Module Production and Testing at Duke

1
Module Production and Testing at Duke

Jack Fowler
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Production Status
3
Module Straightness

• Module 2.1
• 200 microns
• Module 2.2
• 150 microns
• Module 2.3
• 125 microns
• Module 2.4
• 150 microns

• Module 2.5
• 175 microns
• Module 2.6 Initial
• 125 microns

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Module 2.5 Straw Alignment
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High Voltage Testing

• High voltage plates are tested
• initially from supplier
• after the Kapton forming process
• after insertion of straws
• after 1st end outer wire supports are conductive
  glued
• after 2nd end outer wire supports are conductive
  glued
• after sealing glue is applied to outside of HV
  plate
• after potting of inside of module
• after stringing
• after final gluing and leak test

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High Voltage Testing (2)

• High voltage plate tests includes
• visual inspection
• dimensional inspection
• continuity tests
• resistance values
• high voltage breakdown up to 3 kV
• current draw

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High Voltage Testing Results

• Module 2.1
• Pad 63 and 64 short
• Pad 53 trips _at_ 2 kV
• Pad 46 trips _at_ 2 kV
• Pad 36 trips _at_ 2.1 kV
• Module 2.2
• Pad 20 and 30 short
• Module 2.3
• Pad 3 to 4 trip _at_ 2.3 kV
• Pad 9 to 10 trip _at_ 1.8 kV
• Pad 26 and 37 short
• Pad 60 and 61 short

• Module 2.4
• Pad 15 trips _at_ 2.3 kV
• Pad 54 trips _at_ 2.3 kV
• Module 2.5
• no problems through mechanical assembly
• Module 2.6
• no problems through acceptance test

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Straw Resistance Testing

• Straw resistance is tested at Hampton prior to
  shipment
• During production straw resistance is tested
• after straw insertion and the first end outer
  wire supports are conductive glued. This is an
  individual resistance.
• After second end outer wire supports are glued.
  This is a group resistance between pads.

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Straw Resistance Testing Results

• Module 2.1
• No straws over 200 ohms
• Pad resistance range 5.8 to 7.5 ohms
• Module 2.2
• No straws over 200 ohms
• Pad resistance range 5.6 to 7.0 ohms
• Module 2.3
• 96 straws over 200 ohms
• Pad resistance range 5.6 to 8.0 ohms

• Module 2.4
• 6 straws over 200 ohms
• Pad resistance range 4.8 to 8.0 ohms
• Module 2.5
• 1 straw over 200 ohms
• Pad resistance range 5.2 to 7.5 ohms

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Module 2.5 Individual Resistances
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Module 2.5 Island Resistance
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Leak Test Results

• Module 2.1
• no detectable leak
• Module 2.2
• no detectable leak
• Module 2.3
• no detectable leak
• Module 2.4
• no detectable leak
• Module 2.5
• no detectable leak

• Detection Limits

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Stringing Results

• Module 2.1
• 21 days to string
• 12 wires arc, restring
• Module 2.2
• 21 days to string
• 37 wires arc, restring
• Module 2.3
• 16 days to string
• 20 wire arc, restring

• Module 2.4
• 14 days to string
• 12 wires arc, restring
• Module 2.5
• in process
• Improvements made
• deburr twisters
• change lead wire

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Stringing Stations
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Module Completion Summary

• Module 2.1
• Straw 83, stringing problem, dead channel
• Straw 400, stringing problem, dead channel
• Module 2.2
• Straw 292, stringing problem, dead channel
• Module 2.3
• no problems
• Module 2.4
• Straw 48, straw leak, dead channel

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Module Weights

• Module 2.1
• 4.28 kg
• Module 2.2
• unable to measure, gain testing
• Module 2.3
• 4.37 kg
• Module 2.4
• 4.22 kg
• Module 2.5
• 3.97 kg before stringing