19-1 Loading Tooling Design

Ring Loading Tooling

Ring Loading Tooling Drawings: 19-1 Ring.zip

• In the future, review drawings in Mechanics meeting and release/add to Windchill CAD library, to reduce risk of interface issues.

Stave Loading Tooling

Stave Loading Tooling in progress...

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 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

Summary of different requirements for loading 19-1 Inner Barrel Stave:

• Load Triplet modules (drawing, .step)
• Load onto 19-1 IB 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)

Summary of specifications:

• 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):
    • Dowel pins: 6mm OD, h7 tolerance. (Misumi MSH6-60)
    • Bushings: 6mm ID, G6 tolerance. (Misumi JBAUN8-20)

• • Stave position relative to loading tooling baseplate (need +/-.025mm):

• Total for all:
  • Limit: +/-.075mm
  • Root sum square: +/-.026mm

Notes for design of 19-1 Stave tooling:

• Re-use tooling where possible.
• Using beads to set glue thickness; no longer need dial indicators or differential adjusters.
• Use 2 sets of micrometer adjusters (absolute scale).
• Add soft material to vacuum pads for better sealing and smoothness.
• Consider adding a hole pattern for trussing / support below the 19-1 Stave baseplate.
• Reconfirm that Stave and Module CADs / drawings are compatible with tooling, before manufacture.
• Use dowel pins and screw interface to ends of Stave (locate same as in production assembly).
• Consider longer dowel pins in the baseplate (help locate the bridge, without pivoting).
• Consider handling frame integration.

Some past presentations:

• 30 March 2021: Tooling and Plans for Loading, 19-0/1, Stave and Ring