fe hybrid assembly and quality assurance

G.Sguazzoni 1Tracker Week April ‘03

FE hybrid assembly andFE hybrid assembly andquality assurancequality assurance

The hybrid team:Alan Honma, Michael Poettgens, Gabriella

Pasztor, Bernd Reinhold, G.S.

Bruno WittmerCERN –EP Division

““...resistance...resistanceof hybridsof hybrids

isisnotnot

futile…”futile…”

G.Sguazzoni 2Tracker Week April ‘03

Assembly procedure @ CERN Assembly procedure @ CERN

Hybrid assembly test Test during thermal cycle(s)

Pitch Adapter (PA) gluing at the gantry

(PA bonding)

Bare Hybrid (no Pitch Adapter) Reception test

1 2

3

G.Sguazzoni 3Tracker Week April ‘03

Hybrid reception ‘fast’ testHybrid reception ‘fast’ test

Check that no damage occurred during shipping

Fast ARC test FHIT like will be replaced by FHIT

G.Sguazzoni 4Tracker Week April ‘03

Gantry PA assemblyGantry PA assembly

First 50 TOB hybrids glued @ the gantry… all good!!!

Hyb+PA TOB: 16/plate

Gantry time 1h Curing 8h

Spacer+PA TOB: 64/plate

Gantry 30min Curing 8h

Typical requested throughput 52 hyb/day Handling and preparation

is a limiting factor

First 50 TOB hybrids glued @ the gantry… all good!!!

Hyb+PA TOB: 16/plate

Gantry time 1h Curing 8h

Spacer+PA TOB: 64/plate

Gantry 30min Curing 8h

Typical requested throughput 52 hyb/day Handling and preparation

is a limiting factor

G.Sguazzoni 5Tracker Week April ‘03

Hybrid assembly resultsHybrid assembly results

RMSs (in m) indicate assembly precision within bonding requirements

All hybrids have been bonded successfully!!! stability as the glue cures checked and fine!!!

RMSs (in m) indicate assembly precision within bonding requirements

All hybrids have been bonded successfully!!! stability as the glue cures checked and fine!!!

~14 ~11

~42~4350 50

50 50

(x1, y1)

(x2, y2)

x1

y1 y2

x2

G.Sguazzoni 6Tracker Week April ‘03

Post PA assembly testsPost PA assembly tests ...to insure that:

the hybrid is still alive after many operations

the PA bonds are OK no opens, no shorts!

the hybrid+PA survives… …a cooling cycle (TROOM –20oC TROOM) …multiple (~10) thermal cycles (to emulate

CMS shutdowns)

We need a nice test setup!!!

Sample test!!!

G.Sguazzoni 7Tracker Week April ‘03

The nice test setup

The nice test setup

Located in the new CERN Gantry Clean ROOM

Located in the new CERN Gantry Clean ROOM

TestBoxTestBox ElectronicsElectronics

Water/GasmanagementWater/GasmanagementChairChair

Status screensStatus screens

Water leak detectorWater leak detector

G.Sguazzoni 8Tracker Week April ‘03

Test setup block diagramTest setup block diagram

G.Sguazzoni 9Tracker Week April ‘03

Test BoxTest Box 4 hybrid slots

standard/stereo

N2/dry air flushed

temperature sensors humidity sensors Cooling/Heating:

300W Peltier element (24V-14A)

TLOWEST ~ -25oC with

max load (4 running hybrids)

hybrid on the test

plate

G.Sguazzoni 10Tracker Week April ‘03

Readout & GUIReadout & GUI

ARC based readout

automatic cycling/testing of all loaded hybrids

TCP/UDP communication with slow control application

Ready soon: DB compliant

output “One-button”

test

G.Sguazzoni 11Tracker Week April ‘03

Slow control: hardwareSlow control: hardware

Aachen Cooli box controller RS232 interface Peltier driving Temperature/

Humidity sensor readout

safety interlocks

...custom patched for: gas/water flow meter NIM-TTL pulser driving

G.Sguazzoni 12Tracker Week April ‘03

Slow control: softwareSlow control: software

Temperature monitor

Humidity monitor

Peltier current

Safety

TCPUDP

Temperature regulation

Water & gas flow

Custom version of Aachen Cooli Devive Controller – ACDC (LabVIEW)

G.Sguazzoni 13Tracker Week April ‘03

Post PA assembly testsPost PA assembly tests

Typical test sequence during a cooling cycle

Hybrid ON* Ped, Noi Pulser Short

Detection Hybrid OFF*

*Added after problem with hybrid in cold (see later)

TROOM

–20oC

~25 min/4 hybrids

G.Sguazzoni 14Tracker Week April ‘03

Long term cyclesLong term cycles Sample test!!! emulates ~10

CMS running-shutdown periods

Each cycle same tests as the single cycle…

TROOM

–20oC

~5 hours/4 hybrids

last cycle: stronger! (TROOM –25oC +35oC)

G.Sguazzoni 15Tracker Week April ‘03

Noise issues for hybrid+PANoise issues for hybrid+PA

No reference plane below PA PA is a weak point wrt noise injection

ampli channel

GND lines connected to the support plate by a wide copper strip

Hybrid

ARC FEARC FE

Hybrid GND plane

Hybrid Al support plate

PA line

ARC FEadaper

G.Sguazzoni 16Tracker Week April ‘03

Noise comparisonNoise comparison

Grounding scheme comparison

PA lines length

structure

BAD grounding

NEW grounding

G.Sguazzoni 17Tracker Week April ‘03

Short detectionShort detection

1 SHORT = 2 channels lost

G.Sguazzoni 18Tracker Week April ‘03

Short detection principleShort detection principle

Calibration signal is sent every 4 channels

PIN HOLE like effect may also contribute

IN OUT

ch. #N

ch. #N+1

CALsignal

G.Sguazzoni 19Tracker Week April ‘03

Short detectionShort detection Simple and effective threshold criterium

SHORTs

Pulse shape

Pulse heights

G.Sguazzoni 20Tracker Week April ‘03

The first (detected) short!The first (detected) short!

Short = bonding problem PA

APV

G.Sguazzoni 21Tracker Week April ‘03

Open detectionOpen detection

OPEN = 1 channel lost

G.Sguazzoni 22Tracker Week April ‘03

Pulser hardwarePulser hardwareA

RC

NIMpulsertr

igge

r NIMto

TTL

start

out

50“antenna” very close (~1mm) to the bond

pads

Peak - InvOFF Pulser ON Peak

Mode Optimal

latency

OPENS

G.Sguazzoni 23Tracker Week April ‘03

Open detection: basicsOpen detection: basics

Removed Hybrid-PA bonds or scratch on PA lines*

Spikes in the pedestal profile!!!

Removed Hybrid-PA bonds or scratch on PA lines*

Spikes in the pedestal profile!!!

On-board CM subtraction

Pedestal ~unchanged

On-board CM subtraction

Pedestal ~unchanged

*even quite close to the bonding pads

G.Sguazzoni 24Tracker Week April ‘03

The open-detection criteriaThe open-detection criteria

Optimal to detect isolated opens

Difference wrt neighbours

Mean Subtracted Pedestal

OPENSin our test

hybrid

G.Sguazzoni 25Tracker Week April ‘03

The TOB outcome so far…The TOB outcome so far… 78 received Reception TEST

72/74 good; 2 not OK 11 FNAL & 5 UCSB 2 ‘ TEC1.1 ’ Aachen

Assembled 48/48 good

Bonded 45/45 good

Thermal cycle test Standard: 20/20 good

20 FNAL;

Long term: 8/9 good, 1 fails in cold

14846/14848 good bonds; 1 short, no opens

G.Sguazzoni 26Tracker Week April ‘03

PedestalPedestal Large non-uniformities

Max-MinMax-MinAPV wise

Pedestal cuts in module-test draft procedure ~ too tight

Pedestal

Pedestal<Pedestal>

Pedestal<Pedestal>

APV wisePre

lim

inary

!!!

G.Sguazzoni 27Tracker Week April ‘03

Hybrid+PA NoiseHybrid+PA Noise

Normalized Noise cuts (20%) in module test draft procedure

-20oC

ROOM Noise increases in cold

Peltier current?

Prel

imin

ary!

!!

Noise<Noise>

Noise

G.Sguazzoni 28Tracker Week April ‘03

The faulty hybrid:i.e. the kind of nasty problems we are supposed to discover

The faulty hybrid:i.e. the kind of nasty problems we are supposed to discover

The hybrid fails only @–200C No APVs output but answers to I2C commands other strange behaviors (current, DCU readings) only a certain command sequence induces the failure;

otherwise the hybrid works perfectly Test procedure modified to foresee hybrid OFF/ON &

initialization before any group of tests

First crude investigation: No visible defect MUX chip???

…further study needed

G.Sguazzoni 29Tracker Week April ‘03

Test Station throughputTest Station throughput Target:

Nominal: 32 hybrids/day UCSB will take over TOB bonding and testing

– they are duplicating the setup 4 hybrids 40 min (preparation+test)

Limiting factors Cooling time Loading/Unloading

(40min/4hyb) * 32hyb ~ 5h Effective production request could be

higher… A second “CERN” teststation is in preparation (Cooling cycle test could be done on sample

basis or dropped in case no problems are found)

G.Sguazzoni 30Tracker Week April ‘03

ConclusionConclusionHey folks, is there

someone willing to test hybrids on a large

scale?!?!…

Hey folks, is there someone willing to test

hybrids on a large scale?!?!…