Advanced Technology For ILC Calorimeters
Jean-Claude Brient
LLR Director
Laboratoire Leprince-Ringuet, Ecole polythecnique/CNRS-IN2P3

KEK Seminar
December 12, 2017

Laboratory Leprince-Ringuet, at Ecole polytechnique , France
is at the forefront of advanced technology for projects @ CERN, NASA, …
In Japan for ILC and for neutrinos program (T2K, SK, and if HK)
http://llr.in2p3.fr/
Director :brient@llr.in2p3.fr

2

Outline- Mechanical Department @LLR
- Example of LLR France-Japan
successful collaboration- ECAL design for the ILD project

Then J.Nanni will presents you the instrumental aspects

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Mechanical Department @LLR
Ecole polytechnique

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Mechanical Department @ LLR
 The mechanical department is composed of technicians and engineers divided into 2
groups :- Design and Project Management group- Workshop
 The department is in charge of the mechanical design, the construction, thetransportation and the installation on-siteof detectors and physics equipment(prototypes or final detectors)
 The main expertises are:- Computer-Aided Design (CAD) using CATIA software;- Mechanical simulations andFinite Elements Analysis (FEA) with ANSYS;- Advanced machining process :Numerically controlled machines,
Water jet cutting machine, 3D printers…
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LLR machining workshop
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Mechanical Department @ LLR
 Composite activities : design and fabrication of structural components
Example : Example: development and delivery of the carbon
fibre mechanical structure for the calorimeter of the FERMI satellite (SLAC-NASA).

Design and FE
Analysisfor dimensioning
the structure

Integration of crystals (CsI) into the structure

Polymerization phasein our autoclave(125 °C for 3h @10 bars)

dynamic tests
before shipment to
the Naval ResearchLaboratory of Washington

Mould design andfabrication in
our clean room
(ISO7)

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Example of LLR – KYOTO University
successful collaboration

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FRANCE-JAPAN Col. - INGRID
 : INGRID detector @J-PARC (Interactive Neutrino GRID)
used for the T2K long baseline neutrino
oscillation experiment
INGRID consists in 16 identical modules
arranged in horizontal and vertical arraysaround the beam center. Each module has asandwich structure of iron target
plates and scintillator trackers.

INGRID module (x16)17/12/12

ND280 site
INGRID CAD model (from LLR)

Tracking scintillator planes (x 176)
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FRANCE-JAPAN Col. - INGRID
Dynamic modes
 LLR implications were:- Global Design of the detector with FE analysis(dimensions, stress & deformation, reactions to earthquakes…)- Construction (subcontracted to a French company)- Definition and supervise on of each assembly process(Tracking planes, modules, on-site installation…)

LLR teamssembly process

Assembly @Linac building(J-PARC)
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FRANCE-JAPAN Col. - INGRID
Akihiro Minamino (Kyoto)

It works !!!
Good behaviour during the earthquake of March 2011
Typical neutrino interaction event candidate in one of
the modules. A beam neutrino enters from the left.
(The size of the circles is proportional to the observed number ofphoton-electrons at scintillator bars, and black lines show thereconstructed tracks)

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ECAL design for the ILD project

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Some information about ILC calorimeter

1
2

Taking information from the DBD – ILD

Relative cost

1
3

Reducing the radius will reduce the cost of the Yoke and the cost of ECAL and HCAL

Compactness !!!!!
ECAL multilayers (20 to 30) and 22 X0
For a thickness of 20 to 25 cm

Specific Mechanical technology

14Connection over ∼2m long of thin PCB (∼ 1.5 mm), keeping S/N>8 *,good signal quality, etc… For 100 Millions calorimeters channels.
Advanced technology on high integration instrumentation* Mandatory for the DAQ
15

ILD - ECAL concept For the ECAL : the best approach to the analysis is to be able to individually recognize eachparticle of an event using the PFA approach
Density, compactness and ultra granularity with a minimum of dead zones and cracks
best choice: ECAL W / Si

Endcap2

HCAL

Y Θ Z
ΦX

CAD Modelof ILD concept
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Endcap1
Jean-Claude Brient – KEK Seminar

ECAL
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ECAL definition
ECAL Endcap2
Sampling calorimeter as compact as possible(small Molière radius)
ECAL Endcap1
Sampling according to the energy resolution
needed for a total of 24 radiation lengths

Concept :Half of the tungsten plates (absorbers) is
incorporated into a self-supporting alveolar
structure made of composite material
system(carbon/epoxy) to avoid machining step and reduce Fastening(rails)dead zones
Half of W plates supports (H-shaped structure)detection units, called detector slabs, which arethen slid inside each alveolus, sensors are silicon
diodes matrices with very fine segmentation of thereadout (5x5 mm2)
Detector slab


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ECAL barrel

Current general dimensions :L = 4.7 m
Rint = 1.8 m
Thickness = 0.2 m

Alveolar structure
Coolingsystem17/31

ECAL - Physics Prototype(2002-2008)This mechanical concept presents 3 major
engineering challenges :- Wrap W plates into carbon fibers sheets- Obtain heavy structures (due to the weight of W) but
light in terms of dead zones ?
- Thin as much as possible carbon walls (ribs) between
each alveoli for limiting dead material?

Structure 4.2(3×1.4mm of W plates)

Structure 2.8(2×1.4mm of W plates)

Structure 1.4(1.4mm of W plates)

YX
Detector slab (x30)Proof of concept with afirst prototype,used also for physics
validation

Active zone
~10000 pixels in 0.01 m3

H-shaped
structure

0,3 mm thickdetectionlayer

W plates
Impact of theinactive zone
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Alveolar structure
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0,5 mm thick
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ECAL - Detector Slab concept
PCB

SCSI connector

Shielding

Front End
electronics zone

Detector Slab :
1 H-shaped structure including W plate

2 PCB with 6 wafers glued with silver epoxy paste
1 Aluminium shielding (0,1 mm)(ground + Electromagnetic noises protection)Line buffers (To DAQ part differential)
2 calibration switches chips

Silicon wafer

6 active wafers(Cfi / W) structure type H
shielding: 100 µm

3300 µm

PCB: 2100 µm
gap: 445 µm
glue: 110 µm

12 FLC_PHY3
front-end chip
(18 channels per chip)wafer: 525 µm

Cross section
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ground foil: 30 µm
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Physics Prototype – Testbeams
Since 2005 several rounds of testbeams have been conducted at
DESY, CERN, FNAL for development studies, technical runs andphysics@ FNAL, 2008
@ CERN, 2006-2007@ DESY, 2005-2006
Tail Catcher
Muon Tracker

Scint.tile HCAL

W/Si ECAL

Tail Catcher
Muon Tracker

Scint.tile HCAL

W/Si ECAL
W/Si ECAL

ECAL (W/Si) alone

ECAL + AHCAL + TCMT
combined

ECAL + AHCAL + TCMT
combined

technical & physics run
with electrons@ 1-6 GeV

ECAL testbeam withelectrons/pions@ higher energy
AHCAL technical & physics run
with electrons/pions

ECAL testbeam withelectrons/piond@ higher energy
AHCAL technical & physics run
with electrons/pions

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Example : excellent shower
separation@ DESY, 2005
Electron shower @ 3 GeV(configuration 0°)

W/Si ECAL

W/Si ECAL

2 separated electron
showers @ 3 GeV(configuration 30°)

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Example : Combined results@ FNAL, 2008

Scint.tile HCAL

Tail Catcher
Muon Tracker

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W/Si ECAL

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ECAL – ILD prototype








Next step after the physics prototype which validated the main concepts : alveolar structure,slabs, gluing of wafers, integration…
Now: study and validation of most of the technological solutions which could be used for the
final detector (moulding process, cooling system, sizes of structures,…)
Based on barrel module : taking into account real shape, dimensions and industrialization
aspects of the process
Finest cost estimation of one module• 3 structures : 24 X0(W plates : 10×1,4mm + 10×2,8mm + 10×4,2mm)• sizes : 380×380×200 mm3• VFE outside detector• Number of channels : 9720 (pixel size :10×10 mm2)
• Weight : ~ 200 Kg
17/12/12• 1 structure : ~ 23 X0(W plates: 20×2,1mm + 9×4,2mm)• sizes : 1510×545×205 mm3• VFE inside detector• Nb of channels : ~37890 (5.5×5.5 mm2)
• Weight : ~ 700 Kg

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Definition & FEAAll dimensions of the ILD prototype
TSAI-HILL criteria
are defined according to FEA results in
Configuration 0°
static and dynamic (earthquake conditions) andfor all positions of final modules in the barrel(8 cases)
Study of deformations and limit stresses
analysis using composite criteria (TSAI-HILL)
Max stresses are located on the top ribs, a strong
effort is also needed to define correctly its
thickness
Proposal: Study internal stresses by using
new sensors : optical fiber Bragg grating sensors
embedded directly within ribs (strain gauge behaviour)

Global deformation of
ECAL module (static case)

0°
45°
90°

Global déformation(Response spectrum
in lateral only)

Optical fiber
equipped with
BG sensors

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Mechanical tests – Bragg Grating

Non-Destructive tests using 2 optical fibers with
5 bragg gratings along each internal ribs of arepresentative alveolar structure layer.
The fibers are included directly during the manufacturing
step (non-invasive concept)
Study of Bragg grating integration and sensitivity by using
Bending tests (3 pts) on a demonstrator: 6 different static
cases and measurement of variations of the Bragg
wavelength according to a compressive or tensile effectBending tests set-up

Mi

Optical fibers

Thermal sensor

loads :

Good sensitivity, variations are proportional to the deflection :possible to use them in the structure

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Mechanical tests – Destructive

2 types of carbon fibers were studied to obtain alveoli
in order to find the best choice price/wrapping
capabilities (90° without braking fibers) :3K

1K

0.65 mm0.95 mm

Destructive tests are also done on ribs until breakingof the interface in order to complete choice andevaluate limit loads and elongations under tensile andcompression loading Tensile and compression loading
cases

1K

0,7

Cross section

6
Load (kN)

Load (kN)
0,6

5

0,5

4

0,4

Optical fibers
embedded

Lav= 4.1 kN
1K

3

0,3

Lav= 0.39 kN

0,2

2
1

0,1

displacement (mm)displacement (mm)00017/12/12

0,5

1

1,5

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1

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Fabrication process Difficult to obtain a structure in one-shot : very complex
mould, important risks to fail the structure and lose the W Choice was made for an assembly process : Each alveolar
layer is done independently using a simple « alveolar layer »mould (), cut to the right length (with 45°) and assembled
with W plates interleaves in a second curing step using an
second assembly mould ()Top composite platewith metallic inserts
For rails
W layeralveolar layer





(x15)
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Polymerization cycle
 The polymerization of the structure is an Engineering challenge itself. Standard autoclave cycles are
not adapted for so heavy a mould (1,5 tons)
 Need to simulate correctly the curing cycle in order to guaranty a correct polymerization of thestructure with taking into account its thermal inertia.
 According the properties of the resin, we have limited at 10 °C the maximum gradient temperature
between the external and internal parts of the mould.
 Experimental tests have been done to valid the good cure cycle (all mass have been included)Exp. Tests (12 sensors)
Cycle simulated

11
11
2
9 6
3

ΔT~ 10°C

7

4
10

51
88

12

11
8

ΔT~ 10°C OK !

Cure cycle definition : ~28 hours
with 3 steps of 4h @60-80-100°C + 1 step of 12h @120°C
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ILD prototype

5 years of studies and R&D have beennecessary to obtain with success this structure(design with mechanical simulations, definitionof all steps of the fabrication with demonstrator,
study for BG integration for future modules,
optimization of the polymerization for heavy
structure of ~700 Kg…)Some developments will need adapted for the
final Module and specific Endcap geometry,
Construction of 2 modules 0 (barrel + Endcap)
will be necessary for complete validation of thedetector

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ECAL – Construction scenario
 In parallel to ECAL design and development, we are trying to have a description of acomplete construction and assembly scenario of the detector, which is not unique, but
realistic enough to draw conclusions on space, timing and manpower needed
and cost estimation
Steps/Needs

Quantities

Electromagnetic calorimeter
Barrel1

2.1.1 Module structure construction

40

2.1

It’s a requirement made by the Japanese site

2.1.1.1

Place

Unit cost/time

Industry
Several

120

90,3

ton

24000

platesCarbon fibres prepreg 1K for H structure

6000

m2

Industry

0,09

Carbon fibres prepreg 3K for alveolar
structureThin carbon plate (2mm) with 12K fibres

13000

m2

Industry

0,05

40

platesIndustry1platesIndustry

Rails fabrication (male + female parts)

40
80

Metal inserts

960

rails
inserts

Industry
Industry20,5Monolayer alveolar structure
Tools procurements

600

Dimensional inspection of W plates

Thick carbon plate (15mm) with 12K fibres

2.1.1.2

Tools

Material procurements and operations
Tungsten plates (thickness tolerance +- 40µm) Thickness : 1.05 – 2.1 – 4.2 mm

 All inputs are defined using a Work Breakdown
Structure in terms of operations, needs, steps,
quantities, tools, time, manpower …

Unit

3D measurement system HOME/Industry

0,024

Hextool moulds

6mouldsIndustry

50

Steel ground cores

30

cores

Industry

Storage boxes

40

boxes

1
0,300

Specific boxes

Industry

3D measurement system

Industry

Operations
Dimensional inspections (cores & moulds)

Example:Construction of 40 alveolar structures :Main Needs :90 tons of W ; 13000 m2 of Carbon fibres ;600 alveolar layers made with 6 moulds
40 structures obtained with 2 assembly moulds
40 transports boxes …

2.1.1.3

600

Clean room

Industry

600

cures

autoclaveIndustry

Cutting process (15 trapezoidal shape)

600

wrapping
layersDiamond machining

Transport & storage
Quality inspection of cores & moulds for reuse
Production follow-up

40

boxes

Module alveolar structure
Tools procurement

40

all

2 days0,40,05

Industry
Industry
3D measurement system HOME/Industry

0,200

HOME/Industry

1

Assembling mould

2

mouldsIndustry

30

Aluminium cores

150

cores

Industry

0,2module handling toolTransport & storage boxes

1
40

tool

HOME

boxes

Lift table (2T)

1

lift

transport boxes

0,1

Industry
Industry

5,50

Operations
Dimensional inspections (cores & moulds)

1

Assembling and wrapping operations

40

moduleClean roomHome

5 daysCuring process40

moduleautoclaveIndustry

2 days40

module3D measurement system+ crane 2T

40

moduleDimensional inspections and mould cleaning
operations
Transport & storage
Production follow-up

2.1.1.4

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all

Wrapping operations
Curing process

H-shaped slab structure
T lt

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3D measurement system

Home

Home
Industry

5 days
10

1

3000

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ECAL – Assembly scenario
Example : Main steps for the Barrel (proposal)
1) Construction of each module @LLR
2) Transport and storage all modules
3) Assembly by staves of 5 modules using a specificTool and a crane >2 tons.
Once the modules mounted on the tool the slabs can beinserted, the cooling and cabling installed with theelectronics and cooling up to close by patch panels

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ECAL – Assembly scenario
4) The staves are then stored and fully tested
electronically and with cosmics (needs acquisitionand cooling ), calibration…

5) Each stave is then installed using female rails
mounted on the HCAL
Use of the specific tool which allows to present infront of the HCAL each stave, control the alignment
and the orientation (wheel), and then draw
(or push) in; the cables and services are also
connected to the patch panels

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Areas definition
 The storage of 40 modules needs anaera of 14 x 8.5 m, circulation included,
Aera : 120 m²

 Concerning the Stave assembly area, weconsider an area where 4 staves can beworked on in parallel
Area : ~280 m²(the slab boxes are stored on shelvesfacing the assembly zone. In front of acradle enough slabs to equip 2 staves
are stored: 50 boxes + spares)

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Areas definition
 The stave storage (x4) area where the ready staves
are fully tested before installation
Aera : 125 m²

 Summary of the areas occupation :The module storage area is used
The stave assembly area is used
The test area is used
but all tools have to be stored

120m²
300m²
125m²
25 m²

Example of total area for assembly & tests : 570 m²
Important to design all zones, buildings, on the site of the experiment
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Assembly summary
Proposal of assembly scenario:

from structure to stave (with slabs)

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From stave to barrel

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Summary








The mechanical department of LLR is correctly sized for taking in charge detectors
construction, from the CAD Design, construction of the several prototypes (physics,
technological, module 0…) to the installation on site of the experiment
We have successful experience of collaboration with our Japanese colleagues for
proposing some innovative and complex projects of detector, and specially calorimeters
We are able to solve Mechanical Engineering Challenges, in a context of international
project with the R&D phase, tests definition, proposal solutions …
The LLR has also an expertise in electronics and readout system,
see next talk by Jerome

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