Tracker TEDD project at IPNL - Réunion CMS IPNL, 14/05/2018 Nicolas Chanon, Thierry Dupasquier, Nick Lumb, Emilie - Indico
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Tracker TEDD project at IPNL
Réunion CMS IPNL, 14/05/2018
Nicolas Chanon, Thierry Dupasquier, Nick Lumb, Emilie
Schibler, Sébastien Viret
1
TEDD: Tracker Endcap Double Disks
TEDD2
TEDD1
TEDD:
- 1 TEDD1 is made of 2 double-disks of the same type
- 1 TEDD2 is made of 3 double-disks (quasi-identical, last one has additional 4mm
2S module ring)
- 1 double-disk is formed of 4 Dees
2
IPNL responsibilities
IPNL responsibilities in TEDD project:
1) Design of all type of Dees
2) Construction and qualification of all TEDD2 Dees (24)
3) Integration of 12 TEDD2 Dees
4) Mechanical design of TEDD
The team at IPNL
- Nicolas Chanon, Sébastien Viret: Physicists
- Nick Lumb: Dees design and prototyping, technical coordination of
the project
- Thierry Dupasquier: TEDD mechanical design and integration, Dees
prototyping
- Emilie Schibler: TEDD mechanical simulations
- Florent Schirra: Assistant ingénieur
- Alexis Eynard, Lionel Germani: Technicians
3
2S and PS modules
PS module 2S module
4
Double-disks concept: overview
- Recently updated Dees design: top and bottom Dees are now fully identical
Nick Lumb
2x
- Two thin (10mm)
composite disks make
up the Double-Disk
system
- Each single disk
comprised of two semi-
circular ‘Dees’
Module/Dee PS 2S
TEDD1 odd 76 96
TEDD1 even 84 66
TEDD2 odd 52 96
TEDD2 even 70 64
5
Double-disks concept: module overlap
Azimuthal overlap using opposite sides of Dee
Odd rings
R overlap using disk pairs
Even rings
6
Anatomy of a Dee
Sandwich structure
Top CF skin with
holes for inserts
Upper Airex filler
Upper cooling pipe
Groove for lower
cooling pipe
PS cooling pads Lower Airex filler layer
(carbon foam)
2S cooling inserts Lower CF skin
(aluminium)
Embedded cooling pipes alternate between two different Z levels to allow overlap
7
Cooling pipes
Embedded cooling circuits for all Dee types have been designed
- 6 cooling sectors / Dee, highly symmetric
- 2 cooling loops per sector and per disk (odd/even rings)
- Pipe size 2.2mm inner diameter, optimised for ΔT < 10ºC between CO2 and
modules
Full model
TEDD2 odd rings
Orange color: High conductivity
identical paths S4 S3 CF pads (PS)
S5 S2
S6 S1
8
TEDD design (global mechanics)
Thierry
Carbon Fiber +
Dupasquier
Airex Back panel
12 Carbon Fiber Bars
screwed to double-disks
CF Inner tube
Sliding pads:
for tracker tube rails
4 CF Strapping rings
made of 12 elements
9
TEDD design: simulations
First attempt at mechanical simulations:
- Simplified TEDD model: reduced number of inserts, no services yet
- Simulation shows that mechanical deformations are within tolerance
- To be redone with more realistic model including cables (when cabling design will
be ready)
Emilie
Schibler
Max deformation:
0,15 mm
10TEDD integration: design
- Working on design of TEDD mechanical structures
- Depends strongly on how TEDD integration will be done, and
insertion within the global tracker structure (ongoing work)
- Foreseeing to produce prototypes of TEDD integration tools:
mechanical structure and tooling
Tracker tube
supports
Mounting bench
11Dees: first prototype
Cooling
sector S1
Cooling
sector S2
CF pads
40% of full Dee area
Thierry Dupasquier
Good relations with local company
First prototype completed: Oct.2016. (Workshape, Valence)
Aim: - Production of CF skins
- Validation of concept, mechanical
- Machining of Airex
precision of large area structure - Final machining, gluing in autoclave
- Realistic components
at 120ºC, 2 bars
- Final insert machining
12Dees: first prototype
Planarity measurement
Laser scan at Workshape:
- Measurements performed with loose fixations, to not artificially induce
deformations on the prototype
- First prototype result: Flatness 3mm over 1100 mm
- Specifications require 1mm over 2200 mm (full Dee diameter)
13Dees: second prototype
Jan - Dec 2017 (including debugging
flatness problem) +3.5mm
- Tuned thickness, updated pipe diameter…
- Process at room temperature cured the
flatness problem: now reaching 0.4mm
(laser): within specifications!
- Now looking into insert positions:
-3.5mm
promising results (ongoing)
+0.4mm
-0.4mm
Autoclave 2 bar, 25ºC for 24h
14Chapter 9. The Outer Tracker: Additional Information
Dees prototypes: thermal measurements 20
Module, TB2S 1.8 mm 2S Module, TEDD
-1 -1
b , 600 V 3000 fb , 600 V
-1 18 -1
b , 800 V 3000 fb , 800 V
-1 -1
b , 800 V 4000 fb , 800 V
Tsensor - TCO2 [K]
Ongoing work to measure16 ΔT between
CO2 and modules 14
- Goal ΔT < 10ºC between CO2 and
max
modules 12
- “Dummy modules” made of radiator with
10
similar thermal properties as real modules
−35 −30 −25 −20 −40 −35 −30 −25 −20
TCO2 [°C] TCO2 [°C]
20
4.0 mm 2S Module, TEDD
-1
3000 fb , 600 V
18
3000 fb-1, 800 V
4000 fb-1, 800 V
Tsensor - TCO2 [K]
16
14
Simulation,
Tracker TDR
max
12
10
8
−40 −35 −30 −25 −20
TCO2 [°C]
erence between maximum sensor temperature and CO2 temperature vs. CO2
15
the 1.8 mm 2S module in the TB2S (top left) and the TEDD (top right), and theDees production plans
2018 2019 2020 2021 2022 2023
Prototypes Pre-prod Produc-on
2018: Plan to produce a Dee prototype with full size (depending on ongoing
measurements)
2019: Go on with prototype Dee qualification,
2020: Pre-production of 4 Dees. Potential of mounting one double-disk, will be used
later to test prototyping of TEDD integration.
2021-2023: Dee production. Dee qualification: planarity, inserts, and ΔT
measurements.
- Work is being done at IPNL (building Van Der Graf) to build a clean room for Dee
construction and Integration, delivery date May 2018.
- Clean room will receive new fridge (to be ordered) able to contain 1 full Dee in
qualification procedure 400
350
300
- Plan to hire 3 technicians (10 months 250
CORE
200
NON-CORE
each) to carry out Dee production. 150 CDD
100
50
0
2018 2019 2020 2021 2022 2023
16Dees integration: Plans
2018 2019 2020 2021 2022 2023
Prepara-on
Pre-produc-on
Produc-on
Planification of Dee Integration:
- Module reception from assembly centers
- Module tests at reception
- Assembly line for PS and 2S module mounting on Dees
- Cold tests after mounting
- Shipment of the Dees to Louvain and DESY
- Plan to hire 3 technicians (10 months each) for 250
module mounting and tests. 200
- 1 AI (36 months) to setup and run test bench 150 CORE
measurements 100
NON-CORE
CDD
- 1AI (36 months) to setup and run the assembly
50
line,
- AI’s would need to start early enough in the 0
2018 2019 2020 2021 2022 2023
project…
17Shipment
Dees will be shipped to TEDD assembly centres
1) DESY: 12 non-equipped Dees
2) Louvain: 12 equipped Dees
Shipment procedure to be determined in more details.
Shipment of 12 TEDD2 DESY
Dees (non-equipped) - Construction of TEDD1
IPNL Dees
- Integration of Dees
- Construction and qualification
- Integration of 1 TEDD
of 24 TEDD2 Dees
- Integration of 12 TEDD2 Dees
Shipment of 12
Louvain
TEDD2 Dees
- Integration of 1 TEDD
(equipped)
18Conclusions
- Design of Dees completed. Needs to be updated each time module
design is changing module dimensions
- Mechanical design of TEDD, with simulations, is ongoing, and needs
updates from other institutes on cabling scheme
- Prototyping: planarity reaches specifications, insert position measurement
is ongoing, next will be thermal measurements
- First cost estimate of Dee construction and integration is available
Summary of financial aspects:
Activité WBS 2019 2020 2021 2022 2023 Total par categorie (keuros)
R&D Non-core CDD Core R&D Non-core CDD Core R&D Non-core CDD Core R&D Non-core CDD Core R&D Non-core CDD Core R&D Non-core CDD Core
Design & prototype TEDD Dees 2.1.7.1.1 12 12 0 0
Pre-production of TEDD Dees 2.1.7.1.7 76 213 76 0 213
Production of TEDD Dees 2.1.7.1.10 30 25 380 30 25 380 19 25 152 79 75 912
TEDD assembly design 2.1.7.4 96 96 0 0
Procurement of raw materials and components 2.1.7.9 8 73 7 0 0 89
Equipping OT integration centers 2.1.8.1 48 40 146 80 93 30 29 345 120 0
Integration and testing of TEDD Dees 2.1.8.4 24 80 24 78 24 38 72 195 0
681 390 1214
Cost (k€)
CORE 1214
NON-CORE 681
CDD 390
TOTAL 2285
19Tasks for physicists and students
Contributing to Tracker upgrade beam tests
- Next realistic date for a BT at CERN is Oct. 24th to 31st
- Test of mini-module with service hybrid, using CMS pixel telescope, at high SPS rate
- Analyzing Beam test data: module efficiency, resolution…
- No beams at CERN in 2019/2020: next BT will be at FNAL / DESY / PSI (?)
- Participation in BT and analysis is especially well suited for PhD students / post-doc
Setup of a test bench at IPNL
- Similarly to BT, important activity to prepare tests in production : have to prepare as
early as possible, understand the DAQ and related issues
- Setup a DAQ architecture at IPNL to read modules, using FC7 back-end and
microTCA
- Will require time from an engineer with DAQ expertise
- Possibility to use scintillators to trigger on cosmics
- Well suited for post-doc / physicist
Setup of Dee construction procedures, setup of the assembly line
20Back-up slides
21Double-disk linking mechanics
Odd Disk
Joining upper / lower Dees
to make a disk
Even Disk
Odd Disk Even Disk
Outer radius
9 inserts/Dee
Inner radius
4 inserts/Dee
Joining odd/even Dees
22Module cooling contacts
Cooling technology: evaporative CO2
- 2-phase CO2 exploits high latent heat of the liquid: small mass of
liquid needed => small pipe diameter
PS modules (Power ~8W)
- High conductivity carbon foam
2S modules (Power ~5W)
5 Aluminium inserts
pads in contact with CF skin of Dee
- Precision mounting points for 2S
- Modules glued to skins with phase-
modules
change pads, + 3 positioning inserts
23Dees: first prototype
Gluing PS inserts on CF skins (IPNL)
Gluing of 2S inserts + C-foam
pads onto the tubes (IPNL)
Assembly and gluing of the
different layers (Workshape)
24Prototype: Measurement of insert positions
- Measurement arm with ruby tip at Workshape
- Prototype constrained by vacuum on pre-machined platform
- Points compared directly with imported CAD model of ideal object
X-Y position (screw holes) 2S inserts Z positions: Z+ side
Well within specifications, ±50μm (module mounting surfaces)
RMS 14 μm
DeltaX: Z+ side Z+ side: absolute Z
14 Mean -0.004 14
Mean 3.851
12 RMS 0.013 12
RMS 0.014
10 10
Fréquence
Fréquence
8 8
6 6
4 4
2 2
0 0
ou plus...
3.650
3.660
3.670
3.680
3.690
3.700
3.710
3.720
3.730
3.740
3.750
3.760
3.770
3.780
3.790
3.800
3.810
3.820
3.830
3.840
3.850
3.860
3.870
3.880
3.890
3.900
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Classes
Classes
Distance between mounting surfaces on the two sides of the prototype should be difference between
the means of the distributions: 3.851 – (-12.805) = 16.66. Target was 16.44 +/- 0.05mm
There are two complicating factors:
- Mistake during CNC programming: assumed 10mm sandwich thickness instead of 9.6!
- When prototype is turned to measure the second side, link with measurements of first side is lost,
introducing a possible offset
25Dee integration: details
Moving/protecting Dees:
- Dee protection box (to be designed), will receive Dee at Workshape.
- Will be used for transport to IPNL, within the clean room, and for shipment
to TEDD integration centers
- Moveable plexiglass window will allow protection of mounted modules
while mounting the next one
- A chassis with rotating stage will be designed for module integration
Assembly line:
- Precision mounting thanks to mechanical inserts does not require jigs
- Use of protection box and chassis for module mounting
- Process for gluing of PS modules needs to be clarified with CERN
- Cabling of final optical fibers, LV, HV (CORE), that will be used in the
cold tests
26Module tests before/after mounting
Tests at reception:
- Measure leakage current (must be less than 1 nA)
- Setup of a test bench to measure basic module properties: connectivity,
functionality, possibly also noise
- Use FC7 back-end with μTCA crate
- Alternate solution with portative test bench is highly desirable (for instance
with FC7 test card)
Cold tests after mounting:
- Tests of modules at -35ºC: measurement of ΔT
- Number of modules to be tested at once is to be determined (possibly by sector)
- Measurement of module quality (noise) in realistic cold environment, and with
final cabling
- Ultimate solution would be to use final CMS DTC back-end, with ATCA crate
form-factor: would allow to test a whole Dee sector at once
- This might not be ready on time: fall-back solution with several FC7 needs to
be thought already now…
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