us module and rod production overview and plan for the us cms tracker group

US Module and Rod Production Overview and Plan

For the US CMS Tracker Group

April 29, 2005 - J. Incandela 2

TEC R7

TEC R6 TEC R5P TEC R5S

TOB r-phi TOB stereo

Module Types Built in US


Overview

• Module Production • Production statistics to date (production started in late Feb.)

• 702 TOB modules

• 662 with Hamamatsu silicon and 40 with STM silicon

• 123 TEC modules

• 84 with Hamamatsu silicon and 39 with STM silicon

• Current Production Rates

• FNAL: steady pace of 12 TOB modules per day

• UCSB: steady pace of 18 TOB/TEC modules per day

• Production is keeping pace with hybrid deliveries

• High yield and high quality so far, with further improvements expected.

• Ramping to 18 -24 modules/day per site as hybrid deliveries increase

• Rod Production • Was halted for final cleaning of on-board electronics

• Restarted at UCSB this past week at 2 rods per day

• This week: start rod production at FNAL and increase to 3/d at UCSB


US Hybrid Testing Results

Pass Fail % Pass

L12pd 0 0

L34p 575 15 97.5%

L56p 577 8 98.6%

R5N 65 2 97.0%

R5S 47 0 100.00%

R6 87 1 98.9%

R7 0 0

Total 1351 26 98.1%

• US tasks• Final wirebonding from APV

chips to pitch adaptor• Thermal cycle to -20C and

electronic test• Yield 98%• Failed Hybrids

• 26 out of 1377 • 9 can be repaired

• Shorts on pitch adaptor

• Damaged wirebonds• 9 with undiagnosed

problems• Under study

• 8 with unrepairable damage


Module Assembly

• UCSB: • Comfortably build 6 plates of 3 modules per plate per 8 hour day.

• Downtime of a several days due to wire-bonder problems

• Procuring a backup wirebonder to avoid downtime in future

• Plan to stretch to 7 or 8 plates per day relatively soon.

• Have capability to build 10 plates = 30 modules per day.

• FNAL: • Currently have 6 TOB axial and 4 TOB stereo plates

• Have capability to build 8 plates = 24 modules per day

• Modules grades (A and B are both installable classes) :

A B F Fraction A+B

FNAL 286 37 6 98.2%

UCSB 458 14 2 99.6%

Total 744 51 8 99.0%


Module Testing Results

• Yield is high

• 3 of the 7 failures were caused in production and testing:

• 3 failures due to problems in silicon prior to assembly

• 1 is a hybrid or DCU failure

• Improvements underway• We have adapted procedures to

eliminate failures in production

• Alteration of plates, handling procedures etc.

• Fewer failures due to silicon

• Later batches of HPK silicon are even higher quality

A B F % A or B

L12pu 12 0 0 100.0%

L12pd 0 0 0 0.0%

L12su 0 0 0 0.0%

L12sd 0 0 0 0.0%

L34p 188 1 4 97.9%

L56p 467 2 2 99.6%

R5N 32 1 1 97.1%

R5S 0 0 0 0.0%

R6 24 0 0 100.0%

R7 0 0 0 0.0%

Total 723 4 7 98.5%


Module Quality!

• HPK Modules are remarkably high quality

• Tested 596 modules having HPK sensors

• 189 faulty channels in A+B modules out of 492,288 total !

• 20 pinholes (plucked to be opens)

• Many due to wirebonder problems; now fixed

• 63 shorts (plucked to be opens)

• Scratches (only significant in early HPK batches)

• 32 noisy channels

• 74 opens

• Few due to PA and bonding; most inherent in sensors

• Expected number of faults from QA at HPK: 69

• Percentage of bad channels: <0.04%


LT Testing Results: UCSB

•Thermal cycle (+20C to -20C), operate, and test modules in groups of 10 for 24 hours

• Looking for infant mortality

• Yield is very high

Pass Fail % Pass

L12pu 0 0 0.0%

L12pd 12 0 110.0%

L12su 0 0 0.0%

L12sd 0 0 0.0%

L34p 179 1 100.0%

L56p 294 0 100.0%

R5N 34 0 0.0%

R5S 0 0 0.0%

R6 15 0 100.0%

R7 0 0 0.0%

Total 534 1 99.8%


Overall US Production Quality

Summary of the quality of the production

• Hybrid Testing: 98% Yield

• Gantry Assembly: 99% pass mechanical specifications

• ARC Testing (HPK only): 99% Yield• Only 1 failure which is directly related to module production.

• Long Term Testing (HPK only): 99.8% Yield


Rod Assembly, Test, Transport

• US To build ~700 total rods• US Capacity ~ 6 rods/day

• Limited by capacity of thermal cycle test stands

• Testing• Quick test after assembly• Crucial 72 hour test with thermal

and power cycles to find problems before installation in CMS

• Capacity of LT test systems in US is ~ 32 rods per week.

• After substantial experience, and if there are no failures seen in the last 24 hours of testing, we will go to 48 testing. Capacity will rise to 48 rods/week.


Rod LT Testing and Transport

•Long-term testing box:-Complicated system

-8 rods simultaneous operation-Interlocks, monitoring etc.

- Small residual problems

• Transport boxes:- Carefully engineered Studied/Tested at commercial testing facility-Has sustained up to 80 g acceleration without damage to rods


Rod Experience

• Production restarted last week• UCSB produced 9 rods this week, with 8 of 9 testing well.

• UCSB plans to produce 15 rods per week starting next week and FNAL will start to ramp up to the same level starting next week.

• One of 9 rods has unknown intermittent communication problems

• We have seen in preproduction (40 or so rods) that roughly 1 of every 5 to 10 rods has some sort of I2C communication problem.

• Could be any of 4 or 5 sources – under study

• Most likely it is due to

• A software problem that some rods are more sensitive to

• A hardware problem – in rod or module

• The fact that we are using pre-production DAQ modules

• There is also the small probability that it is an intrinsic problem that we will encounter again in operation.


Schedule

• US production is now running smoothly at 600-700 modules/month• Rod production started and will run at high rate to catch up to module

production• Expect to ramp to 800-900 modules/month this summer

• Substantial planning has gone into this. We have identified all sources of potential down time in our production chains and have procured backups and spares as required for minimal work stoppages

• Manpower is very nearly at the level required for peak production• We have roughly 40 people trained for production and we need only

1-2 more technicians.• Components are arriving at substantial levels

• Have large stockpiles of sensors and frames• Hybrids inventory is adequate for 1-2 weeks production

• Sustaining hybrid deliveries is the only current weakness• US is in process of qualifying a hybrid assembly company

• Assembled parts so far appear to be excellent• Place order this June or so for 2000 assembled hybrids


Conclusions

• US Production is underway and sustaining very high throughput with very high and rising yields

• Components are flowing, and efforts are underway to provide contingency in hybrid deliveries

• Rods production has just started, initial yields are reasonably high with one residual issue under study.

• We are confident that we can meet our required schedule

us module and rod production overview and plan for the us cms tracker group

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