Status of the Tracker Outer Barrel

Joe Incandela

University of California Santa Barbara

for the illustrious and colorful

TOB Group

Tracker General Meeting July 15, 2005

(Slides compliments of D. Abbaneo, A. Affolder, C. Campagnari, A. Marchioro, A. Onnela, Lenny Spiegel, and many

others…)

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 2

US Module Assembly Plates

Now in use proposed Totals

Plate Types UCSB FNAL UCSB FNAL Actual If add R7 at FNAL

TOB R-phi 7 8 15 15

TOB Stereo 3 4 7 7

TEC R5 R-phi 3 3 3

R5 Stereo 3 3 3

TEC R6 5 5 5

TEC R7 3 5 3 8

Totals 24 12 5 36 41

We are now setup to process at most 15 plates (20 plates) per day (extended day). A much larger number of plates was prepared to allow us to adapt to whatever variations may occur in component deliveries and tracker needs.

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 3

US Production Cycle

Quick test hybrids on ARC Gantry makes modules.

Modules test on ARC

Assemble rods from modules Rod burn-in Rods shipped to CERN

Thermal cycled module

Wir

e b

on

d

Final pinhole test on ARC

Wire bond

Thermal cycle hybrids

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 4

US Tracker Group

• Brown University• R. Hooper, G. Landsberg, H.D. Nguyen, C. Pehlevan, T. Hartman, H.Y. Jung

• University of California, Riverside (UCR)• G. Hanson, H. Liu, G.Y. Jeng, G. Pasztor, A. Satpathy, R. Stringer

• University of California, Santa Barbara (UCSB)• A. Affolder, S. Burke, C. Campagnari, F. Garberson, D. Hale, J. Incandela,

S. Jaditz, P. Kalavase, S. Kyre, J. Lamb, D. Stuart, D. White + technicians • University of Illinois, Chicago (UIC)

• E. Chabalina, C. Gerber, L. Nigra, T. Ten• Fermilab (FNAL)

• S. Cihangir, M. Demarteau, D. Glenzinski, H. Jensen, A. Ronzhin, J. Spalding, L. Spiegel, S. Tkaczyk + technicians

• University of Kansas (KU)• P. Baringer, A. Bean, L. Christofek, D. Coppage

• Mexican Consortium: • Cinvestav: H. Castilla, R. Perez, A. Sanchez• Puebla: E. Medel, H. Salazar• San Luis Potosi: A. Morelos

• University of Rochester (UR)• R.Demina, R. Eusebi, Yu. Gotra, E. Halkiadakis, S. Korjenevski, S. Lockwood

D. Miner, P. Tipton + technicians

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 5

US Production Steps/Status

Task Capacity Manpower issues Software

Issues?

Hardware

Issues?Hybrid Bonding & Thermal Cycle

84/d None No No

Module Assembly

50/d None No No

Module Bonding >50/d None No No

ARC Testing >50/d None No No

LT Testing 200/wk None No No

ARC LED >50/d None No No

Reinforcing >50/d None No No

Rod Assembly 8/d None No No

Single rod test >8/d None No No

Multi rod test >32/wk None Yes Yes

DAQ Component shortages and/or failures can limit production testing capacity in future

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 6

UCSB TEC Production

• Module Production• R5N, R5S, R6 and R7

• All TEC production equipment is commissioned

• With the possible exception of R7 at UCSB

• General capacity issues• Can (and likely will) saturate our capacity with TEC production (30/d)

• Actual rate depends on need and availability of parts as well as TOB production parts availability and schedule

• Bonding and Testing capacity adequate

• LT testing capacity limit is ~100 per week but could eventually be mostly TEC if necessary (since TOB burn-in will be shifted to rods) or it will have to be sampled

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 7

R7 as of yesterday

• Message from Dean White (UCSB)• We built 9 TOB 4-chip and 3 R7 modules today (July 14). 

• All were grade A.   

• For the 6 sensors on the 3 R7 modules built, the angle between the sensors was 4 mdeg or less, and the individual sensors were all 6 mdeg or less. 

• It will take a bit more time to be confident about the R7 assembly plates, but we appear to be headed in the right direction with the rebuilt pick-up tool.

• We are doing dry runs on one of the other R7 plates. 

• The plan is to build on this plate today 

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 8

FNAL & UCSB Inventory – 7/12/05

  Hybrids Sensors Frames  FNAL UCSB FNAL UCSB FNAL UCSB

  Old New IT Old New IT ST HPK IT ST HPK IT    

L12pu 56 0 - 85 0 - 197 516 - 276 357 - 609 644

L12pd 0 0 - 0 0 - “ “ - “ “ - 609 644

L12su 0 0 - 0 0 - “ “ - “ “ - 251 248

L12sd 0 0 - 0 0 - “ “ - “ “ - 251 248

L34pu 56 0 - 85 79 - “ “ - “ “ 61 720 631

L56pu 0 86 - 0 184 - 272 66 - 159 42 45 720 631

                             

R5p 0 5 - 18 496 - 70

R5s 6 4 - 18 496 - 77

R6 0 1 - 0 170 - 229

R7 0 61 - 0 238 - 243

Hybrids are still the critical path components

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 9

Module Issues

• Now storing ~2000 modules

• We’re making storage for ~400 more TOB modules.

• We’ll need even more storage capacity• Continue in batches of 400 storage units

• Musical wirebonders• FNAL has shipped a K&S 8090 to UCSB which will be

commissioned after the UCSB K&S 8060 has a bond-head replacement.

• Once fully commissioned we ship the 8060 to FNAL

• THIS GIVES BOTH SITES MODULE BONDING CONTINGENCY AS WELL AS ADEQUATE HYBRID BONDING CAPACITY

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 10

US module production (to June 10)

US will build >8,000 modules

US peak Capacity ~250-300 modules per week. One week peak so far ~ 100 85

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 11

Other Planning

• Will help accelerate TEC schedule • R7 production at FNAL in Autumn at 12-15 modules per day.

• UCSB will make R5 and R6 at up to 30 per day when TOB is finished

• Second hybrid line• Go-ahead given for up to 2k circuits – David Stuart (UCSB) will

oversee

• Riverside repair and diagnostics center • Nearly online

• Goal to study the small fraction of rejected hybrids/modules in order to fully categorize and document problems

• Create an encyclopedia and museum of pathology that could be referenced during data-taking if similar problems appear on modules that are then completely inaccessible…

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 12

Rods Overview

• Basic components procured

• Assembly of frames is DONE (modulo ICC)

• Integration of modules on rods is understood• Rate of 8/d in the US is not be a problem …≳

• Testing was problematic and rod production was halted• I2C communication errors seen on 30-50% of rods

• Recent and very substantial effort to understand and remedy

• Many thanks to : A. Marchioro, Wim Beaumont, M. Johnson, G. Maggazu, Slawek Tkaczyk…

• Simple solution (number 6) an improvement but not quite..

• A better solution (number 7) adopted and requires new ICC

• Secondary issues of header errors and failures in LT tests are also under study

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 13

Main cause

SCL on FE-Hybrid

SDAUnequal fall-time of SCL and SDA signals

Picture shows sequence of SCL/SDA signals with SDA pulled-down in AOH and measured on FEH

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 14

Solution 6

AOH

FE-Hybrid

SCL

SDA

82

82

PSUControl

PSU FE

LLD

APV

Jumper creates a common time domain but some recent information from US indicates may still be marginal

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 15

Option 7

AOH

FE-Hybrid

SCL

SDA

100 pF

Parasitic on AOH CA

PSUControl

PSU FE

ICC

CRT245(Line driver)

22

pF

pF

330

LLD

DCU/APV

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 16

Effect of “damping” resistor

SDA with“damping”

SDA without“damping”

SCL not show on this slide

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 17

• Assembly procedures well developed

• Trained personnel (including backups) at both sites

• Takes ~ 1-1.5 hours to assemble a rod

• Not a bottleneck• Long term testing 4 (6) (8) DS (SS6) (SS4) rods/2 days

No issues – everything is in place

US Rod Production - Mechanical

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 18

Single Rod Teststand (SRT)

Many room temperature Tests: • Hardwired thermistors and humidity sensors• CCU ring redundancy• DCU readouts• Leakage current• Pedestals & noise

• Looking for gross problems• No channel level characterization

• Most tests done using LtStruct • currently V29

• Hardwired sensors tested with simple custom box

• Root macro similar to module test macro to generate plots

• Plots etc. uploaded to e-log• Output root and text files saved for ALL tests

• including version number, if tested more than once

Only piece missing: protocol for testing digital functionality, experts will provide

FNAL

UCSB

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 19

Sample SRT output

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 20

Multi Rod Test-stand (MRT)

(Semi) long term test

~ 2 days

6-8 SS rods/load

Thermal cycle

Full channel level characterization

FNAL

UCSB

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 21

Current MRT test cycle

Warm

Test

Cold

Warm Cold Test Warm

Test

Cold

TestWarm Test

Expected to evolve…

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 22

MRT status

1. Hardware: all OK, robust now (was very leaky…)2. DAQ software (LtStruct)

• Much progress recently thanks to great cooperation from Wim et al.

• But there are still a few problems

3. Analysis SW: • DefectAnalyzer V0.28 + some changes: Makes plots

and XML file

• First pass cuts defined…will be refined as we learn…

• Custom perl script

• Compares bad channels with lists from module tests and also flags DCU problems, etc

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 23

Current (limited) production

• While I2C solution 7 is being prepared we are assembling and testing a limited number of rods with "jumpers" (I2C Solution 6)

• Test I2C solution 6

• To be shipped to CERN to populate 1st cooling segment, and possibly the cosmic rack

• Gain experience with (somewhat) large scale rod production

• Somewhat longer testing cycle to double-triple-quadruple-check I2C behavior

• Gain experience with testing protocol• Document/investigate non-I2C failures

• Refine cut requirements

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 24

Part Count as of July 13, 2005

UCSBUCSB FNALFNAL

Rods jumpered with Rods jumpered with “solution 6”“solution 6”

1414 3434

Rods populated with Rods populated with modulesmodules

1414 3434

Rods tested at SRTRods tested at SRT 1010 3333

Rods tested with MRTRods tested with MRT 66 1818

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 25

SRT results – out of 43 tested rods

• 5 with unconnected thermistors (as read out by DCU, i.e., these are not the "hardwired" thermistors)• 4 at FNAL, 1 at UCSB

• 1 fails ring redundancy test• FNAL

• 1 Laser failure• FNAL

• 1 with strange problem, open ring? • UCSB, under investigation

• All 4 SS4 rods (UCSB) have unusually high noise

Discussed in TOB m

eeting

where w

e agreed upon the

actions to be taken

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 26

But also…

• Still low rate of I2C errors 230 that we thought would have been cured by jumper (Solution 6)

• Other not-yet-understood I2C errors

• A few other annoyances like header errors

HW or SW problems?

Experts are actively investigating

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 27

Plans

• After this "limited production" we will stop• Take stock of situation, firm up procedures

• Attack other (non I2C) problems

• Hold a mini-workshop to get the UCSB and FNAL-based people together in August• We will likely consider another fairly substantial

production exercise

• Allows one to hunt more rare problems

• Module storage…

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 28

TOB Wheel Assembly

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 29

TOB Wheel

Measurements with theodolites, photogrammetry, slide calipers, and rulers:

Wheel is correct in shape (better than 0.2 mm)

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 30

TOB wheel construction: complete

• Mechanics complete and rotated into final position• Precision elements of disks and cylinders glued on a single jig yielding

typically 30 m relative precision

• Relative positioning of disks and cylinders limited only by measurement system precision (100 m)

Major achievement by Antti Onnela and the DT2 technical crew!

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 31

Thermal screen operational

Wheel ready for insertion in the tracker support tube and…

The tube with thermal screen are already in the assembly clean room.

Wheel on assembly chariot

Wheel ready

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 32

Preparations for TOB integration - where we are as of yesterday

He leak test stand OKRod precabling stand OKCu power cables two weeksCable “bridge” one weekVacuum system for soldering to be commissionedService supports in productionCooling manifolds in productionReadout hardware FEDs/FEC available - firmware 1 week (?)Power supplies availableTest software to be commissioned on C-Rack Plumbing in 186 (cooling and He) Basically done

DB tools defined - only ribbon registration implemented

------ later ------

Alu cables need to update layout and start production (lengths OK)Cable test box in production in Lyon (mid-August) - need updated pinoutDOHMs finalizing tail lengths - start production

Tra

cker

Ou

ter

Bar

rel-

Ju

ly 1

5, 2

005

– T

rack

er G

ener

al M

eeti

ng

slid

e 33

Summary

• Module production lines have completed 25% of TOB• >99% yield and >99.95% good channels

• Production of 40-50 modules/day can be achieved, provided that we have adequate parts flow and stable testing

• Rod frames production in Helsinki is complete

• Rod integration and testing capacity ≳8 rods/day

• I2C communication problem is understood• Rod integration and testing has restarted in the US with solution 6

• Solution 7 likely definitive – will learn more in coming weeks.

• TOB Wheel is ready and other preparations are in train

• Integration exercises will start soon• Very capable team at CERN

• US may send a team in September (headed by Jeff Spalding)