Assembly of Modules to Cylinders

1. Assembly of Modules to Cylinders Georg Viehhauser SCT PAR, Georg Viehhauser

2. Assembly at Oxford and KEK • Barrels come to Oxford/KEK from RAL with all the services mounted and tested. • Modules are only items left to be added at Oxford/KEK to complete cylinders: • Limited space → high precision during mounting required. • Tasks: • Mechanical location & fixing of module, • Thermal & mechanical connection to cooling system, • Alignment & connection of dogleg. • After mounting: performance has to be verified. • Use all final (or very close to it) ATLAS SCT components (power supplies, off-detector electronics, DCS, cooling). • Compare performance to checks after module assembly. • System studies. • After passing final acceptance checks: Barrels are shipped to CERN for final 4-barrel assembly. SCT PAR, Georg Viehhauser

3. Transport • Transport from RAL to Oxford/KEK: all services, but no modules. • Transport from Oxford/KEK to CERN: with modules. • RAL → Oxford → CERN: B3, B5, B6, all road. • RAL → KEK → CERN: B4, by plane. • Environment: Temperature & humidity controlled, ESD, mechanically isolated. SCT PAR, Georg Viehhauser

4. Transport Box • Two box design • Inner box: • Al protective frame with conductive plastic panels, • Central part stays around barrels all time (even during assembly), • Wrapped air-tight during transport. • Outer box: • Steel structure and panels, • Handling points for shipping. • Mechanical coupling through wire rope isolators. • Plane transports might need different setup. B3 inner box Box assembly SCT PAR, Georg Viehhauser

5. Service Cages • All services, which will later be fanned out on the thermal enclosure, have to be stored safely for assembly and transport (LMTs, capillaries, readout fibres, DCS sensor wires). • Storage assembly has to • satisfy ESD and grounding requirements for checks, • provide temporary connections for services during assembly checks, • clear adjacent barrels for 4-barrel assembly. SCT PAR, Georg Viehhauser

6. Control Room Clean Room Cooling/UPS/ Services Cold Room Oxford Assembly Area- Heavy Lab SCT PAR, Georg Viehhauser

7. Module Reception - Storage • ~1500 modules will be shipped from all over the world to Oxford • Shipping box, which • protects during transport, • provides safe environment for module checks (thermal and electrical connections, so that module can be checked without opening), • has mechanical fiducials to align module for module mounting. • Each module gets tested at Oxford after reception (same tests as at module production site). • Storage in shipping box in humidity & statically controlled area (up to 400 modules). • Modules will be kept in shipping box until immediately before mounting. Position fiducials Module Connector SCT PAR, Georg Viehhauser

8. Barrel Reception • Barrels will be delivered to tent outside of the heavy lab. • After removal of outer box transfer to lifting cart. • Wheel into clean room, lift to cold room floor level and move into cold room. • Remove ends of inner transport box, install cable and fibre supports, connect barrel DCS sensors. • Preassembly checks: • Verify DCS sensor operation. • Connect cooling system and operate cooling system (cold). Verify operation. • Confirm harness integrity. SCT PAR, Georg Viehhauser

9. Assembly Overview • Tight schedules require parallel operation of 1. and 2. on two assembly stations. • But: switch between them is complex. → Do assembly in groups of 96 modules. First 16 rows of lower modules (16×6 = 96), which then get checked. Then mount upper modules and check them out. • Mount modules & make thermal and electrical connections. • Verify performance after mounting. • After completion of barrel: final acceptance test SCT PAR, Georg Viehhauser

10. Module Mounting • High 3d-precision during insertion required → robot. • Additional operations: • Align dogleg to pigtail. • Apply thermal grease on cooling block. • Mate pigtail and dogleg connector. • Mount module cooling block clip. Done by hand with tools held by a tooling frame. Done row-by-row (first lower, than upper): First 1. & 2., then module insertion, then 3. & 4. SCT PAR, Georg Viehhauser

11. Fine adjustment of tool position Tooling support and alignment • Tooling frame with vertical and horizontal travel, attached to front of transport box. • Positioning of tools by stages, aligned by hand with small lasers. • Alignment of robot automatically. Survey of brackets on barrel with laser sensors. Coordinates kept in database for retrieval during mounting. Tooling frame SCT PAR, Georg Viehhauser

12. Procedure I: Align Dogleg • Remove tab with circuit board from module box (module stays covered). • Transfer pigtail connector position to template using position fiducials. • Position template using alignment rods onto barrel. • Adjust dogleg position (align to module mounting bushes) and fix. Alignment rods Template Connector Position fiducials SCT PAR, Georg Viehhauser

13. Grease reservoir Mask Piston Travel Procedure II: Apply Thermal Grease • A rectangular mask covers cooling block (maintains thickness of grease joint). • Opening of mask just slightly smaller than cooling block surface. • Back of cooling block supported from tool. • Grease squeezed out of reservoir by piston lever. • Applicator moves over mask, scrapes off excess grease. SCT PAR, Georg Viehhauser

14. Procedure III: Mount Module • Done by robot (one program): • Pick up module from box • Survey module optically – verify correct pickup, envelope. • Insert module (robot knows where to put it). • Drive in screws (limited torque). Module box Control by touch-screen SCT PAR, Georg Viehhauser

15. Procedure IV: Apply Clips • Same tool used for clip removal. SCT PAR, Georg Viehhauser

16. Procedure V: Electrical Connection • Template aligns connectors on pigtail and dogleg. • Pliers force connectors together. • Same template also used for disconnecting. SCT PAR, Georg Viehhauser

17. Hybrid – Optopackage: ~1.2mm In situ: Component – dogleg: ~1mm Component – connector: >1.7mm Lower module – upper module: ~1.9mm Clearances • Exposed wirebonds on modules demand great care. • All components and module (3-point constrained) must satisfy space envelope as given in SCT drawings. • Clearances during insertion ~1-2mm on each side (depending on barrel). SCT PAR, Georg Viehhauser

18. Fault recovery • Care has been taken to isolate robot from external faults. • Separate UPS. • Compressed air? • Emergency stop button for operator. • Recovery software will return the module into box after retracing approach path. • Ongoing task: more failure modes will show during shake-down before B3 arrival and will be taken care of. SCT PAR, Georg Viehhauser

19. Baseboard Jaw Cooling block Lever Air-driven piston Dismounting Modules • Reverse procedures of mounting. • Disconnect electrically. • Remove cooling block clips. • Remove module – requires splitting of grease layer between module and cooling block. Support splitting mechanically. • Return module into module shipping box. SCT PAR, Georg Viehhauser

20. Time estimates • Estimated times for assembly: • ~5h for 6 modules (1 row of lower or upper modules) = ~45min/module • 96 modules in 80h = 1 week (5d) of 2 daily shifts (8h) each. • → During established assembly: mount modules on one barrel for one week, while testing the other, then swap. SCT PAR, Georg Viehhauser

21. Manpower • Assembly: • 2 ATLAS assembly techs • Up to 1 tech from electronics workshop • 2 staff from Oxford, 1 staff from UCL. • Testing: • 1 postdoc and 1 grad student from Oxford. • Additional manpower from Oxford and other SCT collaborators can be found for limited periods. SCT PAR, Georg Viehhauser

22. Mechanical QA SCT PAR, Georg Viehhauser

23. Cooling System • Evaporative system (cooling capacity ?). • Drives up to 16 cooling loops (B6 + 2). • Two operation modes: • C3F8: about -15° (‘cold’) as in ATLAS. • C4F10: about 10° (‘warm’). • Control as in ATLAS: • Mass flows & pressure drops adjusted so that cooling power exceeds heat load of detector at any time. • Heaters after the detector controlled by simple T-feedback so that remaining liquid evaporates. • No sophisticated control structures, just monitoring (→ DCS). Storage Compressor Condensor SCT PAR, Georg Viehhauser

24. Electrical QA • Repeat measurements as at production sites and after reception (allows for direct comparison). SCT PAR, Georg Viehhauser

25. DCS • Similar system as in ATLAS • Sensor readout (all SCT barrel sensors, system status and environment) using ELMBs. • Control and monitoring of power supplies (14 crates) through ELMB-based crate controllers. • Distributed PVSS system. • Hardware interlock of cooling loop temperature through IBOXs, interlock matrix and interlock card in PS crates. • Additional interlocks for personal safety. IBOXs ELMBs Environment sensors: SCT PAR, Georg Viehhauser

26. Off-Detector Electronics • Optical readout (control & data). • One 9U VME crate with VME CPU, up to 14 RODs and TIM. • One ROD reads 48 modules. • For assembly checks: need 4 RODs. • Only for final acceptance test: • B3: 8 RODs • B5: 12 RODs • B6: 14 RODs • Read out histograms from ROD memory for various characterisation checks. CPU SCTLV2 PS REV C Rod Rev B ROD TIM SCT PAR, Georg Viehhauser

27. Power supplies • Supply HV and LV. • Crate holds also controller (ELMB-based, connected through CAN bus to DCS) and interlock card. • One crate supplies 48 modules. • Assembly checks need 2(4) crates. • Final acceptance tests need 8 (B3), 12 (B5) and 14 (B6) crates. Interlock card Controller LV cards HV cards SCT PAR, Georg Viehhauser

28. Power, ESD and Grounding • Power to critical components (power supplies etc.) backed up by UPS. • Special care has been taken to provide clean ground to allow meaningful electrical checks of assembled barrels. • All items in the cold room conductive and grounded, standard ESD procedures followed. SCT PAR, Georg Viehhauser

29. Status I • Transport infrastructure: • B3 inner transport box complete and at RAL. Outer box needs finishing design and construction. • B3 service cages: mechanical parts are ready. Mock assembly under way. Electrical components to be delivered soon. • Heavy Lab infrastructure: • Clean room ready, used for power supply tests. Ready to receive and store modules. • Still to be done: reception tools (lifting cart etc.) • Cold room: service supports being installed. After that: clean & close. • Power cables: ordered. To be delivered in May. • Readout fibres: ordered. To be delivered in May. • Cooling system: Pipework being installed. SCT PAR, Georg Viehhauser

30. Status II • Tooling: • Most tools have been built and are being tested in the cold room. • Robot: routinely mounting modules. Now programming recovery procedures. • Wait for sector prototype to practise procedures in realistic environment. • Read out and power supplies: • Power supplies: 1 crate with cards in Oxford, ironing out problems with ELMB crate controller. • DCS: Environment monitoring operating, working on power supply control and monitoring. • Off-detector electronics: crate with CPU, TIME and 2 RODs in Oxford. Reads out optically one module on bench (SCTLV2 power supplies). Standard checks working. SCT PAR, Georg Viehhauser

31. Schedule • Until arrival of B3 (expect end of June): • Finish all remaining transport infrastructure. • Finish all the remaining tasks to build infrastructure (cooling system, cables, cold room, etc.). • Test mounting procedures with sector prototype. Shake down procedures. Train technicians. • Get power supplies with control software and off-detector electronics with DAQ software working. • Start receiving modules. • After B3 arrival: • Barrel reception checks. • Start mounting (production ramps up from 6 modules /wk to 96 modules/wk) SCT PAR, Georg Viehhauser