production readiness review

Production Readiness Review

Production steps and quality control

1. Panel production2. HV bar gluing3. Preparation of side material4. Wiring and gluing wires5. Wire soldering6. Preparation of wire plane7. Gluing lateral bars8. Assembly of the chamber9. Chamber conditioning10. Mount FEE and Faraday cage

1. Panel thickness, planarity2. Pad electrical connections3. HV bar height4. Measurement of wire pitch5. Measurement of wire tension6. HV test of each wired panel7. Measure of p (gas leakage)8. Uniformity test w. source9. Test with cosmic rays

LNF – 4 december 2003 – C. Forti

Gold - Gold

Pad - Pad

Copper - Gold

Pad - Pad

Gold - Copper

Type and number of panels needed

Pad - Pad

Copper - Gold

Gold - Copper

Quadrigaps:M3R3 (48 ch)+10%M5R3 (48 ch)+10%

Bigaps:M1R3 (48 ch)+10%M1R4 (120 ch)+10%

Total = 290 chambers794 panels with wires

Time needed:

10 panels/week 80 weeks ~ 1.8 yrs

6 panels/week 132 weeks ~ 2.9 yrs BAD

Bigap M1R3,4

Quadrigap M3,5R3

I will show that 10 panels/weekis a reachable production rate

Production steps: panels and HV bars

PANEL PRODUCTIONMeasure panel thickness

Produce HV bars

Mount R, CConformal coating

PREPARATIONVisual inspectionCheck planarityCheck pad contactsClean panel

HV BAR GLUING

POST-GLUINGVisual inspectionMeasure bar heightSolder connectorsClean panel

Clean HV bars

Description of panels

Sandwich panel

4 gaps

Description of panelsA small quadrigap prototype Cathode pads

Closing bar

Lateral bar

Panel thickness and planarity

According to simulations (Riegler), the requirements on the gain:• G0/1.25 < G < G0*1.25 over 95% of the detector area• G0/1.50 < G < G0*1.50 over 5% of the detector area

where G0 is the nominal gain translate into the following requirement:

Gap = 5 mm ± 90 m (95% of detector area) ± 180 m (5% of detector area)

Since the gap is provided by the 5mm spacers placed between the panels,along their frames, the gap uniformity is related to the uniformity of the panelthickness and to its planarity.

The absolute value of the panel thickness is crucial when a panel is wired onboth sides, because the distances between the wire planes and the panelsurfaces depend on thickness. The requirement is T=9.0 ± 0.2 mm

In LNF chambers, where we wire only one side of the panel, the absolute valueof the thickness is not crucial, while its uniformity is. At the company the panelthickness is measured with a tooling based on inductive sensors.

Device for thickness measurement

7 sensors

Device designed and realised by Roma 2 group

Status of device

The device is well calibrated for Cu-Cu panels. Some more work is needed for precise ABSOLUTE measurement of Gold panels.

Anyway, the system is very precise to thickness fluctuations and is sensitive to variation of planarity along panel width (the most important).

10 hrs measurementRMS = 70 nm

8

m

Thickness and Temp. vs. TimeDown to 1 m jump appreciableFine structure due to air conditioning cycles

All panels measured within specs for thickness absolute value.

Comparison Autom. device vs. Micrometer

9.06

9.16

9.14

8.98

Device calibrated9.07 < t < 9.15

Device not calibratedDevice:8.99 < t < 9.04Micrometer:9.06 < t < 9.12

All measurementswithin ± 40 um

Manual check of thickness

The more recent production:

50 panels over 130 totalhas been measured manuallywith a micrometer.

5500 measurements provide:

< T > = 9.1 mm(T) = 21 m

Even at max production rate(~ 20 panels/day with 3 moulds)a relevant fraction of ~10-15%of the panels will be checkedwith micrometer.

Manual check of planarity

50 m

A check of panel planarity will be performed at LNF on ALL panels , before gluing the HV bars.

planarity < 90 m (95% of detector area) < 180 m (5% of detector area)

Layout of HV bar gluing room

SHELVES FOR PANELS BEFORE GLUING

PREPARE PANEL

SHELVES FOR PANELS AFTER GLUINGCU

PB

OA

RD

GLUING

SO

LD

ER

ING

PREPARATIONVisual inspectionCheck planarityCheck pad contactsClean panel

HV BAR GLUING

POST-GLUINGVisual inspectionMeasure bar heightSold connectorsClean panel

Clean HV bars

GLUING

GLUING

GLUING

AFTER GLUING

HV bar gluing machine

Suction cups

HV barwith R,C

HV barwithout R,C

Schedule of operations in HV bar gluing room

The most pessimistic estimate: production rate=2 panels per dayOne operator free, any 2 days: can help in final chamber assemblyin clean room.

8 9 10 11 12 13 14 15 16 17 18

1,2

5

6

Remove panels from gluing tables (30 min) + Clean the gluing tables (30 min)3,4

Prepare 2 panels for gluing: Visual inspection. Check planarity, eletrical contacts. Clean. Put label, glue ground tape and clean HV bars (2 hrs)

GLUE DRYING5

6Glue bars (30 min)

7

8

GLUE DRYING7

8Glue bars (30 min)

Prepare 2 panels for gluing (2 hrs)

1

1

2

2

LUNCH 3

3

4

4

Visual inspection, check bar height (45 min)

Solder HV connectors (45 min)

LUNCH

LUNCH

7

8

Traveler for “Panel Preparation for gluing of HV bars” (I)

Traveler for “Panel Preparation for gluing of HV bars”

Must come with:

Plot of panel thickness

Version 2 (4-dec-03) Take panel from shelf:UNPREPARED

Panel number : Gold - Gold M1R3 M3R3

Chamber : Gold - Copper M1R4 M5R3

Layer : Pads - Pads

VISUAL INSPECTION Operator Date Time OK

Hospital

List pad # and defects:

PANEL PLANARITY Operator Date Time OK

Hospital

Requirements: 95% of area within +- 90 um / 5% of area within +- 180 um

Comments:

Traveler for “Panel Preparation for gluing of HV bars” (II)

PANEL CLEANING Operator Date Time OK

Hospital

Comments:

PAD CONTACTS Operator Date Time OK

Hospital

Comments:

Ready for bar gluing ? Operator Date Time Put panel on shelf:READY FOR GLUING

YES NO

100 <p< 140 m

DRESSINGROOM

Layout of clean room

WIRING

WIRE GLUING

WIRE PITCH

SOLDERINGPREPARATION

LATERAL BARS

HV TEST

WIRE TENSIONASSEMBLY

LEAKAGE TEST

SHELVES

TA

BL

E

CONDITIONING

CU

PB

OA

RD

TABLE

Clean room LNF

WiringWire gluing

Pitch controlsoldering

Gluing of lateral bars and HV test

Clean room LNF Cut wires, solder connectors

Gluing of lateral bars and HV test

Chamber assemblyGas leakage test

Wiring and wire gluing

Wiring and wire gluing

It is feasible to wire 2 panels/day, corresponding to 2.5 (4-gaps)/weekThe critical point is the waiting time needed before turning the machine and gluing the 2nd panel. We will test if a local increase of temperature shortens this time.We measured the wire tension at 2 different temperatures:Temp = 22 degrees T = 69.08 g Temp = 26 degrees T = 70.41 g = 0.33 g/degree we will increase temperature of ~ 3 degrees

8 9 10 11 12 13 14 15 16 17 18

3

4

Panels

5 and 6

WIRING

GLUE DRYING GLUE DRYING

WIRINGMACHINE

Wire spool back (45 min)

Take out panels 3,4 (15 min) + Put new panels (5,6) on machine (1 hr 15 min)

Wiring (1 hr 45 min)

Put guard wires (30 min)Glue one side (30 min)

Drying (~3 hrs) + glue other side (30 min)

Wire pitch measurement (1hr) + soldering (1 hr)

LUNCH

LUNCH

Wire pitch control

According to simulations (Riegler), the requirements on the gain:• G0/1.25 < G < G0*1.25 over 95% of the detector area• G0/1.50 < G < G0*1.50 over 5% of the detector area

where G0 is the nominal gain translate into the following requirement on the wire pitch:Pitch = 2 mm ± 50 m (95% of wires) ± 100 m (5% of wires)

The check is performed with anautomatic measuring device,based on 2 cameras scanning thepanel, positioned on the same structure supporting the laser heads for wire soldering.

The time for the test is ~ 1 h/panel for the largest chambers and requires one operator.

Wire pitch control

Results are expressed in pixels: 211 pixels correspond to 2 mm.We require: 206 < pitch < 216 for 95% of wires

201 < pitch < 221 for 5% of wiresAll panels checked up to now satisfy these requirements(except one wire of one panel)

Wire soldering

The wire soldering is performed with 2 lasers on each wire side and 2 camerasdisplaying the work of the soldering heads. Here we count on the reliability ofthe automatic system. The operator can only seldom have a look to the monitors.The time of the soldering procedure is ~ 1 hr/panel for the largest chambers andrequires one operator to execute the procedure. Check of soldering and (eventual)retouching is performed on the next table (panel preparation).

8 9 10 11 12 13 14 15 16 17 18

3

4

Panels

5 and 6

WIRING

3


3

4 4

SOLDERINGMACHINE

WIRINGMACHINE







LUNCH

LUNCH

LUNCH

Panel preparation

8 9 10 11 12 13 14 15 16 17 18

After soldering, the panel is moved to another table for:

1. Retouching of soldering2. Cut wire edges3. Clean bars4. Turn panel upside down5. Soldering of HV connectors (for pad-pad panels)6. Check pad integrity7. Final cleaning of panel (opposite side respect to wires) Time = 1 hr 30 min with 1 operator (for big pad-pad panels)

3

3

3

4 4

3 3

SOLDERINGMACHINE

4 4 4

Check soldering (15 min) + Wire cutting (30 min)


PANELPREPARATION

LUNCH

LUNCH Solder connectors (45 min)

Wire tension measurement

The wire tension has to be verified (in order also to detect early possibleanomalies in the wiring machine).The wire elastic limit is ~130 g. For stability requirement, no wire should have atension less than 50 g (Riegler).

Estimated time of the test: approximately 1 hr 30 min per panel for the largestchambers. One operator is needed to place the panel and start the software.The procedure is completely automatic. A data file is provided in output,together with a plot.

We measure the wire tension with an automatic device providing an oscillatingHV to a reference wire placed just above the measured wire (at ~1 mm).The system detects the resonance corresponding to the maximum oscillation ofthe relative capacity between the reference and the measured wire.

For a given wire length and density (13.6 mg/m for our wire), the frequence of the resonance corresponds to a mechanical tension.Typical value is ~ 330 Hz.


Wire Tension Meter developed by Roma 1 group


Panel 4 Chamber 1 Layer 3

55

60

65

70

75

80

0 100 200 300 400 500 600

Wire number

Ten

sio

n (

g)

3

3

3 3

4 4 4

4WTM


Wire tension measurement (1 hr 30 min)Operator needed only at start.

PANELPREPARATION

LUNCH

3LUNCH

Solder connectors (45 min)

8 9 10 11 12 13 14 15 16 17 18

<T>=68 ± 3 g

Traveler for “WTM, gluing of lateral bars and HV test” (I)

Traveler for “WTM, lateral bar gluing and HV test”

Must come with:

Plot of panel thicknessTraveler for “Panel preparation…”Traveler for “HV-BAR gluing”Traveler for “Panel wiring”Traveler for “Panel soldering and preparation”

Version 2 (20-nov-03) Take panel from WTM machine

Panel number : Gold - Gold M1R3 M3R3

Chamber : Gold - Copper M1R4 M5R3

Layer : Pads - Pads

WIRE TENSION

Operator Date Time

OK

Hospital

Requirements: NO wire with T < 50 g or T > 90 g < T > = (T) = Number of files:

Gluing of lateral bars and HV test in air

After wire tension measurement, the panel is moved on table for gluing oflateral bars and high voltage test in air.

We have chosen to perform these operations together on the same tablebecause they both require a relevant amount of time (the night is used).On this table, 2 panels can be glued and HV-tested at the same time.

Gluing of lateral bars and HV test in air

8 9 10 11 12 13 14 15 16 17 18

3,4

3 4WTM

3,4 HV TEST

BAR GLUING + HV TEST

Wire tension measurement (1 hr 30 min)operator needed only at start and stop

Glue lateral bars (30 min) + Start HV test (1 hr)

3LUNCH

HV TEST PANELS 1, 2

HV test: at 2 kV in ~2-3 hours (at 40% rel. humidity) the current usuallydecreases and reaches less than 100 nA/per plane.Current limitation is set to 200 nA per plane in order to not damage the panel.

Gluing of lateral bars: ~ 30 min needed for 2 panels together (1 operator)

Estimated time of the test: approximately 12 hrs including both glue dryingand HV test. The whole night will be used if the gluing starts in the afternoon.This is compatible with the production schedule of 2 panels/day

HV test in air

At HV=2 kV, the current reaches ~ 100 nA within ~ 2-3 hrs for most panels.In 1 case over 7, one whole night was needed.

Traveler for “WTM, lateral bar gluing and HV test” (II)

LATERAL BAR GLUING Operator Date Time OK

Hospital

Comments:

HV TEST IN AIR Requirement: I < 100 nA @ 2 kVafter few hours

OK

Hospital

Operator Date Time HV I (nA) % Hum.

In the future, probably the test will be automatic

Final chamber assembly and gas leak test

After gluing of lateral bars and HV test, the panels are ready to be assembled in the chamber.On the table of chamber assembly we also glue the gas connectors and perform the gas leakage test.Time: assembly = one full day (2 operators) leakage =1 hr 30 min (1 oper.)

8 9 10 11 12 13 14 15 16 17 18

Final chamber assembly

glue

spacerClosing bar

Lateral bar

Final chamber assembly

Total measured height: 65.2 < h < 65.3 mmExpected:5 panels + 4 gaps = 5*9 + 4*5 = 65 mm

Traveler for “Chamber assembly and leak test”

ASSEMBLY Operator Date Time OK

Hospital

O O O

OOO O O

OO

Height (mm)

Height (mm)

O O

Gas leakage test

FIT: p = p0 e-t

p 0 = 4.99 mbar

= -0.29 hr -1

Automatic measurement of p, p and T vs. time recently set up. Correctionsfor T and P variations still not included.

Conditioning and tests

DRESSINGROOM

WIRING

WIRE GLUING

SHELVES CONDITIONING CONDITIONINGUNIFORMITY TEST

PC

RA

CK

S

COSMIC RAY STAND

We have to decide if doing (gas+HV) conditioning in clean room or in the testroom. We don’t know exactly how much time is needed for conditioning,however the shelves can allocate 6 chambers (>2 weeks production).

Uniformity and cosmic ray tests are described in D.Pinci’s talk

MOUNT SPB

Preparation/check of side material

In the laboratory:

• Check and preparation of HV barsVisual inspection, check of integrity, cleaning of the HV bars

• Cleaning of the lateral bars• Cleaning of the closing bars• Check of wire quality samples (15 min/spool)

Visual inspection of wire quality using a microscope (one sample per spool)

• Cleaning of the spacers and of the plastic rings (used to avoid that glue goesunder the spacers)

One person can prepare in one work day the material needed for5 M3R3 chambers, corresponding to ~10 days of wiring (at 2 panels/day rate).

Manpower needed

8 9 10 11 12 13 14 15 16 17 18

Clean room

LUNCH

LUNCH

LUNCH

LUNCH

LUNCH

WIRING

DRYING

LUNCH

every 2 days

2nd day

1st day

LUNCH

LUNCH 2nd day

1st day

LUNCH Bar gluing room 2nd day

1st day

Tests room UNIFORMITY TEST WITH SOURCE AND COSMIC RAY TEST: 1 OPER. EVERY DAY

LUNCH

every 2 daysMOUNT SPB BOARDS, FEE GROUNDING, FARADAY CAGE: 1 OPER. EVERY 2 DAYS

PREPARE SIDE MATERIAL: 1 OPER. ONE DAY/WEEK Laboratory

9/10 people is the need to insure a 2 panel/day production rate

Conclusions

Production and quality control procedures are defined in detail

The time needed for each operation is decreasing rapidly duringlast weeks of intense work we can reach soon a productionrate of 10 wired panels/week

Come to visit our clean room: you will find one panel or chamber in each production/(quality control) step.We will be glad to receive your suggestions.

LNF – 4 december 2003 – C. Forti

Wire quality check

At the moment, we only weigh the wire spool to verify the constancyof wire density (13.6 mg/m).

In the future we plan to check the wire quality samples (~15 min/spool)Visual inspection of wire quality using a microscope (one sample per spool).

The wire in a spool will be ~ 4.2 km, enough for wiring of 10 panelsM3R3 (i.e. 2.5 full chambers). This corresponds to 5 days of wiring.

Production Schedule in clean room8 9 10 11 12 13 14 15 16 17 18

3

4

Panels

5 and 6

WIRING

3

3

3,4

3


3

4 4

3 3

SOLDERINGMACHINE

4 4 4

4WTM

3,4 HV TEST

BAR GLUING + HV TEST

1

DRYING

2 over 1

CHAMBER ASSEMBLY

WIRINGMACHINE








Wire tension measurement (1 hr 30 min)Operator needed only at start.

Glue lateral bars (30 min) + Start HV test (1 hr)

Gas leakage previous chamber (1 hr 30 min)

2

PANELPREPARATION

LUNCH

LUNCH

LUNCH

LUNCH

GAS LEAKAGEPREV. CHAMBER

3LUNCH

LUNCH

HV TEST 1, 2

Glue closing bars (30 min) + Glue panel on top and check height (45 min) + Glue gas connectors (45 min)

gasGLUE DRYING

ON SHELVES UNTIL NEXT DAY (WAITING FOR 3,4)

3 over 2 3 4 over 3 4 5 over 4

LUNCH connect

Solder connectors (45 min)

SPARE PANEL PRODUCTION

The mould

The moulds

M3R3 prototypes small prototypes

The lower half of the M3R3 mould

FR4 foils fixed Both FR4 foils fixed

End of injectionInjection completed and clamps opened

clamps

foamvacuum pipes

SPARE PANEL THICKNESS

The proximity sensor

Inductive proximity switch

Courtesy Danilo Domenici INFN- ROMA2

Calibration

≈ 10mSensitivity = 1.23 V/mm

linear fit around the flexcalibration curve: Vout vs distance

2N

B)Ax(yσ i

2ii

y

maxy)(σ ≈ 20m

RMS of the residuals for linear approx

Max residual for linear approx


Stability and Temperature dependence

3 days stability measure

Down to 1 m jump appreciable

40

m

8

mThermal stresses of mechanics

also contribute at this level

Fine structure due to air conditioning cycles


Temperature dependence

Slope = -7.5 m/0C

Clean correlation over10 hours time2 celsius degree


Spread of measures

Distance vs time corrected for temperature variations

Spread of measures

RMS(10h) = 70 nm !


Measurement of panel thickness

Measurement of panel thickness (with a micrometer)INDUCTIVESENSORS PANELSensitivity =10 m

118 points measured all overan M3R3 panel (1364x346 mm2)

40

40

20 50 70 60 60 60 60 20

10

10

7.826

7.834

7.810

7.811 7.804

7.804

7.839

7.828

7.811

7.858

7.844

7.823

7.848

7.835

7.816

7.837

7.826

7.804

7.832

7.822

7.814

7.836

7.830

7.820

7.850

7.050

7.840

7.93 7.93 7.93 7.94 7.94 7.95 7.96

3D machine AltoCoppia Sens. 12-13

3D machine BassoCoppia Sens. 00-01

MicrometroRosso-Verde misure su vetroBlu misure con nastro Cu 40um

Glass for calibration

Misure nel tempo di pan26

3D view of panel 26

Pan_29 Pan_31

Curva_tara in funz. Spessore cu

SPARE WIRE TENSION

Request on the wire tension

Since the MWPC wires will be vertical, the gravitational sagitta is not the main issue;

The mechanical tension lower limit is given by the request of mechanical stability due to the wire electrostatic reciprocal repulsion:

The upper limit is given by the elastic limit which, for our 30 m diameter wires, is about 120 g.

We consider completely safe the request of a in the range:

V: electrical tension 3 kVC: wire capacitance/length = 0.08 pF/cms: wire spacing = 2 mml: wire length = 30 cm

> 20 g

The wire tension meter

The system was developed for the KLOE drift chamber and the principle of operation is explained in details in NIM A (409) 63,64 1998;

It is based on the measurement of the capacitance between the chamber wire (with radius a) forced to oscillate at a frequency and a sensor wire (with radius b):

The capacitance depends on the distance d:

During each oscillation we measure the resonance frequencies (A and B) of an LC circuit having Ctot = C0+ C(d) in the configurations A and B;

= A - B is a function of the wire oscillation amplitude;

By varying we find the wire resonance frequency 0 which maximizes

A B

d

The resonance peak

The resonance peak is clearly visible and narrow.

= wire mass per unit length

As the damping effect is negligible:

The measurement table

The table for the wire tension measurement was designed and built in Roma1.

MWPC chamber16 ch sensor

high-precisionlinear modules: ball screw drive (5 mm pitch) by “Bosch” with 100 m max certified error after 1.6m. 5 m rms in y.

stepping motor with

(1.8°0.09°)/step controlled via

serial port by a “RTA MIND” driver We measured the X positioning on the last wire after a complete

measurement-run finding an rms of about 10 m.

yx

wire tension gain uniformity cosmic-ray test

production readiness review

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