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Assembly Procedure ALICE Outer Barrel Stave 14 Module 2 Cold Plates 1 StaveMarco Kraan Paul Kuijer Slide 2 We do not have a 3D measuring machine available full time for ALICE We cannot copy the Turin procedure litterally We have only a small experienced technical crew Try to automatize the most critical operations (fine positioning,) We still have until the end of 2015 before it must be ready for production 50-100 staves in ~1 year of production ? General considerations Slide 3 Module positioning table We will use 7 of these tables in a row Each table can move +-2 mm in X and Y and rotate Slide 4 Module vacuum table Removable contact surfaces Vacuum connections O-ring XY Flexible positioning table USB Microscoop Motor End switch Flexible driving bar Tension spring Dowel pin Exploded view Module positioning table Slide 5 Module positioning table Flexible joints with a minimum of slip-stick Compact ; XY adjustment in one plane 3 Linear Actuators Holding force >100 N Feed force 22 N X- TranslationY- TranslationRotation Slide 6 7 position tables on a row 1 3 2 4 5 6 7 One prototype table under construction Slide 7 Two end blocks for positioning the Cold Plate Ruby Slide 8 7 Module vacuum tables Module vacuum table Module vacuum table fit within a defined way Vacuum fix the table About 1 mm distance between each table Storage plate for the Module vacuum tables Slide 9 7 Module vacuum tables placed on Storage plate Vaccum tables easily accessible by hand. 3 Contact screws define the Module position within 0.2-0.3 mm on the table Contact screw One vacuum table is in production Slide 10 Placing the Module When the position of the Module is fine, use vacuum to fix the position on the vacuum table The positioning table will be moved 2 mm away from nominal position to allow easy placement of the vacuum table Vacuum 2mm This should be an easy manual operation (students?) Slide 11 Placing the Module Remove the Contact screws Vacuum This should be an easy manual operation Slide 12 Placing the Module Place the Module + Table on the Position table and slide forward till the Dowelpin is touched Add vacuum to the bottom of the table to fix the position Vacuum Dowelpin This should be an easy operation Slide 13 Positioning the Module With the 2 Microscopes and Labview the tables will be posioned in XY automatically Tedious finepositioning will be done by software Slide 14 Placing the second Module Vacuum Slide 15 Positioning the second Module Slide 16 Positioning third Module Slide 17 Positioning fourth Module Slide 18 Positioning fifth Module Slide 19 Positioning sixth Module Slide 20 Positioning seventh Module Slide 21 Placing Cold plate Glue is added to the Cold plate or the Pixel chips Glue should not be between the chips (under study) Cold plate placement should be an easy operatio due to the dowelpins Sideward flexure of the cold plate to be studied Slide 22 Curing Cold plate Gentle force will be used Vacuum is still on Modules and Tables Dowelpins define ends of cold plates Slide 23 Removing Cold plate + 7 Modules Vacuum is released from Modules When the glue is cured, remove and rotate the Cold Plate in a controlled way with a dedicated pickup tool (to be designed) The dedicated pick-up tool will be turned over and all modules will be tested and soldered. Then the power bus can be connected also Slide 24 Assembly-jig 2 Cold plates + Stave 2 levels with vacuum 2 Microscopes to check the position of one chip in the middle of each cold-plate Dowel pin holes for positioning the Cold Plate Microscope 2 levels Dowel pin holes Slide 25 Assembly of 2 Cold plates + Stave Placing the lowest Cold Plate, again with the same dedicated pickup tool Dowel pins define the ends of the Cold Plate Slide 26 Assembly of 2 Cold plates + Stave Microscopes check the position If needed the sideways flexure of the cold plate can be corrected here manually (to be studied) using microscopes If the power bus gets in the way here then we have to connect it later or transfer to another tool (may depend on PB connection scheme) A test jig to assess the reproducibility of the cold- plate positioning is in preparation Slide 27 Assembly of 2 Cold plates + Stave Dowel pins removed Slide 28 Assembly of 2 Cold plates + Stave 2 Microscopes check the position of one chip in the middle of each Cold plate Slide 29 Assembly of 2 Cold plates + Stave The position of the stave in X-Y will be defined by the dowel pins in the Cold plates The vertical position is defined by two blocks Slide 30 Assembly of 2 Cold plates + Stave The two blocks will be connected to the Stave before placing Glue is added on the Cold Plates on the places where the U- legs are Slide 31 Assembly of 2 Cold plates + Stave Glue Slide 32 Assembly of 2 Cold plates + Stave When the glue is cured, release vacum on Coldplates and remove the OB Stave Slide 33 ALICE Outer Barrel Stave Slide 34 3D measuring machine to be upgraded for optical measurements. But not available full-time (2 days/week?) Clean room 35 m 2 for stave assembly ready Climatisation Vacuum Nitrogen (compressed air) Slide 35 Assembly Procedure: Manual placement of modules on vacuum tables Manual placement of vacuum table on positioning table Automatic positioning with Labview and 2 USB Microscopes, Add glue to the Coldplate or Pixel chips Place the Coldplate (with minimum stress) on top of the 7 modules, press a bit down while curing the glue Remove and rotate in a controlled way the coldplate with modules from the 7 Posioning tables with a pickup tool In this pickup tool the soldering will be done on the FPC and first tests can be done. a.Power bus? Place two Coldplates on dowelpins on a separate gluing jig Add glue to modules or cold plate Position the Stave with the dowelpins on top of the two Cold plates Two staves/week? Slide 36 Backup Slide 37 Assembly of 2 Cold plates + Stave Slide 38 Marker Module 3 Camera Marker Module 2 Aligning 8 microscoops with a Reference Lineaal Reference Lineaal fit on the rubys 14 markers (2/Module) within micron precision 2 markers where readout with one microscoop Slide 39 Assembly of 2 Cold plates + Stave Placing the second (high position) Cold Plate Slide 40 Assembly of 2 Cold plates + Stave Dowel pins removed