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GLAST LAT Project

A.Brez GLAST-LAT International Collaboration Meeting, Roma, Sept. 15-18 2003 1

GLAST-LAT InternationalGLAST-LAT InternationalCollaboration MeetingCollaboration MeetingRoma, Sept. 15-18 2003

EM tower constructionand testAlessandro BrezINFN Pisa

GLAST LAT Project


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Cable Plantwith thermisters

Aluminized Silicon waferscut to nominal dimensions

Electronics mokups:Final dimensionsChips replaced by resistorsto simulate the thermal load

Tower Assemblyand Test

Tray Assembly :19 EM trays5 Minitower trays1 Defected tray1 Bottom tray fordestructive static test

SSD Ladder Assembly.1/3 of the ladders withencapsulated bondings

150

600

36 26

18

GLAST LAT Project


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• Lightweight 4 pieces machined closeout frame, bonded to facesheets and core to form a sandwich structure

Gr/CE Face Sheet

C-C MCM Closeout Wall

Thermal Boss

1 lb/ft3 AluminumHoneycomb Core

C-C StructuralCloseout Wall

0/1/"/'+/%Φ2,34/5

GLAST LAT Project


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• The tray “payload” is bonded to the sandwich structure usingepoxy, with the exception of the SSD bonding, which is donewith silicone.– Silicone decouples the thermal/mechanical effects from the tray

NO63 lb/ft3BOTTOM3% Xo41 lb/ft3TOP18% Xo63 lb/ft3HEAVYNO41 lb/ft3LIGHT3% Xo41 lb/ft3MID

WConverter

Face sheetPlies

HoneycombCore

Tray Type

GLAST LAT Project


Reference wall

Upper plate

TraySkinLower plate

Tray assembly toolTungsten assembly tool

Kapton assembly tool

Trimming tool

Tray assembly toolstotalProduction

seriesEM seriestool

211Kaptontool

101Trimmingtool

312Tungstentool

743assemblytool

Tray assembly rate capability: 3 trays/day

GLAST LAT Project


E.M. Results: DIMENSIONS

trays DIMENSIONS Structural SIDE: mean = 368.56mm, ??= 0.04mm MCM SIDE: mean = 368.52mm, ??= 0.03mm

02468101214161820

368.40 368.50 368.60 368.70mm

Structural SIDEMCM SIDE

GLAST LAT Project


TOP FACE SIDE A

TOP FACE SIDE B

TOP FACE SIDE C

TOP FACE SIDE D

BOTTOM FACE SIDE A

BOTTOM FACE SIDE B

BOTTOM FACE SIDE C

BOTTOM FACE SIDE D

SIDE B SIDE A

SIDE B SIDE C

SIDE D SIDE A

SIDE D SIDE C

SIDE B SIDE D

SIDE A SIDE C

TOP FACE BOTTOM FACE

Measured Surface

TOP FACE

BOTTOM FACE

Geometrical Tolerances

SIDE A

SIDE B

SIDE C

SIDE D

MID TRAYS FLATNESS: TOP FACE & BOTTOM FACE

0

1

2

3

4

5

6

0 25 50 75 100?m

MID TRAYS FLATNESS: CLOSEOUTS

0

2

4

6

8

10

12

0 25 50 75 100?m

E.M. Results: FLATNESS

GLAST LAT Project


MID TRAYS ORTHOGONALITY

0

5

10

15

20

25

30

0 25 50 75 100?m

MID TRAYS PARALLELISMmean = 73 ?m

0

1

2

3

4

5

6

7

0 25 50 75 100?m

E.M. Results: ORTHOGONALITY & PARALLELISM

TOP FACE SIDE A

TOP FACE SIDE B

TOP FACE SIDE C

TOP FACE SIDE D

BOTTOM FACE SIDE A

BOTTOM FACE SIDE B

BOTTOM FACE SIDE C

BOTTOM FACE SIDE D

SIDE B SIDE A

SIDE B SIDE C

SIDE D SIDE A

SIDE D SIDE C

SIDE B SIDE D

SIDE A SIDE C

TOP FACE BOTTOM FACE

Measured Surface

TOP FACE

BOTTOM FACE

Geometrical Tolerances

SIDE A

SIDE B

SIDE C

SIDE D

GLAST LAT Project


E.M. Results: Plyform TRAY DATABASE

GLAST LAT Project


Tray vib set upAccelerometers position:•Control: two mono-axial accelerometerspositioned on two of the four L-shapedblock TP1&TP2•Fixture: three mono axial accelerometersplaced on a corner on one of the four L-shaped block TP6•Tray: one three-axial accelerometer in themiddle TP5

W side on the top

0.5 g0-pkTargetAmplitude

2 oct/minSweep rate

20 ÷ 2000 HzFrequencyrange

Sine sweep

1 min1 min2 minDuration7 grms10.0 grms14.0 grmsOverall0.00650.0130.0262000-6 dB/oct-6 dB/oct-6 dB/oct800-20000.040.080.1650-800

+6 dB/oct+6 dB/oct+6 dB/oct20-500.00650.0130.02620

ASD LaunchLevel(g2/Hz)

ASD AcceptLevel (g2/Hz)

ASD QualLevel (g2/Hz)

Frequency(Hz)

Random vibration

GLAST LAT Project


Vibrational testSine sweep before/after random Random vibration + White noise

Resonance search:ν0= 815 Hz, Q ≈ 51

Resonance check:ν0= 809 Hz, Q ≈ 49

Z accelerometer responseX accelerometer responseY accelerometer response

All the EM trays have been successfully tested at qualification level.No damages or relevant frequency shifts have been observed

TG07 TG07

GLAST LAT Project


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Close-up view of the interfaces on the bottom of a Tracker module. This interface has been substantially redesigned since the May ’02 randomvibration tests of the prototype tower module, during which structural failuresoccurred in the carbon-carbon closeouts of the bottom tray.

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GLAST LAT Project


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The static test will be performed on each bottom tray.The test load on all the axes is equivalent to 3σ Static Equivalent RandomVibration Loads in tension.2 trays have been produced.The first have been successfully tested.The second bottom tray is going to be tested up to failure.Vertical test setup Horizontal test setup, 45o

configuration

GLAST LAT Project


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Jig of ladders alignment

Ladders vacuum kept on the bridges

Jig of tray alignment

Reference dowels

Alignment micrometers

C.M.M. with touch head and optical head

All the assembly operations under C.M.M.Glue spots deposition with automatic dispenserMicrobonding with automatic wedge bonder

GLAST LAT Project


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Tray positioning

Ladder positioning

Microbonding

mechanical ladderswafers alignment errors

0102030405060708090100

-50 -40 -30 -20 -10 0 10 20 30 40 50

?m

? =5.5?mmin=-32?mmax=47?m

GLAST LAT Project


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Z alignment

0

10

20

30

40

50

60

70

-30 20 70 120 170 220 270µm

σ =46 µm

Y alignment

0

2

4

6

8

10

12

14

16

-100 -50 0 50 100

?m

? = 28 ?m

X alignment

0

2

4

6

8

10

12

14

16

-100 -50 0 50 100

?m

? =32 ?m

σ=46µmσ=32µm

σ=28µm

xy

measurementpoints

0.2mm

MCM side

GLAST LAT Project


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Connector saver

Fixationpoints

Handle

N2 inlet

The tray box allows safe shipping and storage.Through the connector savers the tray can be fully tested in the closed box.

GLAST LAT Project


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Trays alignment on assemblyjig

Cablingx

yz

GLAST LAT Project


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Lifting tool

Fixture

residuals from best fit parallelepipedwith base 371.3mmX371.2mm

-0.3

-0.2

-0.1

0

0.1

0.2

0.3

0 200 400 600Z coordinate (mm)

residuals (mm) +Y

-Y-X+X

Geometricaltoleranceswell withinlimits (0.3mm).

GLAST LAT Project


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The July assembly could not end with the tower shake test becauseof several problems:

•Due to a wrong indication in the drawings, the sidewalls were not atspecs (2 missing YS90 tissue layers).

•The fixture and the cable holder, 2 interface frames between theshaker and the tower, had constructive problems that could not beworked out. The fixture and the cable holder are now in SLAC forreworking

Other minor problems found during the assembly:Few screws did not enter to the end ⇒ cleaning of the thread holesThe connectors of the cactus cable were difficult to connect and quite fragile ⇒new connectors and special tools will be used in flight cablesThe thermisters of 2 cables were removed because mounted in the wrong place ⇒these 2 cables will be replaced before the thermal test

GLAST LAT Project


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•Completion of the EM tower (newsidewalls, reworked shaker interfaces)•3 axes tower vibrational test•Tower disassembly for damages check•Single tray thermal tests•Reassembly of the EM tower•EM tower thermo-vacuum test

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