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BTOF demonstrator/mechanics meeting
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US/Pacific
Description
https://ucsc.zoom.us/j/98299273347?pwd=HHm9tGM6hD7aZaIVWWaF16ueAT3gVu.1
Quick recap
The meeting focused on updates and discussions regarding the BTOF (Barrel Time-of-Flight) detector project, with key topics including mechanical design, service hybrid requirements, and assembly strategies across different sites. Simone Mazza reported on new tablet orders and 3D printing of jigs for brewing trials, with plans to assemble the first illustrator board to control silicon heaters and potentially send one to Purdue for thermal testing. The team discussed BNL's expanded role in the project, with Rachid explaining that Brookhaven has been asked to take a more active role in construction and provide facilities for stave and module assembly, including two labs with OGP machines and wire bonding capabilities. Wei presented detailed technical requirements for the service hybrid, explaining that each half-stave requires reading out 56 ASIC chips and powering 56 FPDs, with power delivery challenges requiring three DC-DC converters and careful consideration of voltage drops along the stave length. The team explored options to reduce the service hybrid thickness from 35mm to 25mm, including using CERN's thinner power modules and potentially moving linear regulators (LDOs) to the FPC, though connector specifications remain unknown. Andy raised concerns about the mechanical design constraints and suggested exploring alternative approaches like reducing the width from 60mm to 45mm with carbon fiber skins and cooling pipes, though the team determined this would not provide sufficient height reduction. The conversation ended with discussions about splitting production across multiple sites, with approximately 5,000 total modules needed across four sites including Japan, Korea, BNL, and potentially Purdue.
Next steps
- Simone Mazza: Order a new version of the tablet and 3D print a new jig for another brewing trial next week.
- Simone Mazza: Assemble the first illustrator board to control the silicon heater and have the object in hand in a week or two.
- Simone Mazza: Send one of the assembled objects to Purdue for thermal tests if they want.
- Simone Mazza: Work on the new version of the object more closely related to the final design with the forensic, aiming for a full stave next year.
- Satoshi: Discuss with Amamatsu the possibility of increasing the sensor by a few strips as a solution to the acceptance issue.
- Rachid: Work on alternative engineering solutions to ensure full coverage and solve the service hybrid issue, with results to be shared in one or two weeks.
- Rachid: Provide facilities and participate in the construction of the silicon modules and stave assembly at BNL.
- Grigory: Finalize the drawing for the sensor and 4A6 mock-up this week and drop it to the Machine Shop next week.
- Wei: Obtain and test the CERN bipole 48V DC-DC converter module to explore the 10mm thickness option for the service hybrid.
- Tonko: Stay on top of the Hungarian DC-DC converter development and explore if they can design a version meeting the barrel time of flight requirements.
- Takashi: Look into the information provided by Simone Mazza on possible vendors for long flexes.
- Rachid: Provide a document outlining BNL's official involvement in engineering design, silicon module prototyping and production, and stave production.
Summary
BTOF Detector Project Progress Update
The team discussed progress on the BTOF detector project, with Simone Mazza reporting they are ordering a new tablet version and 3D printing a jig for brewing trials next week, aiming to assemble the first board to control the silicon heater. Rachid and Satoshi outlined BNL's collaboration with Japanese partners to explore alternative engineering solutions and enhance detector acceptance, with plans to share design efforts and facilities across sites including Purdue and potentially Japan, Korea, and GSC. Wei presented detailed requirements for the service hybrid, explaining it needs to power and read out 56 ASICs per half-stave while managing heat generation, with current designs requiring three DC-DC converters and approximately 15mm thickness, though challenges remain in fitting within the 25mm available space.
Service Hybrid Design Constraints
The team discussed design constraints for a service hybrid with a required thickness of 10 millimeters, down from the previously considered 35 millimeter option. Wei presented a potential solution using CERN modules with PCB air core inductors that could fit three modules with a total height of 10 millimeters, including a 5 millimeter cooling structure. The team identified this as a tight fit with limited space for linear converters, and noted that while a custom design in Hungary aims to be cheaper than CERN's modules, it currently only supports 5 watts per module.
Module Design Options Discussion
The team discussed two design options for a module, with Option 1 being currently feasible and Option 2 (the Hungarian design) still in development. A key challenge identified was the interface connector, which must be no more than 5mm in width, creating uncertainty about the final design. When Andy suggested reducing the width from 60mm to 45mm with carbon fiber skin and cooling pipes, Tonko and Wei confirmed this would not be possible as it would require changing the height back to 15mm on both sides, maintaining the 25mm envelope requirement. The team agreed to continue exploring Option 1 while awaiting details from Takashi regarding the connector specifications and LDO placement on FPC.
FPC Power Module Design Discussion
The team discussed connecting LDO voltage regulators to an FPC (flexible printed circuit) board. Tonko proposed creating a compact power module with two LDOs producing 1.2V and 2.5V outputs from 2.7V and 1.8V inputs, connected via bonding pads on the FPC. The group agreed this approach would help with space constraints and heat distribution, though specific connection methods still need to be determined.Rachid and Simone Mazza confirmed that Brookhaven will officially become involved in the BEE project, contributing to silicon module and stave production, design engineering, and assembly. They will present a formal proposal to management within two weeks detailing specific capabilities and collaboration areas. Andy emphasized the need for clear definitions of responsibilities and deliverables to avoid overlap and ensure progress.Wei suggested exploring thinner mechanics for the support structure, particularly at the end sections where additional thickness is currently required. Hansheng agreed to discuss this possibility with Andy and follow up via email.
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