Robotics for Module and Stave
Production
Paul Tipton
Yale University
May 3, 2007
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 (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



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



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 ~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 - 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
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 staging area
P.Tipton
UCSC May 3, 2007
9
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.
4.
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 2mx1m work
space is ~$90K, 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 FY07*
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 FY08
Our plan for the development work is to factorize
problem into:





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 FY08
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
 $101K of gantry purchase and materials for vacuum system
 Will also subsidize engineering (cost to project is $62/hour with
no additional overhead)
Asking for:





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
WBS 4.1.4.4 Prod. Automation
Upgrade R&D
Funds
FY08
Base
Funds
Other
Funds
Materials, Procurements
OPTICS
Cognex or Matrox, camera, optics
framegrabber card, image analysis
DAQ and interface to motion cont.
MOTION
AGS 10,000 2mx1m gantry w/
5cm aluminum baseplate,
Z and Phi axis, DAQ, Control SW
PC for AGS control
Vacuum System
vacuum distribution platform w/
valves, valve actuators,
Additional DAQ channels
GLUE DISPENSING
LBNL
Pickup Head Development
LBNL+Yale
subtotal
32,000
91,000
3,000
7,000
32,000
0 101,000
Personnel/Travel
Yale Engineer for motion system spec
and vacuum system design
Yale shop for vacuum system fabrication
subtotal
GRAND TOTAL
P.Tipton
UCSC May 3, 2007
43,000
23,000
66,000
98,000
18,000
21000
18,000
21000
18,000 122,000
15
Conclusions
In FY07 our progress was good, but very soon
further progress will require us to start spending
money (engineering, then materials)
In FY08 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 FY08.
FY08 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
The CMS Gantry
~1998 technology




Aerotech AGS 10000 Gantry
Added optics and ‘frame-grabbing’
Added custom vacuum plates & chucks
Added pneumatics for glue dispensing
Production recipe:






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