DUNEAPA Electronic Boards: G-Planes Daniel Cherdack University of Houston DUNE US APA NSG Grant Workshop June 10-11, 2019 1
Outline ● Procedures and QA/QC ● Equipment, materials and supplies ● Facilities ● Staffing and scheduling ● Summary of open questions 2
Updated G-Plane Head Board Design 3 A. Laundrie, Docdb 13208
UH HEP Group ● PIs – Cherdack (Grant lead) – Andrew Renshaw (Advisory, Facilities) – Lisa Whitehead Koerner ● Postdocs – 1 ProtonDUNE analysis (UH) – 1 ICARUS HW and analysis (UH/FNAL) – 1 Darkside (Gran Sasso) ● Students – Several students a variety of experiments – ProtoDUNE, DUNE, ICARUS, T2K, NOvA, HUNTER, Darkside ● Pool of undergraduate students (~30 students per year) 4
Procedures ● Foot Boards (8+1+1 per APA): – Incoming inspection, cleaning, prep for processing: 10 – Tooth strip cutting, handling, organizing for production: 10 – Attachment of tooth strips, removal of excess epoxy: 20 <-- Jig required? – Dimensional check, excess epoxy removal, spot cleaning: 10 – Mask solder pads, bag, place in inventory, final inspection, package for storage or shipping: 10 ● Head Boards (16+2+2 per APA): – Incoming inspection, cleaning, prep for processing: 10 – Pin insertion (qty = 4): placement, press, align, glue, bake: 30 <-- Jig required? – Mask solder pads, bag, place in inventory, final inspection, package for storage or shipping: 10 ● Is there a documented procedure for this? ● What equipment, materials and supplies are required? ● Both 5
QA/QC ● Circuit boards: All circuit boards installed on an APA are inspected for dimensional accuracy before being routed through various epoxy and cleaning processes as they are prepped for assembly. Inspection results are documented, and if anomalies are found, an electronic non-conformance report is written. ● CR and G-plane bias board testing: – Acceptance tests of these boards include leakage current measurements (<0.5 nA) and continuity tests on each channel. The tests are performed at room temperature. – ProtoDUNE-SP was used to perform design validation on more than 100 boards that were cycled and tested at LN 2 temperature. No failures were seen during these tests. ^-- No cold tests needed? ● Are procedure for QA/QC test documented? ● What equipment in required to perform these tests? 6
Materials: Known(-ish) ● G-plan electronics boards – Imamingeering Inc. – PSL Part# 8752702 Rev B – Quote# 858432 – Why 1 part, not 6? ● Pins – Mill-max part no: 0307-0-15-15-30-27-04-0 – https://www.mill-max.com/products/receptacle/0307/0307-0-15-15-30-27-04-0?s_term=0307-0-15-15-30-27-04-0&s_type=Quick%2FProduct%2FPart+Number+Search – 40 per APA ● Toothstrips – Protolabs? – PCJGB17 – 0401? ● Epoxy – Gray epoxy 2216 by 3M – 2oz packages? – https://www.3m.com/3M/en_US/company-us/all-3m-products/~/3M-Scotch-Weld-Epoxy-Adhesive-EC-2216-B-A-Gray/?N=5002385+3292667630+4294940354&rt=rud – Epoxy Gun – https://www.3m.com/3M/en_US/company-us/all-3m-products/~/3M-Manual-Gun-for-2-part-cartridges/?N=5002385+3293193962&rt=rud – How many of each will be required? Apply by hand or automate? 7
Materials: Unknown ● Gluing jig ● Pin setting jig ● Pin setting glue ● Oven (for pin set bake) ● Cleaning supplies ● Soldier pad masks ● Bags ● Shipping materials ● Equipment for QA/QC tests 8
From the Preproposal Boards, toothstrips, and pins Materials that stay in the board (epoxy) Jigs, benches, etc Consumables 9
Facilities ● Large lab space – Plenty of room for work and storage – Existing (but currently unused) equipment needs to be moved out ● Clean tent (Renshaw’s lab) ● Cryogenic facilities (Renshaw’s lab) ● Startup funds to purchase other needs 10
Staffing 43.3 = 2 x (26.7 - 5) ● Undergraduates ($15-20/hr, 43.3 hrs/APA) – Inspections, and cleaning – Epoxying – Pin setting – QA/QC – Packing for shipping ● Machinist ($35-45/hr, 25 hrs startup, 5 hrs/APA) – Jig building, and other startup tasks – Tooth strip cutting ● Engineer ($?/hr, 2 hrs/APA) – No one explicitly available, but can be found if needed – PSL docs indicate 2 hrs / APA for foot boards. What is actually required? ● PI, postdoc, graduate students (free) – Oversee board factory operations (hiring, scheduling, supervising, etc) – Paid for by the base grant … assuming I get funded :^) – Base grant application this Fall – Plan to ask for: ● PI: 0.25 FTE for DUNE activities, including the ‘G-Board factory’ ● 0.33 FTE postdoc or equivalent to run the factory 11
Scheduling ● From the preproposal: 15.1%/21.7%/21.7%/21.7%/19.8% ● To decide final schedule need: – APA production schedule – Preferred stockpile at each site (min/max?) ● Should be consistent with production sites for other (similarly installed) boards 12
Summary of Questions ● Are the exact procedures for epoxying and pin setting documented somewhere? ● What are the QA/AC procedure details, and what equipment is required? ● What are the detailed specs for the toothstrips and the epoxy/ applicator? ● What additional equipment is needed (see list on slide 6)? ● What work is an engineer needed for, and can it be done by undergrads, graduate students, a postdoc, PI, or a machinist? ● What is the APA schedule and desired stockpile level? 13
Backup Slides 14
G-Board Pins ● Pins on the top used for G-boards ● Head boards only ● 4 pins per board ● Pins are $0.50 each ● https://www.mill-max.com/ ● Ordered from Bisco Industries ● Bottom diagram for other uses? 15
G-Board Epoxy ● Epoxy Adhesive EC-2216 B/A Gray ● Matches the TDR ● Use the 2 oz Tube Kit (shown), or other size? ● How many boards will one tube cover? ● Is this a good applicator? ● How long do they last? ● Is there a plan for automating the application? 16
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