**Introduction.**

In this parts of our proposal we discussed production of EMU CMS
chambers at USA (figure 1*).* Large CSC chambers (ME234/2 - 148
chambers) - will be build at FNAL's production site. And
[f]{.underline}inal [as]{.underline}sembling and [t]{.underline}esting
(FAST) of will be done at two sites. One FAST site is located at UCLA
campus and operated by Universities of California Consortium. Second
FAST site is located at University of Florida. Production tasks flow,
which show responsibilities of each site, presented at figure 2. Some
part of EMU CMS chambers will be assembled and test at foreign sites
(table 1). Russian collaborators will response for assembling and
testing at PNPI (Sant Peterburg) ME2/1(38) & ME3/1(38) CSC chambers.
ME1/2(74) and ME1/3(74) chambers will be assemble and test at China
(IHEP, Bejin). USA EMU CMS team (FNAL site) will design and develop: all
chambers, assembling technology, tooling and QC/QA procedure for all
type of chambers. Prototypes of all chambers will be build at FNAL.
Physicists and engineers from China and Russia will participate in the
assembling corresponding pre-production prototypes at FNAL. US CMS will
build at FNAL and provide to foreign sites a critical tooling (anode
wires winding machine, wire tension measuring setup, gluing equipment
end etc.). US CMS will supply chamber's parts to foreign sites (panels,
gap and wire-fixation bars, anode wire, glue, etc.). Major site for US
EMU CMS production is located at FNAL (figure 3). FNAL have to cut and
mill panels for whole project and assemble large ME234/2 chambers.
Schedule of CSC chambers production presented on table 1. Later we will
discuss how we are correcting our production schedule, based on recent
experience.

At this chapter, briefly summarizing status of readiness FNAL production
site to start production, we have paid more attention to those places in
production flow, where Yuriy Pischalnikov, as a member of production
team and as a UCLA liaison-physicist, are playing a major role. Those
places are including CSC Panels production (QC/QA issues), CSC
production information database management and operation of Cosmic Ray
Test Station, CSC alignment issues.

**Fermilab as a major EMU CMS production facility.**

Inside CMS EMU project FNAL is the host Laboratory for production of CSC
chamber. Fermilab CSC production team (based on physicists and engineers
from several Universities (including UCLA) and FNAL) has concentrated
during several last years on chambers R&D efforts. During 1998 and 1999
we started to change direction. We still are doing some R&D (like
building chambers prototypes for Radiation damage study, building
prototypes for CERN test beam, etc.). But now we are spending near 100%
of our times building CSC production facilities at FNAL. During last two
years fermilab's production team concentrated on

1). Finalizing design of all prototypes (design of ME234/2; ME1/2 done
and ME2/1; ME2/1; ME1/3 and ME3/1 in working progress (see Table 2).

2). Designing of tooling for production's facilities and for FAST sites

3). Developing QA/QC procedure for panels production and for assembling
chambers

4.) Developing procurement strategy (close work with vendors).

Main facilities, which will be use by EMU CMS collaboration at FNAL to
deliver chambers, are:

1.  LAB8 Panels production facility (figure 4);

2.  MP9 CSC chambers assembling facility (figure 5);

3.  LAB7 -- cosmic rays CSC-factory test facility (figure 6).

    **LAB8 Facility.**

Yuriy Pischalnikov is UCLA physicist, who, as a member of Fermilab
production team, is leading efforts at LAB8. He is working in close
contact with LAB8 management and FNAL production site manager (G.
Apollinari). His goal, as physicist-in-charge, was to develop Quality
Control/ Quality Assurance (QC/QA) program for production of CSC panel.
Also, as a member of Fermilab production team, Yu. Pischalnikov will
maintain his role a physicist-liaison between Panel production site and
chamber's assembling site. His responsibility will include (but not
limited) control of delivering CSC panels in complain with established
and proven QA/QC procedure and according approved by DOE and
collaboration schedule.

Pictures of main facility for CSC panel production -- LAB8 presented at
figure 6. For next 4 year this facility will mainly work for CMS EMU
project. Two major machine Axxiom and Gerber are operating into 2 shift
now. Axxiom is been used to drill holes in panels and cut panels in
trapezoidal shape. And Gerber is been used to mill with precision of 2-3
mills strips on the surface of copper.

We worked closely with technical personal of LAB8 on solving all
technical issues during last year to bring this facility in to
operation. CMS EMU project support: relocation of Axxiom machine into
new (more strong foundation) place inside LAB8, installation of vacuum
lifting equipment. We have developed in collaboration with floor manager
panel production flow scheme (figure 6). We started panel's production
at LAB8 at June, 1999. First several month, as a typical, we slowly and,
some times painfully, went through the learning curve. Now, after more
than 32 weeks in production, we can claim that production speed is
satisfy our schedule. And we have confidence, that LAB8 team can deliver
to CMS EMU project 2736 (see table 1) panel during next 4 years. Plots,
presented at figure 7, are panel's production status. We are keeping
those, weekly update information (Excel file: [Completed Axxiom-Gerber
Panels.xls]{.underline}), on the web-site
(http://tdpc01.fnal.gov/project/UsCmsEmu/Lab8production/).

But main our efforts, before starting panel's production, were
concentrated on developing QC/QA program. There were many driven factors
to leading existing panel's production QC/QA program. One of the crucial
issues in the production of panels is precision of milling strips on the
Gerber machine. We discussed this in details in next chapter.

*[Using Gerber Machine for to mill strip artwork on the SCS
panels]{.underline}*.

Gerber is a more than 20 years old machine. And unfortunately, there are
some features of Gerber, which we can't correct. Accuracy and
repeatability, with which Gerber milled artwork, not as good as we
required. Our requirements for strip's artwork precision are near 1- 2
mils.

If we can't mill strip's artwork with this precision, we must to measure
strips artwork on each panel with 1-2 mils precision afterward. All
strip's position measurements will store at FNAL and CERN CMS data base
("CRYSTAL"-type). Later, we will calculate position of each particular
strip inside global CMS system of coordinate. We will use this info to
calculate momentum of muon during off-line analysis. For purposes of
using CSC chambers into trigger we must to have accuracy of milling
strips vs. axis of panel not worse than +/-20 mils. Our experience
during R&D stage and results from our first 25 "production like" panels,
shown that Gerber can simple keep accuracy inside +/-20 mils
requirement.

How we decided to measure position of strip's artwork? We have evaluated
different techniques for this type of measurements. Best one, from our
point of view, based on using Coordinate Measuring Machine (CMM) figure
8. We used CMM successfully during our R&D stage (see next chapter).
Measurement of one panel required at least 1 day of work at CMM plus
time to analyze the data. Definitely, we can't afford to measure several
thousand CSC panels for whole EMU CMS project. But we decided to use CMM
machine to measure only few panels for each new prototype. We are
planing to build during FY2000 four new prototypes (see table 2))
(ME1/2; ME2/1; ME1/3; ME3/1). For each new prototype we will measure one
panel. Also we are planing to choose some panels for random (one from
several hundred) control (measurement) at CMM. This procedure will be
part of our QA/QC program.

After some design work we come with simple (more robust) solution. We
build manual measuring device figure 9. This tool based on 40 inches
long optical scale (made by Mitutoyo ) and telescope with 60X
amplification. Technicians from LAB8 (which operate Gerber) spend
typically 20-30 minute to measure one panel (13 alignment marks).
Difference between two sets of alignment marks measurements (for several
panels) presented on figure 9. First set of measurements were done at
CMM and second with manual device. This histogram illustrated that
simple manual device provided accuracy better than +/-2 mils.

What is alignment marks and how they reflect position of strips artwork
on panels? Alignment marks is a short grooves (1,5" long), located in
the edges of panels.

Gerber has milled alignment mark's grooves and the strip's artwork
during one panel's installation on Gerber's table.

We are trying to keep Gerber's milling condition, which would provide
strong relation between strips and alignment marks position. Differences
between strips position and corresponding alignment marks presented in
the figure 10. Our knowledge of Gerber's machine operation still don't
allow us to explain difference, which we observed figure 10. We are
working now to eliminate this negative effect in Gerber's operation.

We have defined to make several alignment marks on narrow and wide side
of panels (total 13 alignment marks). Two alignment marks (A & B) at the
narrow side of panel reflect position of a 1^st^ and a 81^st^ grooves at
X=1"**.** Alignment marks C & D at wide side reflect position of a 1^st^
and a 81^st^ grooves at X=144" (for ME234/2). As you can see from
illustration on figure 11**,** four alignment marks will provide us
following information about strip's artwork inside X-Y system of
coordinate: 1) scale in the narrow and wide side, 2) off-set and 3)
rotation. We have build X-Y system of coordinate using panel's two
alignment holes (center of alignment hole is 0;0 and axis X going
through center of alignment slot). We are using the rest of marks for
different purposes related with QA/QC questions (control for consistency
(quality) of LAB8's measurements (figure 12) and with CSC alignment
tasks (location for Retro-reflective targets (see chapter about RRT).

As a part of our CSC panel's production procedure, technician at LAB8
measure (figure 9) and write down into Traveler position of each
alignment marks. Later, we are transferring alignment marks position
information from Travelers into EMU CMS TD (FNAL's Technical Division)
database. Other information, which we will gather during chamber
production, will be also store at this TD database: e.g. tension of
anode wire; capacitance of anode wire and cathode's strips; Chamber's HV
training data; etc.

Yuriy Pischalnikov, as a physicist-in-charge, is managing measurements
and transferring data related with alignment marks into TD database.
Example of alignment marks data (in Excel format) from TD database for
ME234/2 anode panels presented on table 3. Yuriy Pischalnikov is also
doing preliminary analysis of alignment marks data figure 12. This
analysis is a part of our CSC production QA/QC system. TD database will
be accessible through WEB by to all US CMS members. Later all
information from TD database will transfer to CMS CERN database (CRYSTAL
-type). CMS physicists will use this data for off-line physics analysis.

*[Measurements of CSC panels at CMM.]{.underline}*

Accuracy and repeatability, with which Gerber milled strip's artwork on
CSC panels, will directly reflect accuracy of EMU CMS chambers to
measure momentum of muons. EMU CMS requirements for strip's artwork
precision, which coming from ultimate space resolution of EMU Chambers,
are better 2 mils. Task to measure position of grooves on a panels with
size a 5'x 12' is quite ambitious. Best results can obtain by using of
large size Coordinate Measuring Machine (CMM). We were lucky, that
Technical Division (TD FNAL) has large enough size CMM -- CORDEX (figure
8). During R&D stage (last 2 years) we have measured 15 panels.

Probe with 0.3mm diameter ball was used for measurements of profiles of
each groove (figure 8). CMM allow to deliver accuracy of measurements
near several μm. As you can see from plot at figure 8 accuracy of
determination of the center of groove was near 0.1 mills. Data from CMM
were transfer to PC and were analyzed in Excel format using code written
in Visual Basic.

Results of measurements of strips for cathode panel presented at figure
13. According EMU CMS technical requirements strips must to be straight
and deviate from theoretical (drawing) position less that +/-2 mills. As
you see from figure 13, grooves (strips) deviate from straight line not
more than +/-2 mills on the length of 60". This is inside our technical
requirements. But location of grooves deviates from theoretical position
more than 8 mills for groove #81. This deviation of groove position from
nominal (theoretical) position is near the edge of our production's
limits but still is acceptable for CSC production. Deviation of all 81
grooves for 3 P3 prototype panels shown on the figure 13. Measurements
of alignments mark position presented on figure 13 also. Information,
which we obtained from analysis of CMM measurements of first
pre-production prototypes, turned to be very valuable in our efforts to
improve the Gerber's performance. Results of CMM measurements of next
prototypes, which were build after significant Gerber's improvements
presented on Figure 14.

We broadly used CMM measurements to develop QA/QC program for CSC panel
production. As an example, position of holes into CSC panels measured
with CMM, presented on Figure 15. This information, which illustrated
accuracy and repeatability of Axxiom machine, is very important for
assembling of CSC chamber. Using of CMM for panel's measurements was
crucial during developing of Panels alignment procedure (see next
chapter). As we mentioned early we are planing to use CMM machine during
all 4-year period of EMU CMS production. During one more year we will
bring panels for all new prototype to CMM facility. And later, during
production we will use CMM to measure panels, randomly selected at
production line, as a part of our QA/QC program.

*[Using Retro-reflective targets (RRT) to resolve CSC panels
alignment.]{.underline}*

Inside EMU CMS project there is team, which working under CSC alignment
issues. Those people (from FNAL, Wisconsin University and Northeastern
University) are developing alignment of chamber as a whole object inside
global CMS system of coordinate.

But we also need to know position of strip's artwork for each panel vs.
others inside one chamber with accuracy close to couple mils (50 μm).
Panels' strips position for one panel vs. each other for all 6 panels
inside one chamber can be resolve from fitting high energy muon straight
tracks passing chambers (cosmic rays or/and accelerator beam). But this
information will be not enough for "to close the EMU CMS alignment
loop". We still need to know absolute position (and scale) of strip's
artwork on at-least one (better two) panel vs. alignment targets located
on the chamber's frame (or chambers alignment pins).

Yuriy Pischalnikov, as a physicist-in-charge for panel's QC/QA program,
are leading R&D program for develop techniques for transfer panels strip
position to "out-side chamber" system of coordinate.

Main complication of this task is coming from conditions that after
chamber have been assembled, there are no feasibility to see strip's
art-work from out-site chamber. Only alignment marks located on the
narrow and wide sides of panels accessible and can be used for
transferring strip's position. As we discussed previously, we have
measured with CMM relation between strip's grooves and corresponding
alignment marks figure10.

We have proposed to use Photogrammetry technique. We are planing to use
Retro-Reflective Targets (RRT) made by Hubbs (Hubbs Machine &
Manufacturing, INC). RRTs, which we ordered from Hubbs, has
non-concentricity between reflective dot and shaft less than 0.5 mils
(12,5μm). RRT will be mounted on the edge of CSC panels into alignment
marks groove by nesting target's shaft into alignment grooves. Axis of
RRTs shaft and groove must to be parallel (figure 16).

In the frame of R&D program, which must to prove that this techniques
will work, we made test piece of panel with 6 alignment grooves (figure
17). Locations each of 6 alignment marks have been measured on CMM with
accuracy better than 0,2 mils (5 μm) (see previous chapters). After
that, we have nested and glued 6 custom-made RRTs into alignment
grooves. Using Photogrammetry technique we have measured position of
RRTs. Photogrammetry technique have provided us with X; Y; Z and δX;
δY; δZ for each RRT.

Differences between X~1~ -coordinates of center of groove (obtained with
CMM technique) and X~2~ - coordinates of center of RRT (Photogrammetry
output) presented on figure 18. Taking into account: 1) results from
figure 18 (σ~x~\~1 mil), 2) non-concentricity for RRT (σ~x~\~0.5 mil),
3) absolute accuracy of CMM and Photogrammetry (σ~x~\~1 mil), we made
conclusion that proposed techniques will allow us to determinate strip's
position vs. alignment elements of CSC chamber (e.g. Retro-reflective
balls located on the alignment pins ) with +/-1.5 mils accuracy.

Techniques for transferring strip's position (described in this chapter
and developed by Yu.Pischalnikov) will be use as chamber production
techniques for all EMU CMS chambers.

**MP9 facility.**

Fermilab based team of EMU CMS (with support of FNAL management) made
significant progress in creating at MP9 Building (figure 5) major
facility for assembling of CSC chambers. 145 ME234/2 ("large") EMU CMS
chambers will be assembled at MP9. All pre-production prototypes (
Russian's - ME1/2; ME2/1 and Chinese ME1/3 and ME3/1) will be build at
MP9 too.

All major CSC assembling tooling (figures 5 and 19) designed, build and
installed at MP9 at the middle of 1999. QA/QC program for EMU chambers
have been developed. We already tested this QA/QC program during
assembling ME1/2 pre-production prototype. Critical tooling for foreign
sites, designed and build at FNAL, have been installed and tested at
MP9.

Commissions, which included experts, do not related with CMS project,
conducted set of reviews: CSC Design Report, Production Readiness and
Safety reviews.

Fermilab production site is ready to start CSC production. There is some
small slippage in production schedule. We still have some unresolved CSC
integration issues, which are delaying our start to assemble ME234/2 at
a full speed production. Fermilab production team is concentrating now
on building at MP9 pre-production prototypes (ME1/2 - January 2000,
ME2/1-April 2000, ME1/3-May2000, ME3/1-June2000). Goal of this work is
to check foreign sites tooling, train Russian and Chinese colleagues,
verify design of small chambers before going to production. According
update schedule full speed production of ME234/2 -- large CSC chambers
will be started at summer of 2000.

**LAB7- Cosmic Ray Test Station**.

FNAL Cosmic ray setup is located at LAB7. Historically LAB7 facility was
first and only one test setup to test all our previous CSC prototypes
during last several years. Fermilab team, together with FAST's sites
participation, started to work under design of new Cosmic Ray Test
Station (CRTS) at Spring of 1998. We have the goal to design and build
at FNAL CRTS, which can be duplicated at UCLA and UF. Yuriy Pischalnikov
led these efforts. Conceptual design of CRTS (figure 20) was finished at
FNAL at fall of 1998. And at November of 1998 we assembled and tested
major system of CRTS and started tests of prototypes of CSC (P2 and
P3)(figure 6)*.* In parallel with FNAL FAST-site's team (UC and UF)
started to assemble their CRTS, using experience gain by EMU team at
FNAL.

One of the key detector, which we use at CRTS, is scintillating counters
hodoscopes, made from 48 scintillating counters. Each counters is a
scintillating plate with size of 235cm\*30cm\*12cm and 2 PMTs collecting
light from both ends of scintillating plate. The counters serve as a
trigger on cosmic muons. There are total 24 counters assembled in two
rows, top and bottom. Each from these counters is readout by two
photomultipliers (PMT, total 48). The current trigger requires the
coincidence of signals from four photomultipliers of two counters - the
bottom and the top which form the vertical hodoscope. The trigger is
"OR" of these 12 hodoscopes. As a common stop for TDCs of scintillation
counters and front-end anode electronics of the chamber the latest in
time signal from the coincidence of four photomultipliers is used.

Preliminary all counters were tested on a bench, to determinate
efficiency curve vs. HV and estimate of time resolution. After
assembling counter as a trigger system for CRTS we repeated measurements
with the goal to estimate the averaged time resolution of the signal
from PMT and to estimate the contribution of the trigger time vs.
coordinate dependence into the CSC anode \"bunch crossing efficiency\".
The means and resolutions of each hodoscope are shown in figure 21. One
can see that resolutions are within the interval of 0.8-1.0 nsec.

During next 4 years of EMU CMS chamber's production, we are considering
Femilab's CRTS as a testing setup for production site. Major volume of
ME234/2 chambers will be tested at UCLA and UF FAST sites. Fermilab's
CRTS will be played a role of a "fast-response" setup to all concerns,
which would arise during production.

One of the example of "quick-response" from Cosmic Ray Test Station to
chamber's assembling floor is our experience with assembling of P2\*
prototype. Results of measurements of P2\* prototype at CRTS presented
on figure 22. We were able to measure gas gain uniformity from P2\*
chamber just week after chamber has been assembled at MP9. One of the
technical requirement for chamber quality is chamber's gas gain
variation. Gas gain inside whole chamber must to be less than +/-50%.
After gain measurement on CRTS we found that panel #3 has section of
anode wire with gain 1,5-2.0 of average P2\* chamber's gain. Detail
analysis of panel#3 has reveal that we have a problem with our "anode
wire winding" machine. Anode wires at "high gain" region of panel #3
have been placed out of center (see figure 22). Now we fixed this
problem, but this is good example of using of CRTS for "fast response"
during chamber production.

Other example of that type of "fast-response" is utilization of FNAL's
CRTS during last several month. EMU team are using FNAL's CRTS as a
central place to investigate complex of issues related with CSC
integration (grounding and location of front-end electronics on the
chamber, measurements of efficiency of cooling system, cables location,
alignment's questions, etc.).