Download - Fuse Box Production Chiho Wang/Jack Fowler
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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Fuse Box Production
Chiho Wang/Jack Fowler
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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Fuse Box Assembly
1 fuse box “set” supplies HV to 1 “stack” of 3 modules.
32 + 3 (10% spare) = 35 “sets” of fuse boxes to be made.
Each fuse box “set” consists of 6 fuse boxes: 2 of each
module type 22 HV coax cables:
6 for type 1 : 3 HV lines / box
6 for type 2 : 3 HV lines / box
10 for type 3 : 5 HV lines / box
1 HV connector: 51-pin: 22 HV + 22 ground + 2
interlock + 1 case ground + 4 empty
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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What to assemble in the fuse box
Circuit boards = 2 per fuse box Spring contacts = (# fuses) + (4 ground contacts/box) Filter circuits:
1 per HV line = 2 x 1kΩ Resistors + 1 x 870pF Capacitor Mounting nuts (Ultem) = 2 per fuse box Fuses: (contain extra fuses due to symmetry)
Type 1: 44 fuses/module (22/box), 42 in use. Type 2: 68 fuses/module (34/box), 65 in use. Type 3: 104 fuses/module (52/box), 100 in use Total (for 35 sets) = 7560 + spare
Jumpers 1 ground jumper between halves. 1 HV jumper between halves, for type 2 and type 3 only
HV cables
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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Old Fuse Box
GND jumper
GND jumperGND jumper
HV jumper
Mounting NutsSwitched to the other half in new design
Similar jumpers also needed for new fuse box
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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HV Granularity & Current Draws
565-1087 μA/line
999-1253 μA/line498-735 μA/line
3 lines
3 lines
5 lines
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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Implementation
For each type of module: 1 type of fuse box 1 length of cable Applies to (4 HV Kapton positions) x (4 connector
locations). Neighboring modules are supplied from opposite
ends Odd # modules from side A (back side) Even # modules from side C (front side)
The HV cable is made long enough to swing to neighboring modules in case switching side is necessary.
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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Front Side Connections
Nominal Fuse Box
Connection
Pattern repeats
in 4 modules interval
(i.e. every 2 sectors)
Connectors
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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Connections & Naming Convention
Another table to map: straws fuse HV line !
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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Production procedures
Mark/label fuse box Glue circuit board to fuse box
Use high temperature RTV. Along the front edge of ckt to
prevent flux from flowing under circuit board.
Place components on ckt board and oven solder them.
Spring contacts + filter resistors + filter capacitors.
Spring contacts are clamped in place in soldering process.
Clean fuse box Glue mounting nuts Tape together 2 halves of fuse boxes Solder fuses by hand
In case of resistor substitute may use oven soldering.
Clean fuse box(?) Solder HV cable by hand Solder jumper wires by hand Clean fuse box Spot glue HV cable & jumper wires
for strain relief Bake/dry fuse box right before
coating Coat fuses & wires with conformal
coating Label HV cables Cut HV cable to length and attach
connector
At Duke
manpower permitting
Chiho Wang ATLAS TRTDuke University Dubna, May 2005
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Parts Status
G10 boxes: 16 modules/type in hand, ~ end of May Circuit boards: in hand Spring pins: in hand, need cutting, bending Filter resistors + capacitors: in hand Mounting nuts: ½ in hand, ½ to be made Fuses: under production (Substitute resistors: ordered) HV Cable: available from Herve. HV Connectors: in hand Ultem screws: in hand Mounting brackets: quoted, placing order.