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Outline

• Stave Loading Tooling, 19-1 RD53a L1 Stave – .zip - 11 March 2022.zip
• Stave Loading Tooling, 19-1 RD53a L0 Stave
• Ring Loading Tooling, 19-1 RD53a
• Handling Frame, 19-1 RD53a L1 Stave
• Shipping Box, 19-1 RD53a L1 Stave

Stave Loading Tooling, 19-1

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L1 Stave

Version 2, revised, Stave Loading Tooling drawing drafts (not released):

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• Top Level Assembly: REF-000202041 (LOADING FIXTURE ASSY, 19-1 OB L1 STAVE).pdf
• Baseplate: REF-000203575 (BASEPLATE AND PINS, LOADING FIXTURE, OB L1 STAVE, 19-1, V2).pdf
  • REF-000205009 (BASEPLATE AND FEET, LOADING FIXTURE, 19-1 OB L1 STAVE).pdf
• Loading Bridge: REF-000202287 (LOADING BRIDGE, FIXTURE, 19-1 OB L1 STAVE).pdf
  • REF-000202289 (LOADING BRIDGE, OB L1 19-1).pdf
• Covers for loaded modules: REF-000202337 (COVER SECTION, 19-1 OB L1 STAVE).pdf
• Pickup table assy: REF-000202485 (PICK UP TABLE, QUAD, 19-1 OB L1 STAVE LOADING FIXTURE).pdf
  • REF-000203014 (PICK UP TABLE ASSY, RD53a QUAD).pdf
  • REF-000205158 (PICK UP TABLE, RD53a QUAD, 19-1 OB L1 STAVE LOADING).pdf
• Handling Frame Assembly: REF-000203023 (HANDLING FRAME, OB L1 STAVE, 19-1).pdf
  • REF-000203572 (HANDLING FRAME AND PINS, OB L1 STAVE, 19-1).pdf
  • REF-000130209 (MOUNTING, STAVE TO HF, OB L1 19-1).pdf

  • REF-000202292 (HANDLING FRAME, LOADING, 19-1 OB L1 STAVE).pdf

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Loading Tooling, OB L1 Stave:

Section view:

Summary of requirements for loading 19-1 Outer Barrel Stave:

• Load RD53a Quad modules (drawings: 150um, 400um) with connectors oriented as shown in picture above
• Load modules onto 19-1 OB L1 Stave (no drawing yet, preliminary CAD on LBL Windchill site)
• Load without collisions: 200um nominal gap / 100 micron minimum gap between modules (no assembly drawing yet showing modules on stave)
• Glue layer thickness to be 100um -50/+100um
• ESD protection during loading: grounding of tooling
• Mechanical protection of wire bonds during loading: stay clear of wire bonds, handle modules using tooling only, consider covers/shields
• Baseplate to be installed onto glue robot: weight limit 7kg (per manual)
• Stave to be removed from baseplate and transferred to test box for QC testing

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• Closely toleranced pins/bushings – same approach as used for 19-0 tooling
  • Requirement: +/-75um module position tolerance in local support coordinate system (per requirements document "ITk Pixel Module Loading Accuracy Requirements" AT2-IP-ES-006-v3)
  • Distribute tolerances:
    • +/-50um module position relative to loading tooling baseplate coordinate system (to avoid collisions with 100um gap between modules).
      • Dowel pins in baseplate – two per module location.
      • Bridge to have bushing and slot for precision fit onto dowel pins.
    • +/-25um local support position relative to loading tooling baseplate coordinate system (to accurately place modules to meet +/-75um requirement).
      • Dowel pin in baseplate – to accurately locate one end of the Stave in Z.
      • Tooling to fasten to mounting features on ends of Stave.
• Glue with beads to control glue layer thickness
  • 100um dia beads, for ~75um glue layer thickness on carbon fiber.
  • Loading tooling does NOT control the glue layer thickness.
    
    • Loading bridge to rest on the module's pickup areas (vacuum pad locations) during gluing.
    • Loading bridge to have micrometer adjusters to level the tool relative to the baseplate – to apply pressure at all vacuum pad locations during gluing.
    • Loading bridge to have micrometer adjusters to level the tool relative to the pickup table – to make good contact between vacuum pads and module.
• Vacuum pads to pick up modules
  • Vacuum pads to fit within clear areas on modules.
  • Height adjustment of vacuum pads while on pickup table.
  • Vacuum to securely hold modules.
• Tolerances:
  • Module position relative to loading tooling baseplate (need +/-.050mm):
    • Baseplate has:
      • Dowel pin, stepped, 6mm OD, h7 tolerance. (Misumi SWPG6-P6-Q5.5-L12-B12-E3-F15)
      • Dowel pin, stepped, 8mm OD, h7 tolerance. (Misumi HWPG6-P8-Q7.5-L11-B12-E3-F15)
    • Loading bridge has:
      • Bushing, 8mm ID, G6 tolerance. (Misumi JBAUN8-20)
      • Machined slot, 6mm internal width, G6 tolerance.

Dimensioning scheme changed to hole-to-hole tolerancing (instead of hole-to-edge): 

Stave position relative to loading tooling baseplate

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• Total for all:
  • Limit: +/-.074mm100mm
  • Root sum square: +/-.028mm040mm
  • Requirement: +/-.150mm
• Module Nominal Spacing (for 19-1 L1 Stave): .250mm (nominal gap)
  
  • Worst case clearance: 0.012mm
  • Clearance with RSS tolerance (3σ): 0.180mm

A design/drawings were made in 2020 (Version 1, deprecated, not released):

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Stave Loading Tooling, 19-1 IB Stave

Requirements - see OB L1 Stave requirements above.

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Design concept: modify design of 19-1 OB L1 Stave tooling to match Triplet dimensions and pickup areas

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Drawings (not released):  REF-000202479 (SHIPPING AND STORAGE FIXTURE, OB L1 STAVE, 19-1) CHECKPRINT 14FEB2022.zip

Handling Frame with 19-1 OB L1 Stave:

Interface block to join Stave and Handling Frame (drawing not released):

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