AMS02 tracker mechanics status of construction, assembly, integration

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AMS-02 tracker mechanicsstatus ofconstruction,
assembly, integration
Divic RAPIN, UniGe

• Production
• - Ladder integration
• - Installation on planes
• Inner tracker integration
• - Assembly
• - Cabling
• - Temperature sensors
• Quality control
• - Examples

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General view of Silicon tracker

• 5 planes, 8 layers
• Plane 1, layer 1
• Plane 2, layers 23
• Plane 3, layers 45
• Plane 4, layers 67
• Plane 5, layer 8
• 192 ladder modules

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Ladder Assembly Status (Perugia-Geneva)

• ASSEMBLY
• 210 ladders build
• PHASE 2 hybrid box legs gluing
• completed
• EMI SHIELDING
• ( kapton foil wrapping)
• 31 ready for process
• Full test at each step with RA source and noise
  control

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Installation of ladders on support planes (UniGe
clean room)
Plane 3 being stored (under Nitrogen)
Details of fixation on both sides
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Status of installation of ladders on planes

• Plane 1
• - layer 1, 30 ladders to be
  done
• Plane 2
• - layer 2, 24 ladders completed
• - layer 3, 22 ladders completed
• Plane 3
• - layer 4, 20 ladders completed
• - layer 5, 20 ladders completed
• Plane 4
• - layer 6, 22 ladders completed
• - layer 7, 24 ladders completed
• Plane 5
• - layer 8, 30 ladders 4/5 done

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Preliminary tracker assembly at Uni-GE
Dry assembly of shells-planes was made before
installation of ladders on planes.
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Assembly of the inner tracker at UniGe

• Set-up for storage insertion into the magnet.
• The various lengths of the cables were
  calculated. Cables tested in UniGe
• Cables must be installed before the supporting
  shells.
• Extra length must be attached to temporary
  supports.

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Cables (2192 flat cables)

• Cabling scheme, routing, topology and various
  lengths were studied and defined in July 2003
  using mock-up.
• Manufactured by GA in Italy.

Before installation, on all cables
- Electrical tests were performed. - Cable
length checked (by weight). - Cables sorted
according to the integration sequence.
Filipe Da Silva
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Vibration tests of the cables and connexions
Mechanical behaviour and fixation scheme were
studied thanks to the vibration table
of University of Bern. Mr Beat Zahnd
cable alone
cable bundle
connexions/cables for a 3-layer column

• No problems found for cables, connectors and
  connexions
• Distance between cable fixations were determined
  (for vacuum case)
• Cable supporting scheme between vacuum case and
  crates still needs study

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Inner tracker assy at Uni-GE A new clean room
(véranda) was installed to accomodate the Durga
assembly jig (formerly called ETHZ Frankenstein
machine), after modifications for AMS2 geometry.
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Plane 2 in place, supported by its ring
Temporary cable support
Support ring
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Insertion of plane 3
thermal connexions
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Insertion and thermal connexion of plane 4
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For a better support, vertical bars are added to
replace the shells during cabling activities
Last component
Lower conical flange
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Cabling Preliminary work
Documentation
Definition of procedures
Tooling
V0.1
V3.5
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Cabling procedure for half column (simplified)
For 3 ladders

• Check cables allocation
• Weight and clean the cables
• Slide and plug the cables
• Ladder connexion test (darkness)
• - pedestals pattern read-out and check
• - low voltage bias check
• Pack and secure extra cable length
• Documentation

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Installation and test of the first column (M13)
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Storage of the extra length of cables
Lower cable support
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We are proceeding with cabling
Manfred Willenbrock Samuel Delaere
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Temperature sensors for inner tracker

• Facts and wishes
• Plane 3 is the hottest place and cooling loop is
  at Tconst.
• TTCS can accommodate read-out of additional
  Dallas sensors.
• Any connexion topology is acceptable chain,
  star, mixed
• Redundancy impose two identical chains.
• Temperature measurements for each octant on each
  plane.
• Read-out chains are prepared and tested before
  installation.
• Constraints from mechanics
• No possibility for sensor cables to cross the
  shells.
• Apertures through the planes usually occupied by
  flat cables.
• Only apertures on Y (7-wafer ladder columns) are
  available.
• Even turning around a plane between thermal bars
  and shells is difficult.

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Example of a double chain of Dallas sensors
Chains prepared by A. Koulemzine for TOF
Connector cannot be slided trough the planes
using free apertures
Sensors can
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Free apertures
Difficult locations (2 mm clearance from
the edges of the bars to the shell)
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Possible locations for sensors
cables
PL2
No cables through plane 3
PL3
PL4
Possible places where to glue sensors on thermal
bars
cables
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Choice of the tracker collaboration for inner
tracker July 18

• Sensors for outer planes and cooling loops will
  be decided and installed later
• Use a double chain with 1 connector and 4 or 6
  pairs of sensors.
• Fix the connector on an empty slot of top conical
  flange and slide the chain downward trough column
  1P or 1M.
• Install (glue) the sensors on thermal bars on the
  bottom side of plane 3.
• Build special pieces to hold the cables within
  the 2 mm clearance in the delicate locations and
  glue them to thermal bars.
• Other topologies cannot be installed without
  cutting the chain

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Quality control Summary

• Ladders
• data base with status, results of electric tests
  and comments
• manual records of inspections and actions
• Integration of thermal bars on planes
• manual records
• Integration of ladders on planes
• manual records (graphics)
• electronic tests on data base
• Tracker integration
• well defined procedures
• trace is kept (operator, date, comments, etc...)
• Cabling
• idem
• electric tests

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Integration of thermal bars on planes
Quality control example
Control sheet for each bar pair
Control sheet for a plane
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Part of control document used during integration
of ladders on a plane
Example
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Control sheet and procedure for cabling
Example
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ExampleProcedure and control for cable connexion
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A new procedure was needed due to an unforeseen
problem ...
A non-conformity procedure was opened ... (report
is being written)
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Some of the thermal connectors (copper braids)
suffered from the compression applied during
their connexion.

• All damaged threads are broken on one side only
• None found to be loose

Use of space qualified schrumpfschlauch (Kynar
heat shrink tubing) to confine the threads of the
copper braids.
Tests on prototypes
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The procedure is applied to all connectors
- Preliminary cleaning with micro vacuum
cleaner - Nothing found in the filter
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Near future integration operations at UniGe

• Complete the cabling, tests and cable securing
• Installation of thermal sensors
• Mounting shells
• Packing (in Nitrogen) the inner tracker in a box
  convenient for storage and transport to CERN.
• Star tracker support bonding on plane 1
• Completion of outer planes (storage in Nitrogen)
• Evaporators pre-assembly

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Preliminary precaution Make sure that the
heat load on the
detector electronics is acceptable

• One side of the connectors is glued on the
  thermal bar
• Installation and heating (175 deg) must be done
  in situ.
• Possible heating of the hybrid circuit was
  tested.
• No problems since heating time is always less
  than 30 seconds.

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Procedure and controls for heat shrink tubing
installation
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