status of tob modules & rods
DESCRIPTION
Status of TOB Modules & Rods. J. Incandela For the US CMS Tracking Group Tracker Week, Feb. 2004. US CMS Tracker Group. 20 joined group this past year – few more needed at both sites 10 left the group (includes KSU). Brown University R. Hooper, G. Landsberg, C. Nguyen, H. Nguyen - PowerPoint PPT PresentationTRANSCRIPT
Status of TOB Modules & Rods
J. Incandela
For the US CMS Tracking Group
Tracker Week, Feb. 2004
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 2
US CMS Tracker Group
• Brown University• R. Hooper, G. Landsberg, C. Nguyen, H. Nguyen
• University of California, Riverside (UCR)• P. Gartung, G. Hanson, G.Y. Jeng, G. Pasztor
• University of California, Santa Barbara (UCSB)• A. Affolder, S. Burke, C. Campagnari, F. Garberson, D. Hale, J. Incandela, • P. Kalavase, S. Kyre, J. Lamb, R. Taylor, D. Stuart, D. White + technicians
• University of Illinois, Chicago (UIC)• E. Chabalina, C. Gerber, L. Nigra, T. Ten
• Fermilab (FNAL)• M. Demarteau, A. Ronzhin, K. Sogut, L. Spiegel, S. Tkaczyk + technicians
• 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, E. Halkiadakis, A. Hocker, S. Korjenevski, P. Tipton
20 joined group this past year – few more needed at both sites10 left the group (includes KSU)
20 joined group this past year – few more needed at both sites10 left the group (includes KSU)
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 3
TEC R7
TEC R6 TEC R5P TEC R5S
TOB r-phi TOB stereo
Module Types Built in US
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 4
Perspective
• Good parts are arriving• Deliveries will not be smooth – hybrids in particular are a worry
• Prof. David Stuart (UCSB) to take establish parallel US vendor
• The schedule requires • Higher than expected peak production rates
• Extremely robust and stable production lines
• Well trained personnel with backups
• Previous demonstrated module rate 15/day/site
• Module production rates now required:• FNAL: 18/day sustainable and 24/d peak
• UCSB: 21/d sustainable and 30/d peak
• Hybrids wirebonding and thermal testing• Several improvements have been made that reduce the cycle time
of the test-stand to around 30’ (was ranging from 45 to 70 minutes)
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 5
Preparations
• Studied and then improved production work flow
• Analyzed failure modes of all systems• Find everything that could interrupt production: Acquire spares
http://hep.ucsb.edu/cms/cms.html
• Cross-train technicians• All persons with critical tasks must have backups
• Detailed written procedures for every task• Specific training required. Lines of responsibility established.
• A list of 25 procedures can be found at:
http://hep.ucsb.edu/cms/cms_procedures
• US Workshop held at UCSB January 21-22• Purpose: Exchange experience – standardize procedures
• Novel Format: Minimum of powerpoint, counterpoints met directly and in the lab around in equipment in many cases, to exchange ideas
• Led to a consideration of a new structure for communication in US
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 6
FNAL Assembly Capacity
•Added second curing cabinet• 8 plates/day peak rate.
• provide moisture in winter.
•10 TOB assembly plates: • 6 R-Phi and 4 stereo.
•New people• Two technicians in March
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 7
UCSB Assembly Plate/Capacity
Total of 24 plates!(#) = plates added in 2004
Module type Completed Plates
Plates In Process Total Daily Capacity
(# modules)
TOB r-phi 7 (2) 7 21
TOB stereo 3 (1) 3 9
TEC R5P 2 (2) 1 3 9
TEC R5S 2 (2) 1 3 9
TEC R6 5 (4) 5 15
TEC R7 2 (2) 1 3 9
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 8
Modules Enter
Bonded, UntestedModules Shelf
ARCSTesting
If Failed
If Passed
Can We Fix It?Yes
Repairs
Repaired Modules Shelf
Needs RepairShelf in
Bonding Room
Failed ModulesShelf
No Good ARCSTested Modules
Shelf
LT Testing
Bad Thermal Cycle, NeedsRetest Shelf
Chosen forLT Test?
TEC or TOB?
TEC or TOB?
TEC ThermalCycled Ready For
Shipping Shelf
TOB ThermalCycled Ready For
Rod Assembly
TEC Not ThermalCycled Ready For
Shipping Shelf
TOB Not ThermalCycled Ready For
Rod Assembly
No
Yes
If Passed
IfFailed
TEC
TOB
Is the ProblemUnderstood?
Undiagnosed Modules Shelf
Yes NoTEC TOB
Module Testing: Example of Flow Plan
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 9
Testing time trial
• Question• Can (30 hybrids + 30 modules)/day be comfortably sustained ?
• Results• All hybrids and modules completely tested in a standard 8 hour day
• Only used 2 of 3 module test stands available • Further reductions of testing times have been accomplished since the trial
• Found that having full complement of testers in the room at one time actually improved efficiency and communication
• We were able to solve problems faster by shifting manpower and using the integrated experience of all the testers
• Answer: REQUIRED TESTING THROUGHPUT IS SUSTAINABLE
• Aside: Hybrids wirebonding and thermal testing• Several improvements have been made that reduce the cycle time of the test-
stand to around 30’ (was ranging from 45 to 70 minutes) • FNAL and UCSB up and running
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 10
Module LT Systems
•LT systems in final form. • The last steps included
• Backplane modification: FNAL.
• CCU6 to CCU25: UCSB.
•Operation is now stable • I2C errors, missing records &
HV problems are gone.
•Running a 12 scenario.• Allows 20 modules/d/site
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 11
Module Production Summary
• Resumed module production late 2004/early 2005• Pair v4 (type 18) with ST and v5 (type 19) with HPK sensors
• We need ST sensors (>=lot 4).
• FNAL:127 modules• 108 HPK: 84 L3&4, 24 L5&6
• 1 (marginal) Gantry placement failure, 2 handling accidents
• 19 STM: 12 L1&2(r), 7 L3&4
• UCSB: 65 modules – paused to study bias connection• 26 HPK: 24 L3&4, 2 L5&6
• 1 IV failure
• 33 R5S (TEC) 6 R5N (TEC)
• All modules test grade AVersion 3 sub-type 17Version 4 sub-type 18Version 5 sub-type 19
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 12
Current Focus/Issues
• Bias connection: Ag epoxy studied intensely at UCSB.• 3 sensors (ST) out of 28 TOB modules were found to have poor or
open connections to the HV pad.• 20% of sensors on 36 subsequent modules found to have
unexpectedly high impedance bias line connections• Performed numerous tests and have consulted many experts• Yesterday found an important clue
• Gantry placement doesn’t disrupt the surface of the epoxy bead • We will now be able to devise a systematic remedy
• Completing encapsulation studies• Extreme thermal cycles of hybrids completed – no problems seen• Modules heavily irradiated
• No problems yet identified with encapsulation• Sent to UCSB for further study
• 75 modules encapsulated and to be tested at UCSB• Will now cycle 50 times -30 to + 50C (+80C)
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 13
Encapsulation for Reinforcement
• Mainly protects bonds but also an alternative to module reinforcement.•Ideally hybrid bond encapsulation would be done by the vendor or at CERN.
•Other bonds would be encapsulated after the LT test.
• December UCSB did drop tests•No damage for up to 60 g
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 14
ARCS Noise Issue
•Tests of recent FNAL production with HPK sensors found lower average noise - especially for 4-APV modules.
•Practical problem: Great modules fail the ARCS low noise cut!
•Production with STM sensors also showed lower noise.•Ruled out ARCS version and any hardware changes.
•Previously produced modules have unchanged noise performance.
•Points to new hybrid versions: may be batch related
•We should switch from absolute to relative cuts.•Absolute levels should nevertheless be used to flag and thus monitor variations
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 15
ARCS Noise
Reluctant to upload XML files for ‘failing’ modules
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 16
Rods
• Rod assembly well understood• An issue with the stiffer hybrid cable has been resolved
• Single rod testing is under control• Adding a few more "kinks" we get back to where we were with the
softer tails. More details in a presentation by Susanne Kyre to US rod testing meeting:
http://hep.ucsb.edu/people/kyre/stiff-tail-troubles.ppt
• Multi-rod• Have had and resolved many problems with software and hardware
• Achieved major milestones
• Still have some problems to solve
• Need experience with many rods to determine if there are issues with components.
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 17
Stiff Tail Solution
•Stiffer tail deflects the intercconnect card (top left)
•Adding additional kinks to the tail eliminates the problem (top right)
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 18
ROD Testing Status
• All equipment on hand at FNAL and UCSB• Single rod test stands • Multi-rod stands with capacity of 8(6) single (double)-sided rods
• Have been struggling with DAQ stability problems for long term (3 days) burn-in test• Much progress recently
• Frequent communications with Wim B. SW fixes• Improved grounding I2C communication much more reliable
• For the past week systems have been quite stable• Not sure that we are out of the woods yet• But we are clearly on the right track
• Starting to address bad channel diagnostic procedures• Drawing on US experience with module testing
Expect to be ready at start of full production
US Production Status, CMS Tracker Week, Feb. 4, 2005 J. Incandela 19
Summary
• Have studied all possible threats to production stability• Purchased or manufactured spares
• Manpower not yet at comfortable level• FNAL 2 new technicians to start in March
• UCSB 1 technician just hired at UCSB, 2 more being sought• Have 4 new students plus 2 coming spring/summer
• Hiring 2-3 post-docs
• Further increased capacity to ~50 modules/day
• Systems• All stages of production have been exercised and are near to final
except rod testing
• Multi-rod stands rapidly converging