23-Aug-2005 VELO Production UCD

VELO Module Production at Liverpool

T. Bowcock

23-Aug-2005 VELO Production UCD

Overview• Progress to

Production Readiness– Status– Issues/Risks– Timeline

• Summary

23-Aug-2005 VELO Production UCD

Production Readiness• Engineering Review

– Concept of the project

• Point at which we are ready and can be “cleared” to start production– All equipment in place and debugged– QA procedures– Techniques proven

• Specific for VELO– 4 “mechanical” modules– 4 “physics grade” modules – experiment standard

23-Aug-2005 VELO Production UCD

Status• Expected to be past PR(R) in July (or

earlier)– Two major problems arose

• Pitch adaptor (connecting sensors to electronics)- contamination from production at CERN

• Hybrid “twist”

• Components and Procedures

23-Aug-2005 VELO Production UCD

Schematic

23-Aug-2005 VELO Production UCD

Sensors• Remeasurement of current at Micron• Excellent shape from Micron Laser • Improved jigs manufactured (Liverpool and Syracuse) • Mechanical tests on sensors

– 100 cycles on/off on jig does not make 200 micron mechanical snap

– Pressure on edge up to 10kg/mm2 does not cause cracks in Si– Twist of up to 2mm does not significantly

• Mounting in jigs and handling– In production we have decided to move to 2 person mounting of

sensors• High current detectors seem to be isolated to one

crystal, otherwise good.• 21 day vacuum (10-5 mb) test at high voltage

23-Aug-2005 VELO Production UCD

Sensors

23-Aug-2005 VELO Production UCD

Lots of data available from production process

-Implants

-Metal resistances etc.

23-Aug-2005 VELO Production UCD

Yield

23-Aug-2005 VELO Production UCD

Hybrid K-05• Industry was not able to reproduce

flatness achieved in lab– 6 months extra R&D (!)– £15K additional cost

• Move production to “in-house”– 4 substrates per day– Bare substrate ~50 micron twist (10

times better than achieved externally)• Twist on K-04 hybrids measured for

effect on Si • K-05 circuits have been fabricated at

Stevenage Circuits PLC– Error found in testing system and

corrected, this caused additional delay• 7 K-05 have been laminated onto

substrates at Stevenage• 2K-05 (populated) posted yesterday to

Liverpool, remainder at end of week.• Check K-05 functioning by early next

week

23-Aug-2005 VELO Production UCD

Mechanics• In full production, completion soon

• Bases in production (30 complete)

• Paddles mould tools– Paddle production will start in 2 weeks (3/day)

23-Aug-2005 VELO Production UCD

Laser Rig – Hybrid holder (cooled)

Modified Bonding Jig

23-Aug-2005 VELO Production UCD

Bits• Handling frames complete

– Once the hybrid comes to Liverpool (Post population) it doesn’t have to be touched

• Bonding jig modified(works)– Special backend bonding jig built for HK710 (no sensors – remove

leaks)• Table for Laser

– Flat surface surveyable into 2stage x-y drive– Incorporation of bonding jig/w cooling

• Assembly System complete and programmed• Gluing Robot Complete (programming underway)• Equipment for vacuum thermographs

– Dual arm vac vessel/flange being constructed– Allows up to 3 detectors to be tested simultaneously– Motion sensors tested on K-04 substrate (sensitive to ~5microns)

23-Aug-2005 VELO Production UCD

23-Aug-2005 VELO Production UCD

23-Aug-2005 VELO Production UCD

LHCb Assembly System

Programmed

Alignment Plates

23-Aug-2005 VELO Production UCD

More Bits• Cable clamps

– Designed – about to be submitted

• Short cables– Designed, awaiting production order

23-Aug-2005 VELO Production UCD

2-sided bonding• Backends programmed

– K-05 (twisted)

• Frontends– Chips programmed (BE!)– Completing programme to sensors this week

• Double sided bonding on our substrates is OK

23-Aug-2005 VELO Production UCD

Major Issues• Contamination of PA’s at

CERN still not resolved… another bad batch– Require 80% yield good

testing• K-05 yet to be electrically

tested• Assembly of hybrid to

paddle– Assume non-twisted

components– Final adjustment (tested)

using “W-sticks” added to design – removeable for repair

23-Aug-2005 VELO Production UCD

“Minor” Issues• No such thing!

– Transport boxes being designed and fabricated (gas tight, 3000m for aircraft, safe for insertion etc).

• Expensive

– Handling and reception procedures to be finalized (Glasgow/Liverpool mtg before Sept 7)

– Distortions– Outgassing tests

23-Aug-2005 VELO Production UCD

Project Timeline to PRR• Everyday planned …

– Still not in production mode as “fighting problems”

23-Aug-2005 VELO Production UCD

Project Gantt

23-Aug-2005 VELO Production UCD

Current Completion for PRR

0

50

100

150

200

250

18/0

7/2

005

25/0

7/2

005

01/0

8/2

005

08/0

8/2

005

15/0

8/2

005

22/0

8/2

005

29/0

8/2

005

05/0

9/2

005

12/0

9/2

005

19/0

9/2

005

26/0

9/2

005

03/1

0/2

005

10/1

0/2

005

17/1

0/2

005

Tasks

Done

17/08/2005

About 1 week late on current schedule…. Catchup???

Hybrids delayed. Due to arrive today

23-Aug-2005 VELO Production UCD

Realistic Start Schedule• Oct ‘05

– approx 9 months late– last week Oct

• How many modules can we make per week?– Start at 1/week and build up– Maximum capacity 3 (or 4) but we will not be

able to achieve this until Feb 2006

23-Aug-2005 VELO Production UCD

Production at Liverpool

0

5

10

15

20

25

30

35

40

05/09/2005

25/10/2005

14/12/2005

02/02/2006

24/03/2006

13/05/2006

Weekly

CumulativeChristmas & Startup

No major failure

23-Aug-2005 VELO Production UCD

Summary• We should have full VELO complement at

CERN by end of April 2006– If testbeam in April 2006 this may be only

50% can be tested during system test

• Large amount of work left

• Two big “risks” remaining– Pitch adaptor contamination– Paddle-hybrid assembly (manageable)