Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module...
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Transcript of Slide 1-OGP status & module reinforcementDOE review, January 20, 2004 Status of OGP & Module...
Slide 1-OGP status & module reinforcementDOE review, January 20, 2004
Status of OGP & Module reinforcement
Andrea AllenDevelopment Technician
DOE ReviewJanuary 20, 2004
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
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
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
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
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
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
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
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
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
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