 91.7 11.0 300.0adekit 140/50 b-glue(cc) 0.00 0.0 5000.0 0.0 400.0 4600.0 48.0 -5000.0adekit 140/400 b-glue(cc) 400.00 19200.0 4000.0 0.0 0.0 4000.0 10.0 15200.0adekit 145/50 w-glue(cc) 31.25 0.0 5000.0 0.0 300.0 4700.0 48.0 -5000.0adekit 145/400 w-glue(cc) 31.25 1500.0 0.0 0.0 0.0 0.0 0.0 1500.0mixing needles for 50cc 6.00 288.0 200.0 0.0 30.0 170.0 28.3 88.0mixing needles for 400cc 2.00 96.0 120.0 0.0 0.0 120.0 60.0 -24.0tin(m) 73.00 3510.0 7500.0 0.0 200.0 7300.0 48.0 -3990.0side bars 8.00 384.0 66.0 0.0 24.0 42.0 5.3 318.0h.v. wire with pin 48.00 2304.0 224.0 0.0 96.0 128.0 2.7 2080.0closing bars 8.00 384.0 127.0 0.0 8.0 119.0 14.9 257.0plastic rings 64.00 3072.0 2200.0 0.0 64.0 2136.0 33.4 872.0spacers 64.00 3072.0 2100.0 0.0 64.0 2036.0 31.8 972.0gas connectors 4.00 192.0 100.0 0.0 8.0 92.0 23.0 92.0HV distribution bars 4.00 192.0 262.0 0.0 4.0 258.0 48.0 -70.0HV connectors 1.00 48.0 0.0 0.0 0.0 0.0 0.0 48.0OPB cards 12.00 576.0 24.0 0.0 12.0 12.0 1.0 552.0labels 1.00 48.0 48.0 0.0 1.0 47.0 47 0.0we expect:from Potenzafrom CERN closed ch.: 2we buy ourselves good ch. : 1from LNFto be re-checked

total amount of chambers: 48+spare (5?)

tin: 1m=2.5g; 1spool=800g(=320m)

Potenza panels are with H.V.Bars,signal/ground connectors & copper grounding

on the right waymore than we needcritical item



Production center(3/3)Production center(3/3)

1. Panel supply• First delivery problems:

planarity (?) Gluing problems H.V. Bar “A type” where too high..now is O.K. Not very goog surface quality.... now is O.K. No signal connectors Problems with gas path

• Second delivery: 7 panels ( top covers ) Good quality

• Third delivery: 4 panels Some bad planarity and local defects 1 H.V. bar was detached

2. Material supply: O.K.3. Essentially we just started the “learning stage” of the production

ProblemsProblems


8 9 10 11 12 13 14 15 16 17 18

eventually repair it

HVbar "A" and "B" heght measurement

visual inspection+ gas path and corner geometry check

final cleaning--> enter it in the grey room

Preliminary panel preparationPreliminary panel preparation


Wiring, GluingWiring, Gluing, Soldering & WPM, Soldering & WPM

8 9 10 11 12 13 14 15 16 17 18

wiring: 10turns/minute

wire gluing on the "top panel": 1mm/s

pitch measurement on the " top panel":1 mm/s

put new panels (3,4) on the machine/alignement

Put guard wires in position on the "top panel"

1st lunch 2nd lunch

put guard wires in position on "bottom panel"

wire soldering on the "top panel" 0.3mm/s

prepare glue wire gluing on the"bottom panel"

prepare gard wires

prepare gard wires and turn U/D

wire soldering on the "bottom panel": 0.3mm/s

wire pitch measurement on "bottom panel": 1mm/s

prepare glue

first operator (4.5 h) second operator (4.5 h)

get panels (1,2) out of the machine

All the timings refer to the largest chambers we have to build

Glue pre-curing

1 person: WGS machine1 person: panel preparation & tests

1 person: chamber assembling1 person: wire cutting/WTM/side bar gluing


8 9 10 11 12 13 14 15 16 17 18

wire tension measurement, both panels

wire cutting & cleaning HV bar B side

soldering of HV connecting wires on HV bar

turn panls around & side bar gluing

wire cutting & cleaning HV bar A side

HV test in open air

8 9 10 11 12 13 14 15 16 17 18

put the bottom panel in position with the tooling

measure the position with a comparator and put the glue

put the second panel in position with the tooling


put the thirdt panel in position with the tooling


put the thirdt panel in position with the tooling

measure the position with a comparator... .....put the glue

put in place the top cover and measure

Chamber AssemblingChamber Assembling

Wired Panel PreparationWired Panel Preparation


mbP 5

chamberreference

testunderchamber

Gas Leakeage test

Flow in from the bottle

Requirements:• 5 mb overpressure (p0+5mb)• P<=2mb/h• it is done outside the clean areas

Differential manometer


Conclusions and worriesConclusions and worries

1. We already started but we still need a training period

2. Production of two panel/day is feasible but with no margin:• Time contingency in gone• Possible failure in the tooling

We have spare parts for quite everything but the “Marsilli” We are considering the possibility to prepare a spare tensioning

system “LNF/Firenze like”• Lack in material supply (as in recent past)• Not so good quality of the material• Maintenance of the tooling• Maintenance of the Clean Room ( general cleaning, replacement of the

filters)• Time to switch from one chamber type to another

3. Recovery could be possible only having some more man power

4. Two years production it is a very long time to go!• To maintain the production rate• For production quality

ferrara 8 june 2004m.savrié1 production readiness review ferrara mwpc production site

Documents

preproduction chambers

production center17

final m2r3 chambers

total chambers

longest chamber type

chamber types

successful ageing test

new site