Construction of the Tracker End Caps CMS Tracker MPR

22/11/2004D. Contardo

Aachen I, Aachen III, Antwerpen, Brussels, Hamburg, Karlruhe, Louvain, Lyon, Strasbourg, UCSB, Vienna, Zurich ETH

1) TEC Organization2) Petal integration3) TEC+, TEC- integration4) Summary

1 TEC - 9 disks - 144 petals of 8 differents types - 3200 SI-modules of 12 different types

TEC Construction Centres Responsibilities (only)

+ Aachen III : module QC and debug+ Antwerpen, Aachen III, Strasbourg, Louvain and UCSB : sampling LT module test+ Karlsruhe : petal production QC, logistics+ Lyon-Aachen I : beam tests system tests, petal debug

TEC+ Aachen

TEC- Lyon

Meetings :- Weekly video conferences, TEC meetings during CERN weeks and workshops outside CERNhttp://agenda.cern.ch/displayLevel.php?fid=395List of links to all web sites relevant to TEC activities :http://lyoinfo.in2p3.fr/cms/cmstraces/TEC_meetings/The_TEC_links.html Responsibles : - Identified responsibles per center and per task (collaboration of various instituts on identified tasks), contribution to Tracker working goups.

Tools :- Specific tools to monitor parts data, production quality and flow : - DB Browser interfaces : http://cmsdoc.cern.ch/~cmstrkdb/ - Nightly update of module test results : http://www.fynu.ucl.ac.be/themes/he/cms/activities/tracker/Modules/multimodule/CMSTEC/cmstec.php - DB link to excel files for comparison of achieved and expected flows

TEC centres work organization

TEC module production status from DB WEB interface of Louvain updated every night :

http://www.fynu.ucl.ac.be/themes/he/cms/activities/tracker/Modules/multimodule/CMSTEC/cmstec.php

Number of TEC modules (by Location)

Location #Total #ArcTested #LtTested #GradeA #GradeB #GradeC

CERN 1 0 0 0 0 0

LYON 26 9 10 9 0 1

VIENNA 60 32 0 32 0 0

COURIER 18 8 0 8 0 0

LOUVAIN 48 41 48 47 1 0

AACHEN-1 59 14 6 17 0 0

AACHEN-3B 181 164 1 153 0 11

ANTWERPEN 101 91 38 97 1 1

HAMBURG-U 30 26 0 25 1 0

STRASBOURG 58 24 32 35 0 2

ZURICH-ETH 188 186 1 182 1 3

BRUSSEL-VUB 28 9 9 9 0 0

SANTA-BARBARA 15 0 13 13 0 0

KARLSRUHE-IEKP 55 49 15 50 1 2

Total 868 653 173 677 5 20

TEC module production yield ~97%

- Validation of petal design inBeam Tests and System Tests(Aachen I -Lyon)

- Petal Mechanics constructionand test (Aachen I, Louvain)

- InterConnectBoards (Aachen I)

- Assembly and Deep Qualification :two pilot centres (Lyon,Karlsruhe) to develop set-ups Cloned at other PICs.

TEC PETAL INTEGRATION

TEC PETAL INTEGRATION : 1) PETAL DESIGN VALIDATION

Beam test : 1 read-out loop, 1Front+1Back Petal cooling at -20°http://accms04.physik.rwth-aachen.de/%7Ebrauer/testbeam_2004/index.html

http://lyoinfo.in2p3.fr/cms/cmstraces/Beamtest/beamtest_online.html

TEC PETAL INTEGRATION : 1) PETAL DESIGN VALIDATION

Beam test : 1 read-out loop, 1Front+1Back Petal cooling at -20°

TEC PETAL INTEGRATION : 2) PETAL MECHANICS

Link : Petal_production.doc

A/ Cooling Pipes + Manifolds:• Cooling pipes bent in Louvain• Manifolds produced by IPT• Manifold + pipes in welding jig (Aachen)• Laser weld manifolds (IPT)• Leak test with N2 at 12 bar (Aachen)

B/ Prepare petal bodies:

• Glue second skin on underside of Eurocomposite CF plates (ADCO)

• Precut plates into petals (1 plate = 5 petals) in Aachen

• Machine petal bodies into exact shape + machine grooves and holes (IPT)

C/Complete Petals:

• Equip petal with cooling pipe and cooling inserts (also the PEEK inserts for mounting the ICBs) in the gluing jig (Aachen)

• Glue in the AOH bridges (after removal from glueing jig) – (Aachen)

• Glue the second skin on the upper side, thus closing the petal (ADCO)

• Precision machining of inserts (Aachen)

• Glue the 3 feet to mount the petal onto the TEC disk (Aachen)

• Glue protection rims, manifold inserts and 2D label

TEC PETAL INTEGRATION : 2) PETAL MECHANICS

All material available.Production rate: 2 petals/day(Limited by : gluing pipes+inserts in petal -- here the issue is manpower, and precision machining)

Mass production will start in January and will be finished in Dec. '05 (Assume no production in August, plus some contingency).

 

D/Petal testing (Aachen):• Register petal in DB• Check electrical insulation + thermal efficiency of inserts (enter results in DB) E/ Mount the ICBs (Aachen): icbtest.pdf• All ICBs prepared and tested (28/02/2005) (ICBs for 30 front and 30 back petals available 30/11/2004)• Mount ICBs on petals• Readout test on sample basis (10%)

TEC PETAL INTEGRATION : 2) PETAL MECHANICS

12 types of modules, 13 types of optohybrides, 10’s of mechanical piecesAssembly guided by dedicated program :- All steps of assembly described in

order - Component types and status checkedfrom DB - Component functionalities (400)performed automatically after mounting- Petal composition files generated forDB and LT set-up

TEC PETAL INTEGRATION : 3) ASSEMBLY

B. Trocme http://lyoinfo.in2p3.fr/cms/cmstraces/PetalAssembly/Petal_assembly.html

Explicative picture

Comments on:- pieces to be used (centre liner,distance plates...)- screw length- torque mom. to apply- aob...

TEC PETAL INTEGRATION : 3) ASSEMBLY

typical explicative pictures

TEC PETAL INTEGRATION : 3) ASSEMBLY

TEC PETAL INTEGRATION : 4) LONG TERM QUALIFICATION

- commissioning of petal- 3 days of warm cold cycles for stability test- generate result .xml file

G. Dirkes : http://www-ekp.physik.uni-karlsruhe.de/%7Edirkes/petals.htmlhttp://www.fynu.ucl.ac.be/users/o.militaru/SlowControl-petaltest.htm

TEC PETAL INTEGRATION : 4) LONG TERM QUALIFICATION

Software :• Optoscan runs (~12 min)• Time tune runs (~5 min)• Ped runs (~7 min per APV mode)• Cal profile runs (1.5 h per APV

mode) • IV runs (2 h / to be optimised! Expect

8-12min finally)• Latency runs (2 h peak inv on)• Scenarios working• Slow control and interlocks ready

(Louvain)

TEC PETAL INTEGRATION : 4) LONG TERM QUALIFICATION

Constrains for petal integration rates

● Integration takes two days with two operators and can be done in parallel with LT testing

● Commissoning in LT setup takes 1 day, assembly bench needed in case of problems to replace faulty parts

● LT test takes 3 days

Setup

LT

1st day 2nd day3rd day 4th day 5th day 6th dayAssembly Assembly

Commission Lt testing

Rate of 1 petal / week is a conservative estimate

TEC PETAL INTEGRATION : 5) PRODUCTION RATE

Assembly set-up : all hardware available, all centers able to run the assembly program (as a result of recent workshop in Karlsruhe)

Long Term set-up : Still some read-out modules missing (expectedbefore end of 04). Software available to be adapted for none expert operators

Manpower available at all centres : PICsmanpower.ppt1 responsible, 2 operators full time, support for hardware and software.

Qualification of centres : level of commissioning will be controled before assembly of final petals. In the qualification phase, starting in December 04, assembly and LT exercises will be performed with non qualified modules of early production.

4 centres ready for assembly : Aachen, Karlsruhe, Lyon and Strasbourg3 centres have experienced petal assembly and cooling : Aachen, Karlsruhe, Lyon

TEC PETAL INTEGRATION : 5) CENTRES STATUS

1 petal/week/PIC

- First sector of 18 petals (existing modules + first Hybrid batch) mid-Apr. 05

- Start of petal integration May 05

- Ramp-up due to hybrid batch deliveries up to end of July

- Petal production TEC+ Nov. 05

- Petal production TEC- May 06

TEC PETAL INTEGRATION : 5) PRODUCTION SCHEDULE

Large number of centres implies weekly control of all the production from modules to petals to properly dispatch parts from centre to centre (present surface transfers of parts managed through efficient DHL-IN2P3 contract).

TEC INTEGRATION : OVERVIEW

TEC Structures :- TEC mechanics and alignment (Aachen I) - TEC Services (Karlsruhe, Lyon)

TEC Integration :- Before structures ready : Mock-up for preparation of commissioning (DAQ and Slow Sontrol) equipped with first sector (18 petals) (Lyon)- TEC+ structure ready : test of petal insertion, grounding and schielding, and insertion in Tracker tube (Aachen I). Petal integration- TEC- structure ready : cold and system test 1 sector (Lyon). Petal integration starts when TEC+ petals delivered- Back disk + 4 petals test in magnet, (Karlsruhe)

Link : TEC_assembly.doc (Aachen I)

TEC assembly needs a granite table with a hole in the center (measured planarity of Aachen table 7μ).

 

Building the stack :

- Each disk equipped with assembly and petal fixation inserts.

- 12 spacer feet mounted on granite table, Disk1 placed on these feet. -- Rods threaded into the feet and distance holders guaranteeing the z-distance between Disks1 and 2 placed on these rods.

- Disk2 mounted, procedure repeated till the stack is complete.

- Alignment Disk (disk 10) similar to normal disk with spacer profiles glued to ensure rigidity with disk 9 is placed on the TEC stack and the profiles are glued onto Disk9.

 

TEC INTEGRATION : PREPARATION OF STRUCTURE (1)

Adapter plates, onto which SCs will be glued, attached to the U-brackets on the disks.

Service Channels prepared : seal with glue all milled edges and glue in the SC inserts (later to hold the TEC outer covers). Mount and glue the SCs onto the adapter plates.

Same principle is to attach the 4 inner tube segments to the disks.

Structure disassembled : SCs and inner tube segment taken off by unscrewing the adapter plates from the U-brackets on the disks, etc.

Service channel filled with optical ribbons in Karlsruhe, during this time the alignment system components will be mounted on disk#6.

Structure reassembled : Disk1 on the spacer feet on the granite table; the SCs are mounted on Disk1 and the remaining disks are then screwed onto the SCs via the adapter plates.

Bulkhead (holding the cable patch panels) attached to the back end.

Cooling pipes and multiservice and control cables mounted on the TEC structure.

TEC INTEGRATION : PREPARATION OF STRUCTURE (2)

Link : TEC_Services_Installation.docFibre ribbons : qualification at CERN, continuity test at assembly (Karlsruhe) Pipes : air test at 20b (Lancashire), flow with coolant and pressure N2 at 20b tests (Lyon)Cables : Insulation and continuity test (ADAPT), repeated in Lyon

TEC INTEGRATION : PREPARATION OF STRUCTURE (3)

Structure moved from granite table to integration cradle up to Tracker tube insertion

TEC INTEGRATION : PREPARATION OF STRUCTURE (4)

Alignment system : TEC_alignment.doc

TEC INTEGRATION : STRUCTURE SCHEDULE

Link : TEC_assembly.mpp, TEC_assembly171104.html

Summary : - Pre-assembly of TEC+ (granite table) mid-Dec. 04- Pre-assembly of TEC- (granite table) mid-Dec. 04 to mid- Feb. 05 in parallel preparation of TEC+ service channels, pipes + MSC cables,- Assembly TEC+ end of Apr. 05- Move TEC+ to cradle photogrammetry and petal insertion test mid-Jun. 05 in parallel TEC- assembly mid-Jul. 05- TEC+ integration test in tracker tube mid-June to mid-July 05 - TEC+ ready for petal insertion in Aachen mid-Jul. 05- TEC- ready for cold and system test with sector in Lyon mid-July 05

Contingency of 1 month included in schedule

TEC INTEGRATION : PETAL INSERTION AND COMMISSIONING (1)

Link : TEC_integration_V3.1.pdf- Reception of the TEC structure in integration cradle :

- Check cradle functionality (rotation) - Check mechanics and services - Phototgrammetry measurement in Lyon (room temperature and -20°)

- Special petal transport organized by Lyon and Aachen to collect petals- Perform petal reception test (independent of integration) :

TEC INTEGRATION : PETAL INSERTION AND COMMISSIONING (2)

- Mechanical insertion of Back petal towers (9 petals on 9 disks) Disks used as a plate for petal insertion, tool design in progress in Aachen- Connection to services, interface to DB - Rotate the TEC in cradle, repeat operations for Front petals

TEC INTEGRATION : PETAL INSERTION AND COMMISSIONING (2)

Test sequence :- At the beginning test petal functionality after each insertion- Perform test of read-out loops of a sector (pairs of front and Back petals) commissioning tasks plus pedestals, calibration, cooling measurements - Perform laser and cosmic test for alignment

Integration time : 1 week per Tower + 1 week of read-out tests : 1 day per petalContingency in assembly and test procedure

TEC+ petal integration completed : March 06TEC- petal integration completed : June 06

TEC transport to CERN : contact with Hasenkamp expert firm in transport ofprecious and fragile objects in controled atmosphere

TEC INTEGRATION : AACHEN CENTRE

Team : 4 physicists, 2 engineers, 3 technicians Equipments :Clean room facility existing, available end of 04Cooling plant 10kW, Dry air Petal storage facilityRead-out for petal reception available Read-out for TEC integration mid-05

TEC INTEGRATION : LYON CENTERTeam : 3 physicists, 3 engineers, 2 technicians Equipments :- Cold-Dry-Clean room facility 64m2- 2 kWt cooling plant (1 sector)- Dry air system 25m3/hour- Petal storage rack designed (groups of 5 petals with cold walls for multi-petal test)- Read-out for petal reception available - Read-out for TEC integration : 1 VME 9U, 1 FED 9U, Caen PS system with 3PSUs (1 petal) additional hardware spring-05

TEC MPR SUMMARY (1)

TEC petal production

- Petal mechanics production not on critical path

- First petals will be produced in operational centres for full assembly and LT procedure validation end of the year (9 front (tower) and 1 back petals)

- All centres will be qualified by March 05

- Nominal throughput for present schedule is 1 petal per week with an expected contingency to reach 1.5

- Possible increase of assembly throughput with more manpower, alternatives in the procedure to speed-up the petal LT will be investigated

Present schedule driven by hybrid and module flow

(and repartition of geometries in hybrid batches)

All geometries needed at assembly time

TEC MPR SUMMARY (2)

TEC Integration

- Established working plan and schedule for TEC+ and TEC- mechanics delivery

- Established sharing of responsibilities between two integration centres : TEC+ integration in priority while commissioning and system qualification proceed with TEC-

- Established (but flexible) procedure for petal integration and test

- Magnet test foreseen with 4 petals on back disks

TEC MPR SUMMARY (3)

TEC present schedule

TEC+ petals integrated March 06

TEC- petals integrated June 06

TEC Production

0

0.2

0.4

0.6

0.8

1

1.2

Jan-

05

Mar

-05

May

-05

Jul-0

5

Sep-0

5

Nov-05

Jan-

06

Mar

-06

May

-06

Per

cen

tag

e

Assembled TEC Hybrids TECModules

Petal Mechanics Integrated Petals

Integrated Sectors

CMS TEC Community

Mailing-list