19-June-2006

[ATLAS Tracking at SLHC: Development of a Stave Readout
Structure:]{.underline}

[FY2006 Report and FY2007 Plan]{.underline}

Lawrence Berkeley National Lab

Brookhaven National Lab

Hampton University

Yale University

This document describes the US ATLAS stave development plan for FY2007.
The FY2006 effort is within budget. The basic stave construction and
test efforts at LBNL are on schedule. We have not however moved some of
activities out of LBNL as originally scheduled yet. This reflects a
re-adjustment of priorities as the project has evolved. The plans for a
follow-on effort (this document) reflect conclusions reached in FY2006
reflecting the Genoa Meeting and discussions with other non-US ATLAS
colleagues. The plan is also informed by the concurrent proposal for
stave development submitted to the ATLAS Upgrade Steering Group. That
proposal supplements this report as well.

[Completion of FY2006 milestones.]{.underline}

Here we give a status and update on the prior years milestones. The last
column entries are status or new dates.

Phase 1 Milestones (completion dates given):

1.  full electrical specification and schematic for Phase 1 stave 10/04
    done

2.  establishment of test stands at LBNL, BNL, and Hampton 11/04 done

3.  validation of test stand operation on test parts 12/04 done

4.  design and layout of Phase 1 hybrid 12/04 done

5.  fabrication of hybrid 03/05 done

6.  assembly and test of hybrid 04/05 done

7.  re-commission and tests with existing fixtures 03/05 done

8.  assembly of ATLAS staves 06/05 done

9.  initial test of ATLAS staves at LBNL 07/05 done

10. transfer to and test of staves at BNL/Hampton 12/05 8/06

11. irradiation studies of staves 2/06 12/06

12. transfer of assembly methods to BNL 12/05 9/06

[Conclusions from Genoa and ATLAS wide discussions]{.underline}

We left Genoa with a basic concept for an ATLAS tracker (outside the
pixel region). The concept is shown in Figure 1. The tracker consists of
only two types of staves, described below.

-   Inner layer stave: This stave is (approx) 1 meter long. It carries
    (approx) 3 cm long "short-strip" detectors. These are tiled
    alternately on the two faces to give full coverage along the z-axis.
    Each stave holds (approx) 32 detectors, 16 on each side. The pitch
    is 80 microns and there are 768 or 896 strips per detector. The
    hybrids and fanouts are adjacent to the detectors. The scheme is
    shown in Figure 2.

-   Outer layer stave: This stave is (approx) 2 meters long. It carries
    (approx) 10 cm long detectors in a stereo u-v configuration (like
    SCT). Each stave holds (approx) 20 detectors per side (a total of 40
    detectors). There are small (3 mm ) z gaps between each crystal. The
    hybrids and fanouts are glued on top of the crystals. The scheme is
    shown in Figure 2.

-   Alternate powering (serial or DC-DC conversion) are seen as an
    integral aspect of future stave development. Evaluating these as
    part of the stave testing is of equal priority to the mechanical,
    assembly, and packaging aspects.

**[Review of Plan from FY2006 *with comments and accomplishments in
italics*]{.underline}**

*Below we remark specifically on the items in the 2006 plan. Beyond
these items, a number of modules were assembled and tested on and off
the parallel powered stave. They worked as expected and showed, if
anything, improved noise performance on the stave. In particular modules
were operated concurrently with control, clock, and data flowing to and
from other modules. We presume the engineered and compact ground and
power configuration of the stave is a key aspect to this good
performance. See figure below.*

![](media/image1.png){width="5.975in" height="1.1777777777777778in"}

Hybrid + detector in 3^rd^ position mounted on stave with concurrent
operation of detector in position 1.

*Studies of multi-drop LVDS clock distribution on the stave were also
completed. See figure below.*

![](media/image2.wmf){width="1.6362204724409448in"
height="1.2110236220472441in"}![](media/image3.wmf){width="1.6846456692913385in"
height="1.2346456692913386in"}![](media/image4.wmf){width="1.6744094488188976in"
height="1.2251968503937007in"}![](media/image5.wmf){width="1.3543307086614174in"
height="0.7818897637795276in"}

*LVDS signal integrity with significant DC bus cable resistance is still
acceptable for timing and data transmission requirements*

*Abstracts describing all aspects of the project have been submitted to
the 2006 IEEE NSS conference and the 2006 Hiroshima (Carmel) Silicon
Detector conference.*

The basic plan for FY2006 was:

1.  Advance the stave design to study alternative powering schemes: As
    discussed in Genoa, a significant reduction in services is likely to
    come from a change in power distribution. Two basic schemes can be
    considered, serial powering or local DC-DC conversion. Serial
    powering has been studied at RAL using existing SCT modules with
    good results. Voltage conversion is the subject of an IC design
    effort at Berkeley. To incorporate these schemes into the stave will
    require a modification to the hybrid and stave bus cable as well as
    the development or procurement of the basic components.

    1.  Development of serial powering components (LBNL): Serial
        powering can be implemented on the FY2005 stave with the
        addition of a new "power-interface" hybrid. This hybrid would be
        placed between the existing hybrid and the bus cable bond pads.
        The scheme is shown in Figure 4. This hybrid will be designed
        and fabricated in the FY2006 project.

> *In FY2006 this effort became an active collaboration with RAL. The
> "power-interface" hybrid was designed collaboratively. RAL had it
> fabricated and it is scheduled to be tested in modules and stave in
> late June 2006 at LBNL. A serial powering bus cable was also designed
> and is currently in fabrication.*

2.  Development of DC-DC converter circuit (LBNL): As stated, design
    effort is underway with separate funding. The viability of this
    approach will be reviewed. If viewed as promising a second
    power-interface hybrid could be developed as well. (We will explore
    the possibility that a single interface hybrid could be used for
    DC-DC and serial powering tests.

*The IC development effort did not proceed far enough to lead to a DC-DC
"power-interface" hybrid. The serial version of the hybrid pin-out was
designed to also be compatible with DC-DC conversion.*

3.  System level studies of serial and DC-DC powering (BNL): A number of
    critical issues need to be addressed using test boards and available
    components. Also fail-safe schemes need to be studied and evaluated.
    A system level design and specification will be derived.

*Some preliminary engineering work on this aspect has occurred.*

2.  Development of special control and readout electronics to test
    multi-module deadtimeless operation (BNL): The present SCT test
    electronics (MUSTARD-SLOC-CLOAC) are best suited for sequential
    testing of modules. We will explore the development of a
    multi-modular test board which is particularly suited for stave-like
    objects.

*We have chosen a solution the utilizes a commercial module, the
National Instruments PXI based 6151 wave generator/analyzer card to
control and read out multiple hybrid modules. A single card is capable
of controlling and simultaneously acquiring data from at least 14
modules, while two modules can simultaneously read out 30 modules. The
system is further expandable in readout capability in multiplies of 16
modules.*

*Software development has begun at LBL, with further development taking
place at BNL.*

*LabView(LV) and C are the software platforms in use. A full set of
control and acquisition routines have been written in LV and are in the
process of being debugged. A breakout card has been configured to
connect SCT hybrids and modules to 6151.*

*A simple card containing just two ABCD chips is being developed at BNL
to facilitate the software development. It is envisioned these cards
will be provided to other institutions to aid in their setting up
duplicate DAQ system. A preliminary, but almost final layout of one
layer of the card is shown below.*

![](media/image6.wmf)

*Simple ABCD test card*

3.  Development of detectors (BNL): For the outer layer staves the
    existing CDF Run IIb detectors are well suited and still available.
    For the inner layer (SCT region) staves a new short strip detector
    is required. This would have (approx) 3 cm long strips. It might be
    fabricated in a p bulk process. The development and fabrication of a
    quantity of the short detectors would be undertaken.

The large quantity of detectors required (\~100) ruled out in-house
production at BNL. We obtained quotes to produce short strip detectors
from both Hammamatsu and Sintef. As Sintef's quote was higher than
expected, we chose to produce detectors via Hammamatsu. This choice has
the added benefit in that the detector will be very similar to the
present SCT detector, only shorter (about ½ the length). In order that
the detectors are fully compatible with the ABCD chip, we will fabricate
p on n-type detectors. The order has been placed and the detectors are
expected in about six months. These detectors are in integral part of
the 1 meter ATLAS stave test at the center of the 2007 workplan.

4.  Stave mechanics (LBNL and BNL): The inner layer stave would be thin
    and (approx) 1 meter long. This is about 50% longer than the CDF
    stave so is probably not a major deviation. For the outer layers am
    (approx) 2 meter stave is close to optimum. The design of this
    object is certainly more complex technically. We propose to mount
    some engineering effort in this direction. We would initiate this by
    consulting with the Fermilab engineers who developed the CDF stave.
    This would be followed by appropriate fixture development and
    fabrications.

A considerable design and simulation effort has occurred in
collaboration with Bill Miller at ITI, an outside consultant to the
project. This effort is described further in an accompanying report. The
effort has focused on the mechanics and cooling of a 1 meter long stave.
A design has been found which shows minimal gravitational sag (\<60
microns) and negligible thermal deformation (\<10 microns). Fiber
lay-ups and materials have been identified (4/1 fibers) and selected as
well as a cooling tube and core configuration. The design is moving into
engineering drawings and assembly fixture design.

Some effort has gone to consider also the 2 meter stave. The basic
conclusion is that similar sag can be achieved with an intermediate
support at 1 meter.

Preliminary work on developing stave design and measurement capability
has begun at BNL. Initial thermal and mechanical finite element analysis
has begun. As work on the CDF style stave is well advanced at LBL, BNL
is looking into some alternative, though similar designs. Additionally,
BNL will study the implications of a 2-d inner stave should later
simulation demonstrate that 2-d information from the inner staves is
necessary.

Budget (2006)

In the accompanying spread-sheet a budget for all the activities listed
above is calculated.

The estimates for LBNL and BNL are both \$115K. The Hampton tasks are
not specified but it is expected that Hampton will engage with either of
the National Labs on some aspect of the testing and characterization of
the devise, The Hampton cost is \$20K.

*A fraction of the money allocated remains un-committed. This is because
RAL built the serial-power hybrid at no cost to us, the DC-DC effort did
not reach the hybrid phase, and stave fixturing costs were less than
anticipated. The excess funds can be used to support the FY2007 activity
and front load the stave mechanical fixturing in the near term (summer
2006). This is all reflected in the new budget request (attached)*

![](media/image7.wmf){width="5.997222222222222in"
height="3.488888888888889in"}

Figure 1: Overall barrel tracker layout shows intermediate and outer
stave regions with a default of three stave layers in each region.

![](media/image8.wmf){width="5.99375in" height="2.5256944444444445in"}

Figure 2: Concepts for long outer region stave (top) and intermediate
region stave (lower). Hybrids are not show but are on silicon for long
stave (as in test stave under study now) and adjacent to the silicon for
the intermediate stave with gaps between crystals.

![](media/image9.jpeg){width="5.757638888888889in"
height="1.882638888888889in"}

Figure 3: Scheme with new serial or DC-DC powering hybrid shown.

**Report on Mechanical Activities**

The description and plan for mechanical activities towards a 1 meter
stave are in an accompanying report entitled:

**ATLAS Upgrade**

**Stave Mechanical and Cooling Design Study**

**WBS 4.1.4.3**

**Carl Haber**

**Innovative Technologies International (iTi)**

**M. G. D. Gilchriese and C. Haber**

**Lawrence Berkeley National Laboratory**

**June 19, 2006**

The budget for this activity is included below and in the report.

**[Plan for FY2007]{.underline}**

The plan for FY2007 is to complete the FY2006 studies and build and test
an ATLAS specific 1 meter stave.

1.  Completion of FY2006 tasks

    a.  Complete testing of serial powered "CDF style" stave. Most of
        this will occur in summer 2006

    b.  Complete DC-DC converter chip and board, test on a "CDF style"
        stave

    c.  Engineering studies on alternate powering reliability.

    d.  Complete mechanical studies leading the 1 meter stave design.

    e.  Complete software development around NI-6151 module in
        preparation for multi-module tests. Test this new system.

    f.  Test and QA on detector order when it arrives from Hammamatsu.

2.  Design and build electrical components for the 1 meter stave

    a.  A six chip version of the ABCD hybrid, probably with integrated
        serial powering circuitry will be designed and built. A
        preliminary floor plan has already been made.

    b.  A wider thin film fanout.

    c.  Test fixtures, holders, and interface cards.

    d.  A 1 meter version of the bus cable.

3.  Design and build mechanical assembly and test fixtures for the 1
    meter stave. (This is included in Bill Miller's plan and cost
    estimate.)

4.  Design and build electrical assembly and test fixtures for the 1
    meter stave.

    a.  A fixture to test hybrids and detectors together

    b.  A fixture to laminate the bus cable on the stave core

    c.  A fixture to locate the hybrids on the stave

    d.  A fixture to locate the detectors on the stave

    e.  A fixture to hold the stave during wirebonding of hybrids and
        detectors

    f.  A fixture to hold the stave during metrology and survey

    g.  A test box including cooling and electrical feedthroughs.

    h.  A storage and transport box.

5.  Fabricate stave (mechanically) and survey (This is included in Bill
    Miller's plan)

6.  Fabricate and test stave (electrically). Sufficient components will
    be on-hand to populate 3 staves.

**[End of FY2006 and FY2007 Schedule]{.underline}**

Summer 2006:

-   Assemble serial powering components and test on "CDF style" staves

-   Continue DAQ software debug

-   Continue mechanical design study

-   Design 1 meter hybrid, fanout, and bus cable

-   Design 1 meter stave mechanical assembly fixtures (Miller)

-   Procure materials for 1 meter stave

Fall 2006

-   Prepare and present papers at IEEE and Hiroshima meetings

-   Fabricate 1 meter hybrid, fanout, bus cable, test fixtures

-   Fabricate 1 meter stave mechanics and test.

-   Design and fabricate electrical assembly fixtures for 1 meter stave

-   Test DAQ for multimodules

Winter 2006-2007

-   Test and QA on 3 cm detectors

-   Assemble and test 1 meter stave hybrids and components

-   Assembly and test 1 meter staves electrically

-   Design work on 2 meter staves

Spring 2007

-   Continue assembly and test of 1 meter staves

-   Design work on 2 meter staves

Budget for FY2007

The totals are 170,246 (LBNL), 135,000 (BNL), 20,000 (Hampton), and
114,500 (Miller +LBNL mechanical effort) = \$439,746

  --------------- ---------------- --------- --------------- ------------------ ----------- ---------------- -----------
  **FY2007                                                                                                   
  development                                                                                                
  cost for ATLAS                                                                                             
  ID stave                                                                                                   
  prototype                                                                                                  
  15-June-2006                                                                                               
  Carl Haber**                                                                                               

  **Phase 3**                                                                                                

  **4.1.4.1.1**                                                                                              

  **LBNL                                                                                                     
  Section**                                                                                                  

                  **item**         **num**   **materials**   **total**          **hours**   **labor-cost**   **notes**

  **1**           **6 chip AC                                                                                
                  Hybrid**                                                                                   

  1.1             **substrate**                                                                              

  1.1.1           BeO blanks       75        \$25.00         \$1,875                                         1

  **1.2**         **thick film**                                                                             

  1.2.1           CAD                                                           150         \$13,650         2

  1.2.2           NRE              1         \$6,000.00      \$6,000                                         

  1.2.3           printing         120       \$600.00        \$72,000                                        3

  **1.3**         **fanouts**                                                                                

  1.3.1           CAD                                                           40          \$3,640          2

  1.3.2           mask             1         \$1,500.00      \$1,500                                         

  1.3.3           fabrication      150       \$125.00        \$18,750                                        

  1.3.4           dicing           150       \$5.00          \$750                                           

  **1.4**         **components**                                                                             

  1.4.1           discretes        1         \$400.00        \$400                                           

  **1.5**         **assembly**                                                                               

  1.5.1           surface mount    150       \$75.00         \$11,250                                        

  1.5.2           bond chips       150       \$75.00         \$11,250                                        

  1.5.3           misc assy,QC                                                  25          \$1,450          

  **1.6**         **test**                                                                                   

  1.6.1           test PC adapter                                                                            

  1.6.1.1         CAD                                                           25          \$2,275          2

  1.6.1.2         fabrication      1         \$3,000.00      \$3,000                                         

  1.6.2           misc fixtures                                                 25          \$1,900          

  1.6.3           misc components  1         \$1,500.00      \$1,500                                         

  1.7             **holders**      100       \$50.00         \$5,000                                         

  **2**           **1 Meter Bus                                                                              
                  Cable**                                                                                    

  2.1             CAD                                                           100         \$9,100          

  2.2             NRE              1         \$500.00        \$500                                           

  2.3             parts            20        \$400.00        \$8,000                                         

  3               **Interface                                                                                
                  card**                                                                                     

  3.1             CAD                                                           25          \$2,275          2

  3.2             fabrication      1         \$1,500.00      \$1,500                                         

  4               **Stave elect                                                                              
                  assbly**                                                                                   

  4.1             parts            1         \$7,000.00      \$7,000                                         

  4.2             hybrid+det test                                               25          \$1,900          
                  fixt                                                                                       

  4.3             cable lamination                                              25          \$1,900          

  4.4             stave mount fixt                                              80          \$6,080          

  4.5             stave bond fixt                                               80          \$6,080          

  4.6             test box                                                      40          \$3,040          

  4.7             storage box                                                   25          \$1,900          

  4.8             electrical                                                    160         \$9,280          
                  assembly                                                                                   

  6               **Test box**     2         \$700.00        \$1,400                                         

  7               **Student labor                                                           \$35,000         
                  test**                                                                                     

                  total protoyping                           \$151,675                      \$99,470         

                  overhead                   1.0600          \$160,776                                       

                  **SUM**                                    **\$260,246**                                   

                  **est 2006                                 **\$90,000**                                    
                  uncomm**                                                                                   

                  **LBNL REQUEST**                           **\$170,246**                                   

                                                                                                             

  notes:          1\. Substrates                                                                             
                  can contain more                                                                           
                  than one hybrid                                                                            
                  when printed                                                                               

                  2\. CAD includes                                                                           
                  work which can                                                                             
                  be applied to                                                                              
                  final design                                                                               

                  3\. Fabrication                                                                            
                  cost driven by                                                                             
                  quantity,                                                                                  
                  \~factor 2                                                                                 
                  savings in                                                                                 
                  production                                                                                 

                                                                                                             

                                                                                                             

  rates           CAD rate 1                 \$91.00                                                         

                  shops rate                 \$76.00                                                         

                  junior tech                \$58.00                                                         

                  senior tech                \$82.00                                                         

                                                                                                             

                                                                                                             

  **4.1.4.1.2**                                                                                              

  **BNL Section**                                                                                            

                  **item**         **num**   **materials**   **total**          **hours**   **labor-cost**   **notes**

  **1**           **Hamamatsu                                                                                
                  Short Strips**                                                                             

  1.1             Order Remainder  1         \$85,000.00     \$85,000.0                                      

  1.2             QA Testing       1         \$5,000.00      \$5,000.0                                       

  **2**           **NewDaq                                                                                   
                  Software                                                                                   
                  Development**                                                                              

  2.1             1/6 Engineering                                               320         \$20,000         

  3               **Stave          1                                                                         
                  Metreology**                                                                               

  3.1             Optical system   1         \$5,000.00      \$5,000.0                                       

  **4**           **2nd Stave                                                                                
                  Assembly**                                                                                 

  4,1             engineer         1                                            80          \$5,000          

  4.2             tech             1                                            160         \$10,000         

  4.3             fixtures         1         \$5,000.00      \$5,000.0                                       

                                                                                                             

  Subtotal                                   \$100,000.00    \$100,000.0        560         \$35,000.00      

                                                                                                             

  **TOTAL**       **BNL Request**                            **\$135,000**                                   

                                                                                                             

  **4.1.4.1.3**                                                                                              

  **Hampton                                                                                                  
  Section**                                                                                                  

  1               cooling box                                \$5,000                                         

  2               daq modules                                \$5,000                                         

  3               testing and fab                                                           \$10,000         
                  effort                                                                                     

                  subtotal                                   \$10,000                       \$10,000         

                  total                                      **\$20,000**                                    

                                                                                                             

  **4.1.4.3**                                                                                                

  **Cooling                                                                                                  
  Channels (Bill                                                                                             
  Miller                                                                                                     
  Effort)**                                                                                                  

  **4.1.4.3.1**   **Stave                                                                                    
                  materials**                                                                                

  1.1             Pre preg         1         \$17,500.00     \$17,500                                        

  1.2             Honeycomb        1         \$4,000.00      \$4,000                                         

  **4.1.4.3.2**   **Stave                                                                                    
                  design/eng**                                                                               

  2.1             Engineering                                                   300         \$22,500         

  2.2             Design effort                                                 100         \$3,500          

  **4.1.4.3.3**   **Fixtures**                                                                               

  3.1             Fixture          1         \$25,000.00     \$25,000                                        
                  fabrication                                                                                

  **4.1.4.3.4**   **Assembly and                                                                             
                  test**                                                                                     

  4.1             Materials        1         \$5,000.00      \$5,000                                         
                  testing                                                                                    

  4.2             Assembly labor                                                390         \$32,001         4

  4.3             stability test   1         \$5,000.00      \$5,000                                         
                  fixture                                                                                    

  4.4             subtotals                  \$56,500.00     \$56,500                       \$58,001         

  **TOTAL**                                                  **\$114,500.50**                                

                                                                                                             

  **rates**       engineering                \$75.00                                                         

                  design                     \$35.00                                                         

  notes           4\. LBNL tech                                                                              
                  labor                                                                                      
  --------------- ---------------- --------- --------------- ------------------ ----------- ---------------- -----------