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Robotics for Module and Stave Production Paul Tipton Yale University May 3, 2007 P. Robotics for Module and Stave Production Paul Tipton Yale University May 3, 2007 P. Tipton UCSC May 3, 2007

New and Growing Effort Collaboration of BNL (D. Lynn, D. Lissauer, Y. Semertzidis), LBNL 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) P. Tipton UCSC May 3, 2007 2

Motivation 7500 -14000 barrel modules needed Ideally production should last of order one year Motivation 7500 -14000 barrel modules needed Ideally production should last of order one year (e. g. , not three) A few barrel module production sites (<5? ) Leads to ~10 modules/day/site Additional production capacity = schedule contingency P. Tipton UCSC May 3, 2007 3

Other Motivating Factors Likely lowers cost n n n Smaller standing army, shorter production Other Motivating Factors Likely lowers cost n n n 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 P. Tipton UCSC May 3, 2007 4

What exactly are we proposing? ATLAS SCT used automation in n Automatic glue dispensing What exactly are we proposing? ATLAS SCT used automation in n 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) P. Tipton UCSC May 3, 2007 5

Why Start Now? Because we cannot start any sooner CMS gantry development effort took 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 t=0. P. Tipton UCSC May 3, 2007 6

Three Robotics Options (+fixturing) being explored: 1) Buy pieces – servo-motors, stages, control system 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 motioncontrol system 3) Buy a multipurpose work-cell with pick-andplace, optics, and gluing capabilities that requires little in-house engineering & retrofitting 4) Bag robotics and use fixturing P. Tipton UCSC May 3, 2007 7

Sketch of an Option 2 System Rotating pick-up tool Glue dispense X Y cameras Sketch of an Option 2 System Rotating pick-up tool Glue dispense X Y cameras Cartesian gantry with work head P. Tipton UCSC May 3, 2007 8

Module Work Surface 25 10 x 10 detectors 1 meter Pitch adapter and hybrid Module Work Surface 25 10 x 10 detectors 1 meter Pitch adapter and hybrid staging area P. Tipton UCSC May 3, 2007 9

Robotic Assembly Process 1. 2. 3. Load 25 detectors in work space. Nominal positions Robotic Assembly Process 1. 2. 3. Load 25 detectors in work space. Nominal positions are set by pins or edges. Apply vacuum. Load chip packs containing 100 pitch adapters Load 100 hybrids into staging area. Only rough placement is required as determined by footprint marked on work surface. Survey detectors with cameras on head to determine actual positions. Use focus to determine detector height. Survey pitch adapters Survey hybrids Dispense adhesives onto detector surface Pickup first hybrid 4. 5. 6. 7. 8. 1. 2. 3. 9. 10. 11. 12. 13. 14. Calculate rotation and translation to arrive at correct position on detector Move to position Check local fiducials and recalculate correct position for placement Place hybrid down on detector surface. Vertical drive set by detector thickness. Pickup first pitch adapter. Follow sequence similar to 8. 1 -8. 4 Repeat Steps 8 -9 for the rest of the components (99 operations). Inspect, report, end. Technicians remove workplate and set aside for overnight adhesive cure. Next-day inspection on OGP as cross-check, as needed Load each module into a holder for wirebonding and test. P. Tipton UCSC May 3, 2007 10

Stave Production Aerotech 10000 with 2 mx 1 m work space is ~$90 K, Stave Production Aerotech 10000 with 2 mx 1 m work space is ~$90 K, well suited for even the longest proposed staves. Or use smaller workspace and ‘index’ stave through P. Tipton UCSC May 3, 2007 11

Work Accomplished in FY 07* Coalesced as a collaboration around the need to, and Work Accomplished in FY 07* 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 R&D budget of $0 P. Tipton UCSC May 3, 2007 12

Proposed Work for FY 08 Our plan for the development work is to factorize Proposed Work for FY 08 Our plan for the development work is to factorize problem into: w w w motion control - Yale vacuum distribution and control system - Yale optics/pattern recognition - BNL glue dispensing – LBNL pickup heads/parts carriers – LBNL+Yale Specify prototype motion and optics systems Prepare for prototype gantry/optics or work cell purchase in FY 08 Design and construct the vacuum distribution platform Glue dispensing Pickup tool development P. Tipton UCSC May 3, 2007 13

Budget Considerations Materials cost of prototype gantry and vacuum system covered by Yale w Budget Considerations Materials cost of prototype gantry and vacuum system covered by Yale w $101 K of gantry purchase and materials for vacuum system w Will also subsidize engineering (cost to project is $62/hour with no additional overhead) Asking for: n n n P. Tipton 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 UCSC May 3, 2007 14

Budget Details P. Tipton UCSC May 3, 2007 15 Budget Details P. Tipton UCSC May 3, 2007 15

Conclusions In FY 07 our progress was good, but very soon further progress will Conclusions In FY 07 our progress was good, but very soon further progress will require us to start spending money (engineering, then materials) In FY 08 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 FY 08 R&D funds will be highly leveraged in this activity P. Tipton UCSC May 3, 2007 16

Backup Slides P. Tipton UCSC May 3, 2007 17 Backup Slides P. Tipton UCSC May 3, 2007 17

The CMS Gantry ~1998 technology n n Aerotech AGS 10000 Gantry Added optics and The CMS Gantry ~1998 technology n n Aerotech AGS 10000 Gantry Added optics and ‘frame-grabbing’ Added custom vacuum plates & chucks Added pneumatics for glue dispensing Production recipe: n n n 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 P. Tipton UCSC May 3, 2007 18