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CMS Week, CERN, 07-11 June 2004
10 June 2004CMS Week - Module ProductionSalvatore Costa - Catania
Report from
Module BondingWorking Group Meeting
Salvatore CostaUniversità di Catania and INFN – Sezione di Catania
10 June 2004CMS Week - Module Production 2 Salvatore Costa - Catania
Outline
1. Global info on production bonding of the Modules
2. Global review of Module bonding quality indicators
3. Short summaries on specific topics discussed at the WG Meeting
CMS Week, CERN, 07-11 June 2004
10 June 2004CMS Week - Module ProductionSalvatore Costa - Catania
Global
info on production bonding
review of Module bonding quality
10 June 2004CMS Week - Module Production 4 Salvatore Costa - Catania
Production Summary
after Hyb prod resumed with stiffener added to kapton cable
10 June 2004CMS Week - Module Production 5 Salvatore Costa - Catania
Production Rate
• It continues to be globally true that Bonding is not a bottleneck in the production flow.
• In all centers modules are bonded within single-digit number of days from reception
10 June 2004CMS Week - Module Production 6 Salvatore Costa - Catania
Module Pull Tests Performed
# Modules pull tested # Modules pull tested after 01Dec2003 (since last Mtg)after 01Dec2003 (since last Mtg)
Results in DB from 13 Centers out of 14 (up from 9 three Mtgs ago)
Center PA TA PA-Sen Sen-Sen
Bari 77 (67) 80 (69) n/a
Catania 47 (45) 47 (45) n/a
Firenze 9 (9) 5 (5) n/a
Padova 0 (0) 34 (33) n/a
Pisa 7 (1) 34 (27) n/a
Torino 114 (63) 46 (40) n/a
Fermilab 110 (109) 29 (7) 29 (8)
Santa-Barbara 42 (36) 42 (35) 42 (35)
Aachen
Hamburg 20 (15) 20 (15) n/a
Karlsruhe 0 (0) 20 (0) n/a
Strasbourg 0 (0) 27 (27) 27 (27)
Vienna 7 (1) 16 (10) n/a
Zurich 0 (0) 39 (30) n/a
10 June 2004CMS Week - Module Production 7 Salvatore Costa - Catania
Readout bonds
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Av
era
ge
p
ull fo
rc
e (g
)
01Dec-18Apr
19Apr-06Jun
Pull test results
BA CT FI PD PI TO FL FL SB SB HA KA ST ST VI ZH
. ss ss ss
5g
10 June 2004CMS Week - Module Production 8 Salvatore Costa - Catania
Bonding problemsWe had no reports of pathological problems. Non-severe problems:• Catania changed to a new toot type for last module bonded; with
parameters that result into reliable bonding, but still not optimized, had much higher pull forces (13-15 g) but all lift-off’s vs. heel breaks.
• Firenze complained that the filter capacitor gold pad was particularly dirty in a few recent modules, resulting into failing bonds.
• Karlsruhe got their first 38 CMS modules (TEC R3); reported ‘standard’ bonding failures in about 2/3 of the modules, traced to vacuum/support problems
feedback given for jig improvement• Vienna warned that Hybrids in their modules (bonded at Fermilab) have
power bonds in groups of 3 vs. 5 present in Hybrids bonded at CERN.• Zurich reported that out of 108 TEC R4 modules they bonded, “a few”
had floating sensors and needed special care when bonding.
CMS Week, CERN, 07-11 June 2004
10 June 2004CMS Week - Module ProductionSalvatore Costa - Catania
Selected highlights from the
Bonding WG Meeting
of 08 June 2004
10 June 2004CMS Week - Module Production 10 Salvatore Costa - Catania
Pull test data comparison Direct comparisons between centers must involve
correction for loop angles Launched a campaign to document loop in PA test areas,
typically involving these steps1. Document the original bond
2. Straighten bond to (near) triangular shape
3. Measure the angle at the bond foot
4. Determine correction factor for pull strength
• 5/14 centers have already responded and provided their loop doc at the Meeting.
• Will gather missing info and then use it to scale data in PA TA plot.
10 June 2004CMS Week - Module Production 11 Salvatore Costa - Catania
Pull Force correction factor
Correction factor:a = 1 / (2 sin)
(º) corr. factor a
10 2.88
20 1.46
30 1
40 0.79
50 0.65
60 0.58
70 0.53
80 0.51
90 0.5
For symmetrical bond:
10 June 2004CMS Week - Module Production 12 Salvatore Costa - Catania
Loop angle Correction factor
Catania
Correction factor: 1Correction factor: 1
10 June 2004CMS Week - Module Production 13 Salvatore Costa - Catania
Loop angle Correction factor
Padova
Correction factor: 1Correction factor: 1
1800
525
1st2nd
= arctan(525/900) = 30º
10 June 2004CMS Week - Module Production 14 Salvatore Costa - Catania
Module Repair Centers• We were requested to discuss the criteria to decide when to
send a Module to the new official Repair Centers, from a Bonder’s point of view.
• I will report in detail to TPO. General remarks:– We perceive these centers more as debugdebug places where teams of
dedicated people study in deeper detail Modules with non-trivial problems, so that normal production can continue at the usual rate.
– Strictly speaking, trivial mechanical Module bonding failures should not be matter for these Centers: a) there is nothing to study; b) bonding centers (operators) are either able to repair them right away or, if they can’t, then most likely the debug centers can’t either.
– To repair damage to APV-PA bonds (typically caused by handling accidents), send Module back to the Hyb bonding place. […]
– For all other cases, which means a variety of electrical misbehaviors that may or may not be related to bonding problems, report the problem and let the ‘experts’ at the Debug Center decide if they think they want to study that Module [report procedure…]
10 June 2004CMS Week - Module Production 15 Salvatore Costa - Catania
Module grading in Tracker(DB)• ModTest WG has clear criteria to grade Modules according to number of
bad channels and other electric properties: grade A, B, C, F• Gantry is in the process of implementing a similar grading scheme based
on the achieved alignment of components on the Module• Bonding de facto has already a similar scheme, although we never
called it “grading”.– From the Bonding operation, we issue a negative flag in TrackerDB only if
the Module is• Declared unbondable or however unusable at Pre-bonding “inspection”• Declared unusable at Post-bonding inspection
– Currently we never issue a negative flag based on quantitative variables:• Number of unbonded strips• Number of bonding failures• Pull test results
– We do assign, however, different positive flags based on number of unbonded strips (“grading”): 0 <1% unbonded Sensor strips
1 1-3 % unbonded Sensor strips 2 > 3% unbonded Sensor strips
– These thresholds were decided quite arbitrarily about 1.5 years ago.
10 June 2004CMS Week - Module Production 16 Salvatore Costa - Catania
Grading from Bonding (preliminary!) We agreed on:
– Keep Flag -1 if module found unusable at pre- or post-bonding inspection– Not use pull test values for grading because it would require pull test on all modules– Adjust our current grading based on # unbonded strips in order to match the ModTest criteria:
0 : <1% unbonded Sensor strips (matches Grade A) 1 : 1-2 % unbonded Sensor strips (matches Grade B) -1 : > 2% unbonded Sensor strips (matches Grade C) [and perhaps -2, -3,… for different
reasons]
We debated but concluded we need more time before we can come up with a well-thought scheme: Including levels of grading based on indicators of the mechanical quality of the bonds, such as
The number of repaired failures This is delicate because to be meaningful it must include a breakdown of the reported
repaired failures based on reasons for the initial failure and repair manner. The number of bias bonds that could actually be made
Any changes to the grading scheme can only be implemented with a new DB I/F version.We will have to make a script to automatically change in DB the flags for existing data where appropriate (should be just a few).