Module and Stave Production Status

1. Module and Stave Production Status James Fast Fermilab

2. 20cm Gang Production Status • Tooling for 20cm Gang production • Prototype fixtures (2 sets) available for use now • First production batch (3 sets) received, QCed, Ni/Teflon coated • Being assembled by Lab B staff now • Final production batch (5 sets) in fabrication at MSU • Expect delivery this month, ready for use ~4-6 weeks later • Storage Boxes • Gangs will be stored in L2-5 module burn-in boxes • We have 25 boxes assembled at Fermilab • Remaining 300 boxes being fabricated by Brown • Parts are fabricated and procured • Assembly process at Brown is being debugged now • Expect all boxes to be available by September • Procedures and QA/QC • Assembly procedures written and tested • Additional technical staff needs to be trained (scheduled to start 9/9) • Training in operation of Zeiss 500’s as well as sensor handling and gluing • OGP program written to inspect gangs • Need to verify that database is ready for gang production entries

3. L1-L5 Module Tooling Overview • 5 flavors of fixture, all very similar • L1 (160mm finished module length) • 20cm gang & 10-10A, 10-10S (200mm modules) • 20-20A, 20-20S (400mm modules) • Alignment and Gluing • Precision alignment of sensor to sensor <5m • Alignment of hybrid to sensors to ~50m • Module flipping • Backside HV connection from hybrid • Kapton HV insulation to isolate sensor from structure (L1) • Ground contact from hybrid for support structure (L1) • Wirebonding • Axial and stereo can be bonded on same fixtures (3 types) • Reasonably flat (~50m) vacuum chucks 160, 200 & 400mm long • All tooling used successfully with electrical prototype modules

4. L2-5 Module Fixture Status • Four fixtures used in module production • Hybrid alignment fixture: aligns hybrid to handle for next tool • Assembly fixture: aligns sensors (or gangs) and hybrid • Bonding fixture: used for module transfer and wire bonding • Flip fixture: used for making back-side HV connection • Prototype fixtures fabricated long ago • Initial prototypes worked very well • Small modifications implemented to ease module transfers • Second prototypes of these parts have been made and tested • Written procedures and CMM programs developed and tested • Production fixtures • 10-10 axial fixtures are the 20cm gang fixtures • 10-10 stereo require swapping one part on 20cm gang fixtures • 20-20 axial and stereo are identical except one part • Production scheduled to start 2/4/04 • “Finalize design” dependent on final hybrid sign-off (11/03) • Probably possible to do production earlier • Mechanical aspects of hybrids should be stable earlier • Hybrid alignment tools are only ones awaiting approval of fabrication drawings

5. 20-20 Axial Module Fixture

6. Status of L2-5 Electrical Modules • We have produced a total of 7 electrical modules • 10-10 Axial #7, Amitron hybrid, Irradiated sensors (not for stave) • 10-10 Axial #103, OK for stave • 10-10 Stereo #1, OK for stave • 20-20 Axial #8, Amitron hybrid, Electrical test module (not for stave) • 20-20 Axial #108, 9 working chips, OK for first stave but not ideal • 20-20 Stereo #2, Chips 1,2 bad, needs debugging • 20-20 Stereo #12, Chips 6-10 re-bonded & poor hybrid alignment • Additional modules to be produced for electrical staves • Two modules need replacement in order to build 1st stave • Waiting for ~10 sensors to build new 20-20 modules • Need full compliment of electrical modules for 2nd stave • Need an additional ~20 sensors for this

7. QA of L2-5 Electrical Modules • Electrical QA/QC (Cecilia) • Burn-in • Hybrid burn-in is up and running • Need to write procedures and train personnel • Module burn-in is almost there • Need to confirm cooling system operation • Need to complete software for running HV • Need to write procedures and train personnel • Personnel should be integrated to augment Gustavo’s efforts now • Debugging is essentially non-existent still • Need to define grading scheme for hybrids and modules (done?) • Need to define interface from QA/QC to database (done?) • Mechanical QA/QC (Jim) • Some OGP programs written • Need to certify programs for all module types • Need to write procedures, including file naming conventions etc. • Need to write scripts to prepare OGP output files for database

8. Fabrication of mechanical and electrical preproduction staves • Mechanical stave prototype • Modules on stave core 12/18/02, used for cooling studies • C-channels attached in June, 2003 • Mechanical stave pre-production • Scheduled for completion 6/13/03 • Assembled in June/July with extensive QC (done 7/3/03) • Written assembly procedures followed throughout • Electrical grade pre-production staves • Assembly scheduled for 6/16-7/14 (schedule says 2 staves) • One core and set of C-channels are available • Additional cores will be available, using revised tooling, 8/1 • Additional C-channels will be available by 8/1 also • Module assembly and burn-in are delaying assembly now • Need minimum of 30 sensors to complete this task per schedule • Written procedures fleshed out with mechanical staves • Mechanical QC of modules on staves needs to be added to procedures • C-channel grounding out to Junction Cards needs to be finalized