June 8-th 2004W.Baldini1 Ferrara production center Ferrara production center Production Readiness Review OverviewOfOperations P R R

June 8-th 2004 W.Baldini 1

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Overview Overview

Of Of

Operations Operations

PPRR

RR


1. WGS machine: Wiring, gluing, soldering, pitch measurement

2. WTM table: wire cutting, side bars gluing, wire tension measurement, open air HV test (single panel)

3. Assembling table: chamber assembling

4. Service table: HV connections, mylar tape on HV bar A, repairing/fixing problems

Operations overview Operations overview

Clean roomClean room

Outside the clean areaOutside the clean area

1. Gas leakage test

2. OPB mounting and soldering

3. Conditioning / HV test of the chamber

4. Uniformity test with source (?)


Clean room operationsClean room operations

Preliminary operationsPreliminary operations

• Mounting the clamps to fix the panels on the frame (4 in the corners + 3 along each side of the panel)

• Positioning / alignment of panels on the frame

• Check of half gap height

• Protect the cathode with a Kapton foil

• Final cleaning of wire pads with Isopropyl alcohol

Panels entering the clean room have been cleaned already (outside the clean area and in the grey room) and have been checked for geometry and general quality

HV bar A

HV bar B

corners


• We had problems with wires touching the HV bars, this was due to too high HV bars and to the presence of some tin in the points where the fixing clamps go • The HV bars height has been reduced (in Potenza), the clamps have been slightly modified and the tin will be put only after the wiring

Screwed to the frame

Clamp for the panel

Reference surface



1. Wiring

2. While wiring we prepare the guard wires and the glue dispensers (about 5 min before the end of the wiring process)

3. Put the guard wires

4. Gluing

5. Soldering

6. Measurement of the wire pitch (for the first chambers we plan to measure the pitch after each process )

7. Turn the frame and repeat the operations

8. Rough cut of the wires

OperationsOperations on the WGS machine



M1R4(min)

M2R3(min)

M4R1(min)

M4R2(min)

M4R3(min)

M5R1(min)

M5R2(min)

Wiring (14 rpm) 40 50 50 60 50 53 30

Wiring (10 rpm) 56 70 70 84 70 74 42

Soldering 60 75 80 90 85 85 45

Gluing 6 8 8 9 9 8 5

Panels per frame 2 2 6 4 2 6 2

Expected timesExpected times

Preliminary operations: right now it takes about 60-70 min




• Soldering of HV connections

• Gluing of the side bars

• Precise cut of the wires

• Wire tension measurement (for the moment 1 panel at a time). We plan to measure 2 panels at the same time, it needs about half a day of work.

• HV test in air of single panel

Operations on the WTM table

At this point, if all the quality tests are passed (conditions will be shown in the traveler), the panel is ready to be put on a chamber and will be stocked in the shelf: “ready to be assembled”



Assembling of the chamber Assembling of the chamber

• We assemble the chamber using the same tooling used in Frascati

• We plan to distribute the glue automatically (not yet implemented). This allow a better control of the amount of glue

• The height of the chamber is measured (while assembling) in 14 points for each layer

A

B

1 7

814


Clean room operationsClean room operations Assembling of the chamber Assembling of the chamber

We observe some discrepancies form the expected heights, this could be due to:

• Too high pressure on the panel from the “forks”

• Some discrepancies in thickness and planarity of the panels

The problem is still under investigation


Clean room operationsClean room operations Assembling of the chamber Assembling of the chamber

HV_side

A

B

1 7

8

915

16

L1 = 9.50L2 = 23.46L3 = 37.24L4 = 51.14L5 = 64.86

9.5623.4837.1350.9364.87

9.7023.5137.1450.9264.80

9.3523.3937.0850.9664.82

9.8223.5537.2051.0965.00

9.7823.5237.1751.0264.99

9.8423.9037.5651.564.93

9.2723.3937.0551.0965.46

9.0123.3036.8650.5864.67

8.8823.3236.8350.7764.66

9.0423.2936.8250.8464.67

8.9823.3136.9250.8464.76

9.0123.6436.8750.864.75

9.0923.3436.6951.0464.90

The height of all the layers is measured with a micrometer while assembling the chamber.

Exp. Values: L1 = 9.00 mm L2 = 23.00 mm L3 = 37.00 mm L4 = 51.00 mm L5 = 65.00 mm


Operations outside the clean areaOperations outside the clean area

1. Gas leakage test

2. OPB mounting

3. Conditioning/HV test of the chamber: It’s not clear yet how much time it will take the chamber conditioning. We have anyway space for 20 chambers (8 weeks production) in the rack for the conditioning.

4. Uniformity test with source (??)

Once the chamber has been assembled it is moved outside for the following operations:


Operations outside the clean areaOperations outside the clean area

Gas leakage test

mbP 5

chamberreference

testunderchamber

Flow in from the bottle

Differential manometer

Requirements: Requirements: PP<=2mb/h @ 5 mb overpressure<=2mb/h @ 5 mb overpressure

The system has been tested with sealed volumes

Chamber 1 is under test, at presentit shows a very high gas leak


Quality controlQuality control

Wire pitch measurementWire pitch measurement

Pitch distribution right after wiring

Pitch distribution after the gluing of the wires

Pitch distribution after the gluing and soldering processes

Some fine tuning is still needed (optimize the contrast of the images)

Side A

Side B


Quality controlQuality control Wire pitch measurementWire pitch measurement

P4

28 (

L4)

P4

89 (

L1)

P5

35 (

L2)

P4

91 (

L3)

Ch

amb

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Side A: 99.7% < ± 50µm 100% < ± 100 µmSide B: 95.9% < ± 50µm 99.5% < ± 100 µm

Side A: 99.8% < ± 50µm 94.4% < ± 100 µmSide B: 99.7% < ± 50µm 99.8% < ± 100 µm

Side A: 100% < ± 50µm 100% < ± 100 µmSide B: 99.7% < ± 50µm 99.8% < ± 100 µm

Side A: 91.0% < ± 50µm 95.4% < ± 100 µmSide B: 91.0% < ± 50µm 91.4% < ± 100 µm

Side A

Side B


Quality controlQuality control

Wire tension measurement

Laser

Photodiode

wire

Machanical excitation

Panel

This simple and reliable method has been developed together with Firenze and Roma II


Quality controlQuality control Wire tension measurement

Laser

Mechanical

Excitation

Photodiode

At present it takes about 3.5 sec/wire (about 40 min/panel)

With 2 panels it will take less that 2 sec/wire (40 min 2 panels)

We are confident to setup the double panel measurement in about half a day of work



0

10

20

30

40

50

60

70

80

90

100

0 500 1000 1500

Serie1

Serie2

Poli. (Serie2)

p214

0

20

40

60

80

100

0 100 200 300 400 500 600 700

wire number

mec

hani

cal t

ensi

on (g

)

p173

Before the reinforcementof the frame

After the reinforcementof the frame

The wire tension is in average too high (> 75g) it will be reduced by 5 g



P_535

0

20

40

60

80

100

0 100 200 300 400 500 600 700

wire number

mec

han

ical

ten

sio

n

p489

0

20

40

60

80

100

0 200 400 600 800

wire number

wir

e te

nsi

on

(g

)

Serie1

L1 L2

p491

0

20

40

60

80

100

0 200 400 600 800

wire number

wir

e te

nsi

on

(g

)

Serie1

L3P428

0

20

40

60

80

100

0 200 400 600 800

panel number

ma

ch

an

ica

l te

ns

ion

(g

)Serie1

Poli. (Serie1)

L4

T = (76.4 ± 3.6) g T = (77.3 ± 4.0) g

T = (76.3 ± 4.3) g T = (76.1 ± 4.6) g

Ch

amb

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Panel number

Panel type

Chamber Comments

213 L1 ---- 1 diplaced wire (by 1 mm)

175 L3 ---- 1 Broken wire

161 L1 0 No WTM yet

221 L2 0 No WTM yet

208 L3 0 No WTM yet

178 L4 0 No WTM yet

173 L4 ---- Few wires with tension < 50 g

214 L2 ---- Bump on the cathode

489 L1 1 OK

535 L2 1 OK

491 L3 1 OK

428 L4 1 displaced wires

537 L2 OK

384 L3 Several broken wires

602 L1 Under test

437 L3 Wired and glued

494 L4 wired

So far we have produced 15 M2R3 panels, the best 8 panels have been assembled in M2R3-CH0 and M2R3-CH1


Conclusions Conclusions

• All the production and quality control processes are set and working. There are still some fine tuning needed (2 panels measurement with WTM, fine adjustment in the pitch measurement ) but they are essentially in their final version

• So far we have produced 15 M2R3 panels and we have assembled2 chambers. The very first one (M2R3-CH0) was used essentially to exercise the assembling procedure, the second one (M2R3-CH1) is at present under leak test but it shows a high gas leak.

• We have to improve the chamber assembling

• The procedure to optimize all the production steps is almost in its final version

• The learning process of all the people involved is under way

Documents

June 8-th 2004W.Baldini1 Ferrara production center Ferrara production center Production Readiness Review OverviewOfOperations P R R