Paul Tipton

1
Robotics for Module and Stave Production
Paul Tipton Yale University May 3, 2007
2
New and Growing Effort

• Collaboration of BNL (D. Lynn, D.Lissauer,
  Y.Semertzidis), LBNL (C.Haber, G.Gilchriese), and
  Yale (W. Emmet, A.Martin, P.Tipton)

3
Motivation

• 7500-14000 barrel modules needed
• Ideally production should last of order one year
  (e.g., not three)
• A few barrel module production sites (lt5?)
• Leads to 10 modules/day/site
• Additional production capacity schedule
  contingency

4
Other Motivating Factors

• Likely lowers cost
• Smaller standing army, shorter production time
• not enough information yet to estimate true
  savings
• But due diligence demands that we explore
  automation
• Leads to uniformity of production techniques and
  final product over many production sites
• Quality control inspection also automated
• Robotic technology is mature
• Having a plan for automated production makes U.S.
  stave design more compelling attractive
• Robotics likely to help in almost all ID upgrade
  scenarios, not just current U.S./RAL stave design

5
What exactly are we proposing?

• ATLAS SCT used automation in
• Automatic glue dispensing
• Module placement on the CF cylinders
• But module fabrication used fixtures techs
• Want to add robotic pick-and-place technology,
  integrated with optics and glue dispensing, for
  use in both module fabrication and module
  placement on stave frame (e.g., stave production)

6
Why Start Now?

• Because we cannot start any sooner
• CMS gantry development effort took 4 years from
  purchase of prototype until they were ready for
  module production
• We have two processes to perfect (module and
  stave production) but arguably have more
  expertise at t0.

7
Three Robotics Options (fixturing) being
explored

1. Buy pieces servo-motors, stages, control system
   - and build system ourselves
2. Buy large sub-systems and integrate/customize,
   adding optics, vacuum, and glue dispensing to an
   off-the shelf motion-control system
3. Buy a multipurpose work-cell with pick-and-place,
   optics, and gluing capabilities that requires
   little in-house engineering retrofitting
4. Bag robotics and use fixturing

8
Sketch of an Option 2 System
Rotating pick-up tool
Glue dispense
X
Y
cameras
Cartesian gantry with work head
9
Module Work Surface
25 10 x 10 detectors
1 meter
Pitch adapter and hybrid staging area
10
Robotic Assembly Process

1. Load 25 detectors in work space. Nominal
   positions are set by pins or edges. Apply
   vacuum.
2. Load chip packs containing 100 pitch adapters
3. Load 100 hybrids into staging area. Only rough
   placement is required as determined by footprint
   marked on work surface.
4. Survey detectors with cameras on head to
   determine actual positions. Use focus to
   determine detector height.
5. Survey pitch adapters
6. Survey hybrids
7. Dispense adhesives onto detector surface
8. Pickup first hybrid
9. Calculate rotation and translation to arrive at
   correct position on detector
10. Move to position
11. Check local fiducials and recalculate correct
    position for placement
12. Place hybrid down on detector surface. Vertical
    drive set by detector thickness.
13. Pickup first pitch adapter. Follow sequence
    similar to 8.1-8.4
14. Repeat Steps 8-9 for the rest of the components
    (99 operations).
15. Inspect, report, end.
16. Technicians remove workplate and set aside for
    overnight adhesive cure.
17. Next-day inspection on OGP as cross-check, as
    needed
18. Load each module into a holder for wirebonding
    and test.

11
Stave Production

• Aerotech 10000 with 2mx1m work space is 90K,
  well suited for even the longest proposed staves.
• Or use smaller workspace and index stave
  through

12
Work Accomplished in FY07

• Coalesced as a collaboration around the need to,
  and how to, explore robotics
• Made progress in understanding production steps,
  robotic requirements
• Survey products (Areotech, Newport)
• Study CMS system in detail (4 of us to visit FNAL
  next week)
• We have a ball-park cost estimate for the
  hardware for options 2 3

On an Upgrade RD budget of 0
13
Proposed Work for FY08

• Our plan for the development work is to
  factorize problem into
• motion control - Yale
• vacuum distribution and control system - Yale
• optics/pattern recognition - BNL
• glue dispensing LBNL
• pickup heads/parts carriers LBNLYale
• Specify prototype motion and optics systems
• Prepare for prototype gantry/optics or work cell
  purchase in FY08
• Design and construct the vacuum distribution
  platform
• Glue dispensing
• Pickup tool development

14
Budget Considerations

• Materials cost of prototype gantry and vacuum
  system covered by Yale
• 101K of gantry purchase and materials for vacuum
  system
• Will also subsidize engineering (cost to project
  is 62/hour with no additional overhead)
• Asking for
• Balance of engineering costs to specify gantry
  and design vacuum distribution platform at Yale
• Machining time for fabrication of vacuum
  distribution system, also at Yale
• Optics hardware for BNL work to begin
• Glue dispensing
• Pickup tool design

15
Budget Details
16
Conclusions

• In FY07 our progress was good, but very soon
  further progress will require us to start
  spending money (engineering, then materials)
• In FY08 we plan for success, want to be ready for
  a timely purchase of an appropriate prototype
  automated production system, soon after it
  becomes clear what will be the comprising pieces
  and construction steps for module and stave
• This timeframe looks to be the second half of
  FY08.
• FY08 RD funds will be highly leveraged in this
  activity

17
Backup Slides
18
The CMS Gantry

• 1998 technology
• Aerotech AGS 10000 Gantry
• Added optics and frame-grabbing
• Added custom vacuum plates chucks
• Added pneumatics for glue dispensing
• Production recipe
• Establish coordinate system
• Find position of objects
• Glue dispensing
• Pick-and-place
• Inspection
• Load next plate
• Uses fiducials to locate and place each piece
• 3 Modules per tray, up to 8 trays per day
• Second-day inspection on a separate machine as a
  cross-check