Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module...

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Slide 1 -OGP status & module reinforcement OE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review January 20, 2004
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Transcript of Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module...

Page 1: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 1-OGP status & module reinforcementDOE review, January 20, 2004

Status of OGP & Module reinforcement

Andrea AllenDevelopment Technician

DOE ReviewJanuary 20, 2004

Page 2: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 2-OGP status & module reinforcementDOE review, January 20, 2004

Overview of OGP

• OGP is commercial high precision (< 1 μm) automated measuring machine with programmable pattern recognition software

• Higher precision than gantry

• Provides independent survey of modules

• Used to cross check gantry calibration

Page 3: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 3-OGP status & module reinforcementDOE review, January 20, 2004

Status of OGP 2002

• Beginning to write programs on OGP to automate after cure survey. Programs not very repeatable

• Manually enter data from OGP into excel spreadsheets Time consuming Prone to data entry error

Page 4: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 4-OGP status & module reinforcementDOE review, January 20, 2004

Status of OGP today

• Reliable and repeatable programs written for all assembly plates User friendly, only minimal

knowledge of measurement software needed.

• Much faster than surveying on the gantry Can survey 3 plates, 9

modules, on OGP in 20 min, same 3 plates take 45 min on the gantry

Frees gantry for production

Page 5: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 5-OGP status & module reinforcementDOE review, January 20, 2004

New software

• Bought SmartReport software to interface with exiting measurement software Enables direct exportation of survey results into excel Eliminates possibility of data entry error

• Excel macros written to analyze data Automatically converts numbers from OGP coords to

module coords Compares measured values to nominal values Creates text files that are uploaded to database

Page 6: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 6-OGP status & module reinforcementDOE review, January 20, 2004

Broken Bonds in Transport

• Four shipments of modules from the USA to CERN by 3 different methods of transport: All were damaged in similar manner Many broken bonds – particularly between sensor and pitch adaptor Very time consuming repair work

• At UCSB we performed extreme drop tests that also resulted in sensor to sensor bonds being broken as shown above

Page 7: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 7-OGP status & module reinforcementDOE review, January 20, 2004

Reinforcement with Sylgard• After many studies (drop, vibration,

and thermal), TOB and TEC modules all found to be fragile

• UCSB developed a reinforcement technique using Sylgard.

• Sylgard is a silicon based encapsulant Used to encapsulate ALL wire bonds

on innermost layer of CDF Working temperatures –50C to 200C Radiation hard Low thermal conductivity

• Apply this material to back sides of modules at sensor-PA joint and sensor-sensor joint

Page 8: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 8-OGP status & module reinforcementDOE review, January 20, 2004

Drop Test Results

• With minimal packaging we dropped the reinforced modules 1 meter! Almost all bonds broke on

the control module (with no reinforcement)

No obvious deterioration of bond pull strengths for reinforced modules

Module 867 pull strengths (large glue beads)

0

2

4

6

8

10

12

0 100 200 300 400 500 600

Strip Number

Pu

ll S

tren

gth

s (g

)

initial pull test

after glue beads

after cold cycling

1 meter drop after repackaging

Page 9: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 9-OGP status & module reinforcementDOE review, January 20, 2004

Automating reinforcement

• Bought small gantry and glue dispensing robot to automate reinforcement Faster and more uniform

that applying by hand Uses static mixer to

dispense glue eliminating air bubbles in glue

– saves time evacuating air bubbles

Both machines are easy to program and easily communicate with each other

Page 10: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 10-OGP status & module reinforcementDOE review, January 20, 2004

Glue Gantry

• Designed bracket to mount glue dispenser to gantry and fixture for module carriers

• Program written to dispense glue beads Have reinforced 17

modules

• Very fast, can reinforce 20 modules in 15 minutes At peak production plan on

15 modules per day

• Glue beads are very uniform

Page 11: Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module reinforcement Andrea Allen Development Technician DOE Review.

Slide 11-OGP status & module reinforcementDOE review, January 20, 2004

Conclusion

• OGP automated and results are uploaded to database Frees up gantry for production increasing our daily production

capacity

• OGP provides more precise measurements than gantry Also provides an independent measurement of gantry

• Problem found with wire bonds breaking during transportation Studies found application of Sylgard beads to modules solves this

problem

• Bought small gantry to automate reinforcement process Can reinforce modules in a minimal amount of time