# Presentation: 637777

## Detector ProductionWBS 1.1.4

**James Fast**
**Fermilab**

## Detector Production Tasks

**Tasks involved **
**Fabrication of mechanical and electrical preproduction modules and staves**
**Mechanical module prototypes by 11/12/02**
**Mechanical stave prototypes 12/16/02**
**Electrical L1 module prototypes by 1/27/03**
**Electrical L2-5 module prototypes 2/18/03-4/15/03**
**Electrical stave prototypes 7/17/03**
**Fabrication of production modules for all layers**
**Assembly of L2-5 modules into staves**
**All testing required for Quality Assurance**
**Cecilia Gerber is managing electrical testing**

## L0 Modules

**Total of 144 modules to be installed**
**Production rate of 2/day**
**Throughput of 1.6 good modules per day required**
**No CMM required for module assembly**
**Three sets of tooling will be fabricated**
**Production start driven by hybrids**
**Flex and sensors available 2 months earlier**
**Production duration 18+6 weeks, 3/22/04-9/7/04**
**~3-5 week lag for first modules to get through assembly, testing and QA**
**~6 week lag for final modules (repairs) **

## L1 Modules

**Total of 72 modules to be installed**
**Production rate of 2/day**
**Throughput of 1.5 good modules per day required**
**Use Zeiss 500 in Lab C, Lab D CMMs are backup**
**Two fixtures; extra parts to allow higher rate**
**Production start driven by hybrids**
**Sensors available 20 weeks earlier**
**Production duration 10+6 weeks, 1/29/04-5/20/04**
**~3-5 week lag for first modules to get through assembly, testing and QA**
**~6 week lag for final modules (repairs)**

## L2-L5 Modules

**Total of 672 modules to be installed, 800 built**
**Production rate of 8/day**
**Throughput of 5.2 good modules per day required**
**Use 5 Zeiss CMMs in Lab D, Total of 8 fixtures**
**Tooling designed to allow for higher capacity per CMM in case of machine down time**
**Production start driven by hybrids**
**Production duration 12+6 weeks, **
**South Modules 3/16/04-7/23/04**
**North Modules 6/15/04-10/27/04**
**~3-5 week lag for 1st modules to get through assembly, testing and QA**
**~6 week lag for final modules (repairs)**

## L1-L5 Module Tooling

**6 flavors of fixture**
**L1 (160mm finished module length)**
**20cm gang, 10-10A, 10-10S (200mm modules)**
**20-20A, 20-20S (400mm modules)**
**Alignment and Gluing**
**Precision alignment of sensor to sensor <5******
**Alignment of hybrid to sensors to ~50******** **
**Module flipping**
**Backside HV connection from hybrid**
**Kapton HV insulation to isolate sensor from structure**
**Ground contact from hybrid for support structure**
**Wirebonding**
**Axial and stereo can be bonded on same fixtures (4 types)**
**Reasonably flat (~50********) vacuum chucks up to 400mm long**

## L1 Module Fixture

## L1 Flipping Fixture

## L1 Wirebonding Fixture

## 20-20 Axial Module Fixture

## Module Production Flow I

## Module Production Flow II

## CMM Usage for Production

## L2-5 Stave Assembly I

**Duration of 19.4 weeks, including electrical testing**
**South: 7/23/04-12/4/04**
**North: 10/27/04-3/25/05**
**Day 1**
**Vacuum fixture, 600mm long, holds core flat**
**Two vacuum chucks hold axial modules flat and locate them to reference pins of stave core**
**Day 2**
**CMM inspection of axial module locations**
**Stave core with axial modules is flipped**
**Two vacuum chucks hold stereo modules flat and locate them to reference pins of core**
**The same pins used for CMM reference to reduce alignment error between axial and stereo sides**

## L2-5 Stave Assembly II

**Day 3**
**CMM inspection of stereo module locations**
**Electrical testing of modules**
**Installation of C-channels (mechanical stiffeners for stave)**
**Day 4**
**Final electrical testing**
**Final mechanical inspection**
**Certification for installation**
**Small subset may be submitted to additional mechanical testing, e.g. deflection tests**

## L2-L5 Stave Assembly Fixture

## L0-L1 Production Schedule

**L0 and L1 Module Assembly Run in Parallel**
**L0 Module Assembly 3/22/03-9/7/04**
**L1 Module Assembly 1/29/04-5/20/04**
**Mounting of Module on Supports**
**L0 and L1 go in parallel**
**L0 South 5/7/04-7/19/04**
**L1 South 4/19/04-6/28/04**
**North follows South L0-L1 Mating**
**L0 North 8/24/04-11/2/04**
**L1 North 8/24/04-11/2/04 **
**L0-L1 Mating and Testing**
**South 8/17/04-9/7/04**
**North 12/3/04-12/23/04**

## L2-L5 Production Schedule I

**Ganging of sensors into 20cm readout segments precedes arrival of hybrids (complete 1/30/04)**
**Parallel processing of modules for each stave set**
**South Modules (3/16/04-7/23/04)**
**North Modules (6/15/04-10/27/04)**
**All South Stave modules completed before start of stave assembly**
**Human resource limitations drive this sequence**
**Electrical testing personnel: L2 hybrids, North modules, L0 north modules, L0 and L1 South module mounting concurrent**
**High level mechanical: Startup of L0 and L1 South module mounting concurrent**

## L2-L5 Production Schedule II

**Sequential assembly of staves**
**6 weeks “overlap” is testing&repair of all staves**
**South Staves (7/23/04-12/4/04)**
**North Staves (10/27/04-3/25/05)**
**All Staves completed prior to start of installation in cylinders**
**Driven by available CMM resources**
**B&S and Zeiss 850 completing North staves**
**LK completing L0-L1 subassemblies**

## Summary

**Module and Stave production schedules, including CMM usage, and interface between mechanical and electrical tasks, are well understood.**
**The tooling design for modules is flexible so that we can easily increase production rate.**
**Initial fixture designs are complete for L1-5 modules and nearly complete for staves.**
**Initial module fixtures have been ordered. **
**Initial stave fixtures to be ordered this month.**
**On track for mechanical modules by 11/12 and mechanical staves by 12/16.**