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\section{Integration Procedures} |
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\label{sec:Procedures} |
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In this section the operations which are required to assemble a TIB shell will be listed |
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and described in details. |
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The various tests performed during the integration will just be mentioned among the |
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other steps in the sequence of operations: a deeper discussion will be done |
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in section \ref{sec:Tests}. |
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|
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\subsection{Shell Mechanics and Integration Bench} |
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The carbon fiber supporting structure, |
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on which the cooling pipes and the precision mounting ledges |
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have been already glued, is the starting point for the TIB shell integration. |
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To allow for a practical |
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and safe handling of the structure during the integration, the shell is mounted, via an aluminum |
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support frame which minimizes the mechanical stresses, |
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onto an integration bench. The bench allow to rotate the shell around the horizontally placed |
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cylindrical axis. |
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In this way all the internal and external strings can be |
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positioned in an optimal way for components mounting. The structure support frame holds also a |
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number of plastic boxes which are used to temporary store the analog optohybrids fibres and their |
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connectors allowing for their accessibility during the various tests. |
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To identify each string during the shell integration bar code stickers are temporary glued |
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on the structure. The string sticker is read and send to the integration database interface program |
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before each mounting operation.\\ |
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A picture of a Layer 4 mechanical structure mounted on the integration bench is shown in Figure |
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\ref{fig:bench}. |
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TIB and TID have different integration procedures, each one being optimised |
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for the geometry and the best installation and test logical sequence. |
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In this section the steps done to assembly a TIB shell and a TID |
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ring will be described also mentioning the tests performed in between and |
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described in detail in section~\ref{sec:Tests}. |
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|
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The integration process starts from the basic mechanical structure |
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already equipped with cooling pipes and the module support ledges |
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and fully qualified with respect to the precision mounting of the |
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mechanical parts and cooling performances. |
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|
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\subsection{TIB Integration Procedures} |
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|
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The shell is fixed, with the cylinder axis horizontal, onto an |
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integration bench using an aluminum frame to minimize the mechanical |
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stresses applied to the carbon fibre mechanical structure. |
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The bench allows the shell to be rotated around the cylinder |
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axis and is also know as ``roaster''. All the internal and external strings can be |
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positioned in an optimal way for access in a fast, practical and safe way. |
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|
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The shell supporting structure also holds a system consisting of plastic |
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trays to safely arrange the AOH fibres. To easily identify each string a bar code is temporarily stick on the |
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structure.\\ |
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%The string sticker is read and send to the integration database interface program |
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%before each mounting operation.\\ |
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A picture of a Layer 4 mechanical structure mounted on the integration bench is shown in Fig.~\ref{fig:bench}. |
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|
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\begin{figure}[!htb] |
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\begin{center} |
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\includegraphics[width=0.85\textwidth]{Figs/bench.pdf} |
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\end{center} |
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\caption{A shell carbon fiber structure mounted on the integration bench. The cooling pipes |
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and ledges of inner part of the shell are visible.} |
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\caption{A shell carbon fiber structure mounted on the integration bench. |
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The cooling pipes |
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and ledges of inner part of the shell are visible. Stickers, containing |
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bar codes to identify the strings, are temporary fixed on the structure.} |
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\label{fig:bench} % Give a unique label |
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\end{figure} |
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|
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|
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\subsection{Control Ring Preparation} |
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Once the shell has been mounted on the integration bench the next operation is the preparation |
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of the Control Ring cables. |
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As described in section \ref{fig:ctrlring} the readout clock, |
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trigger and slow control signals are distributed to the |
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detector modules via a token ring structured system mounted on the shells. Each TIB layer is |
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served by different Control Rings whose dimensions, in terms of modules, depend on the layer position. |
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For example Layer one and two, which are equipped with |
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double sided modules, have control rings of 3 to 5 |
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strings, while Layer three and four have 13 to 15 single sided strings.\\ |
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The control ring boards (DOHM and AUX) |
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are located on a carbon fiber plate mounted just above the modules on the |
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external part of the shell (see Fig. \ref{fig:dohm}). A carbon fiber cover of the same dimensions |
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of the plate close the control ring from above. An aluminum sheet has been glued |
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both on the plate and the cover to protect the module from possible electrical interference. When |
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monted this aluminum sheet is connected to the cooling manifold ground. |
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|
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\begin{figure}[!htb] |
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\begin{center} |
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\includegraphics[width=0.60\textwidth]{Figs/dohm.pdf} |
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\end{center} |
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\caption{A DOHM and an AUX (the smaller board) with control ring cables connected and mounted on a |
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layer 3 shell.} |
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\label{fig:dohm} % Give a unique label |
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\end{figure} |
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|
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As can be seen in Figure \ref{fig:dohm}, due to the variable number of strings connected and their |
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different positions with respect to the support |
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mechanics and cooling, each control cable have a different length and shape and |
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should be tailored in-situ to minimize the path satisfying all the mechanical constraints. |
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To avoid damages the control cable preparation should be done when the |
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modules are not yet installed on the |
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structure. The control cable preparation has to be done very carefully to |
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avoid mechanical interference with the services (cables, fibers and pipes) |
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that share the narrow space on the shell flange |
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(20mm in the z direction and 6mm in the radial one).????????????????????????????? |
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When the control ring has been cabled it is dismounted from the structure |
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to proceed with AOH and module installation. \\ |
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For layer three and four the part of the control cables |
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which is not protected by the carbon fiber plate |
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is shielded using a thin Aluminum foil. |
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|
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\subsection{Analog Opto Hybrid Installation} |
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\subsubsection{AOH Installation} |
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The small AOH board ($3\times 2.2 cm^2$) |
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is simply screwed to a C-shaped ledge which is directly glued on the string cooling |
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pipes. The mounting |
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operation is complicated by the fact that each AOH has two (single sided modules) |
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or three (double sided modules) |
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two meter long pig-tail optical fibres ending with a connector. Due to mechanical constraints the |
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fibers, and their connectors, should be carefully routed to the outside of the shell through a |
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is screwed to a C-shaped ledge which is directly glued on the string cooling |
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pipes. Due to mechanical constraints, the |
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fibers and their connectors should be carefully routed to the outside of the shell through a |
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number of ledges, holes and pipes keeping |
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them as close as possible to the carbon fiber structure surface to which they are finally fixed |
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using kapton strips. The part of the pig-tail fibers which is not housed on the shell |
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is temporary stored in the plastic |
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boxes fixed to the shell support frame. Their connectors are inserted into |
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optical plugs which |
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ease the many connect-disconnect operations to be done during the tests.\\ |
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Since the optical fibers are quite fragile they have been |
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protected when they cross the most critical points. |
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For example at the |
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shell flange, where the fibers should turn at 90$^\circ$ together with |
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all the other services, |
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they are grouped together and covered by a thin silicon rubber spiral (see Fig. \ref{fig:spiraline}). |
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This procedure resulted in very reliable protection since only 4 fibres out of |
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6984 was found broken at the end of TIB integration. |
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A layer 2 shell with AOH mounted on is shown in Figure \ref{fig:aoh}. |
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using glued kapton strips. The main part of the pig-tail fibers |
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remains out of the shell and is temporary stored in the plastic |
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trays. The optical connectors are inserted |
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into arrays of dummy optical plugs fixed at the far-end of the |
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structure to be always accessible during the various tests which |
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require many connect-disconnect operations.\\ |
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|
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Since the optical fibers are quite fragile, special protections have |
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been arranged in the most critical points. |
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For example at the shell flange the fibers have to be bent by $90^\circ$ and |
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routed together with other services towards the service cylinder. |
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In this particular region the fibres are grouped together and |
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covered by a silicon rubber spiral (see |
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Fig.~\ref{fig:spiraline}). |
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|
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The procedure resulted to be very effective: only few fibres out of |
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a total of 9192 were found broken at the end of TIB/TID integration. |
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|
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A layer 2 shell with AOH mounted on is shown in Fig.~\ref{fig:aoh}. |
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|
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|
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|
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\begin{figure}[!htb] |
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\begin{center} |
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\label{fig:spiraline} % Give a unique label |
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\end{figure} |
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|
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Since the AOH are powered by the module kapton tail they cannot be easily tested before the |
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modules are installed. This was a source of concerns when the integration has started: the |
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operation of changing a broken AOH when the modules are already installed requires dismounting |
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the entire string with the result of a considerable increase of the risk of damage to the |
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mounted objects. The number of AOH that should be replaced was anyway very small at the level |
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of one per shell. |
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|
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|
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\subsection{Mother Cable Installation} |
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The Mother Cables are inserted into the structure when the AOH have been mounted and the optical |
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fibers fixed to the shell and protected. This procedure is in some cases complicated by mechanical |
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constraints at the level of the shell front flange, where the mother cables are entered in the shell, |
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and cooling manifolds. When the Mother Cables are inserted they |
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are connected to the power cables (medusa cables) which are temporary fixed to the shell supporting |
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frame. \\ |
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The 'medusa cables' are multi-strand cables with each conductor separatly insulated. |
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This cable characteristic helps in efficiently use the very limited available space on the TIB |
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front flange allowing to 'distribute' the cable among the other services. \\ |
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To make the control ring redundancy properly working each mother cable has to be provided with a |
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CCU whose address is in a fixed order with respect to its position in the token ring. This |
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position depends on how the control ring has been cabled, so this information |
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has to be taken in mind when the Mother Cables are inserted into the structure.\\ |
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|
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\subsection{Module Mounting} |
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Both single and double sided modules are mounted on the shell by hand. |
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They are fixed on two precision ledges: one supports the module below the front-end |
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hybrid and the other below the carbon fiber frame at the opposite end. |
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The ledges precisely define the module position and also, being in contact with the cooling pipes, |
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act as heath sink for the front-end hybrid and sensor generated power. |
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The shape of the ledges is different for the single sided and for the two kind |
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of double-sided modules, |
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reflecting, in this latter case, the two different orientations of the "stereo" side of the module. |
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Each ledge has two threaded holes (M1 screw type); one of them is concentric with a |
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2 mm diameter socket |
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acting as a slot for the module precision aluminum inset which fixes the detector |
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position. The socket has been precisely drilled with respect to the ledge edges which |
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in turns are the reference position for the precision mask used to glue them on the "shell". |
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All kind of modules have an aluminum pin glued on the carbon fiber frame at the hybrid end |
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and an aluminum U-shaped slot glued at the module opposite end. This two module insets, |
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together with the two ledge sockets and a pin to be inserted into the U-shaped slots, |
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define the module position with respect to the shell.\\ |
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Before mounting a module on the shell the structure is rotated to horizontally place |
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the corresponding string. Then the string bar code sticker is read and entered into the |
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integration database; the mounting location on the string is chosen and the database is |
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queried for an appropriate module. The answer depends on the module type, on the inventory |
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of the available module at the integration centre and on the module depletion |
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Since the AOH is powered by the module kapton tail its test without |
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the corresponding module is not straightforward requiring a temporary |
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connector inserted into the fragile AOH plug. For this reason it has been choosen |
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not to test AOHs immediatly after their installation, despite the |
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operation of changing a broken AOH when the modules are already |
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installed is very difficult and somehow risky for the nearby objects |
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already mounted. Eventually, the number of AOH that had to be replaced |
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was anyway very small, at the level of one per shell/disk. |
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|
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\subsubsection{Mother Cable Installation} |
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The Mother Cables were put in place after the AOH |
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mounting and when all optical fibers have been fixed to the shell and |
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adequately protected. The mother cables are inserted below |
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the ledges by sliding them on |
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the shell surface from the flange. The ledges support keep the |
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mother cable in place (see~\ref{fig:l3detail}). This procedure is in some cases |
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complicated by mechanical |
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constraints at the level of the shell front flange |
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and cooling manifolds. After the Mother Cables have been inserted they |
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are connected to the power cables (medusa cables) which are temporary |
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fixed to the shell supporting frame. \\ |
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The {\em medusa cable} is a bundle of single insulated copper wires with |
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no definited envelope and geometry. This helps in efficiently |
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use the very limited available space on the TIB front flange during the |
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seervice routing.\\ |
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% allowing |
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%to 'distribute' the cable among the other services. \\ |
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To ease the implementation of the control ring redundancy, CCUs are |
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put in the ring with a pre-defined hardware address order. So, for each |
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string position in the ring, care must be taken to choose the proper mother cable, |
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that comes with the correct address CCUM already on it. |
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%, has to be provided with a |
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%CCU whose address is in a fixed order with respect to its position in |
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%the token ring. |
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\begin{figure}[!htb] |
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\begin{center} |
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\includegraphics[width=0.60\textwidth]{Figs/mc_detail_full.png} |
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\end{center} |
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\caption{A symplified $r\phi$ view of TIB L3 as seen from the front-flange.} |
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\label{fig:l3detail} % Give a unique label |
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\end{figure} |
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|
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|
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\subsubsection{Module Mounting}\label{sect:tibmodules} |
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%Both single modules and double sided module assemblies are mounted on the shell by hand. |
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The module is supported below the front-end |
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hybrid and on the opposite side by two aluminum ledges that precisely |
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define its position and, being in contact with the cooling pipes, |
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act as heat sink. |
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%for the front-end hybrid and the sensor generated power |
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The shape of the ledges is different for the single sided modules and |
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for the double-sided module assemblies. In the latter case the |
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``stereo'' module sits on the structure upside-down and the hybrid ledge |
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has a milled slot to leave enough room for the |
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front-end hybrid. The ledge on the opposite side has two different |
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shapes reflecting the two orientations of the ``stereo'' modules. |
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Each ledge has two M1 threaded holes. One is concentric with a 2mm |
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diameter socket. |
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The module features one precision pin on both short sides that fits |
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into the socket (Fig. \ref{fig:insets} c). |
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The milling of the socket and the glueing of the |
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ledge onto the shell are both done by using the same reference, i.e. the |
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precisely machined ledge edges, so to ensure an accurate positioning. |
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The module pin at the hybrid side is glued onto the module frame. The |
| 152 |
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one at the opposite side, however, fits into an 'U'-shaped |
| 153 |
> |
slot a design that allows for movements along the module long side. |
| 154 |
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With such a constraint it is always possible to easily screw down the module |
| 155 |
> |
regardless of the small construction tolerances on the relative position |
| 156 |
> |
of the four holes set. |
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%In a device that will be affected to huge temperature changes, this is an |
| 158 |
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%essential feature to compensate for thermal variations while ensuring |
| 159 |
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%mechanical precision. |
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> |
|
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Before mounting a module on the shell the structure is rotated to place |
| 162 |
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the corresponding string in a horizontal position to ease the following |
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> |
operations. |
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> |
FIXME: Introdurre l'inventory database prima delle procedure d'integrazione, |
| 165 |
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in modo da poterlo nominare qui, e anche prima quando si parla del montaggio |
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di MC e AOH. |
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> |
Then the module inventory database is queried for an |
| 168 |
> |
appropriate module. The answer depends on module type and availability |
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> |
at the integration centre and on the module depletion |
| 170 |
|
voltage (see par.~\ref{sec:biasandvdepl}). \\ |
| 171 |
< |
The chosen module is then prepared: it is optically inspected under a microscope and |
| 172 |
< |
the two 1-D temporary bar code stickers, one from the module frame and the |
| 173 |
< |
other from the front-end hybrid kapton tail, are removed. Finally the module and ledges |
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< |
contact surfaces are inspected and cleaned to allow for an optimal heath exchange with the |
| 175 |
< |
cooling circuit. These preparation operations are often difficoult and, especially for |
| 176 |
< |
the double sided modules, very delicate; for these reasons they amount for |
| 177 |
< |
a considarable fraction of the time spent to mount a module.\\ |
| 178 |
< |
When a module is ready the operator mounts it on the structure by hand. |
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< |
First the module is leaned onto the ledges keeping the microbonds away from the other |
| 180 |
< |
ledges or cooling pipes. |
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%This operation, because of the presence of microbonds on the back |
| 182 |
< |
%side and the more stringent mechanical tollerances, |
| 183 |
< |
%is quite difficult for double sided modules; for this reason a simple mechanical piece has |
| 184 |
< |
%been realized in order to guide the operators hand avoiding possible module damages. |
| 185 |
< |
When the module lies on the ledges the operator sligthly moves it to allow for the insertion |
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< |
pin (Fig. \ref{fig:insets} c) glued on the frame on the front-end hybrid side, to |
| 187 |
< |
enters correctly the ledge precision socket. |
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< |
At this point the module has only the possibility to rotate around the pin axis. |
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This last degree of freedom is then fixed inserting a T-shaped aluminum |
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pin inside the frame U-shaped slot (Fig. \ref{fig:insets} b) and on the ledge precision socket. |
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< |
The U-shaped slot is used instead of a cylindrical hole, to allow for a module position |
| 189 |
< |
matching also in presence of the unavoidable gluing errors on the precision insets and on the |
| 190 |
< |
ledge slot positions. |
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< |
The module is finally fixed to the ledges by four M1 type amagnetic steel screws. |
| 192 |
< |
It should be noted again that the module position is not |
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determined by the screws but only by the precision sockets and the insets and slots positions. \\ |
| 171 |
> |
|
| 172 |
> |
The module identified for mounting then undergoes an optical |
| 173 |
> |
inspection to check for obvious damages and the temporary labels used |
| 174 |
> |
during the production are removed. Finally the module and ledges |
| 175 |
> |
contact surfaces are inspected and cleaned to ensure an optimal heat |
| 176 |
> |
exchange with the cooling circuit. The operations that imply the |
| 177 |
> |
handling of the modules are very delicate and account for |
| 178 |
> |
a considarable fraction of the time spent into module mounting.\\ |
| 179 |
> |
|
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The single sided module or the double side modules assembly is mounted |
| 181 |
> |
on the structure by hand. It is first leaned onto the ledges and then is |
| 182 |
> |
gently slit until the pin at the hybrid side enters into the precision |
| 183 |
> |
socket. At this stage only a rotation around the pin axis is possible. |
| 184 |
> |
The mounting is completed by inserting in the corresponding precision |
| 185 |
> |
socket the T-shaped aluminum pin placed in the U-shaped slot |
| 186 |
> |
(Fig. \ref{fig:insets} b) located on the frame short side opposite to |
| 187 |
> |
the hybrid. The module is finally tighetned by the four M1 screws by |
| 188 |
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using a limited-torque screw driver. |
| 189 |
|
|
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|
\begin{figure}[tbh] |
| 191 |
|
\centering |
| 192 |
|
\includegraphics[width=.7\textwidth]{Figs/collage.pdf} |
| 193 |
|
\caption{TIB single-sided module insets: |
| 194 |
< |
\textbf{a:} The u-shaped slot glued on the carbon fiber module frame; |
| 195 |
< |
\textbf{b:} the T-pin inserted in the slot (seen from below); |
| 194 |
> |
\textbf{a:} The U-shaped slot glued on the carbon fiber module frame; |
| 195 |
> |
\textbf{b:} the T-shaped pin inserted in the slot (seen from below); |
| 196 |
|
\textbf{c:} front-end hybrid side precision insertion pin (seen from below).} |
| 197 |
|
\label{fig:insets} |
| 198 |
|
\end{figure} |
| 199 |
|
|
| 200 |
< |
The clearance between the module most delicate parts (bondings) |
| 201 |
< |
and the other structure present when the operation is performed (cooling pipes and ledges of the |
| 202 |
< |
adjacent strings and modules already mounted) are, in case of single-sided modules, |
| 203 |
< |
sufficiently large for a safe operation. |
| 204 |
< |
For the double-sided modules the cleareances are much reduced being |
| 200 |
> |
The clearance between the module most fragile parts (bondings) |
| 201 |
> |
and the other surrounding structures when the operation is performed |
| 202 |
> |
(cooling pipes and ledges of the |
| 203 |
> |
adjacent strings and modules already mounted) are, in case of single-sided |
| 204 |
> |
modules, |
| 205 |
> |
sufficiently large for a safe operation. For the double-sided module |
| 206 |
> |
assemblies the cleareances are much reduced being |
| 207 |
|
of the order or less than a millimeter. |
| 208 |
< |
In this case, to guide the module during its insertion, a simple mechanical |
| 209 |
< |
tool has been used. This tool simply |
| 210 |
< |
adds temporary constraints (mechanical stops) to the structure avoiding possible accidental contacts |
| 211 |
< |
between the module bondings and the rest of the shell.\\ |
| 212 |
< |
When a module has been mounted on the structure its basic functionality is tested: |
| 213 |
< |
only low voltages are |
| 214 |
< |
switched on and the I$^2$C communications with the various devices present on the hybrid, mother cable |
| 215 |
< |
and AOH are verified. Furthermore the module identity is checked and compared with the one stored on |
| 216 |
< |
the integration database using the DCU hardware ID as a fingerprint of each produced module. |
| 217 |
< |
When a string of three modules has been mounted the I$^2$C communication are again verified and |
| 218 |
< |
a noise run, at 400V bias, is taken. For the tests complete description see section \ref{sec:Tests}. |
| 219 |
< |
|
| 220 |
< |
\subsection{Control Ring Installation} |
| 221 |
< |
The TIB control electronics, which distributes clock, trigger and I$^2$C signals to the modules, |
| 222 |
< |
is located on a carbon fiber support mounted on the shell external surface |
| 223 |
< |
just above the modules. |
| 224 |
< |
A thin aluminum foil has been glued on the support and electrically grounded |
| 208 |
> |
In this case, to ease the mounting, a simple mechanical guidance |
| 209 |
> |
template has been designed to further reduce the risk of possible |
| 210 |
> |
accidental damage of the microbonds or the sensor. |
| 211 |
> |
This template is temporary mounted using the ledges of the adjacent string |
| 212 |
> |
and prevents the module to move into positions where its bondings |
| 213 |
> |
can touch the mechanics. When the module is safely screwed into position |
| 214 |
> |
the template is removed. |
| 215 |
> |
|
| 216 |
> |
Once a module or a double sided assembly is mounted its basic |
| 217 |
> |
functionality is tested by feeding low voltages and checking I$^2$C |
| 218 |
> |
communications with the various devices present on the hybrid, the CCU |
| 219 |
> |
on the mother cable and the AOH. This also allows the module identity |
| 220 |
> |
to be certified by reading the DCU hardware ID. |
| 221 |
> |
Once a string is completed the I$^2$C |
| 222 |
> |
communications are checked again and a pedestal and noise run is taken |
| 223 |
> |
with a bias voltage of 400V. For the tests complete description see |
| 224 |
> |
section~\ref{sec:Tests}. |
| 225 |
> |
|
| 226 |
> |
\subsubsection{Control Ring Installation} |
| 227 |
> |
The control electronics that supervises the control ring |
| 228 |
> |
(DOHM and AUX boards) are located on a carbon fiber skin which is |
| 229 |
> |
mounted on the shell external surface, just above the modules, |
| 230 |
> |
by carbon fiber pillars and aluminum supports (Fig. \ref{fig:dohm}). |
| 231 |
> |
A thin aluminum foil has been glued on the carbon fiber |
| 232 |
> |
skin and electrically grounded |
| 233 |
|
to reduce possible interference between the logical control signals and |
| 234 |
< |
the module analog electronics. The DOHM and, when present, the AUX |
| 235 |
< |
are mounted on the support (Fig. \ref{fig:dohml4}), |
| 236 |
< |
the preformed cables are connected to the Mother Cables. |
| 237 |
< |
The DOHM power cable is similar to the mother cable 'medusas' and it is directly plugger into |
| 238 |
< |
the DOHM. \\ |
| 239 |
< |
|
| 240 |
< |
\begin{figure}[tbh] |
| 241 |
< |
\centering |
| 242 |
< |
\includegraphics[width=.7\textwidth]{Figs/dohm.pdf} |
| 243 |
< |
\caption{A Layer 4 control ring circuitry. The DOHM and AUX boards are visible, the control ring |
| 244 |
< |
cables are connected to the mother cable heads (not visible).} |
| 245 |
< |
\label{fig:dohml4} |
| 234 |
> |
the module analog electronics. All mother cables are then connected to |
| 235 |
> |
the DOHM (and AUX) ports by using a set of appropriately shaped |
| 236 |
> |
flat-cables that have been preprared before, on the empty structure, |
| 237 |
> |
by using dummy replicas of the DOHM/AUX boards and mother cables. |
| 238 |
> |
|
| 239 |
> |
Each shell is equipped by three to six Control Rings, generally |
| 240 |
> |
differing also within the same shell with respect to the number of |
| 241 |
> |
served strings and the geographical distribution of these strings |
| 242 |
> |
into the shell. |
| 243 |
> |
For example, Layer 1 and 2, which are equipped with |
| 244 |
> |
double sided modules, have control rings of 3 to 5 |
| 245 |
> |
strings, while Layer 3 and 4 have 13 to 15 single sided strings.\\ |
| 246 |
> |
\begin{figure}[!htb] |
| 247 |
> |
\begin{center} |
| 248 |
> |
\includegraphics[width=0.60\textwidth]{Figs/dohm.pdf} |
| 249 |
> |
\end{center} |
| 250 |
> |
\caption{A Layer 3 control ring circuitry during the cable preparation |
| 251 |
> |
with a DOHM and an AUX (the smaller board) with control ring cables |
| 252 |
> |
connected to the mother cable heads (not visible).} |
| 253 |
> |
\label{fig:dohm} % Give a unique label |
| 254 |
|
\end{figure} |
| 255 |
|
|
| 256 |
< |
The $4 \times 2$ optical fibers, which connect the two DOH to the FEC, should be very well protected |
| 257 |
< |
to assure a proper functionality of the control ring. In fact using the redundancy architecture |
| 258 |
< |
implemented for this circuitry it is possible to run the ring also in presence of a damaged |
| 259 |
< |
DOH, but the price to pay for a double failure in the DOH connections is of the order of 1-2\% of the |
| 260 |
< |
entire TIB.\\ |
| 261 |
< |
When the control ring is completed it is closed with another |
| 262 |
< |
aluminun shielded carbon fiber cover (Fig. \ref{fig:dohml1}) |
| 263 |
< |
and finally tested (see section \ref{sec:Tests}).\\ |
| 256 |
> |
As can be seen in Fig.~\ref{fig:dohm}, due to the variable number of strings connected and their |
| 257 |
> |
different positions with respect to the support |
| 258 |
> |
mechanics and cooling, each control cable have a different length and shape and |
| 259 |
> |
should be tailored in-situ to minimize the path satisfying all the mechanical constraints. |
| 260 |
> |
Each control cable path has been optimized as a consequence of the |
| 261 |
> |
very limited room available for services. |
| 262 |
> |
For layer three and four the part of the control cables |
| 263 |
> |
which is not protected by the carbon fiber plate |
| 264 |
> |
is shielded using a thin aluminum foil.\\ |
| 265 |
> |
The $4 \times 2$ optical fibers, which connect the two DOH to the FEC, |
| 266 |
> |
are carefully routed and protected at the flange. |
| 267 |
> |
This is a critical point because it is true that the |
| 268 |
> |
redundancy architecture allows the ring to work also if the connection |
| 269 |
> |
to the master DOH fails, but the price to pay if both DOH connections |
| 270 |
> |
fail is of the lost of 1-2\% of the entire system.\\ |
| 271 |
> |
The DOHM cabling is completed by the power cable, very similar to the |
| 272 |
> |
mother cable 'medusas', and by the wiring of two PT1000 temperature |
| 273 |
> |
probes per control ring that comes already glued on the cooling manifolds. |
| 274 |
> |
The four probe wires are in fact routed through the DOHM via the Control |
| 275 |
> |
Ring power cable up to the power supply racks where the interlock |
| 276 |
> |
boards are also located. The four-wire resistance measurement |
| 277 |
> |
of the PT1000 is necessary to avoid the contribution of the |
| 278 |
> |
40 meter long power cable. |
| 279 |
> |
Also a hygrometer is hosted on the DOHM board; it is read out |
| 280 |
> |
through dedicated wires on the Control Ring power cable. These sensors |
| 281 |
> |
are used to monitor the TIB/TID enviromental conditions even |
| 282 |
> |
without the tracker read-out switched on. |
| 283 |
> |
|
| 284 |
> |
A thinner carbon fiber skin is used as a protecting and shielding |
| 285 |
> |
cover of the control ring circutry. Also in this case electrical |
| 286 |
> |
shielding is ensured by an aluminum foil glued to the cover and |
| 287 |
> |
grounded (Fig. \ref{fig:dohml1}). |
| 288 |
> |
When completely installed |
| 289 |
> |
the control ring is tested. |
| 290 |
> |
A complete debug, including the control of the redundancy, is done |
| 291 |
> |
at this level to spot possible malfunctioning which are relatively easy |
| 292 |
> |
to repare at the integration centers. For a complete test description |
| 293 |
> |
see section \ref{sec:Tests}\\ . |
| 294 |
|
|
| 295 |
|
\begin{figure}[tbh] |
| 296 |
|
\centering |
| 297 |
|
\includegraphics[width=.7\textwidth]{Figs/L1DOHM.pdf} |
| 298 |
|
\caption{A Layer 1 completed with its control rings. The DOHM and cable area is covered with |
| 299 |
< |
aa aluminum shielded carbon fiber plate.} |
| 299 |
> |
an aluminum shielded carbon fiber plate.} |
| 300 |
|
\label{fig:dohml1} |
| 301 |
|
\end{figure} |
| 302 |
|
|
| 303 |
< |
Two PT1000 temperature probes per control ring are glued on the cooling manifolds. |
| 304 |
< |
The probe wires are |
| 305 |
< |
routed through the DOHM via the Control Ring power cable up to the power supply racks where an |
| 306 |
< |
interlock boards is located. |
| 307 |
< |
The PT1000 resistance measurement is done using a 4-wire connection to avoid the |
| 308 |
< |
contribution coming from the 40 meters long power cable. One humidometer is located on the |
| 309 |
< |
DOHM board and it is also read out through dedicated wires on the Control ring power cable. |
| 303 |
> |
|
| 304 |
> |
\subsection{TID Integration } |
| 305 |
> |
The integration of the TID rings has required the design of a handling tool that |
| 306 |
> |
allows safe and easy manipulation of the mechanical structure, allows access and integration |
| 307 |
> |
on both side and provide support for the long optical fibers associated with the AOH and the DOH |
| 308 |
> |
of the DOHM. Moreover it should allow the assembly of rings into a full disk. |
| 309 |
> |
|
| 310 |
> |
The handling tool is based on a aluminum crow plate with different mounting positions for: ring |
| 311 |
> |
holding towers (4 to hold each ring) to adapt to any of the three different rings; U-shape |
| 312 |
> |
feets to allow the placing of the ring front side upwards or downwards; stocking cylinder where to |
| 313 |
> |
place and hold the long fibers; aligning jigs with pillar to allow to pair together two crowns |
| 314 |
> |
and join pairs of rings together to allow the assembly of ring into a disk. The handling tool will be called |
| 315 |
> |
in the following as {\it integration crown} and it is shown in Fig.~\ref{fig:ringbench} for different configuration: |
| 316 |
> |
for a R1, R3 rings on the front side and a R1 for both sides. |
| 317 |
> |
|
| 318 |
> |
The integration crown was made as light as possible, but rigid enough not to add mechanical stress to the |
| 319 |
> |
ring or the disk, during the manipulation, specially during rotation |
| 320 |
> |
of the structure (made manually using two handles) and the |
| 321 |
> |
assembly of rings into a disk. Weight???????? |
| 322 |
> |
|
| 323 |
> |
\begin{figure}[!htb] |
| 324 |
> |
\begin{center} |
| 325 |
> |
% \includegraphics[width=0.49\textwidth]{Figs/R1-front.pdf} |
| 326 |
> |
% \includegraphics[width=0.49\textwidth]{Figs/R2-front.pdf} |
| 327 |
> |
% \includegraphics[width=0.49\textwidth]{Figs/R1-back.pdf} |
| 328 |
> |
% \includegraphics[width=0.49\textwidth]{Figs/R3-front.pdf} |
| 329 |
> |
|
| 330 |
> |
\includegraphics[width=0.7\textwidth]{Figs/R1-front.pdf} |
| 331 |
> |
% \includegraphics[width=0.49\textwidth]{Figs/R2-front.pdf} |
| 332 |
> |
\includegraphics[width=0.7\textwidth]{Figs/R1-back.pdf} |
| 333 |
> |
% \includegraphics[width=0.49\textwidth]{Figs/R3-front.pdf} |
| 334 |
> |
\end{center} |
| 335 |
> |
\caption{ The TID integration crown holding R1 rings in front (top) |
| 336 |
> |
and back (bottom) positions. FIXME (Carlo): secondo me ne basta una, cosi' |
| 337 |
> |
si salva un po' di spazio.} |
| 338 |
> |
\label{fig:ringbench} % Give a unique label |
| 339 |
> |
\end{figure} |
| 340 |
> |
Once a new ring structure arrived, it was mounted on an integration crown. In order to identify easily the mother cable positions |
| 341 |
> |
during the integration bar code stickers were temporarelly glued to the ring. The integration work was made |
| 342 |
> |
in parallel on several rings and disks at different steps of integration, therefore several integration crowns were used. |
| 343 |
> |
|
| 344 |
> |
TID cooling ledges for the AOH could arrived with a bending angle outside specification, due to manipulations |
| 345 |
> |
of the ring and some touching that do not compromise the mechanical integrity of the cooling pipe. |
| 346 |
> |
The clearance between parts in a disk is very small, in particular silicon sensors have a minimal distance of 2mm between |
| 347 |
> |
AOH cooling ledges between ring 3 and ring 1, therefore mechanical checks were made and adjustment applied if needed. |
| 348 |
> |
|
| 349 |
> |
\subsubsection{Services Installation } |
| 350 |
> |
The first step of integration was the installation of the services. For the TID a problem to be solved was the routing out of the optical fibers of the DOHs and AOHs: all fibers have to exit from the TID at specific positions relative to holes on Service Cylinder. |
| 351 |
> |
To do that, a set of AOHs associated to each mother cable was found, all fibers were prepared to form a unique bundle that |
| 352 |
> |
could be easily routed in the ring, holding together fibers using silicon rubber spirals. The same was done for pairs of DOHs going to the same DOHM. |
| 353 |
> |
|
| 354 |
> |
All mother cables were prelimanarly tested in a dedicated test bench. The ring integration begin installing all four |
| 355 |
> |
mother cables on each side of the ring: they were placed and screwed to the ring and equipped with |
| 356 |
> |
CCU with the proper $I^2C$ address. The connector of the mother cables reach the outermost radius of the ring to allow the connection to the power cables. |
| 357 |
> |
|
| 358 |
> |
Then the DOHM was fixed: for R2 and R3 the addition of a cable was needed in order to allow power connection at the outer radius of the ring. The ground of the DOHM was connected to a cable to reach the outer ring radius and will be used to make a unique grounding line for all TID+/-. Then the DOHM was equipped with a proper CCU and with the needed two DOHs: their fiber were routed out properly and attached to integration crown via the stocking cylinder. |
| 359 |
> |
|
| 360 |
> |
The control ring cables that connect DOHM to the mother cables were pre-formed in advance and were mounted and adapted into the ring. A |
| 361 |
> |
complete functionality test of the control ring was then performed to verify that the main control ring and the redundancy were working |
| 362 |
> |
fine. |
| 363 |
> |
|
| 364 |
> |
Two temperature sensors PT1000 were finally glued to the cooling manifold and connected to the DOHM. |
| 365 |
> |
|
| 366 |
> |
|
| 367 |
> |
Details of the DOHM integration can be seen in the Fig.~ref{fig:tiddohms}. |
| 368 |
> |
\begin{figure}[!htb] |
| 369 |
> |
\begin{center} |
| 370 |
> |
\includegraphics[width=0.4\textwidth,angle=90]{Figs/dohm-r1.pdf} |
| 371 |
> |
\includegraphics[width=0.4\textwidth,angle=90]{Figs/dohm-r2.pdf} |
| 372 |
> |
\includegraphics[width=0.4\textwidth,angle=90]{Figs/dohm-r3.pdf} |
| 373 |
> |
\end{center} |
| 374 |
> |
\caption{Integration of DOHM in the TID rings, from left to right R1, R2 and R3.} |
| 375 |
> |
\label{fig:tiddohms} % Give a unique label |
| 376 |
> |
\end{figure} |
| 377 |
> |
|
| 378 |
> |
|
| 379 |
> |
Mounting of the AOH followed, screwing them temporarelly to the cooling ledge. The fiber lenght closes to the module was hold in place using foil of kapton properly shaped and glued to the ring. Then fiber bundle was routed up to the outmost ring radius at the position where the mother cables connectors are, and they are mechanical hold there by a kapton foil screwed to the ring: the remaining lenght was then fixed to the stocking cylinders. Some of these working solutions are in shown in Fig.~\ref{fig:tidfibers}. All |
| 380 |
> |
|
| 381 |
> |
\begin{figure}[!htb] |
| 382 |
> |
\begin{center} |
| 383 |
> |
\includegraphics[width=0.4\textwidth,angle=90]{Figs/Fiber-kapton1.pdf} |
| 384 |
> |
\includegraphics[width=0.4\textwidth,angle=90]{Figs/Fiber-kapton3.pdf} |
| 385 |
> |
\includegraphics[height=0.4\textwidth]{Figs/Fiber-kapton2.pdf} |
| 386 |
> |
\end{center} |
| 387 |
> |
\caption{Few examples of solutions found for routing, bind together and fix the AOH fibers in the rings.} |
| 388 |
> |
\label{fig:tidfibers} % Give a unique label |
| 389 |
> |
\end{figure} |
| 390 |
> |
|
| 391 |
> |
\subsubsection{Module Mounting } |
| 392 |
> |
The mounting of TID modules follow exactly the same procedure explained in the TIB section~\ref{sect:tibmodules}. |
| 393 |
> |
Module mounting in rings is easier than in shells, since modules with following azimuthal angle are placed in opposite sides |
| 394 |
> |
of the ring. Neverthelss a lot of care was still needed: the precision pin was often very tight and the |
| 395 |
> |
module cometa was placed on the U-shaped slot and hold down by the side precision insertion pin. Sistamatic |
| 396 |
> |
checks were made on the electrical connection of the module ground with the carbon fiber. |
| 397 |
> |
|
| 398 |
> |
Once a full mother cable was ready, several test as exaplined later in the paper. To perform the noise test, |
| 399 |
> |
the entire ring was darken and measurements were done, first without bias and then with bias up to 100V to check |
| 400 |
> |
good high voltage connection and that no evident physical damage was done to the silicon module. |
| 401 |
> |
|
| 402 |
> |
|
| 403 |
> |
\subsubsection{Assembly of rings into a disk } |
| 404 |
> |
|
| 405 |
> |
Integration crown equipped with alignment cylinder, also alignment ring pieces |
| 406 |
> |
put on place. |
| 407 |
> |
|
| 408 |
> |
Slow manual movement going down, rotating a pair of distance screws. |
| 409 |
> |
|
| 410 |
> |
Lot of care in last millimiter about fitting fixing holes between rings and about parallelism of rings |
| 411 |
> |
and critical point of very close parts. Then, unfix the top ring from the integration crown and |
| 412 |
> |
screwing down the rings. |
| 413 |
> |
|
| 414 |
> |
Passing fibers from one integration crown to the other one. |
| 415 |
> |
|
| 416 |
> |
Detaching the integration crown |
| 417 |
> |
|
| 418 |
> |
Disk assembly proceed for R1 on a R3, then R2 on R1-R3 structure. |
| 419 |
> |
|
| 420 |
> |
|
| 421 |
> |
\begin{figure}[!htb] |
| 422 |
> |
\begin{center} |
| 423 |
> |
\includegraphics[height=0.6\textwidth]{Figs/Disk-assembly.pdf} |
| 424 |
> |
\end{center} |
| 425 |
> |
\caption{Disk assembly.} |
| 426 |
> |
\label{fig:tidassembly} % Give a unique label |
| 427 |
> |
\end{figure} |
| 428 |
> |
|
| 429 |
> |
|
| 430 |
> |
\begin{figure}[!htb] |
| 431 |
> |
\begin{center} |
| 432 |
> |
\includegraphics[height=0.6\textwidth]{Figs/DISK.pdf} |
| 433 |
> |
\end{center} |
| 434 |
> |
\caption{Disk assembled.} |
| 435 |
> |
\label{fig:tidassembly} % Give a unique label |
| 436 |
> |
\end{figure} |
| 437 |
> |
|
| 438 |
> |
|
| 439 |
> |
|
| 440 |
> |
|
| 441 |
|
|
| 442 |
|
|
| 443 |
|
\subsection{Integration Database} |
| 460 |
|
devices and their functional status (good, broken, mounted, dismounted, etc...).\\ |
| 461 |
|
Along with module tests results also an important number is stored for each module: |
| 462 |
|
the hardware identifier of the DCU chip |
| 463 |
< |
embedded with the module (or DcuHardId). This code can be retrieved during data acquisition, |
| 463 |
> |
embedded with the module.% (or DcuHardId). |
| 464 |
> |
This code can be retrieved during data acquisition, |
| 465 |
|
allowing for an unambiguous identification of a module.\\ |
| 466 |
|
A TIB/TID specific key was defined to store the location of mounted devices (named Geographical |
| 467 |
|
Identifier, or GeoId): it is a string |
| 468 |
< |
composed of numerical fields separated by dots, as described in Table~\ref{tab:geoids}. |
| 468 |
> |
composed of numerical fields separated by dots. |
| 469 |
> |
%, as described in Table~\ref{tab:geoids}. |
| 470 |
|
Bar code stickers with the GeoId are glued on the mechanical structure |
| 471 |
< |
before the integration starts (Fig. \ref{fig:stickers}). |
| 471 |
> |
before the integration starts (Fig. \ref{fig:bench}). |
| 472 |
|
|
| 473 |
< |
\begin{figure}[t] |
| 474 |
< |
\centering |
| 475 |
< |
\includegraphics[width=.6\textwidth]{Figs/stickers.pdf} |
| 476 |
< |
\caption{An empty shell with the bar code stickers identifying the strings.} |
| 477 |
< |
\label{fig:stickers} |
| 478 |
< |
\end{figure} |
| 479 |
< |
|
| 480 |
< |
The first 7 numbers in a GeoId identify the string to which a device belongs, while the last |
| 481 |
< |
part of this code represents the physical location where the device is placed. |
| 482 |
< |
|
| 483 |
< |
\begin{table}[h!] |
| 484 |
< |
\begin{center} |
| 485 |
< |
\begin{tabular}{l|ccc} |
| 486 |
< |
& 1 & 2 & free value \\ |
| 487 |
< |
\hline |
| 488 |
< |
a & TIB & TID & \\ |
| 489 |
< |
b & Forward ($z>0$) & Backward ($z<0$) & \\ |
| 490 |
< |
c & Up ($y>0$) & Down ($y<0$) & \\ |
| 491 |
< |
d & & & Layer \# \\ |
| 492 |
< |
e & Inner & Outer & \\ |
| 493 |
< |
f & & & Manifold \# \\ |
| 494 |
< |
g & & & String \# \\ |
| 495 |
< |
\end{tabular} |
| 496 |
< |
\caption[smallcaption] |
| 497 |
< |
{A generic $a.b.c.d.e.f.g$ GeoId identifies a string and must be interpreted according |
| 498 |
< |
to this table. For example of GeoId 1.1.2.4.1.3.2 identifies the second string, of the |
| 499 |
< |
third manifold placed in the inner surface of the Layer 4 Down Forward TIB shell.} |
| 500 |
< |
\label{tab:geoids} |
| 501 |
< |
\end{center} |
| 502 |
< |
\end{table} |
| 473 |
> |
%\begin{figure}[t] |
| 474 |
> |
%\centering |
| 475 |
> |
%\includegraphics[width=.6\textwidth]{Figs/stickers.pdf} |
| 476 |
> |
%\caption{An empty shell with the bar code stickers identifying the strings.} |
| 477 |
> |
%\label{fig:stickers} |
| 478 |
> |
%\end{figure} |
| 479 |
> |
|
| 480 |
> |
The first 7 numbers in a GeoId identify the string to which a device belongs, |
| 481 |
> |
while the last |
| 482 |
> |
part of this code represents the physical location where the device is placed |
| 483 |
> |
in that particular string. |
| 484 |
> |
|
| 485 |
> |
%\begin{table}[h!] |
| 486 |
> |
%\begin{center} |
| 487 |
> |
%\begin{tabular}{l|ccc} |
| 488 |
> |
% & 1 & 2 & free value \\ |
| 489 |
> |
% \hline |
| 490 |
> |
% a & TIB & TID & \\ |
| 491 |
> |
% b & Forward ($z>0$) & Backward ($z<0$) & \\ |
| 492 |
> |
% c & Up ($y>0$) & Down ($y<0$) & \\ |
| 493 |
> |
% d & & & Layer \# \\ |
| 494 |
> |
% e & Inner & Outer & \\ |
| 495 |
> |
% f & & & Manifold \# \\ |
| 496 |
> |
% g & & & String \# \\ |
| 497 |
> |
%\end{tabular} |
| 498 |
> |
%\caption[smallcaption] |
| 499 |
> |
%{A generic $a.b.c.d.e.f.g$ GeoId identifies a string and must be interpreted according |
| 500 |
> |
%to this table. For example of GeoId 1.1.2.4.1.3.2 identifies the second string, of the |
| 501 |
> |
%third manifold placed in the inner surface of the Layer 4 Down Forward TIB shell.} |
| 502 |
> |
%\label{tab:geoids} |
| 503 |
> |
%\end{center} |
| 504 |
> |
%\end{table} |
| 505 |
|
|
| 506 |
|
%The first number identifies TIB (1) against TID (2), |
| 507 |
|
%the second number marks the forward part (1) vs. the backward (2). Hence TIB and TID codes become |
